Honeywell BWTM Ultra Portable Gas Detector

Limited Warranty and Limitation of Liability

BW Technologies by Honeywell LP (Honeywell) warrants that the product will be free from defects in materials and workmanship under normal use and service for a period of three years from the date of shipment to the buyer. This warranty applies only to the sale of new, unused products to the original buyer. Honeywell's warranty obligation is limited, at Honeywell's discretion, to the refund of the purchase price, repair, or replacement of any defective product returned to an authorized Honeywell service center within the warranty period. Honeywell's liability under the terms set forth shall in no event exceed the purchase price actually paid by the buyer for the product.

Because certain countries and states do not allow the limitation of the duration of an implied warranty, or the exclusion or limitation of incidental or consequential damages, the limitations and exclusions of this warranty may not apply to all buyers. Should any provision of this warranty be deemed void or unenforceable by a court of competent jurisdiction, such invalidation shall not affect the validity or enforceability of the remaining provisions.

Warranty Registration: www.honeywellanalytics.com/support/productregistration

This warranty does not cover:

• Fuses or disposable batteries, nor routine replacement of parts due to normal product wear and tear from use.
• Any damage or defect attributable to repair of the product by anyone other than an authorized distributor, or due to the installation of unapproved parts in the product.
• Any product that, in Honeywell's opinion, has been misused, modified, neglected, or damaged accidentally or due to abnormal operating conditions, handling, or use.

The obligations set forth in this warranty are contingent upon the following conditions:

• Proper storage, installation, calibration, use, and maintenance, as well as due compliance with the product manual instructions and any other applicable Honeywell recommendations.
• Prompt notification of any defect to Honeywell by the buyer and, if required, immediate delivery of the product for repair. No product shall be returned to Honeywell until the buyer has received shipping instructions from Honeywell.
• Honeywell's right to request that the buyer provide proof of purchase, such as the original invoice, sales contract, or delivery note, to determine if the product is within the warranty period.

THE BUYER AGREES THAT THIS WARRANTY IS THEIR SOLE AND EXCLUSIVE REMEDY AND THAT IT SUPERSEDES ANY OTHER WARRANTY, WHETHER IMPLIED OR EXPRESS, INCLUDING, WITHOUT LIMITATION, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. HONEYWELL SHALL NOT BE LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL LOSS OR DAMAGE, INCLUDING LOSS OF DATA, WHETHER ARISING FROM BREACH OF WARRANTY, CONTRACT, TORT, NEGLIGENCE, OR ANY OTHER THEORY.

Introduction

The Honeywell BWTM Ultra gas detector provides a warning when hazardous gas levels exceed user-defined alarm setpoints. The detector is a personal safety device. It is your responsibility to react correctly to an alarm. This publication is intended for individuals who understand how to configure, maintain, and operate gas detectors, docking systems, and personal accessories.

Gases Monitored

The detector can monitor up to five gases simultaneously. Four gases are detected by default, and one optional gas can be selected from the following list.

Box Contents

• Honeywell BWTM Ultra Gas Detector
• 1 Screen Protector
• Battery (factory installed)
• Telescopic Screwdriver with two ends
• Charging Adapter
• Quick Reference Guide
• 3 m PVC Tubing
• 1 x 1.1 cm Dust Porous Filter
• 5 module hydrophobic filter
• 2 x 0.3 cm Luer-Lock Male Adapters
• 5 Pump Filters
• USB Memory Stick containing User Manuals

Safety Information

CAUTION: READ FIRST

Use the detector only as specified in this manual; otherwise, the protection provided by the detector may be impaired.

• For critical immediate safety uses, only the instrument capable of sounding alarms and displaying readings on a screen should be used. Wireless infrastructure and communication are for informational monitoring purposes only.
• Use only Honeywell-approved batteries (Part No.: HU-BAT N/P: 50122982-130) with the Honeywell BWTM Ultra detector. Using a different battery may result in explosion or fire.
• The lithium battery in this product poses a risk of fire, explosion, or chemical burn if not used properly. Do not open, crush, disassemble, incinerate, or heat above 100 °C (212 °F). Batteries exposed to heat at 130 °C (266 °F) for 10 minutes may cause fire and explosion. Follow manufacturer instructions. Batteries should only be charged in a hazard-free area.
• Removing the battery pack to disable the detector could cause improper operation and damage the detector.
• Use only a Honeywell-approved battery charger, which is certified for SELV/LVLC (isolated) with a minimum controller output (Um) of 6.3 V.
• If the detector is to be used at an operating temperature near the maximum or minimum level, Honeywell recommends zeroing and powering it on in that environment.
• Charge the detector before using it for the first time. Honeywell also recommends charging the detector after each work shift.
• Calibrate the device regularly based on usage and sensor exposure to poisons and contaminants. Honeywell recommends calibrating at least once every six months.
• For optimal performance, periodically zero the sensor in normal atmosphere (20.9% v/v O2) free of hazardous gases.
• The combustible gas sensor is factory calibrated to 50% LEL of methane. If a different combustible gas is to be monitored in the % LEL range, calibrate the sensor using the appropriate gas.
• The CSA standard has only evaluated the performance of the combustible gas detection unit of this detector.
• Honeywell recommends that the combustible sensor be checked with a known concentration of calibration gas after any exposure to contaminants and poisons, such as sulfur compounds, silicone vapors, halogenated compounds, etc.
• Honeywell recommends performing a functional test of the sensors before daily use to confirm their gas response. Manually check that the audible, visual, and vibrating alarms are activated. Perform a calibration if readings are not within specified limits.
• The detector is designed for use only in potentially explosive atmospheres where oxygen concentrations do not exceed 20.9% (v/v). Oxygen-deficient atmospheres (<10% v/v) may inhibit some sensor outputs.
• Prolonged exposure of the detector to some concentrations of air and combustible gases can strain the detector component and seriously affect its performance. If an alarm occurs due to a high concentration of combustible gases, a calibration should be performed. If necessary, contact a Honeywell service representative to replace the sensor.
• High concentrations of certain toxic gases, such as H2S, may damage the LEL sensor. This effect, known as inhibition, is usually temporary, but under extreme circumstances, it may affect the LEL sensor's sensitivity after exposure to gases that trigger an alarm on the toxic gas sensors.
• The Honeywell BWTM Ultra is supplied with an anti-static coating on the LCD screen to minimize the risk of ignition caused by electrostatic discharge. Periodic inspection of this coating is required to ensure that this surface is not subject to wear, delamination, abrasion, or other defects.
• Care should be taken to avoid exposure to excessively high temperatures, solvents or strong chemicals, sharp edges, or abrasive surfaces. Clean the exterior with a soft, damp cloth.
• Portable safety gas detectors are life-saving safety devices. The accuracy of ambient gas readings depends on various factors, such as the accuracy of the calibration gas standard used for calibration and the frequency of calibration.
• When the Honeywell BW TM Ultra detector is equipped with an infrared (IR) sensor, DO NOT use the BW Ultra in atmospheric pressure above 1.1 bar (110 kPa). The IR sensor used in the detector is designed for use at atmospheric pressure and should not be used at pressures above 1.1 bar (110 kPa).
• DO NOT use the Bluetooth output indication of the BW Ultra for safety purposes.

