User Manual. PolyGard AT-3300_V2. Catalytic bead analog combustible Gas Transmitter Serial no. AT _V2. July 23, 2007 GAAT3300I05V2

Transcription

1 PolyGard AT-00_V Catalytic bead analog combustible Gas Transmitter Serial no. AT _V User Manual July, 007

2 User Manual - PolyGard AT-00-V Page Catalytic bead analog combustible Gas Transmitter General Overview... Description.... Please note... Installation.... Assembly information.... Enclosure... Electrical Connection...6. Instructions...6. Wiring connection...6. Mounting optional relay package AT-R...7 Start-up Operation...7. Calibration...8. Control span voltage calculation Table %v/v <> % LEL Calculation Calibration gas < >Target gas...9. Commissioning optional relay package AT-R Selection of open-circuit or closed-circuit operation Select switching differential Adjust switching voltage..... Calculation of the switching voltage (U threshold )... 6 Inspection and Service Inspection Calibration Replacing of the sensor element... 7 Troubleshooting Diagnostics of the transmitter Diagnostics at optional relay package AT-R... 8 Cross-sensitivity Data... 9 Specifications... 0 Wiring Configuration and Enclosure Dimensions...6 Notes and General Information...9. Intended product application...9. Installers` responsibilities...9. Maintenance...9. Limited warranty...9. Return instructions...9

3 User Manual - PolyGard AT-00-V Page Catalytic bead analog combustible Gas Transmitter General Overview The PolyGard combustible gas analog transmitter is used for detection of flammable gases and vapors in the ambient air to warn of the presence of combustible gas. The PolyGard combustible gas analog transmitter is not suitable for use in explosion-risk areas defined as Class, Div. group A, B, C, D. Description The ambient air being monitored diffuses through a sintered metal disk in the sensor. Here the combustible gases are burned by catalytic means at a heated detector element (pellistor). The resulting combustion heat also heats up the detector element. This heating changes the resistance of the detector element which is proportional to the partial pressure of the combustible gases. In addition to the catalytic detector element, the sensor also has a similarly heated inactive compensator element. Both elements are part of a Wheatstone measuring bridge. Environmental influences such as temperature, ambient moisture or thermal conductivity of the monitored ambient air affect both elements to the same extent so that the influences on the measuring signal are almost completely compensated. The integrated measuring amplifier converts this sensor current into a linear output signal. The zero point (Zero) and the amplification (Gain) are calibrated by potentiometers.

4 User Manual - PolyGard AT-00-V Page Optional relay package AT-R: Note relay package: This option must be purchase at the time of order for installation by factory. It is not possible to add this feature later on! The PolyGard AT-R relay package is used in conjunction with the AT-00 combustible gas analog transmitter. The AT-R provides the transmitters with two relay outputs with adjustable trip/setpoints, switching differential. The relay outputs will change and notify if gas concentration exceeds the adjusted trip/setpoint. If the gas concentration falls below the adjusted trip/setpoint and switching differential the relays again will change state and fall back into their starting position. The relay will trigger on depending on its adjusted power mode. If de-energized it will trigger on. If energized it will trigger off (fail-safe mode) with increasing value. LED number 9 for relay R9 and LED number 0 for relay R0 indicates status of each relay.. Please note Certain substances and gases in the monitored ambient can affect the sensitivity of the sensor, or poison the sensor completely. The following are currently known: - polymerising substances, such as ethylene oxide, acrylonitrile, butadiene, styrene, silicone. - corrosive substances, such as halogenated hydrocarbons. - catalytic poisons, such as sulphur and phosphor compounds, silicon compounds, metal vapors.

