Dräger Polytron 5200, Polytron 53X0 Instructions For Use Manual
WARNING
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 5200/53X0
Instructions for Use
i
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!
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Content
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Content
1 For your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 General safety statements. . . . . . . . . . . . . . . . . . . . 4
1.2 Definition of alert icons. . . . . . . . . . . . . . . . . . . . . . . 4
2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1.1 Explosion proof instrument . . . . . . . . . . . . . . . . . . . 5
2.1.2 Explosion proof instrument with increased safety
wiring compartment (e-box) . . . . . . . . . . . . . . . . . . . 5
2.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Intended operating area and operating conditions. . 6
2.4 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1.1 Installation restrictions . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Electrical installation without e-box . . . . . . . . . . . . . 8
3.2.1 Power and signal wiring . . . . . . . . . . . . . . . . . . . . . . 8
3.2.2 Relay option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2.3 Remote sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Electrical installation with e-box . . . . . . . . . . . . . . . . 9
3.3.1 Field wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3.2 Field wiring: power only version. . . . . . . . . . . . . . . . 9
3.3.3 Field wiring: power and relay, or power, relay and re-
mote sensor version . . . . . . . . . . . . . . . . . . . . . . . 10
3.3.4 Attaching main instrument to e-box . . . . . . . . . . . . 11
3.3.5 Instrument wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.6 Instrument wiring: power only version . . . . . . . . . . 12
3.3.7 Instrument wiring: power and relay, or power, relay
and remote sensor version . . . . . . . . . . . . . . . . . . 12
3.4 Connecting the instrument to a controller
from Dräger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4.1 Electrical connections at the controller . . . . . . . . . 13
3.5 Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5.1 Analog signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5.2 The display and LEDs . . . . . . . . . . . . . . . . . . . . . . 13
3.6 Menu navigation. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6.1 Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6.2 Changing parameter values / status . . . . . . . . . . . 14
3.6.3 Exiting the menu . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.7 Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.7.1 -0- adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.7.2 Spn adj. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.7.3 A1 test / A2 test / Fail test . . . . . . . . . . . . . . . . . . . 16
3.7.4 A1 set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.7.5 A2 set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.7.6 A1 ris or A1 fall. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.7.7 A2 ris or A2 fall. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.7.8 A1 lat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.7.9 A2 lat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.7.10 A1 ack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.7.11 A2 ack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.7.12 Explanation of combining latching and
acknowledgment of alarms . . . . . . . . . . . . . . . . . . 17
3.7.13 A1 energ on or off . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.7.14 A2 energ on or off. . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.7.15 Set gas cat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.7.16 Cal at dSIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.7.17 Cal set 3-5 or stdy . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.7.18 SNR set dd LC dSIR . . . . . . . . . . . . . . . . . . . . . . . 18
3.7.19 Pass set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.7.20 LCD on or LCD off . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1.1 Zero calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1.2 Span calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2.1 Replacing the sensor . . . . . . . . . . . . . . . . . . . . . . . 21
4.3 Replacing the main electronics . . . . . . . . . . . . . . . 21
5 Default settings . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1 Settings which can be changed via the menu. . . . 22
5.2 Fixed settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6 Sensor principle. . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1 Operating principle for DrägerSensor DD, LC . . . . 23
6.2 Operating principle for DrägerSensor DSIR . . . . . . 23
6.3 Contaminating gases for DrägerSensor DD, LC . . 23
7 Disposing of the instrument . . . . . . . . . . . . . . . . 23
8 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.1 Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.2 Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.3 Signal transmission to central control unit . . . . . . . 24
8.4 Voltage of power supply. . . . . . . . . . . . . . . . . . . . . 24
8.5 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.6 Tightening torque and wire size for field
wiring terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.7 Physical specifications . . . . . . . . . . . . . . . . . . . . . . 25
8.8 Environmental parameters. . . . . . . . . . . . . . . . . . . 25
8.9 Ambient influences. . . . . . . . . . . . . . . . . . . . . . . . . 25
9 Order list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.1 Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.1.1 Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.2 Separate sensing head (not included)
when ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.2.1 Polytron 5200 DD remote e . . . . . . . . . . . . . . . . . . 27
9.2.2 Polytron 5200 LC remote e . . . . . . . . . . . . . . . . . . 27
9.2.3 Polytron 5310 remote e . . . . . . . . . . . . . . . . . . . . . 27
9.2.4 Polytron 5300 remote e . . . . . . . . . . . . . . . . . . . . . 27
9.3 Replacement sensors
(all versions except remote e) . . . . . . . . . . . . . . . . 27
9.4 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.4.1 Accessories DD, LC . . . . . . . . . . . . . . . . . . . . . . . . 27
9.4.2 Accessories DSIR, PIR 3000 . . . . . . . . . . . . . . . . . 27
9.5 Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Dräger Polytron 5200 / Dräger Polytron 53X0 3
For your safety
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1 For your safety
1.1 General safety statements
Before using this equipment, carefully read the Instructions
z
for Use (IfU).
