Detcon PI-600 User Manual

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etcon inc.

Detcon Model Series

PI-600

Explosion Proof PID-Based Universal VOC Gas Sensors

(Also covers Model PI-601)

Operator’s Installation & Instruction Manual

December 17, 2009 • Document #2970 • Version 1.6

phone 888-367-4286, 713-559-9200 • fax 281-292-2860 • www.detcon.com • sales@detcon.com

Table of Contents

3.0 Description

3.1 Principle of Operation

3.2 Application

3.3 Specifications

3.4 Installation

3.5 Start-up

3.6 Operating Software & Magnetic Interface

3.7 Software Flow Chart

3.8 Calibration and Plug-in Sensor Maintenance

3.9 Status of Programming: Software Version, Calibration Level, and Sensor Life

3.10 Programming Alarms

3.11 Program Features

3.12 Display Contrast Adjust

3.13 Universal Transmitter Feature (Re-Initialization)

3.14 RS-485 Protocol

3.15 Trouble Shooting Guide

3.16 Spare Parts List

3.17 Warranty

3.18 Service Policy

PI-600 Toxic Gas Sensors PG.2

3.0 DESCRIPTION

Construction of

PID Sensor

Collection Plates

UV Filter Window @ 10.6eV

Electrodeless Lamp Illumination Contacts

Membrane Filter

Krypton

Gas

Target VOC Compounds

etcon MicroSafe™ Model PI-600 and PI-601 universal VOC sensors are non-intrusive “Smart” sensors designed to

D detect and monitor for VOC & toxic gas in the ppm range. One of the primary features of the sensor is its method of automatic calibration which guides the user through each step via instructions displayed on the backlit LCD. The sensor features LED indicators for 2 ALARMS, FAULT and CAL status; 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 universal plug-in transmitter module that mates to a standard connector board. Both are housed in an explosion proof condulet that includes a glass lens. A 16 character alpha/numeric indicator is used to display sensor readings as well as the sensor’s menu driven features via a hand-held programming magnet.

Typical ranges of detection are 0-10ppm, 0-20ppm, 0-50ppm, (using the PI-600) and 0-100ppm, 0-500ppm, and 01,000ppm (using the PI-601). Other ranges are available and all ranges are covered by this manual. To determine sensor model number, reference the label located on the enclosure cover. To determine primary range, reference labeling on the sensor head.

3.0.1 Sensor Technology

The sensors are based on a plug-in replaceable miniature PID (Photo-Ionization Detector) sensor technology. The sensor is sensitive to all ambient gases that have ionization potentials of < 10.6 eV, making it highly sensitive but extremely non-specific. The sensor responds to most all toxic VOC compounds and many other toxic gases as well. The sensor is comprised of a UV emitting lamp that is covered by a specific optical filter which projects only radiation in the 10.6 eV range. Target gases that diffuse into the sensor chamber with ionization potentials of < 10.6 eV, are ionized by the radiation and give up free electrons. The free electrons are captured by the high voltage collection grid and provide a current signal that is directly proportional to the concentration of the target gas.

PI-600 Toxic Gas Sensors PG.3

3.0.2 Universal Microprocessor Control Transmitter Circuit

etcon inc.

Program Switch #2

FLT

ALM

CAL

icroSafe™ Gas Sensor

OUST ON, T EXA S

PGM 2

PGM 1

ALM

MODEL PI-600

ONTRAST

Alarm & Cal LEDs

Program Switch #1

Menu Driven Display

Plug-in Universal Microprocessor Control Circuit

Display Contrast Adjust

UNIVERSAL

RANSMITTER

PPM

VOC

ALARM 1

WHT

BLK

YEL

BLU

VDC Power In

NO/NC

COM

NO/NC

COM

NO/NC

COM

FAULT ALM- 2 ALM -1

Alarm Dry Contacts

ALARM 2

FAULT

4-20 mA Output

RS-485 In

RS-485 Out

Optional 4-20 mA Signal Developing Resistor Use 250 ohm 1/4w

JUMPERS

UN-USED

Jumper Programmable Alarm Outputs Normally Open or Normally Closed

Sensor

Place un-used alarm programming jumper tabs here

PID Sensor Head

Transmitter Electronics in Explosion-Proof housing

he control circuit is microprocessor based and is packaged as a universal plug-in field replaceable module, facilitating

T easy replacement and minimum down time. The universality includes the ability to set it for any range concentration and for any gas type. These gas and range settings must be consistent with the PID Sensor Head it is mated with. Circuit functions include a basic sensor pre-amplifier, on-board power supplies, microprocessor, back lit alpha numeric display, fault, alarm, and calibration status LED indicators, magnetic programming switches, an RS-485 communication port and a linear 4-20 mA DC output.

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 suppression, input filter and lugless terminals for all field wiring.

3.0.4 Explosion Proof Enclosure The transmitter electronics 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 activated through the lens window via a hand-held magnetic programming tool allowing non-intrusive operator interface with the sensor. Calibration can be accomplished without removing the cover or declassifying the area. Electrical classification is Class I; Groups B, C, D; Division 1 (explosion proof).

PI-600 Toxic Gas Sensors PG.4

3.1 PR

Functional

Block

Diagram

Functional

Block

Diagram

nalog 4-20 mA Out

ower In

elays Out

Pre-Amp Display

Tem per atu re

ompensation

Alarm & Fault

elays

RS-485 & 4-20mA

Micro-

rocessor

ransmitter

Power Supply

ensor

lement

/O Circuit

rotection

Serial RS-485 Out

INCIPLE OFOPERATION

Ionizable target gases diffuse into the PID sensor chamber through a sintered f lame arrestor. These target gases are exposed to UV radiation emitted by the PID lamp and this causes a fraction of the molecules to give up a free electron. The free electrons are captured by the high voltage collection grid and provide a current signal that is directly proportional to the concentration of the target gas. This change in current is completely reversible and results in the continuous monitoring of ambient air conditions.

3.2 APPLICATION

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 feet above grade.

3.2.2 Interference Data

Detcon Model PI-600 series PID sensors are subject to interference from many gases. This interaction is shown in the table in Section 3.2.3. The table shows most all gases of interest and the level of signal response they have relative to a standard isobutylene reference gas. This measure is referred to as the Response Factor (RF). As a general rule, the lower the RF value, the stronger the signal from the PID sensor. When determining a cross-interference from one gas to another, find the RF of your target gas and then your interfering gas(es). The cross-interference will be calculated by dividing the RF of your interfering gas by the RF of your target gas.

For example, if your target gas is benzene and you are concerned about a cross-interference to H2S then you would calculate the cross interference to be 3.3/0.50 = 6.2. This shall be interpreted as: it will take 6.2 ppm of H2S to register as 1 ppm benzene on a PID sensor calibrated for benzene.

In many cases, the user will be interested in measuring a multiple of toxic VOC compounds. In this case the sensor will produce a signal that is a composite total of each gases’ individual response, when taking into account the corresponding response factors.

For example, if the target gases are benzene and isobutanol and your PID sensor was calibrated for benzene then the presence of 5 ppm benzene and 5 ppm of isobutanol would each add to the total reading. In this case, the 5 ppm benzene would register as 5 ppm, but the 5 ppm isobutanol would register as the amount of cross interference of isobutanol relative to a benzene calibration. This is calculated as discussed above where you divide the RF of isobutanol by the RF of benzene. Using the look up table this gives you 3.8/0.50 = 7.2. So it takes 7.2 ppm isobutanol to equal 1 part benzene. Since we have 5 ppm isobutanol, that will equal 0.7 ppm on the benzene scale. The total signal will be 5 + 0.7 = 5.7 ppm.

3.2.3 Relative Response Gas Matrix (See next page)

The table shows you the response of the PID sensor to a long list of components. It includes the compound name, synonyms/abbreviations, and chemical formula. It also lists the 10.6 eV Response Factor (the measure of how strong the signal from the sensor is in reference to Isobutylene gas). Isobutylene gas is the standard reference used with PID sensors, the lower the Response Factor, the stronger the signal.

NR = not reccomended (does not register)

? = measureable but no data exist

Confirmed Value = “+” means actual gas has been used to verify RF, “blank” means it is an empirical estimate

IP = is the gases ionization potential (only gases < 10.6eV will respond to sensor)

TWA/Time Weighted Average = generally accepted limit for safe 8 hour exposure (in ppm)

PI-600 Toxic Gas Sensors PG.5

3.2.3 Relative Response Gas Matrix (page 1 of 8)

Compound Name Synonym/Abbreviation Formula Response Factor Confirmed Value IP (eV) TWA

