Strictly follow the Instructions for Use.
The user must fully understand and strictly observe the
instructions. Use the product only for the purposes specified
in the Intended use section of this document.
!
Dräger Polytron 8100
Instructions for Use
Contents
1For your safety .........................................................5
Before using this product, carefully read the Instructions for
Use (IfU).
Strictly follow the Instructions for Use. The user must fully
understand and strictly observe the instructions. Use the
product only for the purposes and under the conditions
specified in this document.
Do not dispose of the Instructions for Use. Ensure that they
are retained and appropriately used by the product user.
Only fully trained and competent users are permitted to use
this product.
Comply with all local and national laws, rules and
regulations associated with this product.
Only trained and competent personnel are permitted to
inspect, repair and maintain the product as detailed in
these Instructions for Use. Further maintenance work that
is not detailed in these Instructions for Use must only be
carried out by Dräger or personnel qualified by Dräger.
Dräger recommends a Dräger service contract for all
maintenance activities.
Maintenance must be performed as described, see
Section 6 on Page 28.
Use only genuine Dräger spare parts and accessories.
Otherwise the proper functioning of the product may be
impaired.
The flameproof / explosion proof joints are not in
accordance with the relevant minimum or maximum values
of EN/IEC 60079-1. The joints are not intended to be reworked by the user.
WARNING
Substitution of components may impair Intrinsic
Safety. This only applies to the instrument or parts of it
which are classified as intrinsically safe.
Only operate the product within the framework of a risk-
based alarm signaling concept.
1.2Definitions of alert icons
The following alert icons are used in this document to provide
and highlight areas of the associated text that require a greater
awareness by the user. A definition of the meaning of each
icon is as follows:
DANGER
!
Indicates an imminently hazardous situation which, if
not avoided, will result in death or serious injury.
WARNING
!
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
!
Indicates a potentially hazardous situation which, if not
avoided, could result in physical injury, or damage to
the product or environment.
It may also be used to alert against unsafe practices.
NOTICE
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Indicates additional information on how to use the
product.
Safe connection of electrical devices
Before connecting this instrument to electrical devices not
mentioned in the IfU consult the manufacturer or an expert.
Using the product in areas subject to explosion hazards:
Instruments or components for use in explosion-hazard
areas which have been tested and approved according to
national, European or international Explosion Protection
Regulations may only be used under the conditions
specified in the approval and with consideration of the
relevant legal regulations.
The instruments or components may not be modified in any
manner. The use of faulty or incomplete parts is forbidden.
The appropriate regulations must be observed at all times
when carrying out repairs on these instruments or
components.
Dräger Polytron 81005
Description
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2Description
2.1Product overview
2.1.1Explosion proof instrument
2.1.2Explosion proof instrument with increased safety
wiring compartment (Docking Station)
1 Enclosure lid
2 Handle
3 Bucket with main electronics (and optional relay)
4 Enclosure bottom
5 Sensor
6 Assembled instrument
1 Enclosure lid
2 Handle
3 Bucket with main electronics (and optional relay)
4 Enclosure bottom
5 Sensor
6 Feed-through cable
7 Docking Station
8 Assembled instrument
6Dräger Polytron 8100
Description
!
!
2.2Intended use
The Dräger Polytron 8000 is an explosion proof instrument for
continuous monitoring of toxic gases or oxygen in the ambient
air. The instrument is housed in a rugged stainless steel or
aluminum enclosure for indoor and outdoor applications. The
instrument can be connected through a sealed conduit or
approved cable gland to a Dräger monitoring system or a
Programmable Logic Controller (PLC). With the optional alarm
relay configuration, the instrument can be operated as a standalone unit. The instrument is designed to be installed in
permanent locations and is approved for use in hazardous,
classified areas, see Section 10.1 on Page 37. With the
optionally integrated relay module, the instrument can be
operated without a central controller (with additional local
alarm signaling).