Strictly follow the Instructions for Use. The user must fully
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understand and strictly observe the instructions. Use the
equipment only for the purposes and under the conditions
specified in this document.
Comply with all local and national laws, rules and regula-
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tions associated with this equipment.
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Only trained and competent personnel are permitted to inspect, repair and service 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 rec
ommends a Dräger service contract for all maintenance activities.
Use only genuine Dräger spare parts and accessories, oth-
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erwise the proper functioning of the equipment may be impaired.
The flameproof/explosion proof joints are not in accor-
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dance with the relevant minimum or maximum values of
EN/IEC 60079-1. The joints are not intended to be reworked by the user.
Do not dispose of the Instructions for Use. Ensure that they
z
are retained and appropriately used by the equipment user.
The measuring function of the gas detection transmitter for
z
explosion protection, according to Annex II, clauses 1.5.5,
1.5.6 and 1.5.7 of Directive 94/9/EC is currently not
covered.
Substitution of components may impair Intrinsic Safety.
z
Only if intrinsic safety is involved.
1.2 Definition of alert icons
To reduce the risk of ignition of a flammable or explosive atmosphere, strictly adhere to the following Caution and Warning
statements.
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:
!
!
-
!
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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
Indicates additional information on how to use the
instrument.
Safe connection of electrical devices
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Never connect this instrument to other electrical devices
before consulting the manufacturer or an expert.
Using the product in areas subject to explosion hazards:
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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.
z
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.
4 Dräger Polytron 5200 / Dräger Polytron 53X0
Description
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2 Description
2.1 Product overview
2.1.1 Explosion proof instrument
1 Enclosure lid
2 Bezel with main
electronics
3 Relay board (optional)
4 Enclosure bottom
5 Sensor
6 Assembled instrument
2.1.2 Explosion proof instrument with increased safety
wiring compartment (e-box)
1 Enclosure lid
2 Bezel with main
electronics
3 Relay board (optional)
4 Enclosure bottom
5 Sensor
6 Feed-through
7 Field wire terminals
(not shown)
8 e-box
9 Assembled instrument
Dräger Polytron 5200 / Dräger Polytron 53X0 5
Description
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2.2 Intended use
The Dräger Polytron 5000 is an explosion-proof instrument for
the continuous monitoring of combustible gases and vapors
containing hydrocarbons. 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 oper
ated as a stand-alone instrument. The instrument is designed
to be installed in permanent locations and is approved for use
in hazardous, classified areas, see Section 8.1 on Page 24.
Caution: Not tested in oxygen enriched atmospheres (>21%
). High off-scale readings may indicate an explosive con-
O
2
centration.
Dräger Polytron 5200 with DrägerSensor
Catalytic bead sensor for monitoring of combustible gases and
vapors containing hydrocarbons.
{
Measuring range: 0 to 100 %LEL
Dräger Polytron 5200 with DrägerSensor® Ex LC
Catalytic bead sensor for monitoring of combustible gases and
vapors containing hydrocarbons.
{
Measuring range: 0 to 10 %LEL
® 3)
Ex DD
2)
2)
2.3 Intended operating area and operating
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&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.
