detcon Inc. | Detcon MicroSafe”™ FP-624C Combustible Gas Sensor (0-100% LEL) Operator's Installation & Instruction Manual November 21, 2007 + Document #2246 + Revision 7.0 | CAUTION: Before operating the Model FP&21C sensor, read this manual thoroughly and verily that the configuration of detiul factory settings are appropaate and correct for your application. The settings include: Target gas and calibration gas (section 3.7), relay contact outputs (section 355d), alarm settings (ection 3.5.5e and 3.10), and RS485 ID (section 3.5.5¢ and 3.12)Table of Contents 3.0 Description 34 Pri iple of Operation 3.2. Application 3.3. Specifications 3.4. Operating Software 3.5. Installation 3.6 Startup 3.7. Target Gas and Calibration Gas Selection 3.8 Calibration 3.9. Status of Programming, Alarms, Calibration Level, RS-485 1D, and Sensor Life 3.10 Programming Alarms 3.11 Program Features 3.12 RS-485 Protocol 3.13. Display Contrast Adjust 3.14 Trouble Shooting Guide 3.15 Spare Parts List 3.16 Warranty 3.17 Service Policy 3.18 Software Flow Chart _ Model FP sbusble Ga3.0 Descriprion Detcon MicroSafe™ Model FP-624C, combustible gas sensors are nomintrusive “Smart” sensors designed to detect and monitor combustible gas in air over the range of 0-100% lower explosive limit (LEL). One of the primary features of the sen- sor is its method of automatic calibration which guides the user through each step via instructions displayed on the backlit LCD. The sensor features field adjustable, fully programmable alarms and provides relays for two alarms plus fault as standard. ‘The sensor comes with two different outputs: analog 4-20 mA, and serial RS-485, “These outputs allow for greater flexibility in system integration and installation. The microprocessor supervised electronics are packaged as a plug.in module that mates to a standard connector board. Both are housed in an explosion proof condulet that includes a glass lens window which allows for the display of sensor readings as well as access to the sensor’s menu driven features via a hand-held programming magnet. ‘The sensor technology is of the catalytic pelistor type. Catalytic pellistors show 4 good response to a long list of combustible gases. The technique is referred to as nonselective and may be used for the detection and monitoring of target com- bustible gases. Model FP-624C sensors are specifically designed to be resistive to poi- sons such as sulfides, chlorides and silicone. The sensors are characteristically stable and capable of providing reliable performance for periods exceeding 5 years in most industrial environments. 3.0.1 Catalytic Detector “The catalytic detector is supplied as a matched pair of elements mounted in a plugin replaceable housing. One ele rent is an active extalytic detector and the other is a non-active compensating element. Each element consists of a fine platinum wire embedded in a bead of alumina. A catalytic mixture is applied to the detecting clement while the compensating element is treated so that eatalytic oxidation of gas does not occur, The beads are mounted in a plug-in ‘module that is enclosed by a sintered porous stainless stel flame arrestor. The plugin sensor module uses gold plat- cd pins and mounts inside the stainless steel sensor head via mating gold plated sockets. ‘Alumina Bead Platinum Wire Boats Sintered Stainless Stee! Can Header Catalyst Gold Pited Pins ‘Construction of Detector Bead 3.0.2. Microprocessor Control Circuit The control circuit is microprocessor based and is packaged as a plug.in field replaceable module, facilitating easy replacement and minimum down time. Circuit functions include a basic sensor preamplifier, sensor temperature control, onboard power supplies, microprocessor, back lit alpha numeric display, alarm status LED indicators, mag- netic programming switches, an RS-485 communication port, and a linear 4-20 mA DC output. ‘Model FRO2HC Combustible Css Sensor PCSProgram Saiteh #1 rey cone ae Plugin Microprocessor Control Circuit Mons: Orvon Display ‘Norm & Cal LDS Program Switeh #2 — 3.0.3 Base Connector Board ‘The base connector board is mounted in the explosion proof enclosure and includes: the ‘mating connector for the control circuit, reverse input and secondary transient suppres- = sion, input filter, alarm relays, lugless termi- oe egos” nals for all field wiring, and a terminal strip “#40 earn for storing unused programming jumper tabs. san The alarm relays are contact rated 5 amps @ noo a 250 VAC, 5 amps @ 30 VDC and coil rated re at 24 VDC, Gold plated program jumpers are used to select either the normally open or ‘normally closed relay contacts. 