Model 1000
CO2 Process Analyzer
PART NO.
MODEL NO.
SERIAL NO.
INPUT VOLTAGE
FREQUENCY
CURRENT LOAD
AREA CLASSIFICATION
3200 A-1 Research Fores t Dr.
The Woodlands, TX 77381
www.detcon.com
detcon inc.
AIR
AIR
INLET
AIR
FLOW
SAMPLE
SAMPLE
FLOW
SAMPLE PRESSURE
10 PSIG (CONSTANT)
INLET
Operator’s Installation and Instruction Manual
Detcon Model 1000 CO2 Analyzer consists of two major assemblies:
1. The Model 1000 Series gas sample conditioning assembly.
2. The Model IR-640/IR642 CO
The Woodlands, Texas 77387
Ph.281.367.4100 / Fax 281.298.2868
September 19, 2011 • Document #2601 • Revision 2.2
DETCON, Inc.
3200 Research Forest Dr.,
www.detcon.com
gas sensors.
2
Model 1000 CO2
This page left intentionally blank
Model 1000 CO2 Instruction Manual ii
Model 1000 CO2
Table of Contents
1.0 Introduction.............................................................................................................................................. 1
1.1 IR-640/IR-642 Description................................................................................................................... 1
1.1.1 Non-dispersive infrared (NDIR) optical sensor........................................................................... 2
1.1.2 Microprocessor Control Circuit................................................................................................... 2
1.1.3 Base Connector Board................................................................................................................. 3
1.1.4 IR-640/IR-642 CO2 Sensor Principal of Operation ..................................................................... 3
1.1.5 Characteristics............................................................................................................................. 4
1.2 Explosion Proof Enclosures ................................................................................................................. 4
2.0 Specifications............................................................................................................................................ 5
3.0 Installation................................................................................................................................................ 6
3.1 Mounting.............................................................................................................................................. 6
3.2 Gas Connections and Sampling System Notes..................................................................................... 6
3.3 Electrical Connections.......................................................................................................................... 7
3.4 Relays and RS-485 Setup..................................................................................................................... 8
4.0 Start Up................................................................................................................................................... 10
5.0 Operating Software ............................................................................................................................... 11
5.1 Programming Magnet Operating Instructions.................................................................................... 11
5.2 Operating Software............................................................................................................................. 11
5.2.1 Normal Operation...................................................................................................................... 12
5.2.2 Calibration Mode....................................................................................................................... 12
5.2.3 Program Mode ........................................................................................................................... 12
5.2.4 Software Flow Chart.................................................................................................................. 14
6.0 Calibration.............................................................................................................................................. 15
6.1 IR-640/IR-642 CO2 Sensor Calibration.............................................................................................. 15
7.0 Programming Sensors ........................................................................................................................... 17
7.1 Alarm Levels...................................................................................................................................... 17
7.2 Alarm Reset........................................................................................................................................ 17
7.3 Other Alarm Functions....................................................................................................................... 17
7.4 Calibration Gas Level......................................................................................................................... 18
8.0 Display Contrast Adjustment............................................................................................................... 18
9.0 Programming Features.......................................................................................................................... 18
10.0 RS-485 Protocol ..................................................................................................................................... 19
11.0 Sensor Replacement............................................................................................................................... 21
12.0 Troubleshooting..................................................................................................................................... 22
13.0 Spare Parts............................................................................................................................................. 23
14.0 Warranty................................................................................................................................................ 24
15.0 Gas Flow and Wiring Diagrams........................................................................................................... 25
Appendix C....................................................................................................................................................... 28
Revision Log.................................................................................................................................................. 28
Model 1000 CO2 Instruction Manual iii
Model 1000 CO2
Table of Figures
Figure 1 IR Sensor Assembly............................................................................................................................ 1
Figure 2 IR Cell Construction...........................................................................................................................2
Figure 3 Control Faceplate................................................................................................................................2
Figure 4 Connector PCA...................................................................................................................................3
Figure 5 IR Block Diagram............................................................................................................................... 4
Figure 6 Principal of Operation.........................................................................................................................4
Figure 7 IR Response Curve .............................................................................................................................4
Figure 8 Explosion proof enclosures.................................................................................................................5
Figure 9 Unit Dimensions .................................................................................................................................6
Figure 10 Unit Overview...................................................................................................................................7
Figure 11 Installation Wiring Connections .......................................................................................................8
Figure 12 Alarm Jumpers.................................................................................................................................. 9
Figure 13 RS485 ID Switches........................................................................................................................... 9
Figure 14 Programming Magnet ................................................................................................... .................... 11
Figure 15 IR-640/IR-642 Software Flow Chart ................................................................................................ 14
Figure 16 Spare parts identification .................................................................................................................23
Figure 17 Unit Flow Diagram..........................................................................................................................25
Figure 18 Pump Box Flow Diagram ................................................................................................................26
Figure 19 Wiring Diagram................................................................................................................................27
Shipping Address: 3200 A-1 Research Forest Dr., The Woodlands Texas 77381
Mailing Address: P.O. Box 8067, The Woodlands Texas 77387-8067
Phone: 888.367.4286, 281.367.4100 • Fax: 281.292.286 0 •
Model 1000 CO2 Instruction Manual iv
www.detcon.com • sales@detcon.com
Model 1000 CO2
1.0 Introduction
The Detcon Model 1000 Series CO
provides a select gas sample mixture to an IR-640/IR-642 CO
determined at time of order.
The NEMA 7X rating is achieved by housing all electronic components in suitable NEMA 7X enclosures.
When located outdoors, the CO
weather exposure. The Model 1000 Series CO
4 enclosure.
The “Power Supply” explosion proof enclosure on the upper right side of the unit houses a 24VDC power
supply, a 24-24VDC Converter, and a terminal PCB labeled for all input and output field wiring. The
“Pump/Flow” explosion proof enclosure located on the upper left houses an air dilution pump, an activated
carbon scrubber, and optional air flow fault and sample flow fault alarm PCB’s.
The analyzer requires a constant, liquid-free, 10±2psig sample pressure, which is provided by the customer or
may be supplied by Detcon as a separate gas sample handling system.
The gas sample conditioning system includes a stainless steel pressure gauge (0-30psig), and a Genie
membrane filter to provide the analyzer with absolute condensate liquid protection. On the bypass port of the
Genie membrane filter, a 15psig over-pressure relief valve and flow control valve are also provided. The flow
control valve can be used as a sample bypass and liquid exhaust vent. The IR-640/IR-642 CO
measures the sample directly. The sample for the CO
valve is provided for manually switching between sample monitoring and span calibrations.
1.1 IR-640/IR-642 Description
Process Analyzer is a 110/220VAC or 24VDC powered analyzer that
2
gas sensor assembly. The ranges of analysis are
2
Process Analyzer package should be appropriately covered from direct
2
Process Analyzer can optionally be ordered with a full NEMA
2
gas sensor
2
sensor is set by a control valve Rotameter. A 3-way
2
Figure 1 IR Sensor Assembly
Detcon MicroSafe™ Model IR-640 carbon dioxide gas sensors are non-intrusive “Smart” sensors designed to
detect and monitor CO
gas in the 0-5% range. The Detcon Model IR-642 is used to measure CO2 gas in
2
ranges from 0-10% up to 0-100%. One of the primary features of the sensors is its method of automatic
calibration, which guides the user through each step via instructions displayed on the backlit LCD. The
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 1 of 28
Model 1000 CO2
sensors feature field adjustable, fully programmable alarms and provide relays for two alarms plus fault as
standard. The sensor comes with two different outputs: analog 4-20mA, 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 a field proven “plug-in replaceable” non-dispersive infrared (NDIR) optical type.