WARNINGS

• FOR SAFETY REASONS, THIS EQUIPMENT SHOULD ONLY BE USED AND SERVICED BY QUALIFIED PERSONNEL. READ AND UNDERSTAND THE INSTRUCTION MANUAL COMPLETELY BEFORE USING OR SERVICING THE EQUIPMENT.
• Replacement of components may affect the intrinsic safety of the equipment.
• Protect the combustible sensor from exposure to lead compounds, silicones, and chlorinated hydrocarbons. Although some organic vapors (such as leaded gasoline and halogenated hydrocarbons) may temporarily inhibit sensor performance, the sensor will recover after calibration in most cases.
• The Canadian Standards Association (CSA) requires that functional tests of the LEL sensor be performed before daily use, with a concentration between 25% and 50% LEL for the calibration gas. The instrument must be calibrated if the LEL value displayed during a functional test is not between 100% and 120% of the expected value for the gas.
• High LEL readings out of scale may indicate an explosive concentration.
• Any rapid increase in reading followed by a drop or erratic value may indicate a dangerous concentration of gas beyond the upper limit of the scale, which could be hazardous.
• Products may contain materials that are regulated for transport under domestic and international hazardous materials regulations. Return the product in accordance with appropriate hazardous articles regulations. Contact the freight carrier for further instructions.
• Dispose of used lithium batteries immediately. Do not disassemble or dispose of them in fire. Do not mix batteries with solid waste streams. Spent batteries must be disposed of by a qualified recycling or hazardous materials handling company. Keep children away from lithium batteries.
• Pellistors used in the Catalytic Combustible Gas Sensor may suffer a loss of sensitivity in the presence of poisons or inhibitors, such as silicones, sulfides, chlorine, lead, or halogenated hydrocarbons.
• DO NOT rely on the Bluetooth output indication of the BW Ultra for safety purposes.
• DO NOT use the screen protector in hazardous locations. The screen protector must be removed in explosive atmospheres.
• Accessories (e.g., 0.3 cm quick connector adapter, 0.3 cm Luer-Lock male adapter, etc.) are not within the scope of intrinsic safety certification.
• Do not install or remove any components when an explosive gas atmosphere is present.

Sensor Poisons and Contaminants

Many chemicals can contaminate and permanently damage sensors. Follow these guidelines when using detergents, solvents, or lubricants near the detector:

• Use water-based cleaning products (not alcohol-based).
• Clean the exterior only with a soft, damp cloth.

These products can damage sensors. Do not use them in the vicinity of the detector:

• Soaps
• Solvents
• Alcohol-based cleaners
• Brake cleaners
• Dishwashing liquids
• Insect repellents
• Methanol (fuel or antifreeze)
• Polishes
• Window and glass cleaners
• Silicone-based cleaners or protectants
• Silicone-containing fabrics
• Aerosols
• Anionic detergents
• Citrus-based cleaners
• Hand sanitizers
• Lubricants
• Mold release agents
• Rust inhibitors
• Silicone-based adhesives, sealants, or gels
• Hand/body/medicinal creams containing silicone

International Symbols

Getting Started

Appearance

The detector's appearance is shown below, with numbered components:

1. Visual Alarm Indicator
2. Exhaust Port
3. Display
4. Button
5. Speaker Opening
6. Pump Inlet
7. Alligator Clip
8. Pump Assembly
9. Charge & IR Interface Port

Main Display

The main startup display will appear as shown in the illustration below:

Display Icons

The detector's display, shown here with common icons, will display the icons indicated in the table below as conditions dictate.

Detector Operations

Powering On the Detector

Turn on the detector in a safe area that has an atmosphere with 20.9% oxygen and no hazardous gases.

1. During first use, charge the battery with the supplied charging adapter for a maximum of 8 hours or until the LED light turns green. Refer to Charging the Battery for more information.
2. Press and hold the Button for three seconds.
3. During first use, the message Warming sensors and a 30-minute countdown will be displayed. In most cases, this countdown lasts only a few minutes.
4. When the detector displays Pump test Block inlet, block the pump inlet with a finger and, after a few seconds, unblock it. The detector will perform a quick pump test. The message Pump Test passed will be displayed. If you do not block the pump inlet, the detector will shut down after two minutes. The detector will then perform a self-diagnostic that includes checking the sensors. This process may take several minutes. If necessary, the display will provide instructions to calibrate newly installed sensors.
5. When the self-diagnostic is complete, press and hold the Button to zero the sensors. After the automatic zeroing is complete, the detector will check the calibration and functional test of the sensors. If the detector identifies that calibration or a functional test is required for any sensor, press the Button and follow the on-screen instructions.

Activating Backlight

To activate the backlight on the display, press the Button.

Powering Off the Detector

1. Press and hold the Button during the shutdown countdown.
2. Release the Button when OFF is displayed.

Navigating the Menu

The main menu consists of four items:

• See Information
• Start Bump Test
• Zero Sensors
• Start Calibration

1. Pressing the Button twice will display the four options on the screen. See Information will appear selected and highlighted by default.
2. Press the Button to change the selection to the next option.
3. Press and hold for three seconds to enter the selected option.
4. Follow the on-screen instructions for the selected operation. Most detector procedures are described in this guide.

