MPower Electronics POLI Manuale utente

POLI

Multi-Gas Meters

Service Manual

Version 1.37

September 2023

POLI Service Manual 
1 
 
Contents 
General Information......................................................................................................................................4 
Maintenance..................................................................................................................................................4 
Replacing Filters..........................................................................................................................4 
Checking Sensor Strength in Diagnostic Mode...........................................................................5 
Removing or Replacing Sensor Modules....................................................................................7 
Cleaning or Changing PID Sensor Detector or Lamp .................................................................8 
PID Lamp Cleaning.................................................................................................................8 
PID Sensor Detector Cleaning ................................................................................................8 
Sampling Pump............................................................................................................................9 
Pump Stall Setting...................................................................................................................9 
Pump Service Procedures........................................................................................................9 
Gas Inlet.....................................................................................................................................11 
Housing Filters ..........................................................................................................................12 
Battery Replacement..................................................................................................................13 
LCD Replacement .....................................................................................................................14 
Troubleshooting.........................................................................................................................15 
Replacement Parts .....................................................................................................................16 
Contact Information....................................................................................................................................17

POLI Service Manual

Read Before Operating

This manual must be carefully read by all individuals who have or will have the responsibility of

using, maintaining or servicing this product. The product will perform as designed only if it is

used, maintained and serviced in accordance with the manufacturer’s instructions. The user

should understand how to set the correct parameters and interpret the obtained results.

CAUTION！

•REMOVE MONITOR COVER ONLY IN AREA KNOWN TO BE NON-HAZARDOUS.

•RECHARGE BATTERY ONLY IN AN AREA KNOWN TO BE NON- HAZARDOUS.

•USE ONLY mPOWER’S RECHARGEABLE LITHIUM BATTERY P/N M004-3002-000.

•USE OF NON-mPower COMPONENTS WILL VOID THE WARRANTY AND CAN

COMPROMISE THE SAFE PERFORMANCE OF THIS PRODUCT

•SUBSTITUTION OF COMPONENTS MAY IMPACT INTRINSIC SAFETY.

CAUTION: HIGH OFF-SCALE READINGS MAY INDICATE AN EXPLOSIVE

CONCENTRATION. ANY RAPID UP-SCALE READING FOLLOWED BY A DECLINING

OR ERRATIC READING MAY INDICATE A GAS CONCENTRATION BEYOND UPPER

SCALE LIMIT WHICH MAY BE HAZARDOUS.

ATTENTION: DES LECTURES SUPÉRIEURES A L’ÉCHELLE PEUVENT INDIQUER

DES CONCENTRATIONS EXPLOSIVES. TOUTE LECTURE RAPIDE ET POSITIVE,

SUIVIE D’UNE BAISSE SUBITE AU ERRATIQUE DE LA VALEUR, PEUT INDIQUER

UNE CONCENTRATION DE GAZ HORS GAMME DE DÉTECTION QUI PEUT ÊTRE

DANGEREUSE.

WARNINGS !

ONLY THE COMBUSTIBLE GAS DETECTION PORTION OF THIS INSTRUMENT HAS

BEEN ASSESSED FOR PERFORMANCE.

UNIQUMENT, LA PORTION POUR DÉTECTOR LES GAZ COMBUSTIBLES DE CET

INSTRUMENT A ÉTÉ ÉVALUÉE.

CAUTION: BEFORE EACH DAY’S USE, THE SENSITIVITY OF THE COMBUSTIBLE

GAS SENSOR MUST BE TESTED ON A KNOWN CONCENTRATION OF METHANE

GAS EQUIVALENT TO 20 TO 50% OF FULLSCALE CONCENTRATION. ACCURACY

MUST BE WITHIN 0 AND +20% OF ACTUAL. ACCURACY MAY BE CORRECTED

BY A CALIBRATION PROCEDURE.

ATTENTION: AVANT CHAQUE UTILISATION JOURNALIERE VERIFIER LA

SENSIBILITE AVEC UNE CONCENTRATION CONNUE DE METHANE EQUIVALENTE

A 20-50% DE LA PLEINE ECHELLE. LA PRECISION DOIT ETRE COMPRISE ENTRE

0-20% DE LA VALEUR VRAIE ET PEUT ETRE CORRIGEE PARUNE PROCEDURE

D’ETALONNAGE.

POLI Service Manual

WARNINGS !

This device complies with part 15 of the FCC Rules. Operation is subject to the following two

conditions: (1) This device may not cause harmful interference, and (2) this device must accept

any interference received, including interference that may cause undesired operation.

CAUTION: Changes or modifications to this unit not expressly approved by the party

responsible for compliance could void the user's authority to operate the equipment.

NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device,

pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against

harmful interference in a residential installation. This equipment generates, uses and can radiate radio

frequency energy and, if not installed and used in accordance with the instructions, may cause harmful

interference to radio communications. However, there is no guarantee that interference will not occur in a

particular installation. If this equipment does cause harmful interference to radio or television reception,

which can be determined by turning the equipment off and on, the user is encouraged to try to correct the

interference by one or more of the following measures:

•Reorient or relocate the receiving antenna.

•Increase the separation between the equipment and receiver.

•Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

•Consult the dealer or an experienced radio/TV technician for help.

Special Conditions for Safe Use

•The POLI multi-gas detector must be calibrated if it does not pass a bump test, when a new

sensor has been installed, or at least once every 180 days, depending on use and sensor

exposure to poisons and contaminants

•No precautions against electrostatic discharge are necessary for portable equipment that has

an enclosure made of plastic, metal or a combination of the two, except where a significant

static-generating mechanism has been identified. Activities such as placing the item on a belt,

operating a keypad or cleaning with a damp cloth, do not present a significant electrostatic

risk. However, where a static-generating mechanism is identified, such as repeated brushing

against clothing, then suitable precautions shall be taken, e.g., the use of anti-static footwear.

Note: Users are recommended to refer to ISA -RP12.13, Part II-1987 for general information on

installation, operation, and maintenance of combustible gas detection instruments.

Proper Product Disposal at the End of Life

The Waste Electrical and Electronic Equipment (WEEE) directive (2002/96/EC) is

intended to promote recycling of electrical and electronic equipment and their

components at end of life. This symbol (crossed-out wheeled bin) indicates separate

collection of waste electrical and electronic equipment in the EU countries. This

product may contain one or more Nickel-metal hydride (NiMH), Lithium-ion, or

Alkaline batteries. Specific battery information is given in this user guide. Batteries

must be recycled or disposed of properly. At the end of its life, this product must

undergo separate collection and recycling from general or household waste. Please use

the return and collection system available in your country for the disposal of this

product.

POLI Service Manual

General Information

The POLI multi-gas detectors (MP400 & MP400P) offer 4- or 5-gas monitoring of oxygen (O2),

combustible (LEL) gases, toxic gases, carbon dioxide (CO2), and volatile organic compounds (VOCs).

The MP400 is a diffusion sampling model with standard O2, LEL, carbon monoxide (CO) and

hydrogen sulfide (H2S) configuration. A firefighter version uses O2, LEL, CO and hydrogen cyanide

(HCN) sensors, and a 5-gas version including sulfur dioxide (SO2) is also avaliable. The MP400P is a

standard model with pump and allows a full selection of sensors, e.g. over 15 different electrochemical

(EC) sensors, pellistor for LEL, non-dispersive infrared (NDIR) for hydrocarbons in both LEL and

Vol% range and photo-ionization detector (PID) for VOCs. The MP400S and MP400H are pumped

and diffusion multi-gas meters used in wireless networks.

This Service Manual describes the advanced maintenance and repair operations not given in the

standard User’s Guide. To perform the operations described herein it is assumed that the service

technician is already famliar with the User’s Guide, including simple maintenance, firmware

configurations and mPower Suite software operations.

Maintenance

The POLI requires little maintenance, aside from daily battery charging, regular filter replacement, and

sensor replacement as needed (1 to 3 years depending on sensor and use conditions). Under extreme

conditions, the pump or battery may need service or replacement.

Replacing Filters

External Filter

If the external filter is dirty or clogged, remove it by unscrewing it from the inlet. Discard it and

replace it with a new water-trap filter. Dirty filters can be recognized by symptoms such as:

•Visible filter discoloration

•Frequent pump stalls

•A high pump current (I) value shown in the Pump Stall menu

We recommend filter replacement at least every month for instruments that are used regularly, and

more frequently, possibly daily, when used under dusty or wet conditions.

Internal Sintered Filter:

New models of POLI shipping beginning late 2023 have a secondary internal filter added to protect the

monitor in case the external water trap filter is lost or disconnected. This filter should be replaced or

cleaned if the monitor flow rate or sensor response decreases notably.

Unscrew the Water Trap

Filter

Unscrew the Luer Inlet/

Filter Retainer

Luer/Filter Retainer

Remove or Replace

Sintered Filter as Needed

POLI Service Manual

Incompatible Chemicals:

The sintered filter should NOT be used with chemicals that may react with it and thus be depleted by

it. Incompatible chemicals include: HCl, HF, Cl2, ClO2, O3, and NO2. Acceptable chemicals include

most VOCs, O2, CH4, CO2, CO, H2, H2S, NH3, HCN, NO, N2O, PH3, SO2, ETO, THT and methyl

mercaptan.

IMPORTANT! A pumped POLI should not be calibrated or operated without a filter. Operation

without a filter may damage the instrument. The only exception to this requirement is for use with

reactive gases that may be partially lost on the filter.