Acetaldehyde C2H4O 5.5 + 10.23 C25

Acetic Acid Ethanoic Acid C2H4O2 22 + 10.66 10

Acetic Anhydride Ethanoic Acid Anhydride C4H6O3 6.1 + 10.14 5

Acetone 2-Propanone C3H6O 1.1 + 9.71 500

Acetonitrile Methyl cyanide, Cyanomethane C2H3N NR 12.19 40

Acetylene Ethyne C2H2 NR 11.40 ne

Acrolein Propenal C3H4O 3.9 + 10.10 0.1

Acrylic Acid Propenoic Acid C3H4O2 12 + 10.60 2

Acrylonitrile Propenenitrile C3H3N NR + 10.91 2

Allyl alcohol C3H6O 2.4 + 9.67 2

Allyl chloride 3-Chloropropene C3H5Cl 4.3 9.9 1

Ammonia H3N 9.7 + 10.16 25

Amyl alcohol mix of n-pentyl acetate & C5H12O 5 10.00 100

2-Methylbutyl acetate

Aniline Aminobenzene C7H7N 0.5 + 7.72 2

Anisole Methoxybenzene C7H8O 0.8 8.21 ne

Arsine Arsenic trihydride AsH3 1.9 + 9.89 0.05

Benzaldehyde C7H6O ? 9.49 ne

Benzene C6H6 0.5 + 9.25 0.5

Benzonitrile Cyanobenzene C7H5N 1.6 9.62 ne

Benzyl alcohol a-Hydroxytoluene, C7H8O 1.1 + 8.26 ne

Hydroxymethylbenzene, Benzenemethanol

Benzyl chloride a-Chlorotoluene, C7H7Cl 0.6 + 9.14 1

Chloromethylbenzene

Benzyl formate Formic acid benzyl ester C8H8O2 0.73 + ne

Boron trifluoride BF3 NR 15.5 C1

Bromine Br3 1.30 + 10.51 0.1

Bromobenzene C6H5Br 0.6 8.98 ne

2-Bromoethyl methyl ether C3H7OBr 0.84 + ~10 ne

Bromoform Tribromomethane CHBr3 2.5 + 10.48 0.5

Bromopropane, 1- n-Propyl bromide C3H7Br 1.5 + 10.18 ne

Butadiene 1,2-Butadiene, Vinyl ethylene C4H6 0.85 + 9.07 2

Butadiene diepoxide, 1, 3- 1,2,3,4-Diepoxybutane C4H6O2 3.5 + ~10 ne

Butane C4H10 67 10.53 ne

Butanol, 1- Butyl alcohol, n-Butanol C4H10O 4.7 + 9.99 C50

Butanol, t- tert-butanol, t-Buty alcohol C4H10O 2.9 + 9.90 100

Butene, 1- 1-Butylene C4H8 0.9 9.58 ne

Butoxyethanol, 2- Butyl Cellosolve, C6H14O2 1.2 + <10 25

Ethyleneglycol monobutyl ether

Butyl acetate, n- C6H12O2 2.6 + 10 150

Butyl acrylate, n- Butyl 2-propenoate, C7H12O2 1.6 + 10

Acrylic acid butyl ester

Butylamine C4H11N 7 8.71

Butylamine, n- C4H11N 1.1 + 8.71 C5

10.6 eV

PI-600 Toxic Gas Sensors PG.6

3.2.3 Relative Response Gas Matrix (page 2 of 8)

Compound Name Synonym/Abbreviation Formula Response Factor Confirmed Value IP (eV) TWA

Butyl cellosolve see 2-Butoxyethanol

Butyl hydroperoxide, t- C4H10O2 1.6 + <10 1

Butyl mercaptan 1-Butanethiol C4H10S 0.52 + 9.14 0.5

Carbon disulfide CS2 1.2 + 10.07 10

Carbon monoxide CO NR + 14.07 50

Carbon tetrachloride Tetrachloromethane CCl4 NR + 11.47 5

Carbonyl sulfide Carbon Oxysulfide COS NR 11.18

Cellosolve see 2-Ethoxyethanol

CFC-14 see Tetrafluoromethane

CFC-113 see 1,1,2-Trichloro-1,2,2-trifluoroethane

Chlorine Cl2 NR 11.48 0.5

Chlorine dioxide ClO2 NR + 10.57 0.1

Chloro-1,3-butadiene, 2- Chloroprene C4H5Cl 3 10

Chlorobenzene Monochlorobenzene C6H5Cl 0.40 + 9.06 10

Chloro-1, 1-difluoroethane, 1-(R-142B) C2H3ClF2 NR 12.0

Chlorodifluoromethane HCFC-22, R-22 CHClF2 NR 12.2 1000

Chloroethane Ethyl chloride C2H5Cl NR + 10.97 100

Chloroethanol Ethylene chlorhydrin C2H5ClO 10.52 C1

Chloroethyl ether, 2- bis(2-chloroethyle) ether C4H8Cl2O 3.0 +5

Chloroethyl methyl ether,2- Methyl 2-chloroethyl ether C3H7ClO 3 ne

Chloroform Trichloromethane CHCl3 NR + 11.37 10

Chloropicrin CCl3NO2 ~400 +?0.1

Chlorotoluene, o- o-Chloromethylbenzene C7H7Cl 0.5 8.83 50

Chlorotoluene, p- p-Chloromethylbenzene C7H7Cl 0.5 8.69 ne

Crotonaldehyde trans-2-Butenal C4H6O 1.1 + 9.73 2

Cumene Isopropylbenzene C9H12 0.54 + 8.73 50

Cyanogen bromide CNBr NR 11.84 ne

Cyanogen chloride CNCl NR 12.34 C0.3

Cyclohexane C6H12 1.4 + 9.86 300

Cyclohexanol Cyclohexyl alcohol C6H12O ? 9.75 50

Cyclohexanone C6H10O 0.9 + 9.14 25

Cyclohexene C6H10 0.8 + 8.95 300

Cyclohexylamine C6H13N 1.2 8.62 10

Cyclopentane C5H10 1.4 10.51 600

Decane C10H22 1.4 + 9.65 ne

Diacetone alcohol 4-Methyl-4-hydroxy-2- pentanone C6H12O2 0.7 50

Dibromoethane,1,2- EDB, Ethylene dibromide, C2H4Br2 1.7 + 10.37 ne

Ethylene bromide

Dichlorobenzene, o 1,2-Dichlorobenzene C6H4Cl2 0.47 + 9.08

Dichlorodifluoromethane CFC-12 CCl2F2 NR + 11.75 1000

Dichloroethane, 1,1- C2H4Cl2 NR 11.06

Dichloroethane, 1,2- EDC, 1,2-DCA, Ethylene dichloride C2H4Cl2 NR + 11.04 10

Dichloroethene, 1,1- 1,1-DCE, Vinylidene chloride C2H2Cl2 0.9 9.79 5

10.6 eV

PI-600 Toxic Gas Sensors PG.7

3.2.3 Relative Response Gas Matrix (page 3 of 8)

Compound Name Synonym/Abbreviation Formula Response Factor Confirmed Value IP (eV) TWA

Dichloroethene, c-1,2- c-1,2-DEC, cis-Dichloroethylene C2H2Cl2 0.8 9.66 200

Dichloroethene, t-1,2- t-1,2-DCE, trans-Dichloroethylene C2H2Cl2 0.45 + 9.65 200

Dichloro-1-fluoroethane, 1,1- R-141B C2H3Cl2F NR + ne

Dichloromethane (see Methylene chloride)

Dichloropentafluoropropane AK-255, mix of ~45% 3,3- dichloro- C3HCl2F5 NR + ne

1,1,1,2,2-pentafluoro- propane (HCFC-225ca) & ~55% 1,3-Dichloro1,1,2,2,3- pentafluoropropane (HCFC-225cb)

Dichloropropane, 1,2 C3H6Cl2 NR 10.87 75

Dichloro-1-propene, 1,3- C3H4C12 0.96 + <10 1

Dichloro-1-propene, 2,3- C3H4Cl2 1.3 + <10 ne

Dichloro-1,1,1-trifluoro R123 C2HCl2F3 NR + 11.5 ne

-ethane, 2,2-

Dichlorvos Vapona; O,O-dimethyl O- C4H7Cl2O4P 0.9 + <9.4 0.1

dichlorovinyl phospate

Dicyclopentadiene DCPD, Cyclopentadiene dimer C10H12 0.5 + 8.8 5

Diesel Fuel #1 m.w. 226 0.9 +

Diesel Fuel #2 m.w. 216 0.7 +

Diethylamine C4H11N 1+ 8.01 5

Diethylaminopropylamine, 3- C7H18N2 1.3

Diethylmaleate C8H12O4 4 ne

Diethyl sulfide see Ethyl sulfide

Diisopropylamine C6H15N 0.74 + 7.73 5

Diketene Ketene dimer C4H4O2 2.0 + 9.6 0.5

Dimethylacetamide, N,N- DMA C4H9NO 0.8 + 8.81 10

Dimethylamine C2H7N 1.5 8.23 5

Dimethyl disulfide C2H6S2 0.20 + 7.4

Dimethyl carbonate Carbonic acid dimethyl ester C3H6O3 ~70 + ~10.5 ne

Dimethyl disulfide DMDS C2H6S2 0.20 + 7.4 ne

Dimethylethylamine DMEA C4H11N 1.0 + 7.74 ~3

Dimethylformamide, N,N- DMF C3H7NO 0.8 9.13 10

Dimethylhydrazine, 1,1- UDMH C2H8N2 0.8 + 7.28 0.01

Dimethyl methylphosphonate DMMP, methyl phosphonic acid C3H9O3P 4.3 + 10.0 ne

dimethyl ester

Dimethyl sulfate C2H6O4S ~20 + 0.1

Dimethyl sulfide see Methyl sulfide

Dimethyl sulfoxide DMSO, Methyl sulfoxide C2H6OS 1.4 + 9.10 ne

Dioxane, 1,4- C4H8O2 1.3 9.19 25

Dowtherm A see Therminol

DS-108F Wipe Solvent Ethyl lactate/Isopar H/ m.w. 118 1.6 + ne

Propoxypropanol ~7:2:1

Epichlorohydrin ECH Chloromethyloxirane, 1- C2H5ClO 8.5 + 10.2 0.5

chloro2,3-epoxypropane

Ethane C2H6 NR + 11.52 ne

Ethanol Ethyl alcohol C2H6O 12 + 10.47 1000

10.6 eV

PI-600 Toxic Gas Sensors PG.8

3.2.3 Relative Response Gas Matrix (page 4 of 8)

Compound Name Synonym/Abbreviation Formula Response Factor Confirmed Value IP (eV) TWA

Ethanolamine

Ethene Ethylene C2H4 10 + 10.51 ne

Ethoxyethanol, 2- Ethyl cellosolve, Ethylene glycol C4H10O2 1.3 9.6 5

Ethyl acetate C4H8O2 4.6 + 10.01 400

Ethyl acrylate C5H8O2 2.4 + (<10.3) 5

Ethylamine C2H7N 0.8 8.86 5

Ethylbenzene C8H10 0.52 + 8.77 100

Ethylene glycol 1,2-Ethanediol C2H6O2 16 + 10.16 C100

Ethylene oxide Oxirane, Epoxyethane C2H4O 13 + 10.57 1

Ethyl ether Diethyl ether C4H10O 1.1 + 9.51 400

Ethyl 3-ethoxypropionate EEP C7H14O3 1.0.75 + ne

Ethyl formate C3H6O2 ? 10.61 100

Ethyl hexyl acrylate, 2- Acrylic acid 2-ethylhexyl ester C11H20O2 1.1 + ne

Ethyl (S)-(-)-lactate see also Ethyl lactate, Ethyl (S)-(-)- C5H10O3 3.2 + ~10 ne DS-108F hydroxypropionate