For safe operation, the connection to a central controller is
necessary. This also applies if all relays are connected
because the fault relay is not activated during maintenance. In
any case, the analog output must be monitored because it
might indicate a special status by a current between 0 and 3.5
mA.
CAUTION
Not tested in oxygen enriched atmospheres
(>21% O2). High off-scale readings may indicate an
explosive concentration.
2.3Intended operating area and conditions
Hazardous areas classified by zones:
The device is intended to be used only in hazardous areas
classified Zone 1 or Zone 2, within a temperature range as
marked on the device, where gases of explosion Groups IIA,
IIB or IIC and temperature class T4 or T6 (depending on the
maximum ambient temperature) or dusts of Groups IIIA, IIIB or
IIIC may be present.
Hazardous areas classified by divisions:
The device is intended to be used only in hazardous areas
Class I or II, Div. 1 or Div. 2, within a temperature range as
marked on the device, where gases or dusts of Groups A, B,
C, D or E, F, G and temperature class T4 or T6 (depending on
the maximum ambient temperature) may be present.
2.4Design
The instrument is powered by 10 to 30 VDC (see Section 10.4
on Page 41). Gas concentrations, status messages, and menu
choices are displayed on a backlit graphic LC-display and 3
colored LEDs. The measured gas concentration is converted
to a 4 to 20 mA analog (per NAMUR recommendation NE43)
or a digital HART output signal. The instrument can be
operated as current source or sink.
Navigation through the menu is done by taping a magnetic
wand on the glass at the appropriate indicator.
WARNING
Danger of explosions. Not to be used in oxygen
enriched atmospheres. None of the Polytron 8000
instruments are certified and approved to be operated
in oxygen enriched atmospheres.
The instrument can be configured, calibrated and maintained
non-intrusively without declassifying the area.
Dräger Polytron 81007
Installation
3Installation
3.1General information for installation
To ensure overall system performance and effectiveness, the
selection of an installation site for the instrument is one of the
most important factors. Strict compliance where possible and
considerable thought must be given to every detail of
installation, particularly:
the local, state, national codes and regulations that govern
the installation of gas monitoring equipment.
the electrical codes that govern the routing and connection
of electrical power and signal cables to gas monitoring
equipment.
for non-conduit installations, an approved cable gland must
be used, see Section 10.1 on Page 37 (e.g. Hawke A501/
421/A/¾” NPT or equivalent). It might be necessary to
connect the shield of the cable to the cable gland and to the
controller in order to improve RFI immunity.
the full range of environmental conditions to which the
instruments will be exposed to.
the physical data of the gas or vapor to be detected.
the specifics of the application, (e.g. possible leaks, air
movement/draft, etc.).
the degree of accessibility required for maintenance
purposes.
the types of optional and accessory equipment that will be
used with the system.
any other limiting factors or regulations that would affect
system performance or installations.
the flameproof / explosion proof enclosure provides three
¾" NPT openings, which can be used for field wiring, direct
attachment of a sensor or wiring of a remote sensor.
unused openings must be closed with a plug. For correct
tightening torques of conduit hubs, cable glands, plugs and
sensor see Section 10.8 on Page 42.
secondary circuit intended to be supplied from an isolating
source (N/A for relay circuits).
the optional increased safety terminal box provides up to
four 20 mm openings, which can be used for field wiring or
wiring of a remote sensor. The permissible cable diameter
range is 7 to 12 mm.
when installed at locations exceeding ambient
temperatures of 55 °C, use only appropriate wiring,
specified for at least 25 °C above the maximum ambient
temperature.
strip wire insulation by 5 to 7 mm.
connect the wires as indicated in wiring figure Section 3 on
the wiring for the optional relay module must be selected
and fused according to the rated voltages, currents and
environmental conditions.
if stranded conductors are used, a ferrule must be used.
3.2Installation restrictions
The instrument must have between 10 to 30 VDC at the
instrument. This ultimately determines the distance the
instrument can be mounted from the controller or power
supply. The instrument accepts wire sizes of 12 to 24 AWG
(0.2 to 2.5 mm2). Use at least a three-conductor, shielded
cable.