5 User Manual - PolyGard AT-00-V Page Installation Note: Avoid any force (e.g. by thumb) during operation or installation on the sensor element. This could destroy the element. Electronics can be destroyed through static electricity. Therefore, do not work on the equipment without a wrist strap connected to earth ground or standing on conductive floor.. Assembly information Pay attention to the ventilation conditions! Always position the transmitter appropriately away from possible discharge and collection points. Location of the sensor must conform to the layout of the area being monitored. Avoid locations where water, oil etc. may influence proper operation and where mechanical damage might be possible. Disregard the ventilation ratio! Do not mount transmitter in the center of the airflow. In larger rooms, it might be necessary to install two or more transmitters where there is not adequate air movement. Do not mount in corners or directly in front of air inlets (e.g. doors, windows, open ramps, dampers, etc.). In areas with undefined air movement, it might be necessary to distribute several transmitters in a vertical and horizontal direction over the whole area to be monitored. Take into account the density if gases being monitored! For gases and vapors with a lower density than air, such as methane, ammonia, acetylene, the transmitter must be located above the potential leak point or at the highest point where the gases or/and vapors can collect in greater concentrations. For gases and vapors with a higher density than air, the transmitter must be located beneath the potential leak or at the lowest point where the gases or/and vapors can collect. Duct model mounting: Mount only in a straight section of duct with minimum air vortex. Keep a minimum distance of. feet ( m) from any curve or obstacle. Mount only in a duct system with a maximum air velocity of 000 ft/min or less. Mounting must be made so that the airflow is in line with probe openings. (see Fig. page 7). Enclosure - Un-screw cover of enclosure. - Carefully unplug the basic PCB mounted on fixed terminal blocks. - Screw the base vertically on wall or on a single gang electrical box. (see Fig. page 7) - For duct model mounting: Cut a hole in the duct and install the probe in the hole. (see Fig. 6 page 7) Screw the housing to the duct using the mounting holes inside enclosure. - Plug in the basic PCB and replace the cover after wiring connection is completed. (see. wiring connection).

6 User Manual - PolyGard AT-00-V Page 6 Electrical Connection. Instructions Note: Electrostatic discharge (ESD) may damage electronic components. During wiring, open the cover only when completely grounded via grounding strap or standing on conductive floor. Connections should be made without any power applied to conductors. Installation of the electrical wiring should be according to the connection diagram and only performed by a trained specialist. Avoid any influence from external interference by using a shielded cable. Recommended cable: 8 AWG shielded, maximum resistance 0.8 Ω/000 ft (7 Ω/000 m) Cable for relay package AT-R: Does not need to be shielded. Cable insulation: Since the PCB mounts on top of the wiring terminations, it is important to ensure that the wire shields or any bare wires do not short to the PCB. Terminal strip X: Connector Connector Connector Connector Connector Connector 6 Connector 7 Signal ( - 0 ma) 0 VDC (DC common) Power supply (+) VDC (8-8 VDC/VAC) NC NC Shield Shield Terminal strip X: (functions only with option relay package AT-R). (see Note relay package page ) Connector - Connector - Potential free relay contact (R9) Potential free relay contact (R0). Wiring connection Unscrew cover of enclosure. Unplug basic PCB from terminal blocks. For single gang electrical box mounting: Pull through cable via hole in base; connect cable leads on terminal block X. For surface mounting (cable entry always from the top) and also for duct mounting Remove cover to access cable. Connect cable leads on terminal block X. Plug the PCB on fixed terminal blocks on base. Screw cover on base. Optional relay package AT-R (see Note relay package page ) Connect cable leads on terminal X.