Viewing General Detector Information

1. Press the Button twice to access the main menu.
2. Select See Information and press the Button to scroll through the following information:
   • Peak Readings
   • STEL Readings
   • TWA Readings
   • Bump Test Intervals
   • Calibration
   • BLE Information (BLE should be enabled)
   • LEL Correction Factor
   • Low Level Alarm Setpoints
   • High Level Alarm Setpoints
   • STEL Setpoints
   • TWA Setpoints

Resetting TWA or STEL Readings

Before starting: TWA/STEL Reset must be enabled in Fleet Manager II to reset readings on the detector.

1. Navigate to the main menu and select > See Information > TWA readings or STEL readings.
2. Press and hold the Button for 3 seconds to reset the readings. A reset message will be displayed.

Resetting Peak Readings

Before starting: Peak Reset must be enabled in Fleet Manager II to reset readings on the detector.

1. Navigate to the main menu and select > See Information > Peak readings.
2. Select Hold to reset peak readings. Press and hold the Button for 3 seconds to reset the readings.

Resetting TWA/STEL and Peak Readings

Before starting: TWA/STEL Reset and Peak Reset must be enabled in Fleet Manager II to reset readings on the detector.

1. Navigate to the main menu and select > See Information > Peak readings.
2. Select Hold to reset all readings. Press and hold the Button for 3 seconds to reset the readings.

Zeroing Sensors

Before starting: Connect nitrogen if it is a CO2 unit.

1. Navigate to the main menu and select Zero Sensors.
2. Press and hold the Button for 3 seconds.

The Zeroing process will start automatically. The display will show all current gas measurements, highlighting entries for values above zero. Ambient air is applied to zero all sensors other than CO2. The display will show all current gas measurements, highlighting entries that have been reset to zero.

3. If you do not zero O2, click NO on the pop-up message: Is this a CO2 unit? Zero value results will be displayed. Press the Button or wait six seconds to finish the Zeroing process.
4. Click Yes if it is a CO2 unit and you wish to apply nitrogen to zero CO2. A two-minute gas measurement process will start automatically. All current gas measurements and entries that have been reset to zero will be displayed.
5. Close the gas supply following the on-screen instructions. Zero value results will be displayed.
6. Press the Button or wait six seconds to finish the Zeroing process. Zero value results will be displayed as follows:
   • A checkmark for sensors that have completed zeroing.
   • A cross symbol for sensors that failed zeroing.
   • An exclamation mark for sensors that skipped zeroing.

Confirming Alarms and Messages

Press and release the Button to perform any of the following actions:

• To confirm a latched alarm
• To confirm a low-level alarm
• To confirm a message that is due today (e.g., calibration and bump test reminders). Note that Force Calibration and Force Bump Test functions cannot be ignored.

Latching Alarms

If enabled, during an alarm condition, the Latching Alarms option causes the audible, visual, and vibrating gas alarms (high and low level) to persist until the alarm is acknowledged and the gas concentration falls below the low-level alarm setpoint. The LCD will display the peak reading until the alarm condition ceases. Local regulations in your region may require Latching Alarms to be enabled.

The detector is supplied with Latching Alarms disabled.

Calibrating the Detector

Perform a calibration to adjust the sensor sensitivity levels and ensure accurate gas responses. The detector can be calibrated in two ways:

• Apply gas from a cylinder to the sensors manually through the pump inlet.
• Use an IntelliDoX module.

Before starting: Move to a normal atmosphere (20.9% v/v O2) free of hazardous gases.

1. Navigate to the main menu and select > Start Calibration.
2. Press and hold the Button for three seconds to display the Powering Off countdown and continue holding it during the Starting Calibration countdown. The detector will activate the zeroing function. The Zeroing process will start automatically and last for five minutes. Current gas measurements will be displayed, and entries for values above zero will be highlighted.
3. Connect the calibration sleeve to the pump inlet. Ensure you use a demand-flow regulator.
4. Confirm that you wish to apply nitrogen to zero CO2.
5. When Apply calibration gas now is displayed, apply the gas and wait for up to five minutes. First, the detector will perform tests to detect a specific gas type. When it detects sufficient gas for sensor calibration, a checkmark will be displayed next to that gas. Calibration will then begin. Gas values will adjust on the screen during calibration.
6. When Turn gas off is displayed, disconnect the device from the gas supply. Checkmarks will be displayed next to the calibrated sensors. These sensors will be reset to the number of days remaining until the next calibration expires (e.g., 180 days). The calibration cycle will take approximately two minutes, after which a pop-up window will prompt the user to Press button to continue.
7. If calibration was successful, Calibration Passed will be displayed. Press the Button to exit calibration.

If calibration failed for some or all gases, the message Cal Error All gases applied mixed results (if the detector did not calibrate correctly for all gases) or the message Fail all gases will be displayed. After pressing the Button, the message Cal overdue will be displayed.

CAUTION
Honeywell recommends performing a functional test of the sensors before daily use to confirm their gas response by exposing the sensors to a gas concentration that exceeds the alarm setpoints.

Initiating a Bump Test

Perform a bump test regularly to test the sensors and alarms. To perform a bump test, expose the sensors to a gas concentration that exceeds the alarm setpoints and confirm that the sensors and alarms are functioning correctly. The detector can pass a bump test in two ways:

• Apply gas from a cylinder to the sensors manually through the pump inlet.
• Use an IntelliDoX module.

Performing a Manual Bump Test

Before starting: Connect the calibration sleeve to the demand-flow regulator on the gas cylinder.

1. Press the Button twice and select > Start Bump test.
2. Press and hold the Button for three seconds.

The detector displays Starting Bump test. Bump test started appears, and then the detector sounds, flashes, and vibrates.