NDIR optical sensors show an excellent response to CO
. The NDIR type sensor is characteristically stable
2
for both span and zero and is capable of providing reliable performance with low maintenance requirements
for periods approaching 5 years in most industrial environments.
1.1.1 Non-dispersive infrared (NDIR) optical sensor
The Detcon NDIR sensor is designed as a miniature single piece “plug-in replaceable” component, which can
easily be changed out in the field. The NDIR sensor consists of an infrared lamp source, two pyroelectric
detectors, and an optical gas sample cavity. The lamp source produces infrared radiation, which interacts with
CO
as it travels through the optical gas sample cavity. The infrared radiation contacts each of two
2
pyroelectric detectors at the completion of the optical path. The “active” pyroelectric detector is cove red by a
filter specific to the part of the IR spectrum where CO
covered by a filter specific to the non-absorbing part of the IR spectrum. When CO
radiation and the signal output from the “active” pyroelectric detector decreases accordingly while the
“reference” detector output remains unchanged. The ratio of the “active” and “reference” detector outputs is
then used to compute CO
concentration.
2
absorbs light. The “reference” pyroelectric detector is
2
is present, it absorbs IR
2
Figure 2 IR Cell Construction
1.1.2 Microprocessor Control Circuit
Figure 3 Control Faceplate
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 2 of 28
Model 1000 CO2
The control circuit is microprocessor based and packaged as a plug-in field replaceable module, facilitating
easy replacement and minimum down time. Circuit functions include a basic sensor pre-amplifier, sensor
temperature measurement, on-board power supplies, microprocessor, back lit alpha numeric display, alarm
status LED indicators, magnetic programming switches, an RS-485 communication port, and a linear 4-20mA
DC output.
1.1.3 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 suppression, input filter, alarm relays, lug less
terminals for all field wiring, and a terminal strip for storing unused programming jumper tabs. The alarm
relays are contact rated 5Amps @ 250VAC, 5Amps @ 30VDC and coil rated at 24VDC. Gold plated program
jumpers are used to select either the normally open or normally closed relay contacts.
Figure 4 Connector PCA
1.1.4 IR-640/IR-642 CO2 Sensor Principal of Operation
CO
in the sample stream diffuses through a sintered stainless steel flame arrestor and into the volume of the
2
sample gas optical cavity. A lamp source provides a cyclical IR radiation source, which travels through the
optical gas sample cavity and terminates at two pyroelectric detectors. The “active” and “reference”
pyroelectric detectors each give an output, which measures the intensity of the radiation contacting their
surface. The “active” pyroelectric detector is covered by an optical filter specific to the part of the IR
spectrum where CO
non-absorbing part of the IR spectrum. When present, CO
signal output from the “active” pyroelectric detector decreases accordingly. The signal output of the
“reference” detector remains unchanged in the presence of CO
detector signal outputs is then used to compute CO
signal outputs, measurement drift caused by changes in the intensity of the lamp source and changes in the
optical path are negated.
absorbs light. The “reference” pyroelectric detector is covered by a filter specific to the
2
absorbs a fraction of the IR radiation and the
2
. The ratio of the “active” and “reference”
2
concentration. By using the ratio of the active/reference
2
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 3 of 28
Model 1000 CO2
Figure 5 IR Block Diagram
1.1.5 Characteristics
The NDIR optical sensor element maintains strong sensitivity to CO
be quarterly and typical span calibration intervals would be quarterly to bi-annual. However, actual field
experience is always the best determination of appropriate calibration intervals.
. Typical zero calibration intervals would
2
Figure 6 Principal of Operation
The NDIR optical sensor readings can be adversely affected by dust, dirt and oil mist accumulation as well as
severe corrosion. These deposits may reduce the optical reflectivity inside the sensor, and although accurate
readings are continually maintained, excessive loss in useable signal eventually gives way to noise and
unstable readings. The optical sensor may, over a period of time (3-7 years), lose its IR lamp source filament,
and in this case, an optical sensor modular replacement is required. The IR-640/IR-642 has an extensive list of
Fault Diagnostics to alert and pinpoint operational problems. See
Troubleshooting, section 12.0.
Figure 7 IR Response Curve
1.2 Explosion Proof Enclosures
The sensors are packaged in cast metal explosion proof enclosures. The enclosures are fitted with a threaded
cover with glass lens window. Magnetic program switches located behind the transmitter module faceplate are
activated through the lens window via a hand-held magnetic programming tool allowing non-intrusive
operator interface with the sensor. All calibration and alarm level adjustments can be accomplished without
removing the cover or declassifying the area. Electrical classification is Class I; Groups B, C, D; Div. 1.
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 4 of 28
Model 1000 CO2
Flow Fault (optional)
Pump/Scrubber
Power Supply/
Terminal PCB
++
24VDC
18-36
OUT
VDC
2.1A
IN
Sensor (side view)
Sensor
Left
Right
Figure 8 Explosion proof enclosures
A 24 VDC power supply and termination PCB for the power, relay contacts, 4-20mA output, and or RS485
signal, are located in the explosion proof enclosure located in the upper right of the unit. The pump, activated
carbon scrubber, and optional low flow fault assembly are located in the explosion proof enclosure located in
the upper right of the unit. Declassify the work area before removing covers.
2.0 Specifications
Sensor Type
Solid-state metal oxide diffusion/adsorption (TP-624C H
Non-Dispersive Infrared (IR-640/IR-642 CO
Sensor)
2
Measurement Range
0.3% up to 5% (IR-640 CO
10% up to 100% (IR-642 CO
Sensor)
2
Sensor)
2
Accuracy/Repeatability
± 5% Full Scale (IR-640/IR-642/IR642 CO
Sensor)
2
Response/Clearing Time
T50<30 seconds, T80<60 seconds (IR-640/IR-642 CO
Operating Temperature
-4°F to +167°F: -20°C to +75°C
Outputs
Linear 4-20mA DC; RS-485 Modbus™; 3 relays (alarm 1, alarm 2, and fault), Contacts rated 5 amps
Sensor Life/Warranty
Sensor: 5-year conditional warranty. Transmitter: 2-year warranty (IR-640/IR-642 CO
Input Voltage
110/220VAC; 22.5-28VDC
Power Consumption
225 mA max (5.4 watts)
Electrical Classification
S Sensor)
2
Sensor)
2
Sensor)
2
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 5 of 28
Model 1000 CO2
Explosion Proof; Class I, Division 1, Groups C, D
Analyzer Weight
75 lbs.
Dimensions
29”H X 29”W X 8”D
3.0 Installation
3.1 Mounting
Securely mount the Model 1000 analyzer panel or (optional) NEMA 4 enclosure in accordance with
Figure 9.
Figure 9 Unit Dimensions
3.2 Gas Connections and Sampling System Notes
1. Install a length of tubing from the desired sample point to the sample Inlet Port (
tubing should be 316 stainless steel of 1/4" O.D.
NOTE: A constant pressure of 10±2psig should be provided to the analyzer for proper operation. In
applications where line pressure varies significantly, two-stage pressure regulation is recommended to
hold the constant pressure. Ideally, the pressure drop from the source to 10 psig for analyzer should be
taken as close to the pipeline as possible. This speeds up response time to actual gas concentration
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 6 of 28
Figure 10). Sample draw
Model 1000 CO2
changes. An insertion probe membrane device is advisable to use for pipeline sources with high levels of
condensates, mist, and contamination.