Ethyl mercaptan Ethanethiol C2H6S 0.56 + 9.29 0.5

Ethyl sulfide Diethyl sulfide C4H10S 0.5 + 8.43 ne

Formaldehyde Formalin CH2O NR 10.87 C0.3

Formic acid CH2O2 NR + 11.33 5

Furfural 2-Furaldehyde C5H4O2 0.92 + 9.21 2

Furfuryl alcohol C5H6O2 0.80 + <9.5 10

Gasoline #1 m.w. 72 0.9 + 300

Gasoline #2, 92 octane m.w. 93 1.0 + 300

Glutaraldehyde 1,5-Pentanedial, Glutaric dialdehyde C5H8O2 0.8 + C0.0

Halothane 2-Bromo-2-chloro-1,1,1- trifluoroethane C2HBrClF3 NR 11.0 50

HCFC-22 (see Chlorodifluoromethane)

HCFC-123 (see 2,2-Dichloro-1,1,1-trifluoroethane, R-123)

HCFC-141B (see 1,1-Dichloro-1-fluorethane)

HCFC-142B (see 1-Chloro-1,1-difluoroethane)

HCFC-134A (see 1,1,1,2-Tetrafluoroethane)

HCFC-225 (see Dichloropentafluoropropane)

Heptane, n- C7H16 2.8 + 9.92 400

Hexamethyldisilazane,1,1,1,3,3,3- HMDS C6H19NSi2 0.2 + ~8.6

Hexane, n C6H14 4.3 + 10.13 50

Hexane, 1- C6H12 9.44

Hexanol, 1- Hexyl alcohol C6H14O 2.5 + 9.86 ne

Hexene, 1- C6H12 0.8 9.44 30

Hydrazine H4N2 2.6 + 8.1

Hydrogen Synthesis gas H2 NR + 15.43 ne

Hydrogen cyanide Hydrocyanic acid HCN NR + 13.60 C4.7

Hydrogen peroxide H2O2 NR + 10.54 1

Hydrogen sulfide H2S 3.3 + 10.45 10

(not recommended)

MEA, Monoethanolamine C2H7NO 1.6 + 8.96 3

monoethyl ether

10.6 eV

PI-600 Toxic Gas Sensors PG.9

3.2.3 Relative Response Gas Matrix (page 5 of 8)

Compound Name Synonym/Abbreviation Formula Response Factor Confirmed Value IP (eV) TWA

Iodine I2 0.1 + 9.40 C0.1

Iodomethane Methyl iodide CH3I 0.2 + 9.54 2

Isoamyl acetate Isopentyl acetate C7H14O2 2.1 <10 100

Isobutne 2-Methylpropane C4H10 100 + 10.57 ne

Isobutanol 2-Methyl-2-propanol C4H10O 3.8 + 10.02 50

Isobutylene Isobutxene, Methyl butene C4H8 1.00 + 9.24 ne

Isobutyl acetate C6H12O2 2.60 150

Isobutyl acrylate Isobutyl 2-propenoate, Acrylic acid C7H12O2 1.5 + ne

Isoflurane 1-Chloro-2,2,2-trifluoroethyl C3H2ClF5O NR ~11.7 ne

Isooctane 2,2,4-Trimethylpentane C8H18 1.2 9.86 ne

Isopar E Solvent Isoparaffinic hydrocarbons m.w. 121 0.8 + ne

Isopar G Solvent Photocopier diluent m.w. 148 0.8 + ne

Isopar K Solvent Isoparaffinic hydrocarbons m.w. 156 0.5 + ne

Isopar L Solvent Isoparaffinic hydrocarbons m.w. 163 0.5 +

Isopar M Solvent Isoparaffinic hydrocarbons m.w. 191 0.7 +

Isopentane 2-Methylbutane C5H12 8.2 ne

Isophorone C9H14O ? 9.07 C5

Isoprene 2-Methyl-1,3-butadiene C5H8 0.63 + 8.85 ne

Isopropanol Isopropyl alcohol, 2-propanol C3H8O 6.0 + 10.12 400

Isopropyl acetate C5H10O2 2.6 9.99 250

Isopropyl ether Diisopropyl ether C6H14O 0.8 9.20 250

Jet fuel JP-4

Jet fuel JP-5 Jet 5, Kerosene type aviaton fuel m.w. 167 0.6 + 15

Jet fuel JP-8 Jet A-1, Kerosene type aviation fuel m.w. 165 0.6 + 15

Limonene, D- (R)-(+)-Limonene C10H16 0.33 + ~8.2 ne

Kerosene (C10-C16 petro.distillate - see Jet Fuels)

MDI (see 4,4'-Methylenebis(phenylisocynate))

Mesitylene 1,3,5-Trimethylbenzene C9H12 0.35 + 8.41 ne

Methane Natural gas CH4 NR + 12.51 ne

Methanol Methyl alcohol, carbinol CH4O NR + 10.85 200

Methoxyethanol, 2- Mehtyl cellosolve, Ethylene glycol C3H8O2 2.4 + 10.1 5

Methoxyethoxyethanol, 2- 2-(2-Methoxyethoxy)ethanol C7H16O3 1.2 + <10 ne

Methyl acetate C3H6O2 6.6 + 10.27 200

Methyl acrylate Methyl 2-propenoate, acrylic acid C4H6O2 3.7 + (9.9) 2

Methylamine Aminomethane CH5N 1.2 8.97

Methyl bromide Bromomethane CH3Br 1.7 + 10.54 1

Methyl t-butyl ether MTBE, tert-Butyl methyl ether C5H12O 0.9 + 9.24 40

Methyl cellosolve (see 2-Methoxyethanol)

Methyl chloride Chloromethane CH3Cl NR + 11.22 50

Methylcyclohexane C7H14 0.97 + 9.64 400

Isobutyl ester

difluoromethyl ether, forane

Jet B, Turbo B, Wide cut type aviation fuel

monomethy ether

Diethylene glycol monomethyl ether

methyl ester

m.w. 115 1.0 + ne

10.6 eV

PI-600 Toxic Gas Sensors PG.10

3.2.3 Relative Response Gas Matrix (page 6 of 8)

Compound Name Synonym/Abbreviation Formula Response Factor Confirmed Value IP (eV) TWA

Methylene bis(phenyl- MDI, Mondur M C15H10N2O2 Very slow ppb level response 0.005 isocyanate), 4,4'-Methylene chloride Dichloromethane CH2Cl2 NR + 11.32 25

Methyl ether Dimethyl ether C2H6O 3.1 + 10.03 ne

Methyl ethyl ketone MEK, 2-Butanone C4H8O2 0.9 + 9.51 200

Methylhydrazine Monomethylhydrazine, C2H6N2 1.2 + 7.7 0.01

Methyl isobutyl ketone MIBK, 4-Methyl-2-pentanone C6H12O 0.8 + 9.30 50

Methyl Isocyanate CH3NCO C2H3NO 4.6 + 10.67 0.02

Methyl isothiocyanate CH3NCS C2H3NS 0.45 + 9.25 ne

Methyl mercaptan Methanethiol CH4S 0.54 9.44 0.5

Methyl methacrylate C5H8O2 1.5 + 9.7 100

Methyl nonafluorobutyl ether HFE-7100DL C5H3F9O NR + ne

Methyl-1,5-pentane- diamine, Dytek-A amine, 2-Methyl C6H16N2 ~0.6 + <9.0 ne 2- (coats lamp) pentamethylenediamine

Methyl propyl ketone MPK, 2-Pentanone C5H12O 0.93 + 9.38 200

Methyl-2-pyrrolidinone, N- NMP, N-Methylpyrrolidone, 1-Methyl- C5H9NO 0.8 + 9.17 ne

Methyl salicylate Methyl 2-hydroxybenzoate C8H8O3 1 ~9 ne

Methylstyrene, a- 2-Propenylbenzene C9H10 0.5 8.18 50

Methyl sulfide DMS, Dimethyl sulfide C2H6S 0.44 + 8.69 ne

Mineral spirits (Stoddard m.w. 144 0.7 + 100 Solvent, see also Viscor 120B)

Mineral spirits Viscor 120B m.w. 142 0.7 + 100 Calibration Fluid, b.p. 156-207°C

Mustard HD, Bis (2-chloroethyl) sulfide C4H8Cl2S 0.6 0.0005

Naphthalene Mothballs C10H8 0.42 + 8.13 10

Nitric oxide NO 5.2 + 9.26 25

Nitrobenzene C6H5NO2 1.9 + 9.81 1

Nitroethane C2H5NO2 NR 10.88 100

Nitrogen dioxide NO2 16.0 + 9.75 3

Nitromethane CH3NO2 NR 11.02 20

Nitropropane, 2- C3H7NO2 NR 10.71 10

Nonane C9H20 1.4 9.72 200

Octane, n- C8H18 1.8 + 9.82 300

Pentane C5H12 8.4 + 10.35 600

Peracetic acid Peroxyacetic acid, Acetyl C2H4O3 NR + ne

Peracetic/Acetic acid mix Peroxyacetic acid, Acetyl

Perchloroethene PCE, Perchloroethylene, C2Cl4 0.57 + 9.32 25

PGME Propylene glycol methyl ether, 107- C6H12O3 1.5 + 100

PGMEA Propylene glycol methyl ether 108 C6H12O3 1.0 + ne

Hydrazomethane

2-pyrrolidinone, 1-Methyl-2-pyrrolidone

Hydroperoxide

C2H4O3/C2H4O2

Hydroperoxide

Tetrachloroethylene

98-2 1-Methoxy-2-propanol

-65-6 acetate, 1-Methoxy-2acetoxypropane, 1-Methoxy-2propanol acetate

10.6 eV

50 + ne

PI-600 Toxic Gas Sensors PG.11

3.2.3 Relative Response Gas Matrix (page 7 of 8)

Compound Name Synonym/Abbreviation Formula Response Factor Confirmed Value IP (eV) TWA