Housing Filters

To replace the filters above each sensor on the front housing, see the separate section entitled “Housing

Filters” below.

Checking Sensor Strength in Diagnostic Mode

Sensor raw signals can be accessed for aid in troubleshooting sensor problems. Connect the instrument

to mPower Suite on a PC or the mobile App, check the “Enable Diagnostic” box in the Configuration

screen (“General” section), and send to the instrument. The main screen will show the sensor type, slot

position, raw sensor reading, and the gas concentration, for example:

Text

Type

Slot

Raw Reading

Concentration

Sensor Temp. (°C)

CO+3=9390, 0

9390

O2+4=28505,20.9

28505

20.9

VOC+1=18550,0.0

PID

18550

LEL+2=264400,0

LEL

264400

T=29,32,29,34,0

top down

The table below lists typical readings for new sensors.* For sensors not in this table, check the mPower

website www.mpowerinc.com for a Technical/Application Note on Diagnostic Mode.

•First check the Raw Zero readings in air. If these are significantly outside the ranges listed

below, there is probably something wrong with the sensor or circuit board.

•Apply calibration gas to the instrument. The readings should increase or decrease, depending

on sensor type, by at least the Delta values listed below. There is no set limit to the minimum

Delta change, but commonly if the Delta approaches the Minimum values listed, the sensor is

getting weak and it is likely time to replace it. A sensor may still be used if it provides adequate

resolution (for the application) on the lowest digit in normal display mode after proper

calibration.

POLI Service Manual

Sensor Raw Counts

Sensor

Test Gas

Raw Air Zero*

Raw Span*

Minimum Delta*

Combustibles (pellistor) LEL

50% LEL CH4

170000-370000

177000-470000

7800

VOC 0-2000 ppm 4-series PID

10 ppm IBE**

100 ppm IBE

9600-44000

10000-49000

16000-92000

660

6600

Oxygen 0-30% lead wool O2

18% O2

0% O2

10000-45000

19000-53000

16000-65000

950

6900

Oxygen 0-30% lead-free O2

18% O2

0% O2

6000-20000

6100-22000

7200-32000

160

1200

Carbon Monoxide 0-1000 ppm CO

60 ppm CO

7300-12000

7500-14000

250

Hydrogen Sulfide up to 200 ppm H2S

15 ppm H2S

7300-12000

8000-18000

770

* Delta = Raw Span reading –Raw Air reading. These values are for reference only and are not to be

construed as hard specifications.

** IBE = Isobutylene

The Right Key can be used to scroll through other Diagnostic Mode screens with more information:

Battery Status

BatV: Fully charged should be close to 3.8V or slightly more, shut off below about 3.3V

AC Stat: 0 unplugged; >710 plugged in to charge adapter

Charge Stat: 0 unplugged; >720 plugged in to charge adapter

gSensor

These are position sensors used by the Man-Down alarm function. Values range from about -1000 to

+1000 depending on the orientation the unit is held in.

Amblite

The ambient light sensor is located in the upper left side alarm window of the POLI. The raw

ambient light readings should be about 3280 in complete darkness and near 0 in full sunlight.

Pump Info

This screen shows the pump speed setting, the pump current draw (with maximum and minimum

readings in parentheses) and the Pump Stall Threshold setting (see below for adjustment procedures).

The pump speed can be toggled between Low and High to check the values and settings for both.

Wireless

Two or more POLI instruments are needed to test the wireless communication function. This feature

appears for all POLI models but is only actually used in wireless models such as MP400S and

MP400H. Pushing “Ping” on one unit causes a single ring on a second unit if communication is

successful.

POLI Service Manual

Removing or Replacing Sensor Modules

WARNING!

Replace sensors only in non-hazardous locations.

All sensors are located inside the sensor compartment on the top side of the POLI circuit board

assembly. They are accessed by removing the six screws (2-mm or 5/64” Allen wrench or 3/32”

flathead screwdriver) in the back of the POLI and then turning the instrument over and lifting off the

front cover.

1. Turn off the instrument, remove the six screws from the back side, and lift off the front cover.

2. Carefully lift out each sensor you wish to inspect or replace.

3. Install the replacement sensor. Make sure the electrical contact pins are aligned with the holes in

the PC board and that the sensor is seated firmly. The location of sensors does not matter except as

noted below. High-power sensors have double winged housings and can only be placed in slots 1

and 2 with double-winged openings. Low-power sensors have single wings and can be inserted into

any of the four sensor slots.

4. The firmware automatically recognizes the sensor type at each location.

5. Reassemble, taking care that the sensor gaskets are set smoothly into the sensor caps.

IMPORTANT! Always perform a full calibration after cleaning or replacing sensors.