2. Whenever possible, the Sample Bypass flow control valve of the Genie membrane filter should be used to
minimize the sample lag time between the sample tap and the analyzer location. It can also be used as a
means to exhaust condensed liquids in the sample line away from the Genie filter and prevent a “loss of
flow” condition. Set a flow of 100-200cc/min. and vent to a safe area using ¼ O.D. tubing. Connect the
tubing to the Over-Pressure Relief valve and vent to a safe area. The pressure relief valve is set at Detcon
to open at 15-20psig. For convenience, the sample bypass and over-pressure relief can be vented together.
Power Supply Box
PART NO.
PART NO.
MODEL NO.
MODEL NO.
SERIAL NO.
SERIAL NO.
INPUT VOLTAGE
INPUT VOLTAGE
FREQUENCY
FREQUENCY
CURRENT LOAD
CURRENT LOAD
AREA CLASSIFICATION
Flow Fault
and Pump Box
AREA CLASSIFICATION
3200 A-1 Research Forest Dr.
3200 A-1 Research Forest Dr.
The Woodlands, TX 77381
The Woodlands, TX 77381
www.detcon.com
www.detcon.com
detcon inc.
detcon inc.
Air Inlet Port
Air Flow Control
Rotameter
Mass Flow Control
CO2 Sample or
Cal Gas Rotameter
Sample Inlet
Pressure Gauge
Sample Inlet Port
NOTE: These can be combined into a single vent
Over Pressure
Relief
Exhaust Vent
SAMPLE
INLET
SAMPLE
INLET
SAMPLE
OUTLET
SAMPLE PRESSURE
10 PSIG (CONSTANT)
CO
2 3-Way Valve
AIR
AIR
INLET
SAMPLE
FLOW
AIR
FLOW
IR Sensor
Vent Port
CO
2
Figure 10 Unit Overview
3. Install a length of 1/4" OD stainless steel tubing from the vent port to an area deemed safe for venting as
shown below. The vent port should be separately vented from the over-pressure relief vent and the sample
by-pass vent.
3.3 Electrical Connections
1. For AC powered unit connect 110/220VAC to the terminal connector labeled “VAC IN” (JP8A) inside the
explosion-proof enclosure on the right. If applicable, connect 24VDC to the Terminal Connector Board
labeled “VDC IN” (JP7A). (
2. The 4-20mA and/or RS-485 signal outputs should be wired from the Terminal Connector Board and then
out the right side of the “Power Supply” explosion-proof enclosure. (
3. Alarm relay contacts are provided on the Terminal Connector Board for three alarms: Fault, Low, and
High (
Figure 11). The contacts consist of common and choice of normally open or normally closed.
Contact output selections are jumper programmable on the sensor connector board. See IR-640/IR-642
wiring diagram for details. These connections also should be wired out of the right side of the “Power
Supply” explosion-proof enclosure (
Sensor.
Figure 11)
Figure 11)
Figure 19). Sensor #1 termination corresponds to IR-640/IR-642 CO2
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 7 of 28
Model 1000 CO2
Customer Connections
INPUT
+
+
24VDC
24VDC
OUT
OUT
2.1A
2.1A
++
24VDC
OUT
2.1A
+
+
18-36
18-36
VDC
VDC
IN
IN
18-36
VDC
IN
117VAC / 24VDC In
4-20mA, RS485,
Alarm/Fault Sensor Relays
Low Flow Air/ Sample Relays
(Optional)
+24VDC
+
-24VDC
-
(Ground)
AIR
SAMPLE
FLOW
FLOW
Figure 11 Installation Wiring Connections
4. Optional Low Flow Fault alarms for Sample gas and Air are also available on the Terminal Connector
Board (
Figure 11). They provide a form “C” relay contact (common, normally open and normally closed)
rated 1 amp at 30 VDC/0.24 amps at 125 VAC. If the optional Air or Sample Flow Fault Boards are
installed the relay contacts are pre-wired to the Terminal Connector Board.
3.4 Relays and RS-485 Setup
Program the alarms via the gold plated jumper tab positions located on the CPU board (
and Alarm 2 have three jumper programmable functions: latching/non-latching relays, normally
energized/normally de-energized relays, and ascending/descending alarm set points. The fault alarm has two
jumper programmable functions: latching/non-latching relay, and normally energized/normally de-energized
relay. The default settings of alarms 1 and 2 (jumpers removed) are normally de-energized, non-latching
relays and alarm points that activate during ascending gas conditions. The Fault alarm default setting is deenergized, latching. The relay Contacts which transferred from the Base Connector PCB to the Analyzer
Terminal Connector PCB are the Common and Normally Open (NO) contacts of the relays. These jumpers
reside on the Base Connector PCB (see
Figure 4).
Figure 12). Alarm 1
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 8 of 28
Model 1000 CO2
If a jumper tab is installed in the latch position, the alarm relay will be in the latching mode. The latching
mode will latch the alarm after alarm conditions have cleared until the alarm reset function is activated. The
non-latching mode (jumper removed) will allow alarms to de-activate automatically once alarm conditions
have cleared. The default Factory set-up for Alarm 1 and Alarm 2 relays is non-latching. The default factory
set-up for the Fault relay is latching.
If a jumper tab is installed in the energize position, that alarm relay will be in the energized mode. The
energized mode will energize or activate the alarm relay when there is no alarm condition and de-energize or
de-activate the alarm relay when there is an alarm condition. The de-energized mode (jumper removed) will
energize or activate the alarm relay during an alarm condition and de-energize or de-activate the alarm relay
when there is no alarm condition. The default Factory set-up for Alarm 1, Alarm 2, and Fault relays are deenergized.
Figure 12 Alarm Jumpers
If a jumper tab is installed in the ascending position, the alarm relay will be in the ascending mode. The
ascending mode will cause an alarm to fire when the gas concentration detected is equal to or rises above the
alarm set point. The descending mode (jumper removed) will cause an alarm to fire when the gas
concentration detected is equal to or falls below the alarm set point. Except in special applications, H
CO
monitoring will require alarms to fire in “ASCENDING” gas conditions. This is the default setting of the
2
S and
2
Analyzer’s Alarms.
Any unused jumper tabs should be stored on the connector board on the terminal strip labeled “Unused
Jumpers”.
If applicable, set the RS-485 ID number via the two rotary dip switches located on the preamp board (see
below). There are 256 different ID numbers available, which are based on the hexadecimal numbering sy stem.
If RS-485 communications are used, each sensor must have its own unique ID number. Use a jeweler’s
screwdriver to set the rotary dipswitches according to the hexadecimal table listed below. If RS-485
communications are not used, leave the dipswitches in the default position, which is zero/zero (0)-(0).
Figure 13 RS485 ID Switches
Replace the plug-in control circuit and replace the junction box cover.