7 User Manual - PolyGard AT-00-V Page 7. Mounting optional relay package AT-R (see Note relay package page ) Static electricity, see section. Unplug basic PCB from the terminal blocks fixed on base. Plug relay package female header X on basic PCB. (see Fig., page 6) Secure on back of PCB the washer and nut. Plug basic PCB into terminal blocks on base. Start-up Operation Only trained technicians should perform the following: Check mounting location. Check airflow direction for duct mounting. Check power voltage. Check PCB EX-S for proper mounting at X and X. Check for correct sensor element (NP-7S) at terminal X PCB EX-S. Optional relay package AT-R: (see Note relay package page ) Check proper mounting of relay package AT-R at board EX-S. Select the desired hysteresis and relay function. Adjust threshold value if not ordered from the factory with setpoint calibrated. Verify transmitter operation (sensor/transmitter was factory calibrated). Note: If calibration is necessary, the sensor element must be powered and be fully stabilized for at least hour. Required instruments to calibrate the transmitter: Test gas bottle with synthetic air. Test gas bottle with Combustible Gas (Target Gas) range 0 % LEL.. Gas pressure regulator with flow meter to control the gas flow to 00 ml/min. Sensor head calibration adapter with tubing (silicone-free, e.g. Viton). Digital voltmeter with range 0-0 VDC, accuracy % and a small screwdriver. Note: Please observe proper handling procedures for test gas bottles!

8 User Manual - PolyGard AT-00-V Page 8. Calibration Zero adjustment Zero-point calibration ( ma) (After sensor warm-up) Connect digital voltmeter to pins X8, Bridge, (Zero point calibration measuring Bridge) with a range selected that will display 0 VDC max.). Connect the calibration adapter to sensor element. Apply sensor element zero calibration gas, (00 ml/min;. psi ± 0%) or other clean air source. Wait two minutes until the signal is stable, adjust signal with zero potentiometer Zero until the signal is 800 mv ± mv and stable. Remove calibration adapter carefully by turning lightly. Span adjustment Note: Combustible calibration gas is toxic, never inhale the gas! Symptoms: dizziness, headache and nausea. Procedure if exposed: Bring into fresh air at once, consult doctor. Connect digital voltmeter to pins X6, Test, (Gain calibration) with a range selected that will display 0 VDC max.). Connect calibration adapter to the sensor element. Apply sensor element span calibration gas ( - 0% LEL), (00 ml/min;. psi ± 0 %). Wait two minutes until the signal is stable, adjust signal with span potentiometer Gain until the signal reads the appropriate mvdc (± mv, see calculation for control voltage.) and is stable. Remove calibration adapter with a careful light turn. Inspect the seating of the sensor element!. Control span voltage calculation 00 (mv) x test gas concentration (% LEL) (mv) Measuring range (% LEL) Example Measuring range concentration 00% LEL * Test gas concentration 0% LEL Control voltage 080 mv * Test Gas Concentration using.% Methane 00 (mv) x 0 (% LEL) (mv) = 080 mv 00 (% LEL)

9 User Manual - PolyGard AT-00-V Page 9.. Table %v/v <> % LEL Type of gas/vapor Chemical mark Sensitivity % % LEL/methane LEL/ % v/v Acetone (CH ) CO 7.60 Ammonia NH 0.00 Benzene C 6 H Ethylene C H 9.0 Ethyl Acetate CH COOC H 7.0 Ethyl Alcohol (Ethanol) C H OH 8.0 Hydrogen H 0.00 Isopropyl Alcohol (CH ) CHOH 7.0 JP Methane* CH Methanol CH OH 6.70 Methyl Ethyl Ketone C H 8 O.90 n-butane C H n-heptane C 7 H n-hexane C 6 H 80.0 n-octane C 8 H n-pentane C H 80.0 Propane C H Tuluene C 7 H according to information of sensor manufacturer. * Use.% Methane v/v = 0% LEL Methane... Calculation Calibration gas < >Target gas Example ÜW Gas = KAL Gas x ( K Gas / Ü Gas ) ÜW Gas = Target gas % LEL KAL Gas = Calibration gas % LEL K Gas = Factor relative sensitivity % LEL Calibration gas = Factor relative sensitivity % LEL Target gas Ü Gas Calibration gas Target gas 0% LEL Methane X% LEL Propane 0% LEL methane x (00/90) =. % LEL propane