The instrument must not be exposed to radiant heat that
will cause the temperature to rise beyond the limits stated
in see Section 10.6 on Page 41. The use of a reflecting
shield is recommended.
The enclosure is weatherproof within environmental
parameters and suitable for outdoor installation. The use of
the optional splash guard (6812510) is recommended to
protect the sensor from water and dust.
Each instrument must be installed and operated in an
environment that conforms to the specifications, see
Section 10 on Page 37.
To insure proper operation of the instrument, the
impedance of the 4 to 20 mA signal loop must not exceed
500 Ohms. Depending on the operating voltage and
according to the application (e.g. HART operation), certain
minimum impedances must be observed (see Section 3.3
on Page 8). The conductors for the power supply must
have an adequately low resistance to insure the correct
supply voltage at the instrument.
NOTICE
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The instrument may be equipped with a dust plug at
the conduit entry. This plug is not explosion proof nor
meant to be watertight, and must be removed before
connecting the instrument to a sealed conduit or
installation of a flameproof cable gland.
3.3Impedance of signal loop
.
Operating mode
Operation
without HART
communication
Operation with
HART
communication
(HART mode)
HART Multidrop
operation
Impedance range of the
signal loop
0 to 230 Ωat 10 V DC
Rising linearly with the
supply voltage from:
0 to 230 Ω at 10 V to
0 to 500 Ω at 16 V
0 to 500 Ω18 to 30 V DC
230 to 270 Ωat 13 V DC
Rising linearly with the
supply voltage from:
230 to 270 Ω at 11 V to
230 to 500 Ω at 16 V
230 to 500 Ω18 to 30 V DC
230 to 500 Ω10 to 30 V DC
Supply
voltage range
10 to 18 V DC
11 to 16 V DC
8Dräger Polytron 8100
Installation
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3.4Mechanical installation
Use the drilling template for mounting on a flat surface.
The mounting surface should be even.
Dräger recommends using M6, 1/4” bolts with hex socket
caps.
The instrument must be accessible for maintenance (e.g.
calibration).
The future use of accessories and maintenance equipment
must be kept in mind.
The access of the gas or vapor to the sensor must not be
obstructed.
3.5Electrical installation without Docking
Station
CAUTION
Ensure wiring for relays and connections for sensor
are made before applying power.
Connection diagram for operation as a current source
3.5.1Power and signal wiring
Loosen set-screw and un-
screw lid from instrument.
Lift the handle and pull-out
the bucket with the main
electronics.
Turn bucket over and pull
off the 5-pin connector.
Connect the three wires for
power and signal to the
appropriate terminal as
indicated in the following
wiring table and figure.
Fasten terminal screws
with the correct torque
according to the table
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tightening torque and wire size for field wiring terminal, see
Section 10.9 on Page 42.
5-way Pin connector (power and signal)
Pin12345
MarkPWR+ PWR- PWR- 4-20 mAPE
Function V+V-V-4 to 20 mA signal
(Operation as
source or sink)
PE
Connection diagram for operation as a current sink
If operated as a stand-alone instrument, wire pin 3 to pin 4.
Plug connector back into socket and tighten screws.
The cable shielding should only be connected at the
controller.
Place bucket back into the enclosure.
Screw the lid back on, until it is seated (see Section 10.8
on Page 42) and tighten set-screw.
3.5.2Relay option
WARNING
At voltages >30 V AC or >42.4 V DC, the relay cables
must be enclosed in protective tubing, or doubleinsulated cables must be used.
If the relay option has been installed, the wires for the alarm
devices will be connected to the 9-pin connector. A piece of
wire insulation (heat shrink tube) and rubber boot are supplied
for extra protection for relay wires.
Turn bucket over and pull off the 9-pin connector.
Cut the heat shrink tube as needed and slide over the relay
wires before insertion into the 9-pin connector.