3. The detector will display a pop-up asking Did you see and hear the alarms? Select Pass and press and hold the Button for three seconds to confirm that the visual, audible, and vibrating alarms are functioning correctly. The message Audio-Visual test passed will be displayed. Skip to Step 5.
4. If the visual, audible, and vibrating alarms fail, select Fail and press and hold the Button. The message Audio-Visual test failed will be displayed. You can then: a) Apply gas and skip to Step 5. b) Press the Button to skip applying gas and follow the on-screen instructions to finish the Bump Test. Bump test results will be displayed, and the test will end.
5. If you wish to apply gas, follow the on-screen instructions. Wait approximately 30 seconds; gas readings will be displayed for each relevant gas sensor. Bump Test pass confirmation will be displayed.
6. After the Turn gas off message is displayed, remove the sleeve from the pump inlet. The detector will remain in an alarm state until the gas is cleared from the sensors. Bump test results will appear, showing checkmarks next to sensors that passed the tests. These sensors will be reset to the number of days remaining until the next Bump Test expires.
7. Press the Button to finish the procedure.

Adjusting IntelliFlash

The IntelliFlash™ function causes the detector, if compliant (e.g., has passed bump test and calibration), to flash a green light emitted every second (factory default setting) from the top visual alarm indicator. In Fleet Manager II, use the IntelliFlash Interval option to change the frequency with which the detector flashes.

Adjusting Reverse IntelliFlash

IntelliFlash flashes a green light when the detector is compliant, but Reverse IntelliFlash™ flashes an amber light when the detector is non-compliant (if any bump test or calibration has expired, or if a sensor is faulty and has been invalidated). Use Fleet Manager II to change the frequency with which the detector flashes in Reverse IntelliFlash.

IntelliFlash and Reverse IntelliFlash can be configured into one of the following four scenarios:

• Scenario 1: When IntelliFlash and Reverse IntelliFlash are enabled, the green LED will flash until the detector deviates from compliance, then the amber LED will flash instead.
• Scenario 2: If IntelliFlash is enabled and Reverse IntelliFlash is disabled, the green LED will flash until the detector deviates from compliance, then it will stop flashing.
• Scenario 3: If IntelliFlash is disabled and Reverse IntelliFlash is enabled, no LED will flash while the detector is compliant. The amber LED will flash if the detector deviates from compliance.
• Scenario 4: When IntelliFlash and Reverse IntelliFlash are disabled, no LED will flash under any circumstances.

Adjusting Confidence and Compliance Tone Interval

The Confidence and Compliance Tone is a sound that indicates to the user that the detector is compliant (e.g., has passed bump test and calibration). In Fleet Manager II, use the Confidence/Compliance Beep option to change the frequency with which the detector beeps for the Confidence and Compliance Tone.

Selecting an Operating Mode

The detector can be used in one of three modes: Essentials Mode, Hole Watch Mode, and Inert Mode. Note: The Honeywell BWTM Ultra always monitors gas levels, regardless of the operating mode. If the detector detects sudden exposure to any gas, the device will flash, vibrate, and emit a loud siren sound. A gas level alarm takes precedence over all other detector functions.

• Essentials Mode: The detector only displays gas readings.
• Hole Watch Mode: Hole Watch Mode is the default operating mode. It is used for confined space monitoring. Use Hole Watch Mode to monitor all gas levels in the same screen view. Hole Watch Mode uses bar graphs that fill up as the detector detects rising gas concentrations.
  • When the detector detects normal gas levels, Hole Watch Mode displays empty bar graphs.
  • When the detector detects non-critical gas levels, Hole Watch Mode displays filled bar graphs.
  • When the detector triggers a single gas alarm, Hole Watch Mode highlights the detected gas level for that gas in a solid bar.
  • When the detector triggers a multiple gas alarm, Hole Watch Mode continues to display the first detected gas level, in addition to highlighting other detected gas levels in a solid bar.
  • For oxygen, Hole Watch Mode displays low and high levels in a bar graph. As the detector detects a low oxygen level, the bar graph fills toward the LO (Low) value. As the detector detects a high oxygen level, the bar graph fills toward the HI (High) value.
• Inert Mode: You can configure Inert Mode in Fleet Manager II. The threshold for performing the operation is 10%. If oxygen readings fall below 10%, the detector displays a pop-up to the user asking to enter Inert Mode. The detector does not automatically start in Inert Mode. When the detector enters Inert Mode, the alarm setpoints are activated. If the detector does not enter Inert Mode, the O2 readings will be considered normal.

Configuring the Detector

You can configure the Honeywell BWTM Ultra detector device and sensor using Fleet Manager II. To configure detector settings, you will need:

• Honeywell BWTM Ultra Detector
• IR Link Adapter or IntelliDoX Docking Station
• Computer with Fleet Manager II software installed.

Note: When the operator configures the Honeywell BWTM Ultra using Fleet Manager II, Honeywell strongly recommends reviewing the detector settings before operation to ensure the settings have been applied correctly and meet performance requirements.

Custom configuration created in Fleet Manager II can be used to configure detector settings. Example: Five detectors must have the same alarm setpoints and bump test reminders. To achieve this, each detector can be configured separately, or Fleet Manager II can be used to create a custom settings configuration. This configuration can then be loaded onto each detector. This saves time and allows settings to be managed from a single location.

Connecting with IntelliDoX

If a detector's calibration has expired and the forced calibration function is enabled, calibration can be performed with an IntelliDoX docking station or through the calibration option from the detector's main menu.

Connecting with an IR Link

The detector can be paired with an IR Link, also known as a dongle or key. An IR connection is located on the bottom of the detector, allowing efficient transfer of Fleet Manager II configurations to multiple detectors. The IR Link will also allow new firmware to be transferred to detectors or data/event logs to be transferred to Fleet Manager II.

Note: You should have the IR Connectivity Kit (sold separately) to transfer data from a computer to the detector.

Bluetooth Pairing

The user can pair the Honeywell BWTM Ultra detector to a mobile device via its built-in Bluetooth Low Energy (BLE) technology. The Honeywell Safety Communicator application, installed on the mobile phone, can then display gas readings and alarms from the connected Honeywell BWTM Ultra unit. Readings and alarms can then be sent to Honeywell's remote monitoring software.