10 User Manual - PolyGard AT-00-V Page 0. Commissioning optional relay package AT-R (see Note relay package page ).. Selection of open-circuit or closed-circuit operation. Each relay can be configured for normally de-energized operation or normally energized operation (fail-safe) via jumper. Operation Relay R9 Jumper pos. Relay R0 Jumper pos. Normally de-energized operation 9 to 8 to 0 Normally energized operation 0 to 9 to Factory setting is for closed-circuit operation... Select switching differential Switch threshold calculation formula: U out = U threshold - U differential (see section.. for U threshold calculations) Two different values of switching differential can be selected via jumper per relay. The jumpers need to be plugged into the correct position to select either % or 0% of the transmitters full range as switching differential. (see table for jumper positions). Threshold calculation Voltage (V) Switch differential (%) Relay R9 Jumper pos. Relay R0 Jumper pos * * Note: At a voltage below.0 V it is not allowed to have a switching differential of 0%. The triggered alarm trip/setpoint would not allow the relay to return to ist starting position. Factory set.

11 User Manual - PolyGard AT-00-V Page.. Adjust switching voltage (see Note relay package page ) Required instruments: Digital multimeter with 0-0 VDC range, accuracy % Small screwdriver Switching voltage can range from V to 9 V = 0% LEL to 90% LEL concentration by adjustment. Adjust switching voltage for relay R 9 Connect digital multimeter at X9 + and -. Adjust potentiometer P9, calculate the switching voltage ± 0 mv, (see section..). Adjust switching voltage for relay R 0 Connect digital multimeter at X0 + and X9-. Adjust potentiometer P0, calculate the switching voltage ± 0 mv, (see section..)... Calculation of the switching voltage (U threshold ) U threshold = 8 (V) x Alarm threshold (% LEL) + (V) Measuring range (% LEL) Example Measuring range Alarm threshold U threshold 00% LEL 0% LEL.6 V 8 (V) x 0 (% LEL) + (V) =.6 V 00 (% LEL)

12 User Manual - PolyGard AT-00-V Page 6 Inspection and Service 6. Inspection Inspection and service of the transmitters should be done by a trained technician and executed on a periodic interval. It is recommended that the sensor operation be verified at least every six months. 6. Calibration (See part. and.) Service at periodic intervals is to be decided by the person responsible for the gas detection system. If span calibration voltage of 00 mv (see note below) is no longer attainable when applying 0% LEL methane in air, then the sensor element has to be replaced. After the sensor element has been replaced a calibration is required. Note: If using a different level of span test gas % LEL, or different sensor range, then the mv needs to be calculated. 6. Replacing of the sensor element only with PCB Static electricity (see section.). Sensor should always be installed without power applied. Unplug basic PCB EX-S carefully from the terminal blocks on the base. Take new PCB EX-S with sensor element of original packing. Plug the PCB EX-S in terminal block X, X carefully. Calibrate (see section. and.)

13 User Manual - PolyGard AT-00-V Page 7 Troubleshooting 7. Diagnostics of the transmitter Trouble Reason Solution Output signal 0 ma and control voltage 0 V Output signal < ma or signal output not correct Control voltage output not correct Power not applied Basic PCB EX-S, X and X not plugged in correctly. Sensor element not calibrated Sensor element sensitivity < 0 % Measure power voltage terminal block X terminal (+) and (8-8 VDC) Plug in the basic PCB EX-S into X and X correctly. Calibrate sensor element output. Replace sensor element 7. Diagnostics at optional relay package AT-R (see Note relay package page ) Trouble Reason Solution No relay switching No or incorrect relay switching No relay switching at calculated threshold setting Relay return differential too long Board AT-R not installed correctly Jumper JP 9 - and 8 - not installed correctly Switching voltage not adjusted correctly Differential jumper not correct Plug AT-R correctly into board See section. for correct setting Check switching voltage (see section..) Check jumper position (see section..) 8 Cross-sensitivity Data See Table % v/v <> % LEL (..)