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 9 of 28
Model 1000 CO2
Table 1 Hexadecimal Table
ID# SW1 SW2 ID# SW1 SW2 ID# SW1 SW2 ID# SW1 SW2 ID# SW1 SW2 ID# SW1 SW2
0 0 0 43 2 B 86 5 4 129 8 1 172 A C 215 D 7
1 0 1 44 2 C 86 5 6 130 8 2 173 A D 216 D 8
2 0 2 45 2 D 87 5 7 131 8 3 174 A E 217 D 9
3 0 3 46 2 E 88 5 8 132 8 4 175 A F 218 D A
4 0 4 47 2 F 89 5 9 133 8 5 176 B 0 219 D B
5 0 5 48 3 0 90 5 A 134 8 6 177 B 1 220 D C
6 0 6 49 3 1 91 5 B 135 8 7 178 B 2 221 D D
7 0 7 50 3 2 92 5 C 136 8 8 179 B 3 222 D E
8 0 8 51 3 3 93 5 D 137 8 9 180 B 4 223 E F
9 0 9 52 3 4 94 5 E 138 8 A 181 B 5 224 E 0
10 0 A 53 3 5 95 5 F 139 8 B 182 B 6 225 E 1
11 0 B 54 3 6 96 6 0 140 8 C 183 B 7 226 E 2
12 0 C 55 3 7 97 6 1 141 8 D 184 B 8 227 E 3
13 0 D 56 3 8 98 6 2 142 8 E 185 B 9 228 E 4
14 0 E 57 3 9 99 6 3 143 8 F 186 B A 229 E 5
15 0 F 56 3 8 100 6 4 144 9 0 187 B B 230 E 6
16 1 0 57 3 9 101 6 5 145 9 1 188 B C 231 E 7
17 1 1 58 3 A 102 6 6 146 9 2 189 B D 232 E 8
18 1 2 59 3 B 103 6 7 147 9 3 190 B E 233 E 9
19 1 3 60 3 C 104 6 8 148 9 4 191 B F 234 E A
20 1 4 61 3 D 105 6 9 149 9 5 192 C 0 235 E B
21 1 5 62 3 E 106 6 A 150 9 6 193 C 1 236 E C
22 1 6 63 3 F 107 6 B 151 9 7 194 C 2 237 E D
23 1 7 64 4 0 108 6 C 152 9 8 195 C 3 238 E E
24 1 8 65 4 1 109 6 D 153 9 9 196 C 4 239 F F
25 1 9 66 4 2 110 6 E 154 9 A 197 C 5 240 F 0
26 1 A 67 4 3 111 6 F 155 9 B 198 C 6 241 F 1
27 1 B 68 4 4 112 7 0 156 9 C 199 C 7 242 F 2
28 1 C 69 4 5 113 7 1 157 9 D 200 C 8 243 F 3
29 1 D 70 4 6 114 7 2 158 9 E 201 C 9 244 F 4
30 1 E 71 4 7 115 7 3 159 9 F 202 C A 245 F 5
31 1 F 72 4 8 116 7 4 160 A 0 203 C B 246 F 6
32 2 0 73 4 9 117 7 5 161 A 1 204 C C 247 F 7
33 2 1 74 4 A 118 7 6 162 A 2 205 C D 248 F 8
34 2 2 75 4 B 119 7 7 163 A 3 206 C E 249 F 9
35 2 3 76 4 C 120 7 8 164 A 4 207 C F 250 F A
36 2 4 77 4 D 121 7 9 165 A 5 208 D 0 251 F B
37 2 5 78 4 E 122 7 A 166 A 6 209 D 1 252 F C
38 2 6 79 4 F 123 7 B 167 A 7 210 D 2 253 F D
39 2 7 80 5 0 124 7 C 168 A 8 211 D 3 254 F E
40 2 8 81 5 1 125 7 D 169 A 9 212 D 4 255 F F
41 2 9 82 5 2 126 7 E 170 A A 213 D 5
42 2 A 83 5 3 127 7 F 171 A B 214 D 6
4.0 Start Up
Upon completion of all tubing connections and field wiring the Model 1000 Series Process Analyzer is ready
for startup. Note that after power is applied, varying readings may occur during sensor warm-up. Allow at
least 1 hour to stabilize (24 hours is best). With sample gas and air flowing, apply system power and observe
the following normal conditions:
a) IR-640/IR-642 “Fault” LED is off
b) A reading close to the anticipated CO
up” cycle.
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 10 of 28
level should be indicated upon conclusion of a 1-minute “warming
2
Model 1000 CO2
NOTE: All alarms will be disabled for 1 minute after power up. In the event of power failure, the alarm
disable period will begin again once power has been restored.
NOTE: Sample flow rates are actual Rotameter set-point flow rates, after accounting for Rotameter gas.
5.0 Operating Software
5.1 Programming Magnet Operating Instructions
Operator interface to MicroSafe™ gas detection products is via magnetic switches located behind the
transmitter faceplate. DO NOT remove the glass lens cover to calibrate or change programming parameters.
Two switches labeled “PGM 1” and “PGM 2” allow for complete calibration and alarm level programming
without removing the enclosure cover, thereby eliminating the need for area de-classification or the use of hot
permits.
Figure 14 Programming Magnet
A magnetic programming tool (
momentary contact, 3-second hold, and 30-second hold. In momentary contact use, the programming magnet
is waved over a switch location. In 3-second hold, the programming magnet is held in place over a switch
location for 3 or more seconds. In 30-second hold, the programming magnet is held in place over a switch
location for 30 or more seconds. Three and 30-second hold is used to enter or exit calibration and program
menus while momentary contact is used to make adjustments. The location of “PGM 1” and “PGM 2” are
shown in section 1.3.
NOTE: If, after entering the calibration or program menus, there is no interaction with the menu items for
more than 30 seconds, the sensor will return to its normal operating condition.
5.2 Operating Software
Figure 14) is used to operate the switches. Switch action is defined as
Operating software is menu listed with operator interface via the two magnetic program switches located under
the faceplate. The two switches are referred to as “PGM 1” and “PGM 2”. The menu list consists of 3 items
which include submenus as indicated below.
01. Normal Operation
a) Current Status
02. Calibration Mode
a) Zero
b) Span
03. Program Menu
a) Program Status
b) Alarm 1 Level
c) Alarm 2 Level
d) Calibration Level
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 11 of 28
Model 1000 CO2
5.2.1 Normal Operation
In normal operation, the display tracks the current status of the sensor and gas concentration and appears as:
“##.# % CO2”. The milliamp current output corresponds to the monitoring level and range of the sensor,
where Full Scale is 20mA.
5.2.2 Calibration Mode
Calibration mode allows for sensor zero and span adjustments. “1-ZERO 2-SPAN”
Zero Adjustment
Zero is set in ambient air with no CO
gas present or with zero gas applied to the sensor. “AUTO ZERO”
2
Span Adjustment
Unless otherwise specified, span adjustment is performed at 50% of full-scale range of CO
. “AUTO SPAN”
2
5.2.3 Program Mode
Program Mode provides a program status menu (View Program Status) to check operational parameters.
Program Mode also allows for the adjustment of alarm set point levels, the calibration gas level setting, the
heater voltage level, range, and linearity correction. The programming menu also allows the calibration gas
level setting and Alarm levels (see
Program Status
View Program Status is a listing that allows the operator to view the gas, range, and software version number
of the program, as well as the current alarm settings, calibration gas level setting, offset value, RS-485 ID
number, and estimated remaining sensor life.
The following procedure is used to view the programming status of the sensor:
a) Enter the programming menu by holding the programming magnet stationary over “PGM 2” for 15
seconds. When the display changes to “VIEW PROG STATUS”, withdraw the magnet. Scroll through
the programming menu by momentarily waving the programming magnet over either “PGM 1” or “PGM
2”. The menu options are: View Program Status, Set Alarm 1 Level, Set Alarm 2 Level, and set Cal
Level.
b) Scroll to the “VIEW PROG STATUS” listing and hold the programming magnet over “PGM 1” for 3
seconds. The display will automatically scroll, at five-second intervals, through the following information
before returning back to the “VIEW PROG STATUS” listing.
¾ Gas type, range of detection and software version number. The menu item appears as: “02044-200056.31”
¾ Alarm set point level of alarm 1. The menu item appears as: “ALM1 SET @ ##%”
¾ Alarm firing direction of alarm 1. The menu item appears as: “ALM1 ASCENDING” or descending.
¾ Alarm relay latch mode of alarm 1. The menu item appears as: “ALM1 NONLATCHING” or latching.
¾ Alarm relay energize state of alarm 1. The menu item appears as: “ALM1 DE-ENERGIZED” or
energized.
¾ Alarm set point level of alarm 2. The menu item appears as: “ALM2 SET @ ##%”
¾ Alarm firing direction of alarm 2. The menu item appears as: “ALM2 ASCENDING” or descending.