Position the heat shrink tube at the edge of wire insulation
and use a heat gun to shrink the tubing securely onto wire
insulation.
Slide rubber boot over the wires.
Dräger Polytron 81009
Installation
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Connect the wires for alarm 1 (pre alarm), alarm 2 (main
alarm) and fault alarm to the terminals, as indicated in the
following wiring table. Fasten terminal screws with the
correct torque according to the table tightening torque and
wire size for field wiring terminals, see Section 10.9 on
Page 42.
With factory default settings and during normal operation,
the relays are energized. This provides “fail-safe”
operation. The terminal designators indicated in the
following wiring table are shown as factory default and
normal operation mode, see Section 7 on Page 34.
Plug connector back into socket and tighten screws.
Put rubber boot over connector.
NOTICE
To ensure that a fault is recognized - without having to
look at the instrument - an alarm device must be
connected to the fault relay.
Loosen set-screw (2), 2mm Allen screw.
Unscrew bayonet ring (3)
and remove blank.
Remove sensor from
packaging.
Insert sensor (4) into the
opening. The Dräger logo
on the sensor must point
to the mark on the sensing
head housing (5).
Lock sensor with bayonet
ring.
Tighten set-screw (2).
Mandatory for Zone 22
installations.
NO = Normally open, NC = Normally closed, C = Common
3.6Electrical installation with Docking
Station
Installing this configuration is a two-step process.
First, the Docking Station is mounted and connected to the
field wires. Second, the main instrument enclosure with the
electronics and sensor is attached to the Docking Station.
The Docking Station can be pre-mounted, wired and sealed
with the supplied cover. Once the site is ready for
commissioning, the instrument is then hooked up to the
Docking Station and taken into operation; avoiding that the
instrument is damaged during the construction phase.
The connection between the Docking Station and the main
instrument is realized via a ‘feed-through’. Depending on the
instrument selected, there are 2 types of feed-through.
3 wire for power (part number 4544182)
9 wire for power and relay (part number 4544169)
3.6.1Field wiring
For field wiring of Docking Station refer to Instructions for use
9033242.
10Dräger Polytron 8100
Installation
!
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3.8Installation of EC sensing head remote
3.8.1Wall or pipe mounting kit
CAUTION
Observe the general installation information, see
Section 3 on Page 8.
Multiple EC sensing heads remote must not be daisychained.
NOTICE
The EC sensor wall or pipe mount kit (part
number. 45 44 213) is required to mount the EC
sensor on a wall or pipe.
The sensing head should be mounted at a lowvibration location at even temperature near a potential
leakage point (avoid direct sunlight).
3.8.2Installing sensor
Loosen set-screw (2), 2 mm Allen screw.
Unscrew bayonet ring (3) and remove blank.
Remove sensor from packaging.
Insert sensor (4) into the opening. The Dräger logo on the
sensor must point to the mark on the sensing head housing
(5).
Lock sensor with bayonet ring.
Tighten set-screw (2). Mandatory for Zone 22 installations.
Install wall or pipe mount set (8) as specified in the
assembly instructions.
Screw the EC sensing head to the wall or pipe mount
bracket (8) using screw and washer (6).
NOTICE
Pay attention to the orientation of the cable
connector (9)!
Select the appropriate protection cap (7) and place it on the
screw.
Dräger Polytron 810011
Installation
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3.9Connecting the EC sensing head remote
to Polytron 8000
Connect remote cable plug (11), to the EC sensing head
remote (12) and lock.
Attach the shield wire (13) to the grounding point (14) of the
bracket (M5 thread).
Loosen set-screw (2), 2 mm Allen screw.
Unscrew bayonet ring (3) and remove blank. Either
bayonet ring can be used: black or silver.
Insert the remote adapter (4) in the opening. The Dräger
logo on the sensor adapter must point to the mark on the
sensing head housing (5).
Lock sensor adapter with bayonet ring.
Attach the shield wire (15) to the ground lug of the
enclosure.
Tighten set-screw (2). Mandatory for Zone 22 installations.