Phenol Hydroxybenzene C6H6O 1.0 + 8.51 5

Phosgene Dichlorocarbonyl CCl2O NR 11.2 0.1

Phosphine in N2 PH3 3.9 + 9.87 0.3

Photocopier Toner Isoparaffin mix 0.5 +

Picoline, 3- 3-Methylpyridine C6H7N 0.9 9.04

Pinene, a- C10H16 0.31 + 8.07 ne

Pinene, b C10H16 0.37 + ~8 100

Piperylene, isomer mix 1,3-Pentadiene C5H8 0.69 + 8.6 100

Propane C3H8 NR + 10.95 2500

Propanol, n- Propyl alcohol C3H8O 5 10.22 200

Propene Propylene C3H6 1.4 + 9.73 ne

Propionaldehyde Propanal C3H6O 1.9 9.95 ne

Propyl acetate, n- C5H10O2 3.5 10.04 200

Propylene carbonate C4H6O3 62 + 10.5 ne

Propylene glycol 1,2-Propanediol C3H8O2 5.5 + <10.2 ne

Propylene oxide Methyloxirane C3H6O 6.6 + 10.22 20

Propyleneimine 2-Methylaziridine C3H7N 1.3 + 9.0 2

Propyl mercaptan, 2- 2-Propanethiol, Isopropyl mercaptan C3H7N 0.66 + 9.2 ne

Pyridine C5H5N 0.7 + 9.25 5

Pyrrolidine (coats lamp) Azacyclohexane C4H9N 1.3 + ~8.0 ne

RR7300 (PGME/PGMEA) 70:30 PGME:PGMEA (1- Methoxy-2-

propanol:1- Methoxy-2-acetoxypropane)

Sarin GB, Isopropyl C4H10FO2P ~3

methylphosphonofluoridate

Stoddard Solvent - see Mineral Spirits

Styrene C8H8 0.40 + 8.43 20

Sulfur dioxide SO2 NR + 12.32

Sulfur hexafluoride SF6 NR 15.3 1000

Sulfuryl fluoride Vikane SO2F2 NR 13.0 6

Tabun Ethyl N, N- C5H11N2O2P 0.8 15ppt

dimethylphosphoramidocyanidate

Tetrachloroethane, 1,1,1,2- C2H2Cl4 NR ~11.1 ne

Tetrachloroethane, 1,1,2,2- C2H2Cl4 NR + ~11.1 1

Tetraethyllead TEL C8H20Pb 0.3 ~11.1 0.008

Tetraethyl orthosilicate Ethyl silicate, TEOS C8H20O4Si 0.7 + ~9.8 10

Tetrafluoroethane, 1,1,1,2- HFC-134A C2H2F4 NR ne

Tetrafluoroethene TFE, Tetrafluoroethylene, C2F4 ~15 10.12 ne

Perfluoroethylene

Tetrafluoromethane CFC-14, Carbon tetrafluoride CF4 NR + >15.3 ne

Tetrahydrofuran THF C4H8O 1.7 + 9.41 200

Tetramethyl orthosilicate Methyl silicate, TMOS C4H12O4Si 1.9 + ~10 1

Therminol VP-1 Dowthern,3:1 Diphenyl oxide:

Biphenyl

Toluene Methylbenzene C7H8 0.50 + 8.82 50

C4H10O2 / C6H12O3

C12H10O C12H10

10.6 eV

1.4 + ne

0.7 + ne

PI-600 Toxic Gas Sensors PG.12

3.2.3 Relative Response Gas Matrix (page 8 of 8)

Compound Name Synonym/Abbreviation Formula Response Factor Confirmed Value IP (eV) TWA

Tolylene-2,4-diisocyanate TDI, 4-Methyl-1,3-phenylene- 2,4- C9H6N2O2 1.4 + 0.002

diisocyanate

Trichlorobenzene, 1,2,4- 1,2,4-TCB C6H3Cl3 0.46 + 9.04 C5

Trichloroethane, 1,1,1- 1,1,1-TCA, Methyl chloroform C2H3Cl3 NR + 11 350

Trichloroethane, 1,1,2- 1,1,2-TCA C2H3Cl3 NR + 11.0 10

Trichloroethene TCE, Trichloroethylene C2HCl3 0.54 + 9.47 50

Trichlorotrifluoroethane, 1,1,2- CFC-113 C2Cl3F3 NR 11.99 1000 CFC-113

Triethylamine TEA C6H15N 0.9 + 7.3 1

Triethyl borate TEB; Boric acid triethyl ester, C6H15O3B 2.2 + ~10

Boron ethoxide

Triethyl phosphate Ethyl phosphate C6H15O4P 3.1 + 9.79 ne

Trifluoroethane, 1,1,2- C2H3F3 NR 12.9 ne

Trimethylamine C3H9N 0.9 7.82 5

Trimethylbenzene, 1,3,5- - (see Mesitylene) 25

Trimethyl borate TMB; Boric acid trimethyl ester, C3H9O3B 5.1 + 10.10 ne

Boron methoxide

Trimethyl phosphate Ethyl phosphate C3H9O4P 8.0 + 9.99 ne

Turpentine Pinenes (85%) + other diisoprenes C10H16 0.3 + ~8 100

Undecane C11H24 2 9.56 ne

Varsol (see Mineral Spirits)

Vinyl actetate C4H6O2 1.2 + 9.19 10

Vinyl bromide Bromoethylene C2H3Br 0.4 9.80 5

Vinyl chloride in N2 Chloroethylene, VCM C2H3Cl 2.0 + 9.99 5

Vinylidene chloride - see 1,1-Dicholorethene

Vinyl-2-pyrrolidinone, 1- NVP, N-vinylpyrrolidone, 1- ethenyl- C6H9NO 0.8 + ne

2-pyrrolidinone

Viscor 120B - see Mineral Spirits - Viscor 120B Calibration Fluid

Xylene, m- C8H10 0.4 + 8.56

Xylene, o- C8H10 0.6 + 8.56

Xylene, p- C8H10 0.5 + 8.44

10.6 eV

None 1

PI-600 Toxic Gas Sensors PG.13

3.3 SPECIFICATIONS

ethod of Detection

Plug-in Miniature PID Sensor

Repeatability

± 2% FS

esponse Time

T90 < 30 seconds

Temperature Range

0-50°C; 32-122°F

Humidity Range

0-99% RH noncondensing

Output

Linear 4-20 mA DC 3 Relays (Alarm 1, Alarm 2, and Fault) contacts rated 5A@ 150VAC, 5A @30 VDC RS-485 Modbus™

Input Voltage

22-28 VDC

Power Consumption

Normal operation = 58 mA (1.4 watts @ 24VDC); Maximum = 128 mA (3.1 watts @ 24VDC)

Electrical Classification

Class 1; Groups B, C, D; Div. 1.

Sensor Warranty

12 Months

3.4 INSTALLATION

Optimum performance of ambient air/gas sensor devices is directly relative to proper location and installation practice.

3.4.1 Field Wiring Table (4-20 mA output) Detcon Model PI-600 toxic gas sensor assemblies require three conductor connection between power supplies and host electronic controllers. Wiring designators are

(DC), –(DC) , and

(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

20 240 800 18 360 1200 16 600 2000 14 900 3000

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.

The RS-485 (if applicable) requires 24 guage, 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 to facilitate serial loop wiring from sensor to sensor. Wiring designators are

A& B

(IN) and A& B(OUT).

3.4.2 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 (3) Ventilation or prevailing wind conditions (4) Personnel exposure (5) Maintenance access

PI-600 Toxic Gas Sensors PG.14

ensity - Placement of sensors relative to the density of the target gas is such that sensors for the detection of heavier than air

EYS

Seal

Fitting

Drain

“T”

Plug any unused ports.

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 4-8 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 connections of the sealed type where seals may either fail or wear. Other leak sources are best determined by facility engineers with experience in similar processes.

Ventilation - Normal ventilation or prevailing wind conditions can dictate efficient location of gas sensors in a manner where the migration of gas clouds is quickly detected.

Personnel Exposure - The undetected migration of gas clouds should not be allowed to approach concentrated personnel areas such as control rooms, maintenance or warehouse buildings. A more general and applicable thought toward selecting sensor location is combining leak source and perimeter protection in the best possible configuration.

Maintenance Access

Consideration should be given to easy access by maintenance personnel as well as the consequences of close proximity to contaminants that may foul the sensor prematurely.

Note: In all installations, the sensor element in SS housing points down relative to grade (Fig. 1). Improper sensor orientation may result in false reading and permanent sensor damage.

3.4.3 Local Electrical Codes

Sensor and transmitter assemblies should be installed in accordance with all local electrical codes. Use appropriate conduit seals. Drains & breathers are recommended. The sensor assemblies are suitable for Class I; Groups B, C, D; Div. 1 environments.

PI-600 Toxic Gas Sensors PG.15

3.4.4 Installation Procedure

ALARM 1

WHT

BLK

YEL

BLU

VDC Power In

NO/NC

COM

NO/NC

COM

NO/NC

COM

FAULT A LM -2 ALM-1

Alarm Dry Contacts

ALARM 2

FAULT

4-20 mA Output

RS-485 In

RS-485 Out

Optional 4-20 mA Signal Developing Resistor Use 250 ohm 1/4w

JUMPERS

UN-USED

Jumper Programmable Alarm Outputs Normally Open or Normally Closed

Sensor

Place un-used alarm programming jumper tabs here

4 3/4"

3/4" NPT

1/4" Dia.

Mounting Holes

7 1/4"

6 1/8" 5 1/2"

3/4" NPT

Rain

Shield

2 1/8"

) Securely mount the sensor junction box in accordance with recommended practice. See dimensional drawing (Fig. 2).

a b) Remove the junction box cover and un-plug the control circuit by grasping the two thumb screws and pulling out-

ward.

c) Observing correct polarity, terminate 3 conductor field wiring, RS-485 wiring, and applicable alarm wiring to the sensor

base connector board in accordance with the detail shown in Figure 3. Normally open and normally closed Form C dry contacts (rated 5 amp @ 150VAC; 5 amp @ 30VDC) are provided for Fault, Alarm 1, and Alarm 2.