¾ Alarm relay latch mode of alarm 2. The menu item appears as: “ALM2 LATCHING” or non-latching.
¾ Alarm relay energize state of alarm 2. The menu item appears as: “ALM2 DE-ENERGIZED” or
energized.
¾ Alarm relay latch mode of the fault alarm. The menu item appears as: “FLT NONLATCHING” or
latching.
Programming Sensors, Section 7.0).
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 12 of 28
Model 1000 CO2
¾ Alarm relay energize state of the fault alarm. The menu item appears as: “FLT ENERGIZED” or de-
energized.
¾ Calibration gas level setting. The menu item appears as: “CalLevel @ #.##%”
¾ Identification of the RS-485 ID number setting. The menu item appears as: “485 ID SET @ ##”
¾ Sensor temperature in °C appears as: “TEMPERATURE ## °C”
¾ Estimated remaining sensor life. The menu item appears as: “OPTICS AT 100%”
c) Exit back to normal operations by holding the programming magnet over “PGM 2” for 3 seconds, or
automatically return to normal operation in 30 seconds.
Alarm 1 Level Adjustment
The alarm 1 level is adjustable over the range 10 to 90% of full-scale range. For CO
gas sensors, the level is
2
factory set at 20% of full-scale range. The menu item appears as: “SET ALM1 @ #.##%”
Alarm 2 Level Adjustment
The alarm 2 level is also adjustable over the range 10 to 90% of full-scale range. For CO
gas sensors, the level
2
is factory set at 40% of full-scale range. The menu item appears as: “SET ALM2 @ #.##%”
Calibration Level Adjustment
The Calibration level is adjustable from 10% to 90% of full-scale range. The menu item appears as: “CAL
LEVEL @ #.##%”
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 13 of 28
Model 1000 CO2
5.2.4 Software Flow Chart
Figure 15 IR-640/IR-642 Software Flow Chart
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 14 of 28
Model 1000 CO2
6.0 Calibration
Model 1000 Series CO2 Process Analyzer is calibrated prior to shipment. Only minimal adjustment should be
required at time of commissioning.
IR-640/IR-642 Initial Calibration Recommendations:
A zero and span calibration should be performed at start-up to assure optimum system performance. After
that, a zero and span calibration interval of every 3 months is recommended.
6.1 IR-640/IR-642 CO2 Sensor Calibration
Material Requirements
9 Detcon Part Number 327-000000-000 MicroSafe™ Programming Magnet
9 Span Gas containing the applicable CO
50% of full-scale range (which is the factory default). Other concentrations can be used as long as they
fall within 10% to 90% of range.
9 Zero gas containing no CO
. Room air may be used as a zero gas.
2
Zero Calibration
Zero Calibration should be performed quarterly in the field.
1) If the ambient air is known to contain no combustible hydrocarbon gas content, it can be used to calibrate
zero. If a zero air or N2 gas cal cylinder is used, attach the gas to the CO
Valve. Turn the 3-Way valve to Calibrate, and adjust the CO2 Gas Rotameter for a flow rate of
250cc/min. Allow the unit 5 minutes to stabilize before executing the AutoZero.
2) Enter the calibration menu by holding the programming magnet stationary over “PGM 1” (see above) for 3
seconds until the display reads “1-ZERO 2-SPAN”, and remove the magnet. Note that the “CAL” LED
comes on.
3) Enter the zero-menu by holding the magnet stationary over “PGM 1” for 3 seconds until the display reads:
“ZERO 0%”, and remove the magnet. The sensor h as now entered the auto zero mode. When complete
the sensor will display “ZERO COMPLETE” for 5 seconds and then return to the normal operation
menu, “0.00 %CO2”.
4) Re-open the sample flow mass flow controller and re-establish the target sample flow rate per the arrow
indicator on the CO
sample Rotameter.
2
Span Calibration
Span gas cylinder containing CO
gas in background air as per the following range table. Background gas may
2
also be nitrogen.
CAUTION: Verification of the correct calibration gas level setting and calibration span gas concentration
is required before “span” calibration can be completed. These two numbers must be equal.
Calibration consists of entering the calibration function and following the menu-displayed instructions. The
display will ask for the application of span gas in a specific concentration. This concentration is equal to the
calibration gas level setting. The factory default setting for span gas concentration is 50% of full-scale range.
In this instance, a span gas containing a concentration equal to 50% of full-scale range is required. If a span
gas containing 50% of range is not available, other concentrations may be used as long as they fall within 10%
to 90% of range. However, any alternate span gas concentration value must be programmed via the calibration
gas level menu before proceeding with span calibration. Follow the instructions below for span calibration.
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 15 of 28
concentration in air. Span gas concentration is recommended at
2
Calibration port of the 3-Way
2
Model 1000 CO2
1) Verify that the current calibration gas level is equal to the calibration span gas concentration. (Refer to
Section
2) If the calibration gas level setting is equal to the calibration span gas concentration, proceed to item “
5.2.3 Program Mode, “View Sensor Status”. The item appears as “CAL LEVEL @ ### %”.)
3)”.
If the calibration gas level setting is not equal to the calibration span gas concentration, adjust the
calibration gas level setting so that it is equal to the calibration span gas concentration.
a) Enter the programming menu by holding the programming magnet stationary over “PGM 2” for 30
seconds until the display reads “VIEW PROG STATUS”, and then withdraw the magnet. Scroll
through the programming menu by momentarily waving the programming magnet over “PGM 1” or
“PGM 2”.
b) From the programming menu scroll to the calibration level listing. The menu item appears as: “SET
CAL LEVEL”. Enter the menu by holding the programming magnet stationary over “PGM 1” for 3
seconds until the display reads “CAL LEVEL @ ##%”, then withdraw the magnet. Use the
programming magnet to increase (PGM 1) or decrease (PGM 2) the display reading until the reading is
equal to the desired calibration span gas concentration.
c) Exit to the programming menu by holding the programming magnet over “PGM1” for 3 seconds.
d) Exit back to normal operation by holding the programming magnet over “PGM 2” for 3 seconds, or,
the sensor will automatically return to normal operation in 30 seconds.
3) Enter the calibration menu by holding the programming magnet stationary over “PGM 1” for 3 seconds.
The display will read “1-ZERO 2-SPAN”. Hold programming magnet stationary over “PGM 2” for 3
seconds, the display will change to “APPLY #.##% CO2”, withdraw the programming magnet. The #.##
indicates the gas concentration requested.
4) Turn the CO
being drawn from the CO
3-way valve so that the arrow is pointing toward the cal gas source. The sample is now
2
Calibration Port.
2
5) Turn the fixed flow regulator on the Cal Gas Bottle to the “ON” position, and set the sample Rotameter
flow valve so the flow is 250cc/min.
6) As the sensor signal changes, the display will change to “SPAN #.##%”. Where “#.##” indicates the
actual gas reading. The readings will increase/decrease until the sensor stabilizes. When the sensor signal
is stable, it will auto span to the requested concentration and the display will change to “SPAN
COMPLETE” for two seconds and then “REMOVE GAS”.
7) Turn the fixed flow regulator on the Cal Gas Bottle to the “OFF” position and remove the gas.
NOTE: If the circuitry is unable to adjust the span to the proper setting the sensor will enter into the
calibration fault mode which will cause the display to alternate between the sensor’s current status
reading and the calibration fault, which appears as: “CAL FAULT”.
8) Return the CO
3-way valve so that the arrow is pointing toward the sample source, and re-establish the
2
target sample gas flow through the sample Rotameter.
9) Span calibration is complete. The total time for span calibration is approximately 10 minutes. The
analyzer will then return to normal operation after the reading falls below the Alarm 1 and Alarm 2 set
point levels.