NOTE: Some PIDs versions interfere with O2Sensors. If an O2sensor gives spurious readings,

make sure to install it in a cross position from a PID, e.g., PID in slot 1, O2in slot 4, not slots 2 or 3.

CAUTION! Wireless MP400S Antennae Interfere with Lead-free O2Sensors in positions 2 and 4

and therefore LF-O2 sensors must be installed in position 1 or 3 in wireless units.

Single-Wing

Low-power

Sensor

Double-Wing

High-power

Sensor

Sensor Slot Identification

Sensor Gasket

in Cap

POLI Service Manual

Cleaning or Changing PID Sensor Detector or Lamp

PID Lamp Cleaning

1. Pry off the PID sensor cover using a small flathead screwdriver.

2. Put on finger gloves and pull out lamp. Replace lamp or clean window as described below.

3. Use a cotton swab wetted with methanol or acetone to clean the flat window surface of the lamp. If

greasy dirt is hard to remove using solvent, the window can be polished using fine alumina powder.

4. Dry the lamp with clean tissue, re-insert into the PID sensor module and close the cover.

5. Some PID versions have a small, 3-pin sensor grid, and/or lamps with 2 conductive coatings on

opposite sides. In such cases, be sure to align the lamp coatings with the electrodes inside the lamp

socket (usually parallel to the 3 sensor grid sockets), to avoid possibility of a short-circuit. Insert

the lamp, then the sensor grid, and then the spacer, filter(s) and cap.

PID Sensor Detector Cleaning

1. Pry off the PID sensor cover and pull out the sensor detector.

2. Put the sensor detector into a beaker of pure methanol or ethanol.

3. Place the beaker into an ultrasonic cleaning bath (jewelry cleaner) and sonicate for 15 minutes.

Remove the sensor and dry it thoroughly. If possible, use a gentle stream of clean air to blow the

residual dust-containing liquid out of the sensor. Complete drying may take a few hours before

reassembly to ensure a stable PID baseline.

4. Always re-calibrate the PID after cleaning the sensor.

Metallic coating strips

3-Pin sensor grid

Alternate PID design

lamp alignment

POLI Service Manual

Sampling Pump

The flow rate should be roughly 150-300 cc/min at low pump speed and 300-400 cc/min at high pump

speed when there is no air leakage. When approaching the end of its useful operating life, the pump

will consume more energy and draw significantly lower flow. Also, if excessive dust or particles enter

the pump, the flow will be reduced. A strong pump should stall and/or nearly stop when a finger is

used to block the inlet. If the pump does not stall and the flow is weak, it is likely that particles are

trapped in the pump gasket or diaphragm. When this occurs, it is necessary to replace or rebuild the

pump, or clean the gasket.

Pump Stall Setting

The Pump Stall setting defines the current draw threshold the detects a blocked pump. During normal

operation if the gas inlet becomes plugged, the pump automatically turns off to avoid further damage.

To adjust the stall threshold, enter the Pump Stall menu and press ‘Change’. When prompted, block the

inlet completely with a finger for 5 seconds and let go. During the blockage the pump should nearly

stall and the current (I) reading should increase to a high value. The Threshold will adjust itself

automatically. A partial blockage may cause only a small change in the current resulting in a poor stall

setting. If the new Threshold seems unsatisfactory for some reason, press ‘Clear’ and repeat the 5-

second blockage. When satisfied, press ‘Done’ followed by ‘Save’ to accept the new Pump Stall

Threshold.

NOTE: A different Pump Stall Threshold must be set for each pump speed. The instrument remembers

the corresponding thresholds so that the user does not need to re-set the threshold each time the pump

speed is changed.

NOTE: The current (I) value is relative and depends on the Pump Speed, the condition of the inlet

filter, and the firmware version. At high speed the I value is typically in the range 5000-5500 for

firmware 7.1 or later and 90-300 for earlier versions, while at low speed it is typically 6500-7500 for

v.7.1 or later and 400-900 for earlier versions. If the I readings are at the high end or above these

ranges, or if there is little or no change when the pump is blocked, some maintenance should be done.

Pump Service Procedures

1. Check for a dirty or plugged filter by removing the inlet 25-mm filter and re-measuring the

flow rate. Replace as needed.

2. Place a finger over the probe inlet and listen for a strain on the pump. It should nearly stop,

but may not stop completely. If the pump tone barely changes, check the flow path, such as the

inlet probe, inlet filter and/or Luer connector.

3. If the pump still gives low flow (or little strain when flow is blocked), clean the pump gasket as

described below:

Pump Stall

Current Pump

Thresh Setting:

I = 526

Thresh = 1235

Change

Done

Change

Clear

Done

Pump Stall

Please Block

Pump For 5 Sec:

I = 526

Thresh = 526

Block

Pump

Pump Stall

Please Block

Pump For 5 Sec:

I = 2350

Thresh = 1837

Clear

Done

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