Note:

Per U.L. approval, these relays may only be used in connecting to devices that are powered by the

ages.

Figure 3

d) Position gold plated jumper tabs located on the connector board in accordance with desired Form C dry contact

outputs: NO = Normally Open; NC = Normally closed (see figure 3).

PI-600 Toxic Gas Sensors PG.16

same

volt-

Note

FAULT

ALARM 1

Latch

Energize

Latch

Ascending

Energize

ALARM 2

Latch

Ascending

Energize

CPU Board - Top View

Alarm Programming Jumpers

Control Circuit - Side View

CPU Board

: If a voltage signal output is desired in place of the 4-20mA output, a 1/4 watt resistor must be installed in posi-

ion R1 of the terminal board. A 250Ω resistor will provide a 1-5V output (– to mA). A 100Ω resistor will provide a

t .4-2V output, etc. This linear signal corresponds to 0-100% of scale (see figure 3).

e) Program the alarms via the gold plated jumper tab positions located on the CPU board (see figure 3A). Alarm 1

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 the alarms (jumpers removed) are normally de-energized relays, non-latching relays, and alarm points that activate dur-

Figure 3A

ing descending gas conditions.

If a jumper tab is installed in the latch position, that 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.

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.

If a jumper tab is installed in the ascending position, that alarm relay will be in the ascending mode. The ascending mode will cause an alarm to fire when the gas concentration detected is greater than or equal to the alarm set point. The descending mode (jumper removed) will cause an alarm to fire when the gas concentration detected is lesser than or equal to the alarm set point. Except in special applications, toxic gas monitoring will require alarms to fire

“ASCENDING”

Any unused jumper tabs should be stored on the connector board on the terminal strip labeled “Unused Jumpers” (see figure 3).

f) If applicable, set the RS-485 ID number via the two rotary dip switches located on the preamp board (see figure

3B). There are 256 different ID numbers available which are based on the hexidecimal numbering system. If RS-485 communications are used, each sensor must have its own unique ID number. Use a jewelers screwdriver to set the rotary dip switches according to the table listed on the following page. If RS-485 communications are not used, leave the dip switches in the default position which is zero/zero (0)-(0).

gas conditions.

PI-600 Toxic Gas Sensors PG.17

) Replace the plug-in control circuit and replace the junction box cover.

Preamp Board - Side View

RS-485 ID Set Dip Switches

Control Circuit - Side View

Preamp Board

SW2SW1

1234

WHT

BLK

YEL

BLU

Remote Transmitter

PM-600-RT

Remote Sensor

PI-600-RS

WHT

BLK

YEL

BLU

Figure 3B

3.4.5 Remote Mounting Applications

Some sensor mounting applications require that the gas sensor head be remotely mounted away from the sensor transmitter. This is usually true in instances where the gas sensor head must be mounted in a location that is difficult to access. Such a location creates problems for maintenance and calibration activities. Detcon provides the PI-600 sensor in a remote-mount configuration in which the sensor (Model PI-600-RS) and the transmitter (Model PI-600-RT) are provided in their own condulet housing and are interfaced together with a four conductor cable. Reference f igure 4 for wiring diagram.

Figure 4

PI-600 Toxic Gas Sensors PG.18

3.5 ST

Upon completion of all mechanical mounting and termination of all field wiring, apply system power and observe the following normal conditions:

a) PI-600 “Fault” LED is off. b) A temporary upscale reading will occur as the sensor powers up. This upscale reading should clear to “0” ppm with-

ART

in approximately 5-10 minutes of turn-on, assuming there is no gas in the area of the sensor.

NOTE 1:

NOTE 2:

3.5.1 Initial Operational Tests

After a warm up period has been allowed for, the sensor should be checked to verify sensitivity to its target gas.

If the display contrast needs adjustment, refer to section 3.11.

If the sensor does not clear to zero after 15 minutes of warm-up, there may be target VOC gases present in the area.

Material Requirements

* Detcon PN 943-000006-132 Calibration Adapter

Span gas containing isobutylene in air. It is recommended that the target gas concentration be 50% of scale at a con-

trolled flow rate of 200 cc/min. For example, a Model PI-600 sensor in the range 0-100ppm would require a test gas of 50ppm isobutylene. For a sensor with a range of 0-10ppm a test gas of 5ppm is recommended, etc. Other concentrations are acceptable as long as they are between 10%-90% of full-scale range.

a) Attach the calibration adapter to the sensor housing. Apply the test gas at a controlled flow rate of 200 cc/min.

Observe that the LCD display increases to a level of ±10% of applied concentration.

b) Remove the test gas and observe that the LCD display decreases to “0 PPM”.

Initial operational tests are complete. Detcon PID gas sensors are pre-calibrated prior to shipment and will, in most cases, not require significant adjustment on start up. However, it is recommended that complete zero and span calibrations be performed within 24 hours of installation. Refer to calibration instructions in later text.

3.6 OPERATING SOFTWARE & MAGNETIC INTERFACE

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 submenus as indicated below. (Note: see section 3.7 for a complete software flow chart.)

01. Normal Operation

a) Current Status

02. Calibration Mode

a) Zero b) Span

03. Program Menu

a) View Program Status b) Alarm 1 Level c) Alarm 2 Level d) Set Calibration Level e) Set Response Factor f) Set Zero Offset

3.6.1 Normal Operation

In normal operation, the display tracks the current status of the sensor and gas concentration and appears as: “0 PPM xxx” (the “xxx” is the abbreviated gas type, ie., “0 PPM VOC”. The mA current output corresponds to the monitoring level of 0-100% of range = 4-20 mA.

PI-600 Toxic Gas Sensors PG.19

3.6.2 Calibration Mode

alibration mode allows for sensor zero and span adjustments. “1-ZERO 2-SPAN”

3.6.2.1 Zero Adjustment

Zero is set in ambient air with no target gas present or with zero gas applied to the sensor. “AUTO ZERO”

3.6.2.2 Span Adjustment

Span adjustment is performed with a target gas concentration of 50% of range in air. Span gas concentrations other than 50% of range may be used. Refer to section 3.6.3.2 for details. “AUTO SPAN”

3.6.3 Program Mode

The program mode provides a program status menu (View Program Status) to check operational parameters. It also allows for the adjustment of the calibration gas level setting.

3.6.3.1 Program Status

The program status scrolls through a menu that displays: * The software version number. * Range is ### * The alarm set point level of alarm 1. The menu item appears as: “ALM1 SET @ ##PPM” * The alarm firing direction of alarm 1. The menu item appears as: “ALM1 ASCENDING” or descending. * The alarm relay latch mode of alarm 1. The menu item appears as: “ALM1 NONLATCHING” or latching. * The alarm relay energize state of alarm 1. The menu item appears as: “ALM1 DE-ENERGIZED” or energized. * The alarm set point level of alarm 2. The menu item appears as: “ALM2 SET @ ##PPM” * 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. * The calibration gas level setting. The menu item appears as: “CalLevel @ xxPPM” * Identification of the RS-485 ID number setting. The menu item appears as: “485 ID SET @ ##” * The response factor setting. The item appears as: “RespFactor = x.xx” * The current zero offset value. The menu item appears as: “ZeroOffset = x.x PPM” * The raw signal from the sensor head. The menu item appears as: “Raw Signal = x.xx V” * The estimated remaining sensor life. The menu item appears as: “SENSOR LIFE 100%”

3.6.3.2 Alarm 1 Level Adjustment

The alarm 1 level is adjustable from 10% to 90% of range. The menu item appears as: “SET ALM1 @ ##PPM”

3.6.3.3 Alarm 2 Level Adjustment

The alarm 2 level is adjustable from 10% to 90% of range. The menu item appears as: “SET ALM2 @ ##PPM”

3.6.3.3 Calibration Level Adjustment

The calibration level is adjustable from 10% to 90% of range. The menu item appears as: “CalLevel @ ##PPM”

3.6.3.4 Response Factor Adjustment

The Response Factor is set according to the primary target gas being detected. The menu item appears as:

“RespFactor = x.xx”

3.6.3.5 Zero Offset

The Zero Offset is settable between 0 and 10 ppm to account for residual backgrounds of active VOCs in ambient air. The menu item appears as: “ZeroOffset = x.x PPM”

3.6.3.6 Raw Signal

The raw signal from the sensor head is displayed for the purpose of troubleshooting.

PI-600 Toxic Gas Sensors PG.20

3.6.4 Programming Magnet Operating Instructions

Magnetic Programming Tool

etcon inc.

Program Switch #2

FLT

ALM

CAL

MicroSafe™ Gas Sensor

HOUS TON , TEX AS

PGM 2

PGM 1

ALM

MODEL PI-600

CONTRAST

Alarm & Cal LEDs

Program Switch #1

Menu Driven Display

Plug-in Universal Microprocessor Control Circuit

Display Contrast Adjust

UNIVERSAL

TRANSMITTER

PPM

VOC

perator interface to MicroSafe™ gas detection products is via magnetic switches located behind the transmitter face

O plate. 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 programming without removing the enclosure cover, thereby eliminating the need for area de-classification or the use of hot permits.

A magnetic programming tool (see figure 5) is used to operate the switches. Switch action is defined as momentary con-

Figure 5

tact, 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 thirty 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 figure 6.

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.