2.4 Design
The instrument is powered by 10 to 30 VDC. Gas concentrations, status messages, and menu choices are displayed on a
4 digit LCD display and 3 colored LEDs. The measured gas
concentration is converted to a 4 to 20 mA analog output
signal. The instrument detects whether it is operating in current
source versus sink mode when power is applied.
Dräger Polytron 5310 with DrägerSensor® IR
IR sensor for monitoring of combustible gases and vapors containing hydrocarbons.
{
Measuring range: 0 to 100 %LEL
Dräger Polytron 5300 with Dräger PIR 3000
2)
1)
IR sensor for monitoring of combustible gases and vapors containing hydrocarbons.
{
Measuring range: 0 to 100 %LEL
1) not yet available
2) Lower Explosion Limit, depending on the substance and the regulations applicable at the respective location.
3) DrägerSensor® is a registered trademark from Dräger
2)
WARNING
!
Explosive. Not to be used in oxygen enriched atmospheres. None of the Polytron 5000 instruments are
certified and approved to be operated in oxygen
enriched atmospheres.
Navigation through the menu is done by tapping a magnetic
wand on the glass at the Up and Down arrows or OK.
The instrument can be configured, calibrated and maintained
non-intrusively without declassifying the area.
6 Dräger Polytron 5200 / Dräger Polytron 53X0
3 Operation
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3.1 Installation
To ensure overall system performance and effectiveness, the
selection of an installation site for the instrument is the most
important factor. Considerable thought must be given to every
detail of installation, particularly:
{
the local, state, federal codes and requirements 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 (e.g. Hawke A501/421/A/¾” NPT or
equivalent) see Section 8.1 on Page 24. 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. For correct tightening torques of conduit hubs,
plugs and sensor
{
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 7-12 mm.
When installed at locations exceeding ambient temper-
{
atures of 55 °C, use only appropriate wiring, specified
for at least 25 °C above the maximum ambient
temperature.
{ Strip wire insulation by 5-7 mm.
see Section 8.5 on Page 24.
Operation
Connect the wires as indicated in wiring figure in sec-
{
tion 3.2.2 (also showing grounding conductor terminal).
3.1.1 Installation 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 in
strument 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 8.8 on Page 25. The use of a reflecting shield is recommended.
The enclosure is weatherproof and suitable for outdoor installation. The use of the optional splash guard 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 8 on
Page 24.
NOTICE
i
i
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.
-
Dräger Polytron 5200 / Dräger Polytron 53X0 7
Operation
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3.2 Electrical installation without e-box
CAUTION
!
!
Ensure wiring for relays and connections for sensor
are made before applying power.
3.2.1 Power and signal wiring
z
Loosen set-screw and unscrew lid from instrument.
1. Pull out the bezel, by grasping the notches on either side of
the display with your fingers and pull it up.
3.2.2 Relay option
If the relay option has been installed, the wires for the alarm
devices will be connected to the 9-pin connector.
Turn bezel over and pull off the 9-pin connector.
z
Connect the wires for alarm 1, alarm 2 and fault to the ter-
z
minals, as indicated in the following wiring table.
z
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 oper
ation mode, see Section 5 on Page 22.
z
Plug connector back into socket.
NOTICE
i
i
To ensure that a fault is recognized - without having to
look at the instrument - an alarm device must be connected to the fault relay.
-
z
Turn bezel over and pull off the 3-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 Tightening torque and wire size for field wiring terminal
see Section 8.6 on Page 24.
If operated as a stand-alone instrument, wire pin 1 to pin 3.
z
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Plug connector back into socket.
z
The cable shielding should only be connected at the controller.
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Place bezel back into the enclosure.
z
Screw the lid back on, until it is seated (correct torque) see
Section 8.5 on Page 24, and tighten set-screw.