3.0.4 Explosion Proof Enclosure The sensors are packaged in a cast metal explosion proof enclosure. The enclosure is fitted with a threaded cover that has a glass lens window, Magnetic program switches located behind the transmitter module face plate are act- vated through the lens window via a hand-held magnetic programming tool allowing non-intrusive operator inter- face with the sensor. All calibration and alarm level adjustments can be accomplished without removing the cover or declasifying the area. Electrical classification is Class I; Groups B, C, Dy Div. 1 3.1 PRINCIPLE OF OPERATION Method of detection is by a controlled rate of diffusion/adsorption. Air and gas diffuse through a sintered stainless steel filter and contact both the active and reference detector beads. The surface of the active detector promotes oxidation of dhe combustible gas molecule while the reference detector has been treated not to support this oxida- tion, The reference detectors serve as a means to maintain zero stability over a wide operating temperature range, ‘When combustible gas molecules oxidize on the surface of the active detector, heat is generated, effectively chan ing the electrical conductance of the active detector. Electronically the detectors form part of a balanced bridge ci- cuit. As the active detector changes in electrical conductanee, the bridge circuit unbalances. This change in output is conditioned by amplifier circuits that are an integral part of the assembly. The sensor response and clearing character istics are quite rapid resulting in a method of continuous and accurate monitoring of ambient ait conditions, ‘Model FPS2UC Combustible Gat Sensor PG40 < — conpensntraterance | — oactouetie output e—! 3.1.2 Characteristics The detector elements maintain good sensitivity to combustible gases in air inthe lower explosive limit range, as shown in the response curve illustration below. However, for gas concentrations above the LEL range, the bridge output decreases. ‘Ambiguous readings above LEL range conditions dictate that alarm circuitry be of the latching type wherein alarms are held in the “on” positon until reset by operations personnel. “The performance of the detector elements may be temporarily impaired by operation in the presence of sub- stances described as inhibitors. These are usually volatile substances containing halogens and the detectors may recover after short periods of operation in clean air. When the inhibiting substance produces a permanent effect on the catalyst with a catastrophic reduction in sensitivity, the detector is said to be poisoned. Examples of poisons arg silicone oils and greases, anticknock petrol additives and phosphate esters, Activated carbon filters will provide adequate protection from poisoning in the majority of cases. Response Curve FRADC Signa Opt on 4 @ 8 w FLEE foworexloeo it) > poy out Sora ns.5 ot Ale 20 9k Ot Powerin Sala | Functional Block Diagram 3.2. APPLICATION Model F?-624C MicroSafe"™ sensors are designed to detect and monitor combustible gas in ambient ar inthe range of (100% LEL. Minimum sensitivity and scale resolution is 1%. Operating temperature range is 40° F, to +175° F. While the sensor is capable of operating outside these temperatures, performance specifications are verified within the limit. 