Figure 6

PI-600 Toxic Gas Sensors PG.21

3.7 SO

NORMAL

OPERATION

CALIBRATION

PGM1 (3) PGM2 (3)

1-ZERO 2-SPAN

LEGEND

PGM1 - program switch location #1

PGM2 - program switch location #2

(M) - momentary pass of magnet

(

3) - 3 second hold of magnet

(30) - 30 second hold of magnet

INC - increase

DEC - decrease

# - numeric value

AUTO ZERO

AUTO SPAN

AS RANGE

PGM1 (3) PGM2 (M)

IEW PROG STATUS

GM2 (3)

GM1 (3)

PGM2 (30)

oftware Version V#.#

GM1 (M)PGM2 (M)

PGM1 (3)

CalLevel @ ##PPM

PGM1 (3) PGM2 (M)

ET CAL LEVEL

PGM2 (3)

GM1 (M)PGM2 (M)

PGM1 (3)

RESPFACTOR = X.XX

PGM1 (3) PGM2 (M)

ET RESPONSE FACTOR

PGM2 (3)

GM1 (M)PGM2 (M)

PGM1 (3)

ZERO OFFSET = X.X PPM

PGM1 (3) PGM2 (M)

ET ZERO OFFSET

PGM2 (3)

GM1 (M)PGM2 (M)

PGM1 (3)

SET ALM1 @ ##PPM

PGM1 (3) PGM2 (M)

SET ALARM 1 LEVEL

PGM2 (3)

GM1 (M)PGM2 (M)

PGM1 (3)

SET ALM2 @ ##PPM

PGM1 (3) PGM2 (M)

SET ALARM 2 LEVEL

PGM2 (3)

LM1 SET @ ##PPM

ALM2 SET @ ##PPM

ALM1 (Firing Direction)

ALM1 (Latch State)

ALM1 (Energize State)

LM2 (Firing Direction)

ALM2 (Latch State)

ALM2 (Energize State)

FLT (Latch State)

FLT (Energize State)

SENSOR LIFE ##%

ZERO OFFSET = X.XX

AW SIGNAL = X.XX V

CAL LEVEL @ ##PPM

485 ID SET @ #

FTWAREFLOW

Figure 7

ART

3.8 CALIBRATION

Material Requirements

* Detcon PN 943-003270-000 MicroSafe™ Programming Magnet * Detcon PN 943-000006-132 Calibration Adapter * Zero Air gas containing no VOC compounds * Span gas containing isobutylene in air. The cal gas concentration is recommended at 50% of range (which is the fac-

3.8.1 Calibration Procedure - Zero

NOTE 1

tory default) at a controlled f low rate of 200 cc/min. Example: for a Model PI-600 sensor with a range of 0-100ppm, a test gas of 50 ppm isobutylene is recommended. For a sensor with a range of 0-10 ppm a test gas of 5 ppm is recommended, etc. Other concentrations can be used as long as they fall within 10% to 90% of range. See section

3.8.2 for details. Reference section 3.9-b-1 if you do not know the sensor target gas or range of detection.

: Before performing a zero calibration, determine if there are any active VOC target gases in the area. If it can

be concluded that there are no active VOC gases in the area, then execute steps b) and c) below.

PI-600 Toxic Gas Sensors PG.22

NOTE 2

: Assuming that there are some residual VOC target gases in the background, you will require the use of the

ero air gas standard to perform a correct zero calibration starting from step a) below.

a) Apply a zero air standard at 200 cc/min for approximately 2-3 minutes then proceed through steps b) and c) with the

gas under continuous f low. After applying gas, tap your fingertip over the exit port of the cal adapter for 10 -30 seconds to expedite the gas purging process.

b) Enter the calibration menu by holding the programming magnet over PGM 1 (see Figure #6) for 3 seconds until the

display reads “1-ZERO 2-SPAN”, then withdraw the magnet. Note that the Cal LED should now be illuminated.

c) Next, enter the zero menu by holding the magnet stationary over “PGM 1” for 3 seconds until the display reads:

“Setting Zero”, then withdraw the magnet. The sensor has now entered the auto zero mode. When it is complete the display will read “ZERO COMPLETE” for 5 seconds and then return to the normal operations menu reading.

d) Remove the zero air gas and cal adapter and allow the sensor 3-5 minutes to rest on ambient air. If there are residual

active VOC gases in the area, then the sensor will read higher than 0.0 ppm. If this is the case, then you can use the Zero Offset feature to correct for this residual background amount.

e) Set the Zero Offset value according to the concentration value found following the zero calibration procedure. See

section 3.8.1.1 below.

3.8.1.1 Using the Zero Offset Feature

If it is determined that there is a constant and non-negligible amount of residual active VOC gases in the background

air, the Zero Offset feature can be used to correct for this.

a) Observe the sensor’s concentration reading on air after a zero air calibration procedure. This represents the back-

ground VOC contribution that you will be offsetting.

b) Access the Zero Offset software feature by applying the magnet to PGM2 for 15 seconds. Then use the magnet to

momentarily pass over PGM1 and advance to the “Set Zero Offset” menu. Then apply the magnet to PGM1 for 3 seconds to access this menu. The menu should now read as “Zero Offset = X.X. Use PGM1 to increment this number up to your desired offset level. When the correct offset is set, apply the magnet to PGM1 for 3 seconds to accept the value. Then apply the magnet to PGM2 for 3 seconds to return to Normal Operation.

c) When done correctly, the unit should read 0.0 when back in Normal Operation.

3.8.2 Calibration Procedure - Span

3.8.2.1 Set Response Factor

All span calibrations are recommended to be done with a calibration standard consisting of isobutylene in an air background. If your target gas is different than the isobutylene span gas, you will be required to apply the correct Response Factor. Look up the Response Factor for your target gas in the Table shown in Section 3.2.3.

a) Enter the programming menu by holding the magnet stationary over “PGM2” for 15 seconds until the display reads “View Program Status”, then withdraw the magnet. At this point you can scroll through the programming menu by momentarily waving the magnet over “PGM1” or “PGM2”. The menu options are: View Program Status, Set Cal Level, Set Response Factor, and Set Zero Offset. Scroll to the “Set Response Factor” selection.

b) Select “Set Response Factor” by holding the magnet over “PGM1” for 3 seconds until the display reads “RespFactor = x.xx”, then withdraw the magnet. Use the magnet to make an adjustment to “PGM1” to increase or “PGM2” to decrease the displayed value until the value is equal to the desired “Response Factor” value from Section 3.2.3.

NOTE:

If you have multiple target gases, then select the target gas with the highest Response Factor from the Table.

This provides for the safest and earliest warning levels.

NOTE:

If you are span calibrating with the target gas, instead of isobutylene, then the response factor should be left at 1.0

3.8.2.2 Span Calibration

NOTE

: Isobutylene is the recommended calibration gas for this sensor.

CAUTION:

Verification of the correct calibration gas level setting and calibration span gas concentration is

required before “span” calibration. These two numbers must be equal.

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Span calibration consists of entering the calibration function and following the menu-displayed instructions. The dis-

lay will ask for the application of span gas in a specific concentration. This concentration must be equal to the calibra-

p tion gas level setting. The factory default setting for span gas concentration is 50% of range. In this instance, a span gas containing a concentration equal to 50% of 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.

a) Verify the current calibration gas level setting as indicated by the programming status menu. To do this, follow the

instructions in section 3.9 and make note of the setting found in listing number 2. The item appears as

“GasLevel @ xxPPM”.

b) If the calibration gas level setting is equal to your calibration span gas concentration, proceed to item “f”. If not,

adjust the calibration gas level setting so that it is equal to your calibration span gas concentration, as instructed in items “c” through “e”.

c) Enter the programming menu by holding the programming magnet stationary over “PGM 2” for 15 seconds until

the display reads “VIEW PROG STATUS”, 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 Cal Level, Set Response Factor, and Set Zero Offset.

d) 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 “CalGas @ ##PPM”, then withdraw the magnet. Use the programming magnet to make an adjustment to “PGM 1” to increase or “PGM 2” to decrease the display reading until the reading is equal to the desired calibration span gas concentration. Exit the programming menu by holding the programming magnet over “PGM1” for 3 seconds.

e) Exit back to normal operation by holding the programming magnet over “PGM 2” for 3 seconds, or automatically

return to normal operation in 30 seconds.

f) From the calibration menu “1-ZERO 2-SPAN” proceed into the span adjust function by holding the program-

ming magnet stationary over “PGM 2” for 3 seconds then withdraw the programming magnet. At this point the display will ask for the application of the target gas and concentration. The display reads “APPLY xxPPM ISO” The x’s here will indicate the actual concentration requested.

g) Apply the calibration test gas at a flow rate of 200 cc/min. After applying the span gas, hold your fingertip (block-

ing) over the exit port of the cal adapter for 10-30 seconds. This helps to expedite the purging of the internal sensor chamber. As the sensor signal changes, the display will change to “AutoSpan xxPPM”. The “xx” part of the reading indicates the actual gas reading which will increase until the sensor stabilizes. When the sensor signal is stable it will auto span to the correct ppm reading and the display will change to “SPAN COMPLETE” for 3 seconds, then to “SENSOR LIFE: xxx%”and then “REMOVE GAS”. Remove the gas. When the signal level has fallen below 10% of full scale, the display will return to the normal operating mode.

NOTE 1: If there is not a minimal response to the cal gas in the first minute, 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 screen which appears as: “SPAN FAULT #1” (see section 3.8.3).

NOTE 2: If during the auto-span function the sensor fails to meet a minimum signal stability criteria, the sensor will enter the calibration fault mode which will cause the display to alternate between the sensor’s current status reading and the calibration fault screen which appears as: “SPAN FAULT #2” (see section 3.8.3).

3.8.3

Additional Notes

1. Upon entering the calibration menu, the 4-20 mA signal drops to 2 mA and is held at this level until you return to

normal operation.

2. 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 the fault LED (see section 3.10) and will cause the display to alternate between the sensor’s current status reading and the calibration fault description. In these cases, the previous calibration points will remain in memory. If this occurs you may attempt to recalibrate by entering the calibration menu as described in section 3.8.1-a. If the sensor fails again, defer to technical trouble shooting (see section 3.13).

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3.8.4 Calibration Frequency

n most applications, monthly to quarterly calibration intervals will assure reliable detection. However, industrial envi-

I ronments differ. Upon initial installation and commissioning, close frequency tests should be performed, weekly to monthly. Test results should be recorded and reviewed to determine a suitable calibration interval.