1. On the mobile device, enable Bluetooth and search for available detectors. On the Honeywell BWTM Ultra detector, the Bluetooth connection is enabled by default.
2. On the mobile device, select the detector, then enter 100000.

Note: Pairing is not allowed during startup, calibration, or bump testing.

Warning: Wireless infrastructure and communication should only be used for informational monitoring.

Replacing a Sensor

Use only Honeywell-designated sensors for Honeywell BWTM Ultra detectors. Replace sensors in a non-hazardous location. The Honeywell BWTM Ultra detector can be configured for up to 5 gases and may contain simulator sensors.

Reviewing Logs

Many detector events are logged and can be reviewed via IntelliDoX or BLE. Commonly logged events include:

• Bump test failure
• Self-test failure
• Last calibration failure
• Calibration overdue
• Forced calibration
• Calibration cancelled
• Calibration error
• Calibration passed
• Sensors in alarm
• System reset
• Sensors zeroed
• Data logs vs. Event logs
• Message "Turn cal gas off..." displayed

Maintenance

General Maintenance

Perform the following tasks to keep the detector in good working order:

• Regularly bump test, calibrate, and inspect the detector.
• Maintain an operational log of all maintenance tasks, bump tests, and calibrations, as well as all alarm events.
• Keep the exterior of the detector clean.

Gas Cylinder Guidelines

• Use high-grade calibration gas approved by the National Institute of Standards and Technology.
• Check the cylinder's expiration date before use.
• Do not use any expired gas cylinder.
• Contact Honeywell if certified detector calibration is required.

Charging the Battery

You can charge the battery using the supplied charging adapter, which is certified for SELV/LVLC (isolated) with a minimum controller output (Um) of 6.3 V. The battery may take up to 8 hours to charge fully within a temperature range of 5 °C to 35 °C (41 °F to 95 °F).

Note: If recharging with power on, charging may not be completed within 8 hours.

Maintaining the Battery

Lithium-ion batteries do not respond well to full discharge cycles followed by a full charge cycle. Recharge the battery before it depletes. Do not charge the battery at very low or very high temperatures. 30 °C (86 °F) is considered a high temperature and should be avoided whenever possible. The runtime of a rechargeable battery decreases by approximately 20% over a two-year period of normal use.

Real-Time Clock Display

The real-time clock is displayed in the upper left corner of the detector's screen. It can be configured via Fleet Manager II in either 12-hour or 24-hour formats. The date display can also be configured in various formats via Fleet Manager II. Time/date information is retained even when the detector's battery is being changed.

Languages

Honeywell BWTM Ultra is offered in eighteen languages: English, French, German, Portuguese, Spanish, Simplified Chinese, Russian, Italian, Dutch, Slovak, Czech, Polish, Norwegian, Danish, Swedish, Finnish, Turkish, and Arabic. Languages can be configured via Fleet Manager II. Custom startup text can be entered in all languages except Simplified Chinese via Fleet Manager II.

Cleaning the Detector

Clean the exterior of the detector with a soft, damp cloth. Use only water-based cleaners (not alcohol-based). Do not use soaps, solvents, or polishes.

Updating Firmware

Update firmware via IR Link using the Fleet Manager II software.

Before starting:

• You should have the IR Connectivity Kit (sold separately) to transfer data from a computer to the detector.
• Download and save the firmware update file to a PC or network drive. Do not rename the file.
• Download the BWFleetManager2.exe file and install Fleet Manager II.
• For more information, refer to the Fleet Manager II User Manual.

1. Power on the detector.
2. Launch the Fleet Manager II application:
   • Expand Administration from the left pane.
   • Click Login/Logout.
   • Enter the default password: Admin.
   • Click OK to continue.
3. In the left pane, select Devices > Configure device via IR link. In the Device Selection window:
   • Select Honeywell BWTM Ultra.
   • Click OK.
4. In the Honeywell BWTM Ultra configuration window, click Bootloader to select the binary file. In the Honeywell BWTM Ultra Bootloader window, click Choose File.
5. In the Choose Firmware File to Update window, select the downloaded file, then click Open.
6. Connect the Honeywell BWTM Ultra detector to the computer using the IR Link connector.
7. Click Send to start the file transfer to the gas detector. After the transfer is complete, the Bootloader process will begin. During Bootloader, the display will go blank and the detector will beep several times.
8. The message Programming Succeeded will be displayed. Press the Button to finish the procedure, then disconnect the detector from the computer.

Service

Replacing the Printed Circuit Board (PCB)

1. Power off the instrument.
2. Remove the front housing:
   • Turn the instrument face down and unscrew the battery pack.
   • Remove the battery pack and the four screws from the battery compartment.
   • Remove the two screws located at the top of the instrument and separate the rear housing from the front housing.
   • Remove the two screws holding the PCB assembly in place.
   • Remove the PCB assembly from the front housing.
3. Remove the LCD display:
   • Unclip the two clips on the upper sides of the LCD housing.
   • Swing the LCD display forward to expose the ZIF connector.
   • Lift the latch on the ZIF connector, then pull the LCD cable forward and remove the LCD assembly.
4. Unclip the two clips holding the manifold bracket in place and carefully pull the manifold bracket upward to remove it from the PCB.
5. Lift the latch on the 4R+ sensor ZIF connector and pull the 4R+ sensor cable assembly forward to disconnect the pump connector from the PCB.
6. Retrieve the new PCB.
7. Connect the pump to the PCB.
8. Align the clips on the manifold bracket and press down to clip the clips to the PCB.
9. Insert the 4R+ sensor ribbon cable into the ZIF connector and press down the latch on the 4R+ sensor ZIF connector to clip the cable.
10. Reconnect the 4R+ sensor cable.
11. Attach the LCD display:
    • Insert the LCD ribbon cable into the ZIF connector and press down the latch on the ZIF connector to clip the cable.
    • Lever the LCD assembly back into place against the PCB, then press down until the side clips engage.
12. Attach the housings:
    • On the front housing, ensure the LCD gasket aligns with the pins. The frame should be facing upward.
    • Place the PCB inside the front housing and insert the two screws (torque 0.339-0.452 N·m) to secure both pieces.
    • Reinstall the rear housing and install the four screws inside the battery compartment (torque 0.452-0.565 N·m).
    • Reinstall the two screws at the top of the instrument (torque 0.452-0.565 N·m).
13. Install the battery pack:
    • To correctly seat the battery pack, first engage the hooks on the bottom of the battery pack.
    • Press the battery pack into place.
    • Tighten the battery retention screw (torque 0.452-0.565 N·m).
14. Power on the instrument and allow the sensors to stabilize. Calibrate the sensors.