3.2.1 Sensor Placement/Mounting ‘Sensor location should be reviewed by facility engineering and safety personnel. Area leak sources and perimeter mounting are typically used to determine number and location of sensors. The sensors are generally located 2 - 4 fect above grade. ‘Model FPS2C Combustible Gss Sensor PGS3.2.2. Response to Different Gases Aa attractive feature of the catalytic detector elements is their almost universal response to lower explosive limits of hydrocarbons, Most detectable gases produce a similar output, however the signal amplitudes differ. The table in section 3.7 lists theoretical factors (K factors) for different gases which are a measure of their signal amplitude as compared to methane which has a K factor of 1.00. Since these factors are theoretical, they will only give a guide to the response expected in other gases. The Model FP-624C sensor can be configured to detect any of the listed gases. ‘The gas selected for detection is referred to as the target gas. The sensor can also be configured to allow the user to calibrate with a listed gas other than the target gas. This selection is referred to as the calibration gas. Unless other: wise specified, Model FP-624C sensors are configured to detect methane and are calibrated with methane to a scale of 0-100% LEL. Refer to section 3.7 for details. 3.3. SPECIFICATIONS Mothod of Detection Catalytic detector diffusion/adsorption Measurment Range 0-100% (lower explosive limit) LEL Accuracy/Repeatabilty +.39% LEL in 0-50% LEL Range: + 59% LEL in 51-100% LEL Range Response/Clearing Tim 'T50 <10 seeonels; T90 <30 seconds Zoro Drift < 5% pet year Operating Temperature Range “40° to +175° F; 40° 10 +75°C Operating Humidity Range 099% non-condensing Output 3 relays (alarm 1, alarm 2, and fault) contact rated 5 amps @ 250 VAC, § amps @ 30 VDC Linear 420 mA DC; RS-485 Modbus™ Input Voltage 22528 VDC Power Consumption ‘Normal operation ~ 84 mA (2 watts}; Full alm = 128 mA (3.1 wats) Electrical Classification Explosion Proof, Class Di. 1; Groups B, C, D Safety Approvals CSA/NRTL (US OSHA Certified) Sensor Warranty 2 year conditional 3.4 OPERATING SOFTWARE Operating software is menu listed with operator interface via the two magnetic program switches located under the face plate. The two switches are referred to as *PGM 1” and “PGM 2”, The menu list consists of 3 items which include sub-menus as indicated below. (Note: see the last page of this manual for a complete software flow chart.) 01. Normal Operation a) Current Status 02, Calibration Mode a) Zero ») Span 03. Program Menu a) Program Status ») Alarm 1 Level Model FPOHC Combustible Ges Sensor PGS¢) Alarm 2 Level al) Target gas selection (gas K factor) «) Calibration gas selection (cal K factot) 4) Calibration Level a) Set Bridge Volts 3.4.1 Normal Operation in normal operation, the display tracks the current status of the sensor and gas concentration and appeats as “0 % LEL”. The mA current output corresponds to the monitoring level and range of 0-100% = 4-20 mA. 3.4.2 Calibration Mode Calibration mode allows for sensor zero and span adjustments. “1-ZERO 2-SPAN” (3421 Zero Adjustment Zero is set in ambient air with no combustible ga present or with zero gas applied to the sensor. “AUTO ZERO” Jh22 Span Adiastment Uniess otherwise specified, span adjustment is performed at 50% LEL methane in air. “AUTO SPAN” 3.4.3. Program Mode ‘The program mode provides a program status menu, allows for the adjustment of alarm set point levels, the selec- tion of the target gas K factor, the selection of the calibration gas K factor and the selection of the calibration gas level setting. 431 Program Status The program status scrolls through a menu that displays The gas type, range of detection and software version number, The ment item appears as: “LEL 0-100 V6.4” * The alarm set point level of alarm 1. The menu item appears as: “ALM SET @ #4#%” The alarm firing direction of alarm 1. The menu item appears as: “ALM1 ASCENDING” or descending, The alatm relay latch mode of alarm J. The menu item appears as: “ALM1 NONLATCHING" or latching. * The alarm relay energize state of alarm 1. The menu item appears as: “ALM DE-ENERGIZED” or energized. The alarm set point level of alarm 2. The menu item appears as: “ALM2 SET @ ##%6” "The alarm firing direction of alarm 2. The menu item appears as: “ALM2 ASCENDING” or descending. “The alarm relay latch mode of alarm 2. The menu item appears as: "ALM2 LATCHING" or nonlatching. The alarm relay energize state of alarm 2. The menu item appears as: “ALM2 DE-ENERGIZED” or energized. The alarm relay latch mode of the fault alarm. The menu item appears as: “FLT NONLATCHING” or latching * The alarm relay energize state of the fault alarm. The