3.8.5 PID Plug-In Sensor Maintenance

The plug-in PID Sensor will need to be properly maintained to achieve proper long-term performance. All PID sensors use a UV lamp that has a finite lifetime. The Detcon PID UV lamp source is expected to last a least 1 year. However, from the time of installation a gradual loss in UV lamp strength is expected. (See Figure 8) As the UV lamp strength decreases the sensor signal will decrease accordingly. This dictates that periodic span calibrations are required to maintain calibration accuracy.

Figure 8

To determine the present signal strength of the PID sensor, execute a valid span calibration and view the Sensor Life from the ‘

View Program Status

ing the plug-in sensor, cleaning the UV Lamp, or replacing the UV Lamp.

If the PID sensor seems to be losing signal strength at a rate faster than Figure 8 estimates, the sensor is most likely experiencing contamination film build-up on the UV optical filter. This will happen when exposed to certain gases or ambient contaminations that collect on the surafce of the UV filter. The result is a decrease in the amount of emitted UV from the lamp source. This is known to happen with gases that can be polymerized by UV light (such as heavy complex VOC’s), airborne oil vapors, and very fine dust. As UV Filter contamination occurs, the sensor’s signal strength falls off in addition to the expected loss rate shown in Figure 8. This phenomenon can be reversed by disassembling the sensor and carefully cleaning the UV lamp filter using a specialized cloth.

It is also possible under certain ambient contamination conditions that the sensor’s Detector Cell can have a partially conductive film that forms across the contact grids. This condition causes the zero background signal to gradually increase to the point where it becomes unacceptable for the range of signal input to the transmiter electronics. When this occurs the detector cell should be replaced. This can be checked by examining the amount of raw signal that is produced during exposure to zero gas. Refer to the ‘View Program Status’ menu and record the Raw Signal report after 5 minutes of zero gas exposure. A value that exceds 2.65V would be evidence of this problem.

3.8.5.1 General recomendations for Sensor Maintenance

’ menu. Any Sensor Life value less than 30% should result in the user’s choice of replac-

1) For normal environmental exposure and signal decay, replace the plug-in sensor every 9-12 months (especially if there are no skilled technicians to handle proper UV lamp replacement).

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) If skilled technicians are available, replace just the UV lamp every 9-12 months.

3) For abnormally high rates of signal decay, clean the UV lamp monthly, using a Lamp Cleaning Kit, and replace the

UV lamp every 9-12 months.

4) For any proven cases where the zero baseline has drifted up, replace the detector cell.

3.8.5.2 PID Plug-In Sensor Maintenance Procedure

All piD Sensor Cells contain six user replacable parts.

Disassembly

1) Power down the instrument and remove the sensor cell.

2) Remove the f iltercap by applying a slight upward pressure with the tip of a screwdriver or an Exacto Blade just below the hole in the cap and between the cap and the housing.

3) With a fine tipped tweezers, remove both of the Filter Media and set aside.

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4) Using an Exacto Blade, remove the spacer and set it aside

5) With fine tipped tweezers, carfully remove the cell assembly by prying under the cell’s edge where the connector pins are located.

6) With fine tipped tweezers, grasp the lamp by placing the tips in the housing notch and gently pull it out. Be careful not to scratch the lamp lens or chip the edges.

Cleaning the Lamp

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Grab the lamp by the cylindrical glass body and clean the window by rubbing it against the polishing pad. Use a circular motion and try to keep the window surface f lat relative to the pad. Five seconds of rubbing should be enough in most cases. Another indication of cleaning completeness is that about 1/16th of the pads surface is used in the process.

Reassembly

1) Install the lamp into the sensor, making sure that the lamps metalized pads are aligned with the corresponding exci-

tation springs inside the lamp cavity.

2) With the end of the clean tweezers, or a clean blade of a screwdriver, press down firmly, being careful not to scratch

the surface of the lamp.

3) Using fine tipped tweezers, install the cell assembly. Align the pins with the corresponding sockets on the sensor

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and push down on the end with the pins. Make sure the cell assembly is flush with the lamp window.

4) Place the spacer around the assembly.

5) Place the f ilter media over the Cell Assembly centered on the top of the sensor. Make sure the filters are installed in

the correct order. Filter Media #2 first, then Filter Media #1 on top, with the shiny side up.

6) Align the Cap Key with the notch on the housing. Starting at the side opposite the notch, press down until the

Filter Cap snaps on to the housing. If the Cap Key is incorrectly aligned there will be a noticable buldge on the side of the Cap.

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3.9 STATUS OF PROGRAMMING, CALIBRATION LEVEL, AND SENSOR LIFE

The programming menu has a “View Program Status” listing that allows the operator to view the gas, range, and software version number of the program, as well as current alarm settings, the calibration gas level setting, RS-485 ID, and estimated remaining sensor life. The programming menu also allows the changing of alarm levels (see section 3.10) and the calibration gas level setting (see section 3.8.2.2).

The following procedure is used to view the programming status of the sensor:

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”, 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, and Set Cal Level.

b) Next, scroll to the “VIEW PROG STATUS” listing and then hold the programming magnet over “PGM 1” for 3

seconds. The menu will then automatically scroll, at five second intervals, through the following information before returning back to the “VIEW PROG STATUS” listing.

The software version number.

1 2 -

Range is ###.

3 - The alarm set point level of alarm 1. The menu item appears as: “ALM1 SET @ xxPPM” 4 - The alarm firing direction of alarm 1. The menu item appears as: “ALM1 ASCENDING” 5 - The alarm relay latch mode of alarm 1. The menu item appears as: “ALM1 NONLATCHING” 6 - The alarm relay energize state of alarm 1. The menu item appears as: “ALM1 DE-ENERGIZED” 7 - The alarm set point level of alarm 2. The menu item appears as: “ALM2 SET @ xxPPM” 8 - The alarm firing direction of alarm 2. The menu item appears as: “ALM2 ASCENDING” 9 - The alarm relay latch mode of alarm 2. The menu item appears as: “ALM2 LATCHING” 10 - The alarm relay energize state of alarm 2. The menu item appears as: “ALM2 DE-ENERGIZED” 11 - The alarm relay latch mode of the fault alarm. The menu item appears as: “FLT NONLATCHING” 12 - The alarm relay energize state of the fault alarm. The menu item appears as: “FLT ENERGIZED” 13 - Calibration gas level setting. The menu item appears as: “CalLevel @ xxPPM” 14 - Identification of the RS-485 ID number setting. The menu item appears as: “485 ID SET @ 1” 15 - Response Factor Setting. The menu item appears as: “RespFactor = x.xx” 16 - Zero Offset Setting. The menu item appears as: “ZeroOffset = x.x” 17 - Raw signal from sensor head. The menu item appears as: “RawSignal = x.xxV” 18 - The estimated remaining sensor life. The menu item appears as: “SENSOR LIFE 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.

3.10 PROGRAMMING ALARMS

3.10.1 Alarm Levels

Both alarm 1 and alarm 2 levels are factory set prior to shipment. Alarm 1 is set at 20% of range and alarm 2 at 40% of range. Both alarms can be set in 1% increments from 10% to 90% of range. The following procedure is used to change alarm set points:

PI-600 Toxic Gas Sensors PG.30

a) First, enter the programming menu by holding the programming magnet stationary over “PGM 2” for 30 seconds

ntil the display reads “VIEW PROG STATUS”, then withdraw the magnet. At this point you can scroll

u 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

“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 @ ##PPM”, then withdraw the magnet. Use the programming magnet to make an adjustment to “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

“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 @ ##PPM”, then withdraw the magnet. Use the programming magnet to make an adjustment to “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 automatically

return to normal operation in 30 seconds.

3.10.2 Alarm Reset

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.

3.10.3 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. See section 3.4.4 for details.

From the programming menu scroll to the alarm 1 level listing. The menu item appears as:

From the programming menu scroll to the alarm 2 level listing. The menu item appears as:

3.11 PROGRAM FEATURES

Detcon MicroSafe™ PID gas sensors incorporate a comprehensive program to accommodate easy operator interface 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 range, it will cause the display to flash the highest reading of its range on and off.

Under Range Fault(s)

If the sensor should drift below a zero baseline of -10% of range, the display will indicate a fault: “ZERO FAULT”. This is typically fixed by performing another zero cal. When the total negative zero drift exceeds the acceptable threshold the display will indicate “SENSOR FAULT” and you will longer be able to zero calibrate.

Span Fault #1

If during span calibration the sensor circuitry is unable to attain a minimum defined response to span gas, 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: “SPAN FAULT #1”. The previous calibration settings will remain saved in memory. Previous span calibration is retained.

Span Fault #2

If during the span routine, the sensor circuitry is unable to attain a minimum defined stabilization point, the sensor will enter into the calibration fault mode and cause the display to alternate between the sensor’s current status reading and the

PI-600 Toxic Gas Sensors PG.31

alibration fault screen which appears as “SPAN FAULT #2”. Previous span calibration is retained.

Memory Fault

If new data points cannot successfully be stored to memory the display will indicate: “MEMORY FAULT”.

Fail-Safe/Fault Supervision

Detcon MicroSafe™ sensors are programmed for fail-safe operation. All fault conditions will illuminate the fault LED, and cause the display to read its corresponding fault condition: “ZERO FAULT”, “SENSOR FAULT”, “SPAN FAULT #1”, or “SPAN FAULT #2”. A “SENSOR FAULT” and “ZERO FAULT” will cause the mA output to drop to zero (0) mA.

Sensor Life

The “Sensor Life” feature gauges the remaining sensor life based on signal output from the PID sensor cell. When a sensor life of 25% or less remains, the sensor cell should be replaced within a reasonable maintenance schedule.

3.12 DISPLAY CONTRAST ADJUST

Detcon MicroSafe™ sensors feature a 16 character backlit liquid crystal display. Like most LCDs, 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 jewelers screwdriver to turn the contrast adjust screw located beneath the metallic face plate. The adjustment location is marked “CONTRAST”. See figure 6 for location.