Additional Notes
a) Upon entering the calibration menu, the 4-20mA signal drops to 2mA and is held at this level until the
sensor returns to normal operation.
b) If during calibration the sensor circuitry is unable to attain the proper adjustment for zero or span, the
sensor will enter into the calibration fault mode, which will activate fault alarm functions and cause the
display to alternate between the sensor’s current status reading and the calibration fault screen which
appears as: “CAL FAULT”. If this occurs, attempt to recalibrate by entering the calibration menu. If the
sensor fails again, refer to Section
12.0, Troubleshooting.
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 16 of 28
Model 1000 CO2
7.0 Programming Sensors
7.1 Alarm Levels
Both alarm 1 and alarm 2 levels are factory set prior to shipment. Alarm 1 is set at 20% of full-scale range;
alarm 2 at 40% of full-scale range. Both alarms can be set in 0.01% increments from 10 to 90% of full-scale
range. The following procedure is used to change alarm set points:
a) First, enter the programming menu by holding the programming magnet stationary over “PGM 2” for 30
seconds until the display reads “VIEW PROG STATUS”, and then withdraw the magnet. At this point,
you can scroll through the programming menu by momentarily waving the programming magnet over
“PGM 1” or “PGM 2”. The menu options are: View Program Status, Set Alarm 1 Level, Set Alarm 2
Level, and Set Cal Level.
b) ALARM 1 LEVEL
appears as: “SET ALARM 1 LEVEL”. Enter the menu by holding the programming magnet stationary
over “PGM 1” for 3 seconds until the display reads “SET ALM1 @ #.##%”, then withdraw the magnet.
Use the programming magnet to make adjustments using “PGM 1” to increase or “PGM 2” to decrease the
display reading until the reading is equal to the desired alarm set point. Exit to the programming menu by
holding the programming magnet over “PGM1” for 3 seconds, or automatically return to the programming
menu in 30 seconds.
c) ALARM 2 LEVEL
appears as: “SET ALARM 2 LEVEL”. Enter the menu by holding the programming magnet stationary
over “PGM 1” for 3 seconds until the display reads “SET ALM2 @ #.##%”, then withdraw the magnet.
Use the programming magnet to make adjustments using “PGM 1” to increase or “PGM 2” to decrease the
display reading until the reading is equal to the desired alarm set point. Exit to the programming menu by
holding the programming magnet over “PGM1” for 3 seconds, or automatically return to the programming
menu in 30 seconds.
d) Exit back to normal operations by holding the programming magnet over “PGM 2” for 3 seconds, or, the
sensor will automatically return to normal operation in 30 seconds.
7.2 Alarm Reset
: From the programming menu scroll to the alarm 1 level listing. The menu item
: From the programming menu scroll to the alarm 2 level listing. The menu item
An alarm condition will cause the applicable alarm to activate its corresponding relay and LED. If alarm 1,
alarm 2, or fault alarms have been programmed for latching relays, an alarm-reset function must be activated
to reset the alarms after an alarm condition has cleared. To reset the alarms, simply wave the programming
magnet over either “PGM 1” or “PGM 2”, momentarily, while in normal operations mode and note that the
corresponding alarm LED(s) turn off.
7.3 Other Alarm Functions
Alarms are factory programmed to be non-latching, de-energized; and to fire under ascending gas conditions.
The fault alarm relay is programmed as normally energized, which is useful for detecting a 24VDC power
source failure. All alarm functions are programmable via jumper tabs. Changing alarm functions requires the
sensor housing to be opened, thus declassification of the area is required.
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 17 of 28
Model 1000 CO2
7.4 Calibration Gas Level
If the calibration gas level setting does not equal the calibration span gas concentration, or the calibration gas
level needs to be changed, adjust the calibration gas level setting so that it is equal to the calibration span gas
concentration.
a) Enter the programming menu by holding the programming magnet stationary over “PGM 2” for 30
seconds until the display reads “VIEW PROG STATUS”, and then withdraw the magnet. Scroll through
the programming menu by momentarily waving the programming magnet over “PGM 1” or “PGM 2”.
b) From the programming menu scroll to the calibration level listing. The menu item appears as: “SET CAL
LEVEL”. Enter the menu by holding the programming magnet stationary over “PGM 1” for 3 seconds
until the display reads “CAL LEVEL @ ##%”, then withdraw the magnet. Use the programming magnet
to increase (PGM 1) or decrease (PGM 2) the display reading until the reading is equal to the desired
calibration span gas concentration.
c) Exit to the programming menu by holding the programming magnet over “PGM1” for 3 seconds.
d) Exit back to normal operation by holding the programming magnet over “PGM 2” for 3 seconds, or, the
sensor will automatically return to normal operation in 30 seconds.
8.0 Display Contrast Adjustment
Detcon MicroSafe™ sensors feature a 16-character backlit liquid crystal display. Like most LCD’s, character
contrast can be affected by viewing angle and temperature. Temperature compensation circuitry included in
the MicroSafe™ design will compensate for this characteristic; however temperature extremes may still cause
a shift in the contrast. Display contrast can be adjusted by the user if necessary. However, changing the
contrast requires that the sensor housing be opened, thus, declassification of the area is required.
To adjust the display contrast, remove the enclosure cover, and use a jeweler’s screwdriver to turn the contrast
adjust screw located beneath the metallic faceplate. The adjustment location is marked “CONTRAST”.
9.0 Programming Features
Model IR-640/IR-642 MicroSafe™ Sensors incorporate a comprehensive program to accommodate easy
operator inter face and fail-safe operation. Program features are detailed in this section. Each sensor is factory
tested, programmed, and calibrated prior to shipment.
Over Range
When the sensor detects gas greater than 100% of the full-scale range, it will cause the display to flash
“OVER-RANGE” on and off.
Optics Life
The Optics Life feature is a reference based on the signal output from the optical sensor. When an optical
sensor life of 25% or less remains; the optical sensor should be replaced within a reasonable maintenance
schedule.
Calibration Fault
If during calibration the sensor circuitry is unable to attain the proper adjustment for zero or span, the sensor
will enter into the calibration fault mode and cause the display to alternate between the sensor’s current status
reading and the calibration fault screen which appears as: “CAL FAULT.2”.
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 18 of 28
Model 1000 CO2
The following conditions will cause a calibration fault:
1 - Zero calibration cannot converge.
2 - Auto span cannot converge (too noisy or too unstable).
3 - Span gas is not applied before 1 minute elapses.
Fail-Safe/Fault Supervision
Model IR-640/IR-642 MicroSafe™ sensors are programmed for fail-safe operation. All of the fault conditions
listed below will activate the fault relay, illuminate the fault LED, cause the mA output to drop to zero (0mA),
and cause the display to read its corresponding fault condition.
Memory Error
If the processor can’t save values to memory, the display will indicate: “MEMORY ERROR”.
Zero Fault
If the sensor should drift below -10% of range, the display will indicate: “ZERO FAULT”.
Lamp Fault
If the lamp signal is lost, the display will indicate: “LAMP FAULT.2”.
Reference Peak High Fault
If the reference peak signal is too high (>3600), the display will indicate: “SIGNAL FAULT.31”.
Active Peak High Fault
If the active peak signal is too high (>3600), the display will indicate: “SIGNAL FAULT.32”.
Reference Peak Low Fault
If the reference peak signal is too low (<500), the display will indicate: “SIGNAL FAULT.41”.
Active Peak Low Fault
If the active peak signal is too low (<500), the display will indicate: “SIGNAL FAULT.42”.
Reference Peak to Peak Low Fault
If the reference peak to peak signal is too low (<200), the display will indicate: “SIGNAL FAULT.51”.