menu item appears as: “FLT ENERGIZED” or deenergized. * Identification of the target gas K factor. The menu item appears as: “GAS FACTOR #.iH#” ® Identification of the calibration gas K factor. The menu item appears as: “CAL FACTOR #44” * The calibration gas level setting. The menu item appears as: “CalLevel @ xx%" * Identification of the RS485 ID number setting. The menu item appears as: “485 ID SET @ ##” The estimated remaining sensor life. The menu item appears as: "SENSOR LIFE 100%" 3432 Alarm 1 Level Adjustment The alarm I level is adjustable over the range 10 to 90%, For combustible gas sensors, the level is factory set at 20%, The menu item appears as: “SET ALM1 @ 20%" 3433 Alarm 2 Level Adjastment ‘The alarm 2 level is also adjustable over the range 10 to 90%. For combustible gas sensors, the level is factory set at 40%, The menu item appears as: “SET ALM2@ 40%" BAA Target Gas Selection ‘The target gas K factor is adjustable over the range 0.79 to 5.65. For combustible gas sensors configured for the detection of methane, the level is factory set at 1.00, The menu item appears as: “GAS FACTOR 1.00" BAIS Calibration Gas Selection The calibration gas K factor is adjustable over the range 0.79 to 5.65. For combustible gas sensors that are calibrated using methane, the level is factory set at 1,00, The menu item appears as: “CAL FACTOR 1.00” ‘Model FP&2IC Combustible Gas Sensor PG?I436 Calibration Level Adjustment ‘The Calibration level is adjustable from 10% to 90% LBL. ‘The menu item appears as; “CalLevel @ ##%" BAI Set Bridge Vols For applications where the sensor is remotely mounted away fom the sensor transmitter, the detector bridge voltage is adjustable to compensate for differing wire resistances. The menu item appears as: “SET BRIDGE VOLTS” 3.5 INSTALLATION Optimum performance of ambient air/gas sensor devices is directly relative to proper location and installation practice 3.5.1 Field Wiring Table (1.20 mA output) Detcon Model FP-624C combustible gas sensor assemblies require three conductor connection between power sup- plies and host electronic controllers. Wiring designators are + (DC), = (DC) , and mA (sensor signal). Maximum single conductor resistance between sensor and controller is 10 ohms. Maximum wire size for termination in the sensor assembly terminal board is 14 gauge. AWG Meters Feet 20 240800 18 3601200 16 600-2000 1% 9003000 Note 1: This wiring table is based on stranded tinned copper wire and is designed to serve as a reference only, Note 2: Shielded cable may be required in installations where cable trays or conduit runs include high voltage lines or other sources of induced interference. Note 3: The supply of power must be from an isolating source with overcurrent protection as follows AWG Overcurrent Protection AWG Overcurrent Protection 2 3A 16 10A 2 5A 4 20A 8 7A 2 25K ‘The RS-485 (if applicable) requires 24 gauge, two conductor, shielded, twisted pair cable between sensor and host PC, Use Belden part number 9841. Two sets of terminals are located on the connector board to facilitate serial loop wiring from sensor to sensor. Wiring designators are A &e B (IN) and A & B (OUT), 3.5.2. Sensor Location Selection of sensor location is critical to the overall safe performance of the product. Five factors play an important role in selection of sensor locations: (1) Density of the gas to be detected 2) Most probable leak sources within the industrial process (G) Ventilation or prevailing wind conditions (4) Personnel exposure (5) Accessibility for routine maintenance Deasity - Placement of sensors relative to the density of the target gas is such that sensors for the detection of heavier than air gases should be located within 2-4 feet of grade as these heavy gases will tend to settle in low lying areas. For gases lighter than air, sensor placement should be 48 feet above grade in open areas or in pitched areas of enclosed spaces. Leak Sources - Most probable leak sources within an industrial process include flanges, valves, and tubing connec tions of the sealed type where seals may ether fail or wear. Other leak sources are best determined by facility eng neers with experience in similar processes. Model FP&2IC Combustible Gis Sesor PGS