14 User Manual - PolyGard AT-00-V Page 9 Specifications Electrical Power supply 8-8 VAC/VDC (polarity protected) Power consumption ma, (. VA), max. - w/relay package AT-R 70 ma, (.7VA), max. RFI/EMI protection.0 ft. (0. m) radiated Sensor Performance Gas detected Combustible gases and vapors (refer to table, section..) Sensor element Catalytic bead (pellistor), diffusion Range 0-00% LEL/ methane (linear 0 to 60 % LEL) Detection limit 0. % LEL Accuracy ± % of reading Repeatability ± % of reading Long-term zero point drift <.% LEL methane /year Long-term sensitivity drift < % LEL/ methane /month Response time t 90 0 sec. methane Sensor life expectancy year, normal operating environment Sensor coverage Dependent on the target gas Mounting height Dependent on the target gas Type of Control Analog output signal Proportional, - 0 ma, load 00 Ω linear 0-60 % LEL, polarity prot. Option () relay contacts, potential free, max. 0 VAC/VDC 0. A Operating Environment Working temperature F to F (-0 C to + 0 C) Storage temperature F to 0 F ( C to + 0 C) Humidity - continuous to 90% RH non-condensing - intermitted 0 to 99% RH non- condensing Working pressure Atmospheric ±0% Physical characteristics Enclosure material Galvanized steel w/zinc coating, corrosion resistant Enclosure color Light gray Wall mounting NEMA (IP ) gerneral purpose Installation Wall (surface) mounted or single gang electrical box Dimensions (HxWxD).9 x.9 x.8 in. ( x x 6 mm) Cable entry hole for ½ in. conduit wall (surface) mounting and hole on back side of base plate for single gang electrical box mounting Wire connection Terminal blocks, screw type for lead wire Wire size Min. AWG (0. mm ) max. AWG (. mm ) Wire distance Max. loop resist. 00 Ω (= wire resist. + controller input resist.) Weight 0.7 ibs. (0. kg) Approvals/Listings UL Recognized and CSA Certified combustible sensor City of Los Angeles EMV-Compliance 89/6/EWG CE Warranty Two years material and workmanship

15 User Manual - PolyGard AT-00-V Page Options Enclosures Duct mounted NEMA (IP ) - w/probe 7/8 in. ( mm) diameter and 7.6 in. (8 mm) length - cable entry hole for ½ in. conduit Wall mounted NEMA X w/splash guard (IP 6) - material ABS UL9V0 - color Light gray - Dimensions (HxWxD).80 x.7 x. in. ( x 0 x 87 mm) Relay package AT-R Type () SPDT (R9), () SPST (R0) Contact rating 0 VAC/VDC, 0. A max. Setpoint Adjustable setting for each relay within 0-90% of full range - Factory set Lo = 0% LEL, Hi = 0% LEL Switching differential Jumper selectable, % or 0% of full range - Factory set % Relay mode Jumper selectable, de-energized or energized (fail-safe) for each relay - Factory set de-energized Status indicator () LED s, one for each relay Heater, built-in Power supply VAC/VDC ± %, 0/60Hz Power consumption.0 A ( VA) max. For ambient temperature - 0 F (-0 C) Thermostatic control F (0 C) ± F ( C)

16 User Manual - PolyGard AT-00-V Page 6 0 Wiring Configuration and Enclosure Dimensions Wiring Configuration Fig. Power supply 8-8 VDC -0 VDC + X 7 6 Transmitter AT-00 shield shield shield NC V/DC 0V/DC -0mA R9 R0 X -0 ma VDC Controller shield wiring0 X Optional heater VAC/DC A 0 V Shield: Connect Shield to either terminal, 6 or 7. Shield should be grounded at either the sensor or controller. DO NOT ground Shield at both ends. For stand-alone relay operation (w/o controller) place 0.0 Ω resistor between terminals (common) and (signal). Printed circuit board EX-S, with installed optional relay package AT-R. Fig. X 7 6 GND V GND AO BR BR 7 6 AT-R X0 - P0 X9 P9 9 X - - X6 X8 + + Test Gain Zero Bridge P Sensor P + X K9 K0 K0 K9 X NO NC COM NO COM Analog Bus EX-S-00 00