3.13 UNIVERSAL TRANSMITTER FEATURE (RE-INITIALIZATION)

The Model PI-600 uses a universal transmitter design that allows the transmitter to be set up for any target gas and any toxic concentration range. The original transmitter set-up is done at Detcon Inc. as part of the sensor test and calibration procedure, but it may also be changed in the field if necessary. The Universal Transmitter feature is a signif icant convenience to the user because it allows hardware f lexibility and minimizes the spare parts requirements to handle unexpected transmitter failures of different gas/ranges. It is however, absolutely critical that changes to gas/range set-up of the Universal Transmitter be consistent with the gas type and range of the PID Sensor Head that it is connected to. The PID sensor head will display the range it is set up for, based on the isobutylene reference calibration.

NOTE: it is mated with.

If the Universal Transmitter needs to be changed for gas type and range follow this procedure. First, unplug the transmitter temporarily and then plug it back in. While the message “Universal Transmitter” appears, take the program magnet and swipe it over magnet PGM1. This will reveal the set-up options for gas range and gas type.

Swipe over PGM1to advance through the options for gas range which include: 1, 2, 3….10 ppm 10, 15, 20……100 ppm 100, 200, 300…..1000 ppm 1000, 2000, 3000 …..10,000 ppm When the correct range is displayed, hold magnet over PGM1 for 3 seconds to accept the selection.

Next is your selection for the gas type that will be displayed. Note, the default gas is “VOC”. In this set-up you will enter the alpha-numeric characters of the gas type. There is space for the chemical formula name of up to six characters. Use PGM1 and PGM2 swipes to advance through the alphabet and numbers 0-9 selection (there is a blank space after

9). When the correct alphanumeric character is highlighted, hold the magnet over PGM1 for 3 seconds to lock it in.

This moves you to the next blank and the procedure is repeated until the chemical formula is completed. After the 6th character is locked in the transmitter will proceed to normal operation.

If the Universal Transmitter is changed for gas type and range, it must be consistent with the PID sensor head

PI-600 Toxic Gas Sensors PG.32

NOTE 1: If the gas symbol has more than 6 characters, the symbol can be replaced by an abbreviated version of the

arget gas name such as TOL or TOLUEN for Toluene which has a the symbol C6H5CH3. For epichlorohydrin (sym-

t bol C3H5OCL) you can substitute the name EPI or EPICHL etc.

NOTE 2: When the Universal Transmitter is re-initialized and a new gas and range is entered, the previous customer settings for span gas value, response factor, and zero offset are reset to default levels. This must be re-programmed back to the customer specific settings.

3.14 RS-485 PROTOCOL

Detcon MicroSafe™ toxic gas sensors feature Modbus™ compatible communications protocol and are addressable via rotary dip switches 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 dip switches located on the preamp circuit board. 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 3.2.5.4-f for details on changing the RS-485 ID number.

The following section explains the details of the Modbus™ protocol that the 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.

Gas type is one of the following: 01=CO, 02=H2S, 03=SO2, 04=H2, 05=HCN, 06=CL2, 07=NO2, 08=NO, 09=HCL, 10=NH3, 11=LEL, 12=O2

Sensor life is an estimated remaining use of the sensor head, between 0% and 100% Example: 85=85% sensor life

i.e. 100 for 0-100 ppm, 50 for 0-50 ppm, etc.

The current gas reading as a whole number. If the reading is displayed as 23.5 on the display, this register would contain the number 235.

High Byte Low Byte

This is the trip point for the first alarm.

High Byte Low Byte

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40004 Alarm 2 Set point

This is the trip point for the second alarm.

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 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

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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, half duplex 485.

On ranges set from 1 ppm to 10 ppm the reading and alarm set points are displayed as ##.##ppm. On ranges set from 15 ppm to 50 ppm the reading and alarm set points are displayed as ##.#ppm. To accommodate these fractional readings using the Modbus™ interface, the reading and alarm set points are multi-

plied by 100 before they are stored for retrieval by a Modbus™ command. Examples: The transmitter is set for a range of 5 ppm.

The display on the transmitter reads 2.74 ppm. The transmitter is polled for its reading using a Modbus™ command. The value returned in the response is decimal 274. Obtain the correct reading by dividing. 274/100 = 2.74 ppm.

The transmitter is set for a range of 25 ppm. The display on the transmitter reads 22.9 ppm. The transmitter is polled for its reading using a Modbus™ command. The value returned in the response is decimal 2290. Obtain the correct reading by dividing. 2290/100 = 22.9 ppm.

On ranges above 50 ppm there is no math involved. The readings are stored the same as they are seen on the transmitters display.

3.15 TROUBLE SHOOTING

Sensor reads Over-range after Power-up Probable Cause: Sensor requiring additional stabilization time, VOC gases present in background air, Improper zero or span calibration.

1. Verify that there is not large amounts of target gas or interfering gases in background.

2. Redo zero and span calibrations.

3. Make sure transmitter range is consistent with PID sensor head range.

Reading Higher than Anticipated Probable Causes: Target or Interfering gases in background, Incorrect calibration for Zero or Span.

1. Verify no target or interfering gases are present. If so, use the Zero Offset feature.

2. Redo Zero and Span calibrations with validated Zero Gas and Span Gas standards.

Reading Lower than Anticipated Probable Causes: Zero Calibration done before unit finished stabilizing, Incorrect Span Calibration.

1. Redo Zero and Span calibrations with validated Zero Gas and Span Gas standards.

2. Disengage Zero Offset feature if it is not necessary.

3. Contact Detcon to determine if target gas will not diffuse past the 316 Stainless Steel flame arrestor.

Zero Calibration Fault Probable Causes: Target gas or Interfering gases in background during Zero Calibration, Failed PID sensor.

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1. Verify no target or interfering gases are present.

. Redo Zero calibration with validated Zero Gas standard.

3. If recovering after a start-up, give more time to stabilize.

Span Calibration Fault Probable Causes: Failed PID sensor (failed UV lamp bulb, optical window needs cleaning), ice/mud/dust blocking protective membrane, invalid span calibration gas due to age, type, and contamination or insufficient flow rate.

1. Verify there is no ice/mud/dust blocking the sensor’sFlame Arrestor.

2. Redo Span Calibration with validated Isobutylene Span Gas standard.

3. Reinitialize unit by plugging in transmitter while holding the magnet on PGM1. Scroll through and select the correct gas type. Make sure all customer settings are re-entered after “reinitialization”.

4. Clean UV Lamp Filter or replace UV Lamp.

5. Replace with new PID sensor.

Noisy Sensor (continuous drift) or suddenly Spiking Probable Cause: Unstable power source, Inadequate grounding, Inadequate RFI protection.

1. Verify power Source output and stability.

2. Contact Detcon for assistance in optimizing shielding and grounding.

3. Add RFI Protection accessory available from Detcon.

LCD Difficult to Read Probable Cause: Needs adjustment.

1. Adjust contrast pot as necessary.

Reporting “ERROR @ XXXXXXX” Probable Cause: Span calibration calculation error.

1. Reinitialize unit by plugging in transmitter and the swiping the magnet over PGM1 while “Universal Transmitter” is displayed. Scroll through and select the correct gas type and range (see section 3.12 Universal Transmitter Features). Make sure all customer specific settings are re-entered after “reinitialization”.

3.16 SPARE PARTS LIST

943-000006-132 Calibration Adapter 500-001794-004 Connector board 327-000000-000 Programming Magnet 897-850800-000 3 port enclosure less cover 897-850700-000 Enclosure glass lens cover 960-202200-000 Condensation prevention packet (replace annually). 926-P16480-range PI-600 Series Universal Plug-in Control Circuit 370-P10000-000 Plug-in Replaceable PID sensor for 0-20 ppm and lower ranges (PI-600 Model) 370-P20000-000 Plug-in Replaceable PID sensor for =>50 ppm ranges (PI-601 Model) 975-600020-000 PID 10.6eV Replacement Lamp 975-600100-000 PID Detector Replacement Cell 975-520040-000 PID Lamp Cleaning Kit 390-404142-range* PID sensor head assembly

* Does not include plug-in replacement sensor cell.

Specify 3 Digit Range for PID sensor head as per examples below: If greater than 999ppm, use a “K” (for 1000). If greater than 9,900ppm use a “P” (for %).

005 = 5 ppm 010 = 10 ppm 020 = 20 ppm 025 = 25 ppm

PI-600 Toxic Gas Sensors PG.36

050 = 50 ppm

Enclosure less cover

Connector Board

Enclosure glass lens cover

Plug-in control circuit

Programming Magnet

PID Sensor Head

Plug-in PID Sensor Cell

Condensation Prevention Packet (replace annually)

00 = 100 ppm

1 250 = 250 ppm 500 = 500 ppm 01K = 1,000 ppm 05K = 5,000 ppm

3.17 WARRANTY

Detcon, Inc., as manufacturer, warrants each new PID plug-in sensor cell, for a specified period under the conditions described as follows: The warranty period begins on the date of shipment to the original purchaser and ends 12 months thereafter. The sensor cell is warranted to be free from defects in material and workmanship. Should any sensor cell fail to perform in accordance with published specif ications within the warranty period, return the defective part to Detcon, Inc., 3200 A-1 Research Forest Dr., The Woodlands, Texas 77381, for necessary repairs or replacement.

NOTE: cleaning,

3.18 SERVICE POLICY

Detcon, Inc., as manufacturer, warrants under intended normal use each new PI-600 series plug-in signal transmitter Control Circuit and PID Sensor Head 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 signal Transmitter shall be repaired or replaced as is deemed necessary by Detcon, Inc., for a fixed fee of $65.00. Any failed PID Sensor Head circuit shall be repaired or replaced as is deemed necessary by Detcon, Inc., for a fixed fee of $75.00. 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.

The warranty does not cover conditions where the detector cell or lamp may be dirty and can be restored by

Shipping Address: 3200 A-1 Research Forest Dr., The Woodlands, Texas 7381

Mailing Address: P.O. Box 8067, The Woodlands, Texas 77387-8067

phone 888-367-4286, 713-559-9200 • fax 281-292-2860 • www.detcon.com • sales@detcon.com

PI-600 Toxic Gas Sensors PG.37

Detcon PI-600 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual