Emerson RLDS Installation And Operation Manual

Refrigerant Leak Detection System (RLDS) Installation and Operation Manual
026-1309 Rev 8
Class A compliance for RLDS under CE Requirements. Meets Part 15 Subpart B requirements of the FCC Rules. In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures. ETL, report no 3151009LAX-001 to:
ANSI/UL 61010-1
CAN/CSA 22.2 No 61010-1 & CE Mark
READ ALL INSTRUCTIONS CAREFULLY
If the equipment is not used in the manner specified by the manufacturer, the protection provided by the equipment may be impaired.
Emerson
1065 Big Shanty Road NW, Suite 100
Kennesaw, GA 30144
770-425-2724 • www.emerson.com
Contents
1 INTRODUCTION.......................................................................................................................................................... 1
1.1. HOW TO USE THIS MANUAL ........................................................................................................................................ 1
1.2. NOTES........................................................................................................................................................................... 1
1.3. SAFETY PRECAUTIONS.................................................................................................................................................. 1
1.3.1. AC Power Supply .................................................................................................................................................. 1
1.3.2. Protective Grounding............................................................................................................................................ 1
1.3.3. Explosive Atmosphere........................................................................................................................................... 1
1.3.4. Proper Exhaust Venting........................................................................................................................................ 1
1.3.5. Working Inside Instrument.................................................................................................................................... 1
1.3.6. Misuse and Modifications to the Instrument......................................................................................................... 1
1.3.7. In Case of Malfunction.......................................................................................................................................... 1
1.3.8. RLDS Fusing......................................................................................................................................................... 2
1.3.9. Installation Category ............................................................................................................................................ 2
1.3.10. Altitude Limit....................................................................................................................................................... 2
1.3.11. Cleaning .............................................................................................................................................................. 2
1.4. WARNING AND CAUTION STATEMENTS ....................................................................................................................... 2
1.4.1. Warning Statements .............................................................................................................................................. 2
1.4.2. Caution Statements ............................................................................................................................................... 2
2 FUNCTIONAL OVERVIEW ....................................................................................................................................... 3
2.1. GENERAL DESCRIPTION................................................................................................................................................ 3
2.2. COMMUNICATION OPTIONS .......................................................................................................................................... 3
2.3. UNDERSTANDING MONITORING LEVELS ...................................................................................................................... 3
2.4. RESPONSE TO THE PRESENCE OF MULTIPLE REFRIGERANTS ....................................................................................... 4
2.5. SUGGESTED LOCATION OF SAMPLING POINTS ............................................................................................................. 4
3 RLDS INSTALLATION ............................................................................................................................................... 6
3.1. RLDS - INSTALLATION CONSIDERATIONS ................................................................................................................... 6
3.1.1. Warnings and Cautions......................................................................................................................................... 6
3.1.2. Inspection .............................................................................................................................................................. 6
3.1.3. Monitor Location .................................................................................................................................................. 6
3.2. RLDS MOUNTING INSTRUCTIONS ................................................................................................................................ 6
3.2.1. Screw Locations .................................................................................................................................................... 6
3.2.2. Installation ............................................................................................................................................................ 7
3.3. RLDS - CONNECTING AIR LINES ................................................................................................................................. 7
3.3.1. Overview ............................................................................................................................................................... 7
3.3.2. Tubing Considerations.......................................................................................................................................... 7
3.3.3. Connecting Purge Line ......................................................................................................................................... 7
3.3.4. Connecting Exhaust Line ...................................................................................................................................... 8
3.3.5. Connecting Sample Intake Lines........................................................................................................................... 8
3.3.6. Considerations ...................................................................................................................................................... 8
3.4. SPLITTER KITS .............................................................................................................................................................. 9
3.4.1. Overview ............................................................................................................................................................... 9
3.4.2. Installation ............................................................................................................................................................ 9
3.5. RLDS INTERIOR ......................................................................................................................................................... 10
3.6. RLDS ELECTRICAL WIRING....................................................................................................................................... 11
3.6.1. Warnings and Cautions....................................................................................................................................... 11
4 CONNECTING COMMUNICATION DEVICES ................................................................................................... 13
Table of Contents • v
4.1. E2 MODBUS DIRECT SUPPORT FOR RLDS .............................................................................................................. 13
4.1.1. Network Connection to E2 .................................................................................................................................. 13
4.1.1.1. COM Port Associations - E2 Versions 3.xx and Below ................................................................................................... 13
4.1.1.2. COM Port Associations - E2 Versions 4.0 and Above..................................................................................................... 13
4.1.1.3. E2 Termination ................................................................................................................................................................. 14
4.1.2. E2 Setup of RLDS................................................................................................................................................ 14
4.1.2.1. Set Up Network Ports ....................................................................................................................................................... 14
4.1.2.2. Add and Connect RLDS ................................................................................................................................................... 14
4.2. E2, EINSTEIN, AND REFLECS CONTROLLERS (THE RLDS GATEWAY BOARD)....................................................... 15
4.2.1. Powering the Gateway Board ............................................................................................................................. 16
4.2.2. Gateway Board Networking ................................................................................................................................ 16
4.2.2.1. Changing Terminator Switch Settings.............................................................................................................................. 17
4.2.2.2. RLDS Node Address ........................................................................................................................................................ 17
4.2.3. Connecting to an E2, Einstein, or REFLECS Site Controller............................................................................. 17
4.2.4. Connecting the Gateway Board to the E2, Einstein, or REFLECS Network...................................................... 18
4.2.4.1. Wire Connection ............................................................................................................................................................... 18
4.2.4.2. Setting the Board Numbering Dip Switch ........................................................................................................................ 18
4.2.4.3. Setting the Baud Rate Dip Switches ................................................................................................................................. 19
4.2.4.4. Setting the RS485 I/O Termination Jumpers.................................................................................................................... 20
4.2.5. Gateway Board Status LEDs............................................................................................................................... 20
4.2.5.1. The General Status LED ................................................................................................................................................... 20
4.2.5.2. The Alarm LED ................................................................................................................................................................ 20
4.2.5.3. RS485 I/O Network Status LED ....................................................................................................................................... 21
4.2.5.4. Receiver Bus Network Status LED................................................................................................................................... 21
5 RLDS - CONNECTING EXTERNAL ALARMS..................................................................................................... 22
5.1. OVERVIEW .................................................................................................................................................................. 22
5.2. CONNECTION............................................................................................................................................................... 22
6 RLDS HARDWARE SPECIFICATIONS ................................................................................................................. 23
7 PROGRAMMING SETUP AND UI NAVIGATION FOR RLDS - DISPLAY SCREENS.................................. 25
7.1. NAVIGATION KEYS ..................................................................................................................................................... 25
7.2. INITIAL POWER UP...................................................................................................................................................... 25
7.3. NAVIGATE TO THE FIRST SETUP SCREEN ................................................................................................................... 25
7.4. NAVIGATE TO THE SECOND SETUP SCREEN ............................................................................................................... 26
7.5. LOCATION ................................................................................................................................................................... 26
7.6. NUMBER OF ZONES INSTALLED .................................................................................................................................. 26
7.7. ALARM ACKNOWLEDGE (ACK) - MODE ..................................................................................................................... 26
7.8. AUDIBLE ALARM ........................................................................................................................................................ 26
7.9. ZONE HOLD MODE ..................................................................................................................................................... 27
7.10. ZONE HOLD TIME ..................................................................................................................................................... 27
7.11. DETECTION LIMIT ..................................................................................................................................................... 27
7.12. LOOP2 FACTOR ......................................................................................................................................................... 27
7.13. RE-ZERO MODE ........................................................................................................................................................ 27
7.14. NAVIGATING TO THE THIRD SETUP SCREEN ............................................................................................................ 28
7.15. SERVICE TIMEOUT .................................................................................................................................................... 28
7.16. NODE ADDRESS ........................................................................................................................................................ 28
7.17. PASSWORD ................................................................................................................................................................ 28
7.18. ACCESSING ADDITIONAL FEATURES ........................................................................................................................ 28
7.19. DET DIGIPOT............................................................................................................................................................ 29
7.20. SENSOR TEMPERATURE COEFFICIENT ...................................................................................................................... 29
7.21. ACQUIRING TEMPERATURE COEFFICIENT (FACTORY USE ONLY) ........................................................................... 29
7.22. IR DIGIPOT................................................................................................................................................................ 29
8 GENERAL OPERATION OF RLDS - UI................................................................................................................. 30
vi • RLDS I&O Manual 026-1309 Rev 8
8.1. FUNCTIONAL OVERVIEW ............................................................................................................................................ 30
8.2.
THE ZONE SCREEN ..................................................................................................................................................... 30
8.2.1. Location .............................................................................................................................................................. 30
8.2.2. Refrigerant Type ................................................................................................................................................. 30
8.2.3. Distance .............................................................................................................................................................. 30
8.2.4. Zone Temperature............................................................................................................................................... 30
8.2.5. Current Detection Reading ................................................................................................................................. 30
8.2.6. Log Interval......................................................................................................................................................... 31
8.3. NAVIGATING TO THE SECOND HOME SCREEN ........................................................................................................... 31
8.3.1. Leak Level ........................................................................................................................................................... 31
8.3.2. Spill Level............................................................................................................................................................ 31
8.3.3. Evacuation Level................................................................................................................................................. 31
8.3.4. Resetting the Peak PPM Value ........................................................................................................................... 31
8.4. ALARM CONDITIONS .................................................................................................................................................. 32
8.5. FAULT CONDITIONS .................................................................................................................................................... 32
8.6. ALARMS...................................................................................................................................................................... 32
8.6.1. Functional Overview........................................................................................................................................... 32
8.6.2. Responding to Alarms ......................................................................................................................................... 32
8.6.3. Alarm Detail Screen............................................................................................................................................ 33
8.6.4. Acknowledging Alarms ....................................................................................................................................... 33
8.7. SYSTEM FAULTS ......................................................................................................................................................... 33
8.7.1. Functional Overview........................................................................................................................................... 33
8.7.2. Navigating to the Fault Screen ........................................................................................................................... 34
8.7.2.1. Critical Faults.................................................................................................................................................................... 34
8.7.2.2. Non-Critical Faults ........................................................................................................................................................... 34
8.7.3. Reset to Factory Default Settings........................................................................................................................ 35
8.7.3.1. Resetting the RLDS .......................................................................................................................................................... 35
8.7.4. Clearing System Faults ....................................................................................................................................... 35
8.7.5. Viewing Fault Log............................................................................................................................................... 35
8.7.6. Viewing Flow Log ............................................................................................................................................... 36
8.8. THE TREND SCREEN ................................................................................................................................................... 36
8.8.1. Navigating to the Trend Screen .......................................................................................................................... 36
8.9. THE CALIBRATION SCREEN ........................................................................................................................................ 36
8.9.1. Overview ............................................................................................................................................................. 36
8.9.2. Navigating to the Calibration Screen ................................................................................................................. 37
8.9.3. Adjusting Calibration Factor.............................................................................................................................. 37
8.9.4. CO2 Atmospheric Concentration
(RLDS-CO2 Units Only) ................................................................................................................................................. 37
8.9.5. Calibration Procedure ........................................................................................................................................ 37
8.9.6. Programming New Gases ................................................................................................................................... 38
8.10. THE DIAGNOSTIC SCREEN ........................................................................................................................................ 39
8.10.1. Navigating to the Diagnostic Screen ................................................................................................................ 39
8.10.2. Diagnostic Screen Overview............................................................................................................................. 39
8.11. SERVICE MODE ......................................................................................................................................................... 40
9 QUICK SETUPS FOR HAND-HELD TERMINAL (HHT).................................................................................... 47
9.1. TIME/DATE SETUP ...................................................................................................................................................... 47
9.2. ZONE SETUP ............................................................................................................................................................... 47
9.2.1. General Configuration 1 Screen......................................................................................................................... 47
9.2.2. General Configuration 2 Screen......................................................................................................................... 48
9.2.3. Zone Config Screen 1.......................................................................................................................................... 48
9.2.4. Zone Config Screen 2.......................................................................................................................................... 49
9.3. STATUS OPTION SCREEN ....................................................................................................................................... 49
9.3.1. Zone Status Screen .............................................................................................................................................. 49
Table of Contents • vii
9.3.2. General Controller (CTRL STATUS) Screen ...................................................................................................... 50
10 HAND-HELD TERMINAL (HHT) FOR USE WITH THE GATEWAY AND RLDS CONTROLLER ......... 51
10.1. HHT KEY OPERATIONS ............................................................................................................................................ 51
11 MAIN SCREENS ....................................................................................................................................................... 52
11.1. HOME SCREEN (F1 SCREEN)..................................................................................................................................... 52
11.2. RLDS ENABLE SCREEN ............................................................................................................................................ 52
11.3. SELECT RLDS SCREEN (F2 SCREEN)..................................................................................................................... 52
11.4. OPERATION SELECT (OPTION) SCREEN .................................................................................................................. 53
11.4.1. RLDS STATUS (STATUS OPTION) Screen...................................................................................................... 53
11.4.2. RLDS FAULTS (SYSTEM FAULTS) screen...................................................................................................... 53
11.4.3. RLDS Configuration Option (CONFIG OPTION) Screen................................................................................ 54
11.4.4. General Configuration 1 Screen ....................................................................................................................... 54
11.4.5. General Configuration 2 Screen ....................................................................................................................... 54
11.4.6. Zone Config Screen 1 ........................................................................................................................................ 55
11.4.7. Zone Config Screen 2 ........................................................................................................................................ 55
11.4.8. Time/Date Screen .............................................................................................................................................. 56
11.4.9. Calibrate Gas Screen 1 ..................................................................................................................................... 56
11.4.10. Calibrate Gas Screen 2 ................................................................................................................................... 56
11.4.11. Calibrate Gas Screen 3 ................................................................................................................................... 56
11.4.11.1. Calibrate Gas Screen 3 Continued ................................................................................................................................ 57
11.5. STATUS OPTION SCREEN ..................................................................................................................................... 57
11.5.1. Zone Status Screen ............................................................................................................................................ 57
11.5.2. General Controller (CTRL STATUS) Screen.................................................................................................... 57
11.5.3. DIAGNOSTICS Screen 1: Sensor Data Register.............................................................................................. 58
11.5.4. Screen 2: Sensor Data Register ........................................................................................................................ 58
11.5.5. Screen 3: Sensor Data Register ........................................................................................................................ 58
11.5.6. Screen 4: Sensor Data Register ........................................................................................................................ 59
11.5.7. Screen 5: Sensor Data Register ........................................................................................................................ 59
11.5.8. Screen 6: Sensor Data Register ........................................................................................................................ 59
11.5.9. Screen 7: Communication Statistics.................................................................................................................. 59
12 RLDS SETUP ON REFLECS, E2, AND EINSTEIN CONTROLLER INTERFACES ..................................... 60
12.1. REFLECS SETUP FOR RLDS ................................................................................................................................... 60
12.2. E2 VERSION 3.01 AND BELOW SETUP FOR RLDS (WITHOUT GATEWAY)................................................................ 60
12.3. EINSTEIN SETUP FOR RLDS ..................................................................................................................................... 62
13 RLDS MAINTENANCE............................................................................................................................................ 63
13.1. WARNINGS AND CAUTIONS ...................................................................................................................................... 63
13.2. CHARCOAL FILTER ................................................................................................................................................... 63
13.3. HYDROPHOBIC FILTER .............................................................................................................................................. 63
13.4. SERVICING AIR LINES AND REPLACING TERMINATION FILTERS.............................................................................. 63
13.5. ANNUAL MAINTENANCE........................................................................................................................................... 63
13.5.1. Checking Pump and Bench Diagnostics ........................................................................................................... 63
13.5.2. Gas Testing........................................................................................................................................................ 64
13.5.3. Annual Maintenance Checklist.......................................................................................................................... 65
13.6. REPLACEMENT PARTS AND PART DESCRIPTIONS ..................................................................................................... 66
14 APPENDIX: RLDS CALIBRATION....................................................................................................................... 69
14.1. CALIBRATION CHECK ............................................................................................................................................... 69
14.1.1. Testing with Gas Verification Kit...................................................................................................................... 69
INDEX ............................................................................................................................................................................. 71
viii • RLDS I&O Manual 026-1309 Rev 8

1 Introduction

1.1. How to Use This Manual

A switch or circuit breaker rated 1.0 A, 250 VAC, with a minimum terminal spacing of 3.0 mm must be attached to the monitor’s AC power leads. This switch must also be located in close proximity to the monitor, and be within easy reach of the operator. This switch should also be clearly marked as the monitor’s type of equipment.
• A switch or circuit-breaker must be included in the building installation
This manual provides important information on how to install, operate, and service the RLDS.
Please read this manual carefully before use.
If you have a working knowledge of refrigerant monitors, you will find this manual useful as a reference tool. If you are new to the use of refrigerant monitors, you can educate yourself about the principles of refrigerant gas detection and the proper operation of this device by reading this manual thoroughly.

1.2. Notes

Emerson Electronics and Solutions reserves the right to change the operation or specifications of this instrument at any time without notice.
If any errors or ambiguities are discovered in this manual, promptly inform Emerson Electronics and Solutions.
No part of this manual may be reproduced or recreated, in any form or by any means, without the express prior permission of Emerson Electronics and Solutions.
• The switch must be in close proximity to the equipment and within easy reach of the operator
• The switch must be clearly marked as the disconnecting device for the equipment

1.3.2. Protective Grounding

Under no circumstances should the RLDS be operated without connection to a protective ground. Doing so poses a potential shock hazard and is also a violation of electrical safety standards applicable to this type of equipment.

1.3.3. Explosive Atmosphere

Do not operate this equipment in the presence of flammable liquids, vapors, or aerosols. Operation of any electrical instrument in such an environment constitutes a safety hazard.

1.3.4. Proper Exhaust Venting

It is imperative that the exhaust port on this instrument be properly vented as described in this manual. Failure to do so constitutes a safety hazard.

1.3.5. Working Inside Instrument

1.3. Safety Precautions

1.3.1. AC Power Supply

Ensure the source voltage matches the voltage of the product before energizing the equipment.
The RLDS uses a universal power supply that is capable of accepting inputs of 100 to 240 VAC, 50/60 Hz. The monitor’s power consumption is 20 Watts.
It is highly recommended that th e RLDS be placed on a separate circuit (with UPS or surge protection) and be connected directly to the AC power source.
How to Use This Manual Introduction • 1
Extreme care should be exercised when accessing the interior of the monitor. Only qualified electrical maintenance personnel should perform connections and adjustments. Always de-energize the power supply before opening the monitor’s enclosure.

1.3.6. Misuse and Modifications to the Instrument

The protection provided by the monitor may be impaired if the monitor is used in a manner not specified by Emerson Electronics and Solutions. Modifications to this monitor, not expressly approved, will void the warranty.

1.3.7. In Case of Malfunction

Do not continue to use this equipment if there are any symptoms of malfunction or failure. In the case of such occurrence, de-energize the power supply and contact a qualified repair technician or the nearest Service Center. ONLY the provided knockouts are to be used for electrical and communication wiring. Drilling into the box will void the warranty.

1.3.8. RLDS Fusing

50VAC
(Type “F”)
F1, F2
Table 1-1 - Fusing Requirements
1AMP, 2
FAST ACTING

1.3.9. Installation Category

Installation Category II, Pollution Degree II, as defined by UL.

1.3.10. Altitude Limit

RLDS 6,562 ft (2,000 m)

1.4. Warning and Caution Statements

1.4.1. Warning Statements

The use of the word WARNING in this manual denotes a potential hazard associated with the use of this equipment. It calls attention to a procedure, practice, or condition, or the like, which if not correctly performed or adhered to, could result in injury or death of personnel using this instrument.

1.4.2. Caution Statements

The use of the word CAUTION in this manual denotes a potential hazard associated with the use of this equipment. It calls attention to a procedure, practice, condition, or the like, which if not correctly performed or adhered to, could result in damage to the equipment.

1.3.11. Cleaning

If, during period maintenance inspection it becomes necessary to clean the outside of the case, use a DRY CLOTH. To avoid shock hazard and/or equipment damage, DO NOT USE SOAP AND
WATER.
2 • RLDS I&O Manual 026-1309 Rev 8
2 Functional
Overview

2.1. General Description

Refrigerant monitors are specified to support compliance to federal, state and local safety codes governing refrigerant emissions. Avoiding significant refrigerant loss reduces equipment replacement costs, maintains equipment efficiency, promotes safety, and protects the environment.
The RLDS provides for the continuous monitoring of refrigerant gas levels in up to 16 separate test zones or channels. The instrument is easily programmed to monitor a variety of gases and independent leak (small), spill (medium), and evacuation (large) levels may be designated for each zone. The instrument also retains a log of previous readings that can be easily accessed for analysis.
of the fault. All 800# models of the RLDS come with the number of line-end filters (plus one extra) to match the number of zones for each model.
Figure 2-1 - RLDS Front View
2.2. Communication
An audible alarm and front panel indicators are provided to signal alarm and fault conditions, and relay contacts are provided that can be used to trigger external alarm devices in the event of a system fault, or if a leak (small), spill (medium), or evacuation (large) level of gas is detected. The system also may be fitted with an optional two-channel 4-20mA current loop board for connection to remote monitoring equipment.
The RLDS requires only minor periodic maintenance such as the occasional replacement of filters. The monitor incorporates active diagnostics that continuously monitor the system for proper operation. A front panel indicator is provided to alert an operator of system malfunctions, and fault codes are generated that enable the user to identify the cause
Options
The RLDS features full two-way communications via an RS485 interface. MODBUS RTU is the communication protocol standard and can be connected directly to an E2, Einstein, or REFLECS controller.
Please refer to Section 4, Connecting Communica- tion Devices for a more complete discussion of communication protocols.

2.3. Understanding Monitoring Levels

Effective use of this instrument requires an understanding of what constitutes reasonable alarm setpoints for the type of gases being monitored.
All AC&R systems leak some refrigerant. Refrigerant manufacturers define allowable exposure levels and threshold limit values in units of parts per million (PPM). In a good “tight” installation these background levels will be acceptably low and often do not require corrective action. You can reduce nuisance alarms and needless service calls if the alarm levels are set at practical limits.
General Description Functional Overview • 3
Recommended monitoring levels based on compliance to ANSI/BSR ASHRAE 15-2007 and ASHRAE Safety Code 34-2007 have been developed and are listed in Table 8-1 and Section 6, RLDS Hardware Specifications.
Setting the unit at these recommended alarm levels will satisfy the needs of most users. However, the PPM levels generated by system leaks into the environment are greatly influenced by the volume of air in the sampling area, air circulation, size of the leak, distance to the monitoring point, and a host of other variables. In some cases the set points may need to be adjusted either up or down to achieve effective monitoring. Please contact your representative (770-425-2724) for assistance in obtaining these levels.

2.4. Response to the Presence of Multiple Refrigerants

The RLDS is a refrigerant level monitor, not a gas analyzer. You must program the monitor to test for a specific refrigerant in each zone, and it will only return accurate concentration readings for that particular refrigerant. If a leak occurs of another refrigerant gas type, the monitor may return false readings.
Most applications only require detection of a single refrigerant and the problems that are associated with monitoring multiple gases are rarely an issue. If there is a possibility of multiple refrigerants leaking in the same sampling zone, you should consider carefully which refrigerant compound you program the unit to monitor, or make system design considerations to cover this event. Please consult your sales engineer for assistance in setting up the RLDS system to cover this event.
line is not at the exact point of the refrigerant leak, the unit will read a diluted mixture of the refrigerant gas and air and may require adjustment of alarm levels.
The farther away an RLDS sample point is from a refrigerant leak, the longer it will take to detect the leak, and the lower the concentration of refrigerant in the air will be; therefore, place the termination of the collection line as near as possible to the point where refrigerant leaks are the most likely.
It should also be noted that refrigerant gas is hea vier tha n air and t ends to c ollect be low the p oint of a leak; therefore, samples taken near the floor will have a greater concentration of gas than those collected above the source of a leak; therefore, sampling points should ideally be located as close as possible to the source of potential leaks. If this is impractical, then the alarm setpoints should be adjusted for that zone to compensate for the dilution of the refrigerant gas. Line-end filters should be mounted 12” (30 cm) to 18” (45 cm) above the floor.
DO NOT
be disabled by setting the distance parameter to zero feet in the zone setup screen.
The RLDS should be centrally located in the mechanical room and be readily accessible for easy visual monitoring and servicing. The combined length of sample tubing, plus exhaust tubing, should not exceed 1200 feet (365 meters) for any zone. The fresh air purge line should draw from an a rea that does not contain any refrigerant gas. The exhaust line should run to an outside location if possible. The comb ined length o f the purge line and the exhaust line cannot exceed 300 feet (91 meters).
Ideally, two to three pick up points spaced around each chiller will provide sufficient coverage. It may be necessary to perform a “smoke” test of the mechanical room to determine the best locations. The smoke test would provide the pattern of air currents present in the mechanical room.
block any of the zones. Unused zones may
NOTE: For information about using the
2.5. Suggested Location of
RLDS in wet locations, see Section 3.3.6., Con­siderations.
Sampling Points
At the point of origin of a refrigerant leak, the gas is highly concentrated. As the refrigerant is dispersed into the air, the gas molecules diffuse, causing a dilution of the original concentration. The RLDS measures the refrigerant concentration at the sample collection point, so if the termination of the collection
4 • RLDS I&O Manual 026-1309 Rev 8
Sample Inlet Pickup Points
Chiller
Machine Room
Sample Inlet Pickup Point
Exhaust Fan
Outside Hallway
Aux Horn/Strobe
Fresh air purge from area away
from refrigerant
gas
RLDS
Figure 2-2 - RLDS Mechanical Room Placement
The user interface on the RLDS is the main interface by which you program the unit, acknowledge alarms, and observe conditions inside of the mechanical room. Note that there are two additional alarm relay contacts in the RLDS that can be programmed to alarm with Leak, Spill, Evacuate, Fault, or Monitor On.
Suggested Location of Sampling Points Functional Overview • 5

3 RLDS Installation

Solenoid Connections (this side)
Display Screen
Alarm Light (Red)
System Fault Light (Yellow)
Monitor ON Light (Green)
WARNING: Shock hazard! Always de-energize the power supply before working on the interior of the equipment.
Figure 3-1 - RLDS Diagram
Standard accessories needed for a four (4)-point Sys­tem:
Accessory Part Number
Five (5) Line-End Filters (Assembly)
Charcoal Filter 275-0275
RLDS Instruction Manual 026-1309
Table 3-1 - RLDS Accessories and Part Numbers
275-0300

3.1. RLDS - Installation Considerations

3.1.1. Warnings and Cautions

WARNING: Explosion hazard! Do not mount or operate this equipment in an area that may
contain or in the presence of flammable liquids, vapors, or aerosols. Operation of any electrical equipment in such an environment constitutes a safety hazard.
CAUTION: The RLDS contains sensitive electronic components that can be easily damaged. Do not to touch nor disturb any of these components.

3.1.2. Inspection

The RLDS has been thoroughly inspected and tested prior to shipment from the factory. Nevertheless, it is recommended that the monitor be re-checked prior to installation. Inspect the outside of the enclosure to make sure there are no obvious signs of shipping damage. Open the enclosure and inspect the interior of the unit for loose components that may have become dislodged during shipment. If damage is discovered, please contact Technical Support for assistance (770-425-2724).

3.1.3. Monitor Location

The RLDS should be centrally located in the facility and should be easily accessible for visual monitoring and servicing. Intake sample lines can be up to 1200 feet (365 meters), but it is important to remember that sampling cycle time is proportional to the total number and length of individual sample lines.
Dirt, grease, and oils can adversely affect the operation of the RLDS. The monitor should be installed out of direct sunlight in a clean, dry area that is not subject to temperature or humidity extremes. Installation of the monitor in a mechanical room is acceptable provided reasonable environmental conditions exist. If there is a question, consider installing the unit outside of the mechanical room in a cleaner area of the facility. The location should allow the monitor to be easily accessible for visual monitoring and servicing.

3.2. RLDS Mounting Instructions

WARNING: Drilling holes in the RLDS enclosure may damage the unit and will void the warranty. Please use the knockouts provided for electrical connections.
6 • RLDS I&O Manual 026-1309 Rev 8

3.2.1. Screw Locations

The RLDS should be installed plumb and level and securely fastened to a rigid mounting surface. The enclosure utilizes keyhole mounting brackets
designed for 1/4” (6.35 mm) fasteners. Locate the
TOP
Mounting Instructions
Four 1/4 inch fasteners are required to mount the RLDS enclosure. Allow approximately 1/4 inch of each fastener to remain exposed. The enclosure can slide directly onto the screw heads for mounting. Verify the position of enclosure on the fasteners, and then tighten all fasteners.
Not To Scale
13 9/16”
8 55/64”
12 1/4”
2 1/32”
9 5/16”
2 55/64”
Exhaust Port
Inlet/Purge Ports
four screws as shown in the diagram below and allow the screw heads to protrude approximately 1/4” (6.35 mm).
installed to vent residual gas away from the monitor. All air line connections, located on the left side of the enclosure, are indicated in Figure 3-3.
Figure 3-2 - RLDS Mounting Dimensions

3.2.2. Installation

Hold the monitor flat against the mounting surface and allow it to slide down, engaging the screw heads in the keyhole slots of the mounting brackets. Adjust the screws as necessary to hold the monitor securely against the mounting surface.

3.3. RLDS - Connecting Air Lines

3.3.1. Overview

Individual sample lines are run from the RLDS to each area of the facility to be monitored. Additionally, a purge line is installed to provide clean air for resetting the infrared zero baseline. An exhaust line is
Figure 3-3 - RLDS (Tubing Connections)

3.3.2. Tubing Considerations

Use 1/4” (6.35 mm) outside diameter (0.04” wall) (1.02 mm wall) flex tubing for all air lines or equivalent. The tubing should be clean and free of residual moisture or other contaminants. The tubing should be cut cleanly with a sharp knife and care should be taken not to distort the tubing end.
To connect the air lines to the monitor simp ly push the tubing firmly onto the connector. To remove a line, depress the plastic ring on the connector with one hand while withdrawing the tube with your other hand. All tubing bends should have a radius of no less than 5” (12 cm) to ensure proper airflow. If kinks or obstructions occur in any of the air lines, the instrument may not function properly.

3.3.3. Connecting Purge Line

RLDS - Connecting Air Lines RLDS Installation • 7
A purge line is required to draw fresh air into the in­strument and should not exceed 300 feet (91 meters) in length. A charcoal filter assembly has been
provided to ensure clean air is being drawn in through the purge line. This filter should be mounted close to the RLDS.
increase monitoring capacity. Please contact Technical Assistance (770-425-2724) for more information.
It is advisable to terminate the purge line outdoors, provided the input is not exposed to rain, snow, ice, exhaust fumes, or other airborne contaminates. If an outdoor installation is impractical, the line should be run to an area inside the facility that you are certain is not contaminated with ambient refrigerant gas.
A line-end filter should be attached to the end of the purge line. If this is not possible, an optional charcoal filter assembly (P/N 275-0275) can be used to filter refrigerant from the purge line, and may be mounted adjacent to the monitor. A line-end filter assembly (P/N 275-0300) should be attached to the end of the purge line when the charcoal filter is not used.
CAUTION: (CO2 Only): Because CO2 is present in ambient air, the purge line MUST
BE run outside, away from any known sources of CO
gas. An atmospheric CO2
2
concentration value can be manually entered by the user in the CAL screen. CO
units. See Section 8.9.4. CO2 Atmospheric Concentra­tion (RLDS-CO2 Units Only).
is supported by RLDS-CO2
2
Sample intake lines can be up to 1200 feet (365 meters) when no exhaust tubing is used. Otherwise, the combined length of the sample line and the exhaust line cannot exceed 1200 feet (365 meters). All line terminations should be positioned to reduce the possibility of mists, aerosols, oil, water, dust, or other contaminates being drawn into the instrument. A line-end filter (included) should be attached to the end of each sample intake line. Line-end filters should be placed 12” to 18” (30 to 45 cm) above the floor.
IMPORTANT: DO NOT
block any of the zones. Unused zones may be disabled by setting their length parameter to zero feet in the Zone Setup screen
(Section 8.2., The Zone Screen).
Please refer to the earlier section (Section 2.5., Suggested Location of Sampling Points) to learn more about where to locate the monitoring points.
CAUTION: The introduction of contaminants through the air intake lines can result in serious and permanent damage to the monitor.

3.3.4. Connecting Exhaust Line

An exhaust line (¼” OD tubing) (6.35 mm) can be used when it is required to vent gas samples away from the instrument and should not exceed 300 feet (91 meters). The exhaust line should terminate in a location that is completely isolated from the purge line termination point and other areas of the facility that will be monitored. Ideally this line should terminate outdoors in a location that is not exposed to the elements. This line does not require a line-end filter. If the exhaust line terminates outside the building, position the tubing so that no water or moisture can enter it.

3.3.5. Connecting Sample Intake Lines

The RLDS is designed to accommodate up to 16 separate sample intake lines. The standard configuration of the unit includes one manifold of four intake connectors and one purge connector. Additional manifolds can be easily installed to

3.3.6. Considerations

For maximum protection, the RLDS may be shut down when a System Fault occurs. This might be desired, for example, when the RLDS is used in wet locations such as meat preparation rooms. When water is pulled into the system, a System Fault will occur, closing the fault relay located at the bottom of the main control board. To turn power off to the RLDS when this occurs, wire the fault relay into a spare 16AI input. Route the power supply to the RLDS through an 8RO output using the normally closed contacts. Program the E2/Einstein to alarm the fault input on a contact closure and turn on the 8RO output when this occurs. This can be done using a Digital Sensor Control application in the E2/Einstein. Refer to the E2 Installation and Operation manual (P/N 026-1614) for details on setting up a Digital Sensor Control application.
8 • RLDS I&O Manual 026-1309 Rev 8

3.4. Splitter Kits

3.4.1. Overview

Two-way splitter (P/N 275-0304) and three-way splitter (P/N 275-0305) kits for a zone are used with the RLDS to allow you to pinpoint critical points of the refrigeration system, and allow further monitoring in small spaces with a high probability for leakage. Splitter kits allow you to place more sensors in each zone, which enable potential leaks to be detected more quickly.
CAUTION: Keep pick-up tube the same length to create the averaging effect of the splitter system. Point the filter vertically downward or
horizontally with a slight downward tilt to avoid moisture collecting in the filter from condensation.
Figure 3-6 - Improper Wire Length of a Two-way Splitter
The alarm setpoint must be changed due to the averaging effect of the splitter system. The pick-up lines for the splitter tube must be the same length from the splitter to each of the end-of-line filters to balance the splitter system and create the averaging effect.
Figure 3-4 - Types of Splitter Kits

3.4.2. Installation

Sensors can be installed on walls, drains, or areas with potential air flow. Any ¼” tubing can be used to configure the two or three point sensors.
Figure 3-5 - Proper Wire Length of a Two-way Splitter
A two-way splitter kit requires reduction of the original alarm setpoint by ½ so the setpoint becomes half of the original value. A three-way splitter kit requires reduction of the original setpoint by ⅓ so the setpoint becomes a third of the original value.
For example, if the alarm setpoint alarm value is 1000, with a two-way splitter the value becomes 500 PPM. With a three-way splitter the value becomes 333 PPM.
Part Number Description
275-0304 Two-way Splitter Kit contains:
1 two-way push-fit splitter, 2 line-end filters (tubing not included)
275-0305 Three-way Splitter Kit contains:
1 three-way push-fit splitter, 3 line-end filters (tubing not included)
270-0810 ¼” Sample Tubing (100 ft.)
Table 3-2 - Splitter Kit and Tubing Part Numbers
Splitter Kits RLDS Installation • 9

3.5. RLDS Interior

Universal Power Supply
Intake Manifold Solenoid Connectors
Dual 4-20 mA Outputs (Signal Out Only) Screw Terminal
Microcontroller Board
Intake Manifold Solenoids
AC Input Terminals
IR Bench Gas Out
Gas Sample Pump
AC Input Ground Stud
Main Board
IR Bench Gas In
AC Input
Ground Stud
Hydrophobic Filter
Dual 4-20 mA Outputs Option Card Socket
Microcontroller Board
RLDS Main Circuit Board
Terminator Switch
Relay Connector Alarm 1,2,3 Fault
Factory Default
RS485 Connector
4-20 mA Output Only (DO NOT APPLY POWER)
CPU Reset
Relay Connectors: Leak, Spill, Evacuate, Fault
RS485 Connector
AC Input Terminals
Figure 3-7 - Diagram of RLDS Interior
Figure 3-8 - RLDS Processor Board Layout
Figure 3-9 - Relay, RS485, and AC Input Connections
10 • RLDS I&O Manual 026-1309 Rev 8
Figure 3-10 - Switch and Fuse Locations
Factory Default
CPU Reset
Line Fuses 1 1 Amp, 250 V
NOTE: The plastic cable ties surrounding the air pump are to ensure safe handling during shipment. Remove before operating the unit.
Reinstall a plastic cable around the air pump if the unit is shipped back to Emerson Electronics and Solutions for service or repair. This prevents damage during shipment.

3.6. RLDS Electrical Wiring

The RLDS uses a universal power supply that is capable of accepting inputs of 100 to 240 VAC, 50/60 Hz. The monitor's power consumption is 20 Watts. It is highly recommended that the monitor be connected directly to the AC power source, preferably on its own circuit. The AC power connection should be completed with UL approved 3-conductor wire (minimum 16 AWG), rated 300 VAC at 221°F (105°C).
Locate a convenient service knockout and install electrical conduit in the typical manner.
NOTE: For more information on power specifications, contact your Emerson Electronics and Solutions representative for more information.
Locate the AC power connector on the inside of the instrument and remove it from the circuit board. Secure the wire leads to the connector orienting them as shown in the diagram. Carefully plug the connector back onto the circuit board. finally, locate the ground lug and securely fasten the ground lead.
A second connector is provided to wire an external device through the RLDS power circuit. Locate the connector and complete the wiring as described above.

3.6.1. Warnings and Cautions

WARNING: Electrical installation should be performed by a certified electrician and must comply with all applicable local, state, and federal electrical safety codes.
WARNING: Under no circumstances should this instrument be operated without connection
to a protective ground. The AC power ground wire must first be connected to the monitor's ground stud. Doing so poses a potential shock hazard and is also a violation of electrical safety standards applicable to this type of equipment.
WARNING: Copper conductors for connection to supply mains must be made in accordance with NEC/CEC and local codes.
WARNING: Drilling holes in the RLDS
enclosure may damage the unit and will void
the warranty. Only use the knockouts provided
for electrical connections.
Locate the AC Input Terminals and Ground Stud on the inside of the monitor (Figure 3-7). Secure the incoming AC power neutral (white/blue) and live (black/brown) wires to the LINE 1 and LINE 2 terminals.
Using the supplied crimp-on ring terminals, washers, and nuts, connect the incoming AC power ground wire (green) to the monitor's AC input ground stud, and then install a separate wire between the ground stud and the GND terminal.
RLDS Electrical Wiring RLDS Installation • 11
• A switch or circuit breaker rated 1.0 A, 250 VAC must be attached to the unit’s AC power leads.
• This switch must also be located in close proximity to the monitor, and be within easy reach of the operator.
• This switch should also be clearly marked as the unit’s main AC disconnect device. The circuit breaker or switch must disconnect all
current-carrying conductors (i.e., Live and Neutral).
Figure 3-11 - AC Input Power and Ground Connections
12 • RLDS I&O Manual 026-1309 Rev 8
4 Connecting
E2 PIB COM PORT ASSOCIATIONS
COM1
COM4
COM6
COM2
Serial Device RS485 COM Port (2 Connectors)
RS485 COM Card (2 Connectors)
Serial Device RS232 Port
POWER INTERFACE BOARD (PIB)
E2 Modem/Expansion COM Card Mounted Above PIB
Plug-In Modem Card
COM3
E2 Enclosure (Right Side)
RS485
RS232
E2 PIB COM PORT ASSOCIATIONS
COM1
Serial Device
RS232 Port
POWER INTERFACE BOARD
(PIB)
E2 Enclosure (Right Side)
COM2 COM6
COM4
Serial Device RS485 COM Ports
Plug-In Modem Card
COM3
Communication Devices
COM4 and COM6, which are optional ports requiring expansion cards). COM ports can only be used for one function; in other words, if COM2 is set up as the I/O network, you cannot connect MODBUS devices to COM2. Ensure your E2 is equipped with an RS485 COM Card (P/N 637-4890) and configured in E2
General Services (
, Serial tab) to
enable COM4 or an E2 Expansion COM Card (P/N 637- 4871) to enable COM6.

4.1. E2 MODBUS Direct Support for RLDS

4.1.1. Network Connection to E2

Connecting an RLDS to an E2 unit requires the E2 version 3.01 and above. Contact Emerson Electronics and Solutions for upgrade information if the controller is a version prior to 3.01.