NOTICE
The EC sensing head remote is automatically
recognized by the instrument.
3.10 Connecting the instrument to a controller
from Dräger
NOTICE
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For hook-up information, please refer to the
Instructions for Use which was included with the
Dräger controller (e.g. Regard, QuadGard).
Electrical connections at the controller
Connect the shield of the wires to the instrument earth ground
of the controller (e.g. chassis, ground busbar, etc.).
3.11 Connecting the instrument to a PC
The separately available Polytron 8000 IR interface
connection kit is intended for use with the Polytron 8000 and
enables communication between the Polytron 8000 and a PC
using the PolySoft 8000 software.
3.12 PolySoft 8000 PC software (optional)
The PolySoft 8000 PC software is used to display instrument
information, edit configuration settings and download the
instrument memory.
CAUTION
After modifying parameters with the PolySoft 8000
PC-software or another software, verify all parameters
by downloading or by checking them on the
Polytron 8000.
12Dräger Polytron 8100
3.13 Installing software dongles
00833300.eps
The following software dongles are available for the
Polytron 8000:
Installation
Sensor test dongle
83 17 619
Diagnostic dongle
83 17 860
Activates the sensor self-test
(only for certain sensors)
Activates the sensor self-test, the
display of the sensor vitality and the
sensor diagnostic functions
(only for certain sensors and functions)
To install a software dongle:
Switch off power to the instrument or declassify the area
according to the local regulations.
Loosen set-screw and unscrew lid from instrument.
Lift the handle and pull-out the bucket with the main
electronics.
Insert the dongle in the slot with the Dräger logo facing
upwards.
Place bucket back into the enclosure.
Screw the lid back on, until it is seated (see Section 10.8
on Page 42), and tighten set-screw.
Switch power back on.
Dräger Polytron 810013
Operation
!
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4Operation
4.1Normal operation
WARNING
Before leaving the instrument for normal operation,
check the configuration and calibration for the proper
settings.
Switch power supply on.
The instrument will go through a start-up sequence (LCD / LED
test, software version, and initialization) and start the warm-up
period. The display shows that the sensor will be ready for
measurement in hh:mm:ss (countdown) and the instrument
transmits the maintenance signal, see Section 10.3 on
Page 41.
After the warm-up period, the instrument goes into normal
operation. The display shows the current gas concentration,
the selected gas and the units of measurement. The green
LED is lit.
NOTICE
The correct date and time settings are important for
many functions see Section 5.7.3 on Page 20.
4.1.1Analog signals
The current output of the instrument during normal operation is
between 4 and 20 mA and is proportional to the detected gas
concentration.
Polytron 8000 uses different current values to indicate various
modes of operation. The factory default settings are user
adjustable for application specific requirements, see Section 7
on Page 34. This follows the NAMUR recommendation NE43.
4.1.2The display and LEDs
In normal operation, the display shows the measured gas
concentration, the selected gas and the unit of measurement.
The green LED is lit.
The following symbols may also be displayed:
" ", when the measuring range is exceeded
" - - - - " and " X " when a fault has been detected. The
yellow LED is lit, see Section 6.3 on Page 31.
"SIL", when SIL status is activated.
If the optional relay board is installed:
When the first alarm (pre alarm) has been triggered the red
LED blinks in single mode. The A1 relay is asserted.
When the second alarm (main alarm) has been triggered
the red LED blinks in double mode. The A2 relay is
asserted.
If the A2 is configured as acknowledgeable, and the A1 is
configured as non-acknowledgeable, then, when an A2
alarm occurs, the red LED will blink in double blink A2
mode. After the alarm is acknowledged, the red LED will
blink in single blink mode to indicate A1 is still active.
4.1.3The LED symbols
NOTICE
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The alarm triggering function is only available when
the optionally integrated relay module is used.
SymbolLEDDescription
redAlarm triggered
yellowFault
green
4.1.4Status indicators in the display
The following status indicators may appear on the right side of
the display.