Active Peak to Peak Low Fault
If the active peak to peak signal is too low (<200), the display will indicate: “SIGNAL FAULT.52”.
10.0 RS-485 Protocol
Detcon MicroSafe™ sensors feature Modbus™ compatible communications protocol and are addressable via
rotary dipswitches for multi-point communications. Other protocols are available. Contact the Detcon factory
for specific protocol requirements. Communication is two wire, half duplex 485, 9600 baud, 8 data bits, 1 stop
bit, no parity, with the sensor set up as a slave device. A master controller up to 4000 feet away can
theoretically poll up to 256 different sensors. This number may not be realistic in harsh environments where
noise and/or wiring conditions would make it impractical to place so many devices on the same pair of wires.
If a multi-point system is being utilized, each sensor should be set for a different address. Typical address
settings are: 01, 02, 03, 04, 05, 06, 07, 08, 09, 0A, 0B, 0C, 0D, 0E, 0F, 10, 11, etc.
In most instances, RS-485 ID numbers are factory set or set during installation before commissioning. If
required, the RS-485 ID number can be set via rotary dipswitches located on the preamp circuit board.
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 19 of 28
Model 1000 CO2
However, any change to the RS-485 ID number would require the sensor housing to be opened, thus
declassification of the area would be required. See section
3.4 for details on changing the RS-485 ID number.
The following section explains the details of the Modbus™ protocol that the Detcon MicroSafe™ sensor
supports.
Code 03 - Read Holding Registers is the only code supported by the transmitter. Each transmitter contains 6
holding registers which reflect its current status.
Register # High Byte Low Byte
40000 Gas type Sensor Life
Gas type is one of the following:
01=CO, 02= H
S, 03=SO2, 04=H2, 05=HCN, 06=CL2, 07=NO2, 08=NO, 09=HCL, 10=NH3, 11=LEL, 12=O2
2
Sensor life is an estimated remaining use of the sensor head, between 0% and 100%
Example: 85=85% sensor life
Register # High Byte Low Byte
40001 Detectable Range
i.e.: 100 for 0-100 ppm, 50 for 0-50% LEL, etc.
Register # High Byte Low Byte
40002 Current Gas Reading
The current gas reading is a whole number. If the reading is displayed as 23.5 on the display, this register
would contain the number 235.
Register # High Byte Low Byte
40003 Alarm 1 Set point
This is the trip point for the first alarm.
Register # High Byte Low Byte
40004 Alarm 2 Set point
This is the trip point for the second alarm.
Register # High Byte Low Byte
40005 Status Bits Status Bits
High Byte
Bit 7 Not used, always 0
Bit 6 Not used, always 0
Bit 5 Not used, always 0
Bit 4 Not used, always 0
Bit 3 1-Unit is in calibration 0-Normal operation
Bit 2 1-Alarm 2 is ascending 0-Alarm 2 is descending
Bit 1 1-Alarm 2 is normally energized 0-Alarm 2 is normally de-energized
Bit 0 1-Alarm 2 is latching 0-Alarm 2 is non-latching
Low Byte
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 20 of 28
Model 1000 CO2
Bit 7 1-Alarm 2 Relay is energized 0-Alarm 2 Relay is not energized
Bit 6 1-Alarm 1 is ascending 0-Alarm 1 is descending
Bit 5 1-Alarm 1 is normally energized 0-Alarm 1 is normally de-energized
Bit 4 1-Alarm 1 is latching 0-Alarm 1 is non-latching
Bit 3 1-Alarm 1 Relay is energized 0-Alarm 1 Relay is not energized
Bit 2 1-Fault is normally energized 0-Fault is normally de-energized
Bit 1 1-Fault is latching 0-Fault is non-latching
Bit 0 1-Fault Relay is energized 0-Fault Relay is not energized
The following is a typical Master Query for device # 8:
Field Name HEX DEC RTU
Slave Address 08 8 0000 1000
Function 03 3 0000 0011
Start Address Hi 00 0 0000 0000
Start Address Lo 00 0 0000 0000
No. of Registers Hi 00 0 0000 0000
No. of Registers Lo 06 6 0000 0110
CRC ## # #### ####
CRC ## # #### ####
The following is a typical Slave Response from device # 8:
Field Name HEX DEC RTU
Slave Address 08 8 0000 1000
Function 03 3 0000 0011
Byte Count 0C 12 0000 1100
Reg40000 Data Hi 02 2 0000 0010
Reg40000 Data Lo 64 100 0110 0100
Reg40001 Data Hi 00 0 0000 0000
Reg40001 Data Lo 64 100 0110 0100
Reg40002 Data Hi 00 0 0000 0000
Reg40002 Data Lo 07 7 0000 0111
Reg40003 Data Hi 00 0 0000 0000
Reg40003 Data Lo 0A 10 0000 1010
Reg40004 Data Hi 00 0 0000 0000
Reg40004 Data Lo 14 20 0001 0100
Reg40005 Data Hi 05 5 0000 0101
Reg40005 Data Lo 50 80 0101 0000
CRC ## # #### ####
CRC ## # #### ####
Additional Notes:
The calibration LED will light when the transmitter is sending a response to a Master Query. Communications
are 9600 baud, 8 data bits, 1 stop bit, No parity, and half duplex 485.
11.0 Sensor Replacement
Should the optical gas sensor element (part number 370-365878-111(IR-640) or 370-287724-332 (IR-642))
require replacement, use the following procedure:
1 - (A) If the sensor is mounted in a classified area, system power to the transmitter must first be removed
before proceeding further.
(B) If the sensor is in an unclassified area, remove front enclosure cover and unplug transmitter module.
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 21 of 28
Model 1000 CO2
2 - Remove gas inlet adapter and tubing connections to expose sensor housing (see illustration page 35).
3 - Remove lower half of sensor housing using an Allen wrench (3 screws).
4 - Remove existing optical sensor and replace with new optical sensor.
5 - Re-install lower half of sensor housing.
6 - Restore system power (if classified) or plug in transmitter module and replace enclosure cover (if
unclassified).
7 - As the unit reports “WARMING UP” message, use the magnetic programming tool and swipe across
PGM1 or
PGM2. This will take the unit into a one-time gain setting mode which takes 1 minute to complete.
8 - Perform a new zero calibration followed by a new span calibration.