Replacing the LCD Display

1. Power off the instrument.
2. Remove the battery:
   • Turn the instrument face down and unscrew the battery pack.
   • Remove the battery pack and the four screws from the battery compartment.
3. Remove the front housing:
   • Remove the two screws located at the top of the instrument and separate the rear housing from the front housing.
   • Remove the two screws holding the PCB in place.
   • Remove the PCB assembly from the front housing.
4. Remove the LCD display:
   • Unclip the two clips on the upper sides of the LCD housing.
   • Swing the LCD display forward to expose the ZIF connector.
   • Lift the latch on the ZIF connector, pull the LCD cable forward, and remove the LCD assembly.
   • Pull the LCD cable forward and remove the LCD assembly.
5. Retrieve the new LCD display.
6. Attach the LCD display:
   • Insert the LCD ribbon cable into the ZIF connector and press down the latch on the ZIF connector to clip the cable.
   • Lever the LCD assembly back into place against the PCB, then press down until the side clips engage.
   • On the front housing, ensure the LCD gasket aligns with the pins. The frame should be facing upward.
7. Attach the front housing:
   • Place the PCB inside the front housing and insert the two screws (torque 0.339-0.452 N·m) to secure both pieces.
   • Reinstall the rear housing and install the four screws inside the battery compartment (torque 0.452-0.565 N·m).
   • Reinstall the 2 screws at the top of the instrument (torque 0.452-0.565 N·m).
8. Attach the battery:
   • To correctly seat the battery pack, first engage the hooks on the bottom of the battery pack.
   • Press the battery pack into place and tighten the battery retention screw (torque 0.452-0.565 N·m).
9. Power on the instrument and allow the sensors to stabilize.

Replacing Series 1 Sensors

1. Power off the instrument.
2. Remove the battery:
   • Turn the instrument face down and unscrew the battery pack.
   • Remove the battery pack and the four screws from the battery compartment.
3. Remove the sensor:
   • Remove the two screws located at the top of the instrument and separate the rear housing from the front housing.
   • Pull back the two retaining clips on the manifold.
   • Lift the manifold to one side and away from the pump as far as possible.
   • Pull the sensor manifold to remove it from the pump manifold.
   • Remove the desired sensor.
4. Install the new sensor:
   • Note the orientation keying and then press the sensor down until it seats.
   • Insert the manifold inlet into the pump manifold.
   • Push the manifold down, and when the two latches engage, you will hear two clicks.
5. Reinstall the rear housing and install the four screws into the battery compartment (torque 0.452-0.565 N·m).
6. Reinstall the 2 screws at the top of the instrument (torque 0.452-0.565 N·m).
7. Attach the battery:
   • To correctly seat the battery pack, first engage the hooks on the bottom of the battery pack.
   • Press the battery pack into place and tighten the battery retention screw (torque 0.452-0.565 N·m).
8. Power on the instrument and allow the sensors to stabilize.

Replacing 4R+ Sensors

1. Power off the instrument.
2. Remove the battery:
   • Turn the instrument face down and unscrew the battery pack.
   • Remove the battery pack and the 4 screws from the battery compartment.
3. Remove the sensor:
   • Remove the two screws located at the top of the instrument and separate the rear housing from the front housing.
   • Disconnect the 4R+ sensor cable.
   • Press the PRESS mark on the manifold towards the top of the instrument.
   • Pull the tabs on the sensor to remove it from the manifold.
4. Install the new sensor:
   • Retrieve the new sensor and insert it into the manifold, aligning the sensor guides with the instrument slots.
   • Push the sensor forward until it stops moving.
   • Reconnect the 4R+ sensor cable.
5. Reinstall the rear housing and install the four screws into the battery compartment (torque 0.452-0.565 N·m).
6. Reinstall the two screws at the top of the instrument (torque 0.452-0.565 N·m).
7. To correctly seat the battery pack, first engage the hooks on the bottom of the battery pack.
8. Press the battery pack into place and tighten the battery retention screw (torque 0.452-0.565 N·m).
9. Power on the instrument and allow the sensors to stabilize.
10. Calibrate the new sensor.

Replacing the Pump

1. Power off the instrument.
2. Remove the battery:
   • Turn the instrument face down and unscrew the battery pack.
   • Remove the battery pack and the four screws from the battery compartment.
3. Remove the two screws located at the top of the instrument and separate the rear housing from the front housing.
4. Remove the pump:
   • Pull the pump to remove it from the manifold assembly.
   • Release the clip on the pump connector and pull the pump connector out.
5. Install the new pump:
   • Retrieve the new pump and insert the pump connector.
   • Fold the pump wires to pass through the bottom of the pump motor.
   • Insert the pump into the manifold assembly.
6. Reinstall the rear housing and install the 4 screws into the battery compartment (torque 0.452-0.565 N·m).
7. Reinstall the two screws at the top of the instrument (torque 0.452-0.565 N·m).
8. To correctly seat the battery pack, first engage the hooks on the bottom of the battery pack.
9. Press the battery pack into place and tighten the battery retention screw (torque 0.452-0.565 N·m).

Replacing the Battery

1. Power off the instrument.
2. Turn the instrument face down and unscrew the battery pack.
3. Remove the battery pack.
4. To correctly seat the new battery pack, first engage the hooks on the bottom of the battery pack.
5. Press the battery pack into place and tighten the battery retention screw (torque 0.452-0.565 N·m).

Note: Use only Honeywell HU-BAT battery pack.

Replacing the Pump Inlet Filter

1. Power off the instrument.
2. Unscrew the screw on the pump inlet cover.
3. Turn the cover counter-clockwise.
4. Remove the cover.
5. Remove the particle filter and the hydrophobic filter.
6. First install the new hydrophobic filter, then the new particle filter.
7. Place the filter cover and turn it clockwise until it stops.
8. Tighten the screw (torque 0.339-0.452 N·m).

Replace the Pump Filter

1. Power off the instrument.
2. Remove the battery:
   • Turn the instrument face down and remove the battery screw.
   • Remove the battery and the four screws from the battery compartment.
3. Remove the sensor manifold:
   • Remove the two screws at the top of the instrument and separate the rear housing from the front housing.
   • Remove the screw in the corner of the manifold.
   • Release the two retaining clips on the manifold.
   • Move the manifold sideways and upward to separate it from the pump. Remove the sensor manifold from the pump manifold.
4. Gently separate the pump filter from the red restrictor.
5. Lift the pump filter and remove it.
6. Install the new pump filter:
   • Place the new pump filter into the instrument.
   • Gently connect the pump filter to the red restrictor.
7. Insert the manifold inlet into the pump manifold.
8. Push the manifold down so that the two latches engage, listen for the latches to click, and then reinstall the screw in the corner of the manifold.
9. Reinstall the rear housing and install the four screws back into the battery compartment (torque 4-5 in-lbs).
10. Reinstall the two screws at the top of the instrument (torque 4-5 in-lbs).
11. Connect the battery:
    • To correctly seat the battery, first engage the hooks on the bottom of the battery.
    • Push the battery into place and tighten the battery retention screw (torque 4-5 in-lbs).
12. Power on the instrument and allow the sensors to stabilize.

Appendices

Auto Gas Detection

During calibration, when gas is applied, the detector will wait for a maximum of 300 seconds to allow the gas to stabilize. If the gas has not stabilized after this time, the detector will display the message Gas unstable. If the gas stabilizes within the 300 seconds, it will be automatically detected, and you will not need to select it from the menu. The gas name and the message Span calibration in progress will be displayed. If a four-gas mixture was used, the detector will display the names of the four gases.

Gas Alarm Setpoints

Gas alarms will trigger when gas concentrations are detected above or below the defined setpoints. Gas alarms are described as follows:

Specifications

Detector Dimensions: 8.1 x 14.6 x 5.1 cm (3.2 x 5.75 x 2.0 in). Weight: 444.2 g (15.67 oz). Operating Temperatures: -20 °C to +50 °C (-4 °F to +122 °F). Battery operating times: 10 hours. Rechargeable Battery: 8 hours charge time within a temperature range of 5 °C to 35 °C (41 °F to 95 °F). Storage Temperature: -40 °C to +50 °C (-40 °F to +122 °F). Operating Humidity: 0% to 95% relative humidity (non-condensing). Detection Range: H2S: 0 ppm to 100 ppm (in 1 ppm or 0.1 ppm increments). CO: 0 ppm to 500 ppm (in 1 ppm increments). O2: 0% to 30% vol. (in 0.1% vol. increments). Combustible (LEL): 0% to 100% LEL (in 1% LEL increments) or 0% to 5% v/v Methane. Alarm States: STEALTH, TWA alarm, STEL alarm, Low Level alarm, High Level alarm, Multi-gas alarm, Low Battery alarm, Confidence Tone, Auto-off alarm. Audible Alarm: 95 dB at 30 cm (typically 100 dB) from the audible alert at variable pulses. Visual Alarm: Red Light Emitting Diodes (LEDs). Display: Alphanumeric Liquid Crystal Display (LCD). Display Resolution: 160 x 240 pixels. Backlight: Activates when the push button is pressed and turns off after 5 seconds; also activates during an alarm condition. Self-diagnostic: Initiates at power-up. Calibration: Automatic Zero and Automatic Span.

Standards and Certifications

The Honeywell BWTM Ultra gas detector complies with the following standards and certifications:

• UL: E480011 Class I, Division I, Groups A, B, C, and D, Temperature Code T4, -40 °C Tamb +50 °C; Class I, Zone 0, AEx ia IIC T4 Ga, -40 °C Tamb +50 °C (without LEL and IR sensors installed); Class I, Zone 0, AEx da ia IIC T4 Ga, -40 °C Tamb +50 °C (with LEL sensor installed and without IR sensor installed); Class I, Zone 0, AEx ia IIC T4 Ga, -20 °C Tamb +50 °C (with IR sensor installed and without LEL sensor installed); Class I, Zone 0, AEx da ia IIC T4 Ga, -20 °C Tamb +50 °C (with LEL and IR sensors installed).
• CSA: E480011 Class I, Division I, Groups A, B, C, and D, Temperature Code T4, -40 °C Tamb +50 °C; Ex ia IIC T4 Ga, -40 °C Tamb +50 °C (without LEL and IR sensors installed); Ex da ia IIC T4 Ga, -40 °C Tamb +50 °C (with LEL sensor installed and without IR sensor installed); Ex ia IIC T4 Ga, -20 °C Tamb +50 °C (with IR sensor installed and without LEL sensor installed); Ex da ia IIC T4 Ga, -20 °C Tamb +50 °C (with LEL and IR sensors installed).
• IECEx: UL 18.0061X IEC 60079-0:2017 IEC 60079-11:2011 IEC 60079-1:2014 IEC 60079-26:2014
• ATEX: DEMKO 18 ATEX 1833X EN IEC 60079-0:2018 EN 60079-11:2012 EN 60079-1:2014 EN 60079-26:2015
• FCC Compliance: This device complies with Part 15 of the FCC Rules. Operation is subject to two conditions: (1) this device may not cause harmful interference, and (2) it must accept any interference received, including interference that may cause undesired operation. This transmitter must not be co-located or operated in conjunction with any other transmitter or antenna. This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment. End users must follow the specific operating instructions for compliance with RF exposure regulations.
• Industry Canada (IC) Notices, Canada: This device complies with Industry Canada license-exempt RSS standard(s). Operation is subject to two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation. This device complies with FCC/ISED radiation exposure limits set forth for an uncontrolled environment and FCC/ISED Radio Frequency (RF) Exposure Guidelines. This device presents very low levels of RF energy; therefore, it is deemed compliant without Maximum Permissive Exposure (MPE) limit evaluation.

North American Combustible Gas Performance Certification: The Honeywell BWTM Ultra is approved for compliance with ISA 60079-29-1 and CSA C22.2 No. 152. Only the Honeywell BWTM Ultra Catalytic Bead Combustible Sensor was evaluated for compliance with CSA C22.2 No. 152 and ISA 60079-29-1. The evaluation is only valid with a pump flow rate of 300 ml/min, a 3 m hose length, and CH4 (Methane) gas. Other options are outside the scope of CSA C22.2 No. 152 and ISA 60079-29-1. For compliance with CSA C22.2 No. 152 and ISA 60079-29-1, the adjustable alarm point must not exceed 60% LEL, and the maximum alarm must be set as a latched alarm. Regarding ISA 60079-29-1, the Honeywell BWTM Ultra only passed tests for IP54 ingress protection rating. Other IP ingress protection ratings are outside the scope of ISA 60079-29-1. The Honeywell BWTM Ultra passed pressure tests to withstand 80, 100, and 120 kPa in compliance with ISA 60079-29-1. Values outside the 80 kPa to 120 kPa range are NOT within the scope of ISA 60079-29-1.

Compliance with Radio Equipment Directive (RED): Honeywell Analytics Asia Pacific Co., Ltd. hereby declares that this gas detector, Honeywell BWTM Ultra, is in compliance with the essential requirements and other relevant provisions of Directive 2014/53/EU.

Label Information

BW Ultra Battery Label

BW Ultra Instrument Label

Part Number Format

The BW Ultra explosion-proof type varies based on sensor configuration. The user can identify the sensor configuration by the part number format.

Example Part Number Structure:

HU (Honeywell Universal) - [Sensor Type Code] - [Country Code] - [Housing Color]

Sensor Type Codes:

• M1: CO Sensor
• H1: H2S Sensor
• W1: Sensor 1 LEL 75
• W2: Sensor 1 LEL 75C
• W3: Sensor 1 LEL 75M
• X1: Oxygen Sensor
• Q1: PID Sensor
• W4: LEL IR Sensor
• B1: IR CO2 Sensor
• S1: SO2 Sensor
• A1: NH3 Sensor
• R1: H2 Sensor
• C1: Cl2 Sensor
• D1: NO2 Sensor
• Z1: HCN Sensor
• N1: NO Sensor
• M2: CO-H Sensor
• 00: Simulator Sensor

Country Codes:

• 1 letter of the alphabet: country code

Housing Color:

• Y: Yellow housing
• B: Black housing

Troubleshooting

Glossary

• ACGIH: The ACGIH method is defined as the cumulative (total) infinite average, whether it is a 2-hour or 8-hour average.
• Alarm TWA: Time-Weighted Average (TWA) is a safety measure used to calculate cumulative gas averages. The average is calculated using the U.S. OSHA (Occupational Safety and Health Administration) or ACGIH (American Conference of Governmental Industrial Hygienists) method, to ensure the detector alarms when the TWA has been accumulated.
• Atmosphere Normal: A fresh air environment with 20.9% v/v oxygen (O2), free of hazardous gases.
• Band: A group of two to five connected IntelliDoX modules. Modules that are connected share gas, network, and power connections.
• BLE: Bluetooth Low Energy.
• Calibration: A two-step compliance test that determines the measurement scale for the detector's response to gas. In the first step, a reference reading is taken in a clean, uncontaminated environment. In the second step, sensors are exposed to known gas concentrations. The detector uses the reference base and known gas concentrations to determine the measurement scale.
• Docking Station: A zone or area dedicated to a specific activity. A compliance testing docking station may contain various IntelliDoX modules and several connected module bands.
• Fleet Manager: A proprietary, Windows-based software developed by Honeywell to configure and manage docking modules, calibrations, bump tests, and data logs. Fleet Manager II is available for download at www.honeywellanalytics.com.
• IR: Infrared. IR is invisible radiant energy that can be used to establish short-range wireless communications between enabled devices.
• Stealth Mode: When enabled, the backlight, visual alarms, and audible alarms are disabled. During an alarm condition, the vibrating alarm is activated, and readings are displayed on the LCD.
• IntelliDoX Docking Module: An automatic calibration and bump test docking station intended for use with portable gas detectors manufactured by Honeywell.
• OSHA: The U.S. OSHA method is defined as a variable average that accumulates over an 8-hour average. If the worker is in the work zone longer, the older accumulated values (first hour) are replaced by the most recent values (ninth hour). This process will continue throughout the work shift until the detector is turned off.
• PPM: Parts per million, a measure of concentration.
• Bump Test: A compliance test that confirms the detector's response to target gases by exposing the detector to a known gas concentration. Other procedures are specified to occur automatically when the detector is inserted into a docking module; such procedures may be performed in conjunction with the bump test.
• Data Log: A data log is a file that contains detailed, date-stamped records relating to configuration settings and detector operations. The data log is continuously updated. Records covering the entire operational life of the detector are retained.
• Event Log: An event log is a file that contains detailed, time-stamped log data relating to gas events and compliance tests. The event log is updated when an event occurs. A specified number of records are retained with the most recent events.
• Reboot: Operating system restart for the module.
• STEL: Short-Term Exposure Limit is the maximum permissible gas concentration to which a worker may be safely exposed for brief periods (5 to 15 minutes maximum).
• Operational Life: The period of operational use required to reach the specified operating limit. Operational life includes normal operating time, alarm time, and all types of downtime.
• Useful Life: The expected durability of a product, as specified by the manufacturer.
• V/V: Percent by volume concentration.

Contact Honeywell

Headquarters
Honeywell Analytics
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Calgary, Alberta Canada T2G 4E8
Toll Free: 1-888-749-8878

United States
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Toll Free: 1-888-749-8878

Asia
Honeywell Analytics Asia Pacific
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Tel: +82 (0) 2 6909 0300
Analytics.ap@honeywell.com

Europe
Honeywell Analytics
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8604 Hegnau
Switzerland
Toll Free: 00800-333-22244
Other Countries, Toll Free: 1-403-248-9226
Bwa.customerservice@honeywell.com
www.honeywellanalytics.com