3 Pin Connector (Power and Signal)
Pin 1 2 3
Mark + none S
Function V + V -
4-20 mA
signal
1 Connector for DrägerSensor DD, LC, and DSIR
9 Pin Connector (Relays)
Fault Relay A2 Relay A1 Relay
Pin 1 2 3 4 5 6 7 8 9
Mark NO C NC NO C NC NO C NC
3.2.3 Remote sensor
The remote junction box (part number 4544098 for stainless
steel or 4544099 for aluminum) allows sensor installation at a
location away from the instrument electronics. This remote installation permits easy setup when the sensor must be located
in a difficult to reach or awkward position, see Polytron 5000
Junction Box Instructions for Use 4544286 for more details.
8 Dräger Polytron 5200 / Dräger Polytron 53X0
Operation
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3.3 Electrical installation with e-box
Installing this configuration is a two step process.
First, the e-box is mounted and connected to the field wires.
Second, the main instrument enclosure with the electronics
and sensor is attached to the e-box.
The e-box 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 e-box and taken into operation; avoiding that the instrument is damaged during the
construction phase.
The connection between the e-box and the main instrument is
realized via a ‘feed-through’. Depending on the instrument
selected, there are 3 types of feed-through.
{
3 wire for power (part number 4544182)
{
9 wire for power and relay (part number 4544169)
{
14 wire for power, relay and remote sensor (part
number 4544168)
In some e-boxes, the field wires are terminated in spring clamp
terminals.
Screw driver or special tool
3.3.1 Field wiring
Connect all applicable field wires to the respective terminals.
3.3.2 Field wiring: power only version
Solid Oval (Power Only)
Terminal 1 (top) Terminal 2 Terminal 3
V + V - 4 to 20 mA Signal
1. Insert screw driver (width 3 mm) into the spring clamp
terminal.
2. Press spring down to open the clamp in the lower part.
Insert stripped cable end or ferrule (for stranded wires) into
the lower part.
3. Remove screw driver. The electrical connection is ensured
via the constant pressure of the spring.
or
1. Insert special tool (part number 8318376) into the spring
clamp terminal.
2. Press spring down to open the clamp in the lower part.
Insert stripped cable end or ferrule (for stranded wires) into
the lower part.
3. Remove special tool. The electrical connection is ensured
via the constant pressure of the spring.
WARNING
!
Bare cables must not stick out of the spring terminals.
The method of explosion protection during maintenance is based on the condition that it is not possible
to contact bare cable parts by a probe of 2.5 mm diameter (definition of IP 30).
Dräger Polytron 5200 / Dräger Polytron 53X0 9
Operation
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3.3.3 Field wiring: power and relay, or power, relay and
remote sensor version
Solid Oval (Power) X1
Terminal 1
(top)
V + V - V -
Terminal 2 Terminal 3 Te rmin a l 4 Terminal 5
4 to 20 mA
Signal
Ground
Dashed Oval (Relay) X2
Terminal
1 (left) 2 3 4 5 6 7
Fault Fault Alarm 2 Alarm 2 Alarm 1 Alarm 1 Ground
Solid Rectangle (Remote) X3
Sensing Head Polytron SE Ex PR M1 DD 6812711
Sensing Head Polytron SE Ex PR M2 DD 6812710
Sensing Head Polytron SE Ex PR M3 DD 6812718
Sensing Head Polytron SE Ex HT M DD 6812720
Sensing Head Polytron SE Ex LC M1 DD 6812722
Sensing Head Polytron SE Ex LC M2 DD 6812721
Sensing Head Polytron SE Ex LC M3 DD 6812719
Sensing Head DrägerSensor IR complete Set e 6811165
Sensing Head DrägerSensor IR complete Set e 6811265
Sensing Head Dräger PIR 3000 complete Set e 6811160
Sensing Head Dräger PIR 3000 complete Set e 6811270
1) not yet available
Sensor Wire Color
S1 S2 S3 S4 S5
Wire S2
Black
to
Yell ow
S1
Wire S2
Black
to
Yell ow
S1
Wire S2
Black
to
Yell ow
S1
1
1
----- ----- Brown Black Red
Wire S4
to
S5
Wire S4
to
S5
Wire S4
to
S5
Brown
Brown
Brown
10 Dräger Polytron 5200 / Dräger Polytron 53X0
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