12.0 Troubleshooting
Reading higher or lower than anticipated
Probable Cause: No sample flow or bad Span or Zero Calibration
1. Check for adequate sample and air f lows (per range table)
2. Check span gas is same as programmed Autospan value
3. Check Span Calibration for valid concentration
4. Re-calibrate with known good span gas
5. Re-zero calibrate with CO
“Span Fault” Error
1. Check for adequate sample flow and airflow (per range table)
2. Check span gas is same as programmed Autospan value
3. Check Span Calibration for valid concentration
4. Re-calibrate with known good span gas this should clear error.
“Memory Fault” or “Error @ XXXXXX” Message
Probable Cause: Microprocessor error that must be cleared
1. Unplug transmitter module and re-plug transmitter, this may clear the fault. If not…..
2. Un-plug/Re-plug transmitter module and swipe magnet over PGM1 in the first 3 seconds
3. This re-initializes the sensor in a process that takes 1-2 minutes
4. Re-set programmed values for cal gas and alarms, as these are lost in re-initializing
5. Re-Zero and Re-span to restore normal operation
6. This should clear any Memory or “Error @ XXXXXX” conditions
“Signal Fault .XX” Message
Probable Cause: Problematic IR sensor housing assembly or Faulty IR Sensor
1. Unplug transmitter module and re-plug transmitter, this may clear the fault.
If not:
2. Un-plug/Re-plug transmitter module and swipe magnet over PGM1 in the first 3 seconds
3. This re-initializes the sensor in a process that takes 1-2 minutes
4. Re-set programmed values for cal gas and alarms, as these are lost in re-initializing
5. Re-Zero and Re-span to restore normal operation
6. This may clear any “Signal Fault @ XXXXXX” conditions
7. Replace IR sensor and/or IR sensor housing assembly if necessary.
“Lamp Fault”
Probable Cause: IR Sensor in need of Replacement
1. Unplug transmitter module and re-plug transmitter, this may clear the fault.
2. Remove lower section of IR Sensor housing and determine if IR light source is on and blinking
3. If light source is not blinking, replace the IR sensor.
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 22 of 28
free gas
2
Model 1000 CO2
13.0 Spare Parts
Part# Description
327-000000-000 Programming Magnet
351-152021-400 24 VDC Pump Assembly
360-205421-024 24 VDC Power Supply
360-2424GH-030 24V DC-DC Converter
943-200000-000 Activated Carbon Scrubber
943-010013-505 500 CC Fixed Flow Regulator
823-101085-882 Genie Membrane Filter
350-300000-000 0.5Lpm Rotameter no valve
348-900000-000 1Lpm Rotameter with valve
350-523081-02K Mass flow controller
308-091000-030 Pressure Gauge 0-30 PSI
942-400123-2X5 Calibration Span Gas (2.5% CO
942-400123-005 Calibration Span Gas (5% CO
926-405502-015 Transmitter Module 0-15%ppm Range (for CO
926-405502-020 Transmitter Module 0-20%ppm Range (for CO
500-002042-000 IR Connector board
370-365878-111 CO
370-287724-332 CO
390-000088-000 CO
Plug-in Optical Replacement Sensor (IR640)
2
Plug-in Optical Replacement Sensor (IR-642)
2
Sensor Housing Assembly (does not include replacement cell)
2
24VDC Power Supply
(Mounted under Connector PCA)
, balance air)
2
, balance air)
2
gas sensor)
2
gas sensor)
2
24V DC-DC
Converter
+
+
24VDC
18-36
OUT
VDC
2.1A
IN
PART NO.
MODEL NO.
SERIAL NO.
INPUT VOLTAGE
FREQUENCY
CURRENT LOAD
AREA CLASSIFICATION
3200 A-1 Research Forest Dr.
The Woodlands, TX 77381
www.detcon.com
detcon inc.
AIR
1.0Lpm Air
Rotameter
Mass Flow Control
0.5Lpm Sample
Rotameter
SAMPLE PRESSURE
10 PSIG (CONSTANT)
AIR
INLET
SAMPLE
FLOW
AIR
FLOW
0-30psi
Pressure Guage
SAMPLE
INLET
Genie Membrane
Filter
IR-640/642
Transmitter
Module
IR Sensor Head and Plug-in
Replacement Sensor
Figure 16 Spare parts identification
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 23 of 28
Model 1000 CO2
14.0 Warranty
Detcon Inc., as manufacturer, warrants under intended normal use each new Model 1000 Series H
Analyzer gas detection system to be free from defects in material and workmanship for a period of one year
from the date of shipment to the original purchaser. All warranties and service policies are FOB the Detcon
Inc. facility located in The Woodlands, Texas.
Sensor Transmitter
Detcon, Inc., as manufacturer, warrants under intended normal use each new MicroSafe™ plug-in control
circuit to be free from defects in material and workmanship for a period of two years from the date of shipment
to the original purchaser.
Detcon, Inc., further provides for a five year fixed fee service policy wherein any failed transmitter shall be
repaired or replaced as is deemed necessary by Detcon, Inc., for a fixed fee of $65.00. The fixed fee service
policy shall affect any factory repair for the period following the two-year warranty and shall end five years
after expiration of the warranty. All warranties and service policies are FOB the Detcon facility located in The
Woodlands, Texas.
Terms & Conditions
The original serial number must be legible on each sensor element base.
Shipping point is FOB the Detcon factory.
Net payment is due within 30 days of invoice.
Detcon, Inc. reserves the right to refund the original purchase price in lieu of sensor replacement.
IR-640/IR-642 CO
Plug-in Sensor Warranty
2
Detcon, Inc., as manufacturer, warrants each plug-in optical sensor to be free from defects in material and
workmanship under intended normal use for a period of 5 years according to the following schedule:
2 Years No Charge
3rd 25% of replacement charge
4th 50% of replacement charge
5th 75% of replacement charge
Beyond 100%% of replacement charge
S Process
2
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 24 of 28
Model 1000 CO2
15.0 Gas Flow and Wiring Diagrams
PART NO.
MODEL NO.
SERIAL NO.
INPUT VOLTAGE
FREQUENCY
CURRENT LOAD
AREA CLASSIFICATION
3200 A-1 Research Forest Dr.
The Woodlands, TX 77381
www.detcon.com
detcon inc.
AIR
AIR
INLET
AIR
FLOW
Sample
SAMPLE
SAMPLE
FLOW
SAMPLE PRESSURE
10 PSIG (CONSTANT)
INLET
Input
SAMPLE CALIBRATE
VentVentVent
Figure 17 Unit Flow Diagram
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 25 of 28
Model 1000 CO2
Sample Flow
Fault
Figure 18 Pump Box Flow Diagram
Air Flow
Fault
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 26 of 28
Model 1000 CO2
Red 18AWG
Black 18AWG
30
31
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
Blue 18AWG
Gray 18AWG
Violet 18AWG
White 18AWG
Orange 18AWG
Tan 18AWG
+
24VDC
OUT
2.1A
Blue 18AWG
Black 18AWG
Green 18AWG
Brown 18AWG
Yellow 18AWG
+
18-36
VDC
IN
Tan 18AWG
Gray 18AWG
White 18AWG
Brown 18AWG
Yellow 18AWG
40
41
Red 18AWG
Gray 18AWG
Gray 18AWG
Black 18AWG
Green 18AWG
Brown 18AWG
Brown 18AWG
Orange 18AWG
Orange 18AWG
Connector Board
32 33 34 35 36 37 38 39
40 41
Red 18AWG
Red 18AWG
Red 18AWG
Black 18AWG
Black 18AWG
Red 18AWG
Black 18AWG
Red 18AWG
Black 18AWG
Black 18AWG
24VDC +
24VDC Com
120VAC (L1)
Neutral (N)
Ground
DC IN
(Optional)
AC IN
Customer Supplied
Power Supply
Box Assembly
White 18AWG
Black 18AWG
Green 18AWG
Black 18AWG
Gnd
P1
NFS40-7624
24VDC Power
321
L1 N
Supply
+
+
25
26
Green 16AWG
J1
123456
J1
Green 16AWG
Pump Box
Assembly
192021
123
Sample
Flow Fault
(Optional)
11
1213141516
COM
COM
Fault
mA
A
B
A
B
VDC Power In
4-20mA Output
RS-485 In
RS-485 Out
Assembly
Alarm Dry Contacts
Sensor
38
39
18
17
1
2
COM
30
31
Red
Black
Pump
Assembly
34
35
Air Flow
Fault (optional)
33
32
123
222324
Figure 19 Wiring Diagram
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 27 of 28
Model 1000 CO2
Appendix C
Revision Log
Revision Date Changes made Approvals
2.0 3/30/09 Combined Low range and High range CO2 manuals into
one
2.1 06/01/11 Updated drawings and Spare parts list. Added Revision
Log
2.2 9/19/11 Updated notation regarding VDC input in section 3.3 to
match wiring diagram
BM
LU
LU
Model 1000 CO2 Instruction Manual Rev. 2.2 Page 28 of 28
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