17 User Manual - PolyGard AT-00-V Page 7 Assembly Dimensions Fig. Fig..9 in. ( mm).7 in. (70 mm) X 7 6 GND V GND AO BR BR AT-R X9 9 X - - X6 X8 + + Test Gain Zero Bridge P + X0 P0 Sensor P P9 + X K9 K0 K0 K9 EX-S X NO NC COM NO COM Analog Bus D=0.6 in. ( mm) D=0.88 in. (, mm) Cable entry X 7 X d=0.6 in. ( mm) 0.8 in.( mm).8 in. (6 mm). in. (8 mm) Hole for mounting.9 in. ( mm) GehaemATS gehaem0 Duct mounting enclosure Cutout for duct model Fig. Fig in. ( mm) 0.88 in. (. mm) 0.8 in. ( mm) 7.6 in (8 mm).8 in. (6 mm) gehaem0 0.6 in. ( mm) Gehäuse

18 User Manual - PolyGard AT-00-V Page 8 Enclosure, NEMA X with splash quard Fig. 7.8 in. ( mm). in. (0 mm).7 in. (0 mm). in. (90 mm) 0.6 in. (6 mm) X 7 6 GND V GND AO BR BR 7 6 AT-R X6 - X8 + Test Gain Zero + Bridge P + X0 - P0 Sensor X9 P P9 + X 9 X K9 K0 K0 K9 X NO NC COM NO COM Analog Bus EX-S in. (6 mm) atsplash Enclosure, NEMA X with splash quard Fig. 8. in (8 mm) atsplash

19 User Manual - PolyGard AT-00-V Page 9 Notes and General Information It is important to read this user manual thoroughly and clearly understand the information and instructions. The PolyGard transmitters must be used within product specification capabilities. The appropriate operating and maintenance instructions and recommendations must be followed. Due to ongoing product development, MSR reserves the right to change specifications without notice. The information contained herein is based upon data considered to be accurate. However, no guarantee is expressed or implied regarding the accuracy of this data.. Intended product application The PolyGard AT 00 combustible gas transmitters are designed and manufactured for control applications for energy savings and OSHA air quality compliance in commercial buildings and manufacturing plants (i.e., detection and automatic exhaust fan control for automotive maintenance facilities, enclosed parking garages, engine repair shops, warehouses with forklifts, fire stations, tunnels, etc.).. Installers` responsibilities It is the installer`s responsibility to ensure that all PolyGard transmitters are installed in compliance with all national and local codes and OSHA requirements. Installation should be implemented only by individuals familiar with proper installation techniques and with codes, standards and proper safety procedures for control installations and the latest edition of the National Electrical Code (ANSI/NFPA70). It is also essential to strictly follow all instructions as provided in the user manual.. Maintenance It is recommended that the PolyGard transmitter performance check is done on a routine schedule. Any performance deviations may be serviced based on needed requirements. Re-calibration and part replacement may be implemented in the field by a qualified individual and with the appropriate tools. Alternatively, the easily removable plug-in transmitter card with the sensor may be returned for service to INTEC Controls.. Limited warranty MSR and INTEC Controls warrant the PolyGard transmitters for a period of two () years from the date of shipment against defects in material or workmanship. Should any evidence of defects in material or workmanship occur during the warranty period, MSR or INTEC Controls will repair or replace the product at their own discretion, without charge. This warranty does not apply to units that have been altered, had repair attempted, or been subjected to abuse, accidental or otherwise. The warranty also does not apply to units in which the sensor element has been overexposed or gas poisoned. The above warranty is in lieu of all other express warranties, obligations or liabilities. This warranty extends only to the PolyGard transmitter. MSR and INTEC Controls shall not be liable for any incidental or consequential damages arising out of or related to the use of the PolyGard transmitters.. Return instructions If the PolyGard transmitter needs to be returned to INTEC Controls for service, an RMA number must be obtained prior to sending.