Warning message available – to display warnings, see
Section 5.2.1 on Page 18.
Error message available – to display errors, see
Section 5.2.2 on Page 18.
Maintenance signal is transmitted, see Section 5.8.2 on
Page 22.
Measuring range of analog interface exceeded
Measurement less than range of analog interface
Analog interface is set to a fixed value (e.g. Multidrop HART
communication) and is not transmitting any measurement
signal.
"Preventive" maintenance: The sensor is ready for operation.
"Preventive" maintenance: The sensor is ready for operation
but is close to the end of its life cycle.
"Preventive" maintenance: The sensor is still ready for
operation but should be changed as soon as possible.
The data-logger is active in Roll mode.
To activate/deactivate, see Section 5.10.2 on Page 27.
The data-logger is active in Stack mode.
To activate/deactivate, see Section 5.10.2 on Page 27.
SIL
SIL is activated (refer to the Polytron 8000 Safety Manual
part number 9033307).
Power ON
Normal operation
4.2Activating the Info mode
No password required.
The Info mode is used to show instrument relevant information.
This will not interrupt the normal operation of the instrument.
Tap and hold [UP] for more than 3 seconds.
The instrument information is shown on several screens.
No changes can be made.
Tap [UP] / [DOWN] to switch between the screens.
The Info mode can be exited at any time by tapping [OK].
If no key is tapped within 30 seconds, the instrument will
automatically return to normal operation.
14Dräger Polytron 8100
Operation
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SW Version
: 1
Part No.
: 8317778
Serial No.
: ARUA0001
DeviceCode: 00006317
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Sensorname: O
2
Part No. : 6809630
Serial No.
: XXXXXXX
EEPROM Typ
: 1
EEPROM Vers.: 1
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Gasname : O
2
Range : 25.00 Vo
4–20 SP
: 25.00 Vo
Alarm A1
: 19.00 Vo
Alarm A2
: 23.00 Vo
Sensor Config.
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Example of the Info mode
Depending on sensor the screens may vary:
1. Screen - Instrument information:
Date and Time
Software version
Part number of the instrument electronics
Serial number of the instrument electronics
Instrument code
2. Screen - Sensor information:
Installed sensor
Part number of the sensor
Serial number of the sensor
Software version
Software revision
4.4Menu navigation
Tapping the magnetic wand (part number 4544101: blue body,
white logo) over [UP] / [DOWN] scrolls through the menu
selections.
Tapping [OK] confirms a selection.
NOTICE
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The instrument is designed for the magnetic wand to
be used with the enclosure lid in place. If the enclosure
lid is not in place, the magnetic wand may activate two
or more buttons at once (cross-talk).
3. Screen - Sensor configuration:
Selected gas
Maximum measuring range and units for the sensor
Measuring range and units for the analog interface. Only
shown if the 4 to 20 mA interface is enabled.
A1 Alarm set point and units
A2 Alarm set point and units
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4.3Activating the Quick Menu
No password required.
Tap and hold [DOWN] for 1 to 2 seconds.
The selected information about status or instrument
settings can be retrieved (e.g. warning messages, error
messages, installed modules and calibration data, time/
concentration graph, see Section 5.7.5 on Page 21.
No changes can be made.
4.4.1Password
A password consists of a 4-digit alphanumeric value.
From normal operation, tap and hold [DOWN] for more
than 3 seconds.
The message “Enter the password” will be displayed.
Confirm with [OK].
The screen to enter the password will be displayed with the
first digit on the left blinking.
Tap [UP] / [DOWN] to increment or decrement this digit,
then tap [OK].
The second digit will blink; set the correct value by tapping
[UP] / [DOWN], then tap [OK].
Repeat the process for the other two digits.
Tap [OK] when the full password is displayed.
If the displayed value matches the set password, access will
be given to the menu. If an incorrect password is entered, the
instrument will indicate “wrong password” and show the
dashes and blinking digit again, see Section 5.7.2 on Page 20.