4.1.1.1. COM Port Associations - E2 Versions 3.xx and Below

Connect the MODBUS network cable to the three-terminal connector on the COM port you wish to assign as MODBUS. Wire RS485+ to the RLDS+ RS485- to the RLDS- and the shield cable to the RLDS GND.

4.1.1.2. COM Port Associations - E2 Versions 4.0 and Above

Figure 4-1 - Location of E2 COM Ports - E2 PIB Board (E2 version 3.xx and below)
An E2 has up to three COM ports that can be assigned for MODBUS communication (COM2, an RS485 port on the E2 power interface board, and
E2 MODBUS Direct Support for RLDS Connecting Communication Devices • 13
Figure 4-2 - Location of E2 COM Ports - E2 PIB Board (E2 version 4.0 and above)
An E2 has three COM ports that can be assigned for MODBUS communication (COM2). COM ports can only be used for one function; in other words, if COM2 is set up as the I/O network, you cannot connect MODBUS devices to COM2. Ensure your E2
is configured in E2 General Services ( Serial tab)
to enable COM4 or COM6.
,
Connect the MODBUS network cable to the three-terminal connector on the COM port you wish to assign as MODBUS. Wire RS485+ to the RLDS+ RS485- to the RLDS- and the shield cable to the RLDS GND.

4.1.1.3. E2 Termination

For E2 versions 3.xx and below, if the E2 will be the first device in the daisy-chain, set the port’s termination jumpers to the TERMINATED & BIASED position (all three jumpers UP); otherwise, set all jumpers DOWN if not the first device.
For E2 versions 4.0 and above, if the E2 is the beginning of all RS485 I/O or MODBUS Networks, all three of these jumpers should be set to the UP position. For MODBUS, the jumpers should all be in the top-most position (MOD). For I/O Net, the jumpers should be in the middle position (I/O). For no termination, set the jumpers to the down position (NO).

4.1.2. E2 Setup of RLDS

4.1.2.1. Set Up Network Ports

Before setting up a RLDS, the port on the E2 that has the MODBUS cable connected must be set up as a MODBUS port.
Figure 4-3 - Serial Communications Manager Screen
4. This screen will have a “Connection” field for all COM ports on the E2. Highlight the COM port connection field that will be used, and press
 - LOOK UP. From the list of
network types, select MODBUS.
5. Four fields will become visible underneath the COM port connection field, which pertain to the way the device communicates:
Baud - Default setting is 19200. Leave this field at the default value.
1. Log in to the E2 with Level 4 access.
2. Press
3. Press
followed by  - General
Controller Info.
+ to open the Serial tab of the
General Controller Info setup screens:
Data Size - Leave this field at the default value (8).
Parity - Leave this field at the default value (None).
Stop Bits - RLDS value is one (1).
6. Press
to save changes and exit.

4.1.2.2. Add and Connect RLDS

To enable communications between E2 and the RLDS, the devices must be added and addressed in E2.
1. Log in to the E2 with Level 4 access.
2. Press
 - Connected I/O Boards
14 • RLDS I&O Manual 026-1309 Rev 8
and Controllers.
Online - The RLDS is communicating normally.
Offline - The RLDS is not communicating, has not been commissioned, is not functional, or is not powered up. Verify the RLDS is powered up, wired correctly, and has the proper network address, baud rate, and parity.
No Port - No port is set up in the E2 Serial Configuration Manager to be a MODBUS port.
Figure 4-4 - Connected I/O Screen
3. On the ECT tab screen enter the number of RLDS Panels in the RLDS number field.
4. Press
5. Locate the RLDS you added to the network list
to return to the Network Setup
menu, then select (Figure 4-5).
(press
and to scroll through the list) and
highlight with the cursor. Press Setup.
 - Network Summary
for
7. To commission the device, select Commission and choose the MODBUS network address.
 -
Figure 4-5 - Network Summary Screen
Each RLDS is assigned a MODBUS address automatically when it is created.
6. Locate the RLDS you set up, and look at each device’s status in the Status field. You will see one of the following messages:
E2 MODBUS Direct Support for RLDS Connecting Communication Devices • 15
4.2. E2, Einstein, and
12
12
JP7
REFLECS Controllers
In addition to being an interface with the site controller, the Gateway Board also allows you use a Hand-held Terminal (HHT) device to program the RLDS and view status.
(The RLDS Gateway Board)
Figure 4-6 - RLDS Gateway Board Layout (P/N 810-3760)
NOTE: Before installing the Gateway board, verify that jumper JP7 (if present on the board) is set to the “NORMAL” position (not the “TEST” position). Operating the Gateway with
the jumper in TEST position may cause board damage.

4.2.1. Powering the Gateway Board

Input Voltage 24VAC, Class 2, 50/60Hz
Power 5VA
Table 4-1 - Gateway Power Requirements
The Gateway board requires 24VAC power from a Class 2 center-tapped transformer.
Emerson Electronics and Solutions supplies several sizes of center-tapped transformers for powering multiple 16AIs, 8ROs, and other RS485 peripheral boards of the E2, Einstein, and REFLECS systems.
Refer to your controller’s user manual for information on how to use the center-tapped transformers listed in Table 4-2 to power multiple RS485 I/O devices.
Figure 4-7 shows how to connect the 56VA and 80VA transformers to the Gateway power connector.
Three-Board Six-Board
P/N 640-0056 640-0080
Power Rating 56 VA 80 VA
Table 4-2 - Power Ratings for Emerson Transformers
The RLDS may be connected to an Emerson Electronics and Solutions controller using a Gateway Board. The Gateway Board is a special interface device that allows an E2, Einstein, or REFLECS site controller to communicate with up to three RLDS units as if each of them were a standard 16AI Analog Input board, and allows for programming with the Hand-Held Terminal (HHT).
The Gateway Board communicates with the RLDS units via the MODBUS network, which is connected to the Gateway’s “Receiver Bus” network terminal. The Gateway communicates with site controllers (E2, Einstein, or REFLECS) via the RS485 I/O Network (COM A & COM D for REFLECS).
16 • RLDS I&O Manual 026-1309 Rev 8
Figure 4-7 - Pinout for the 56VA (640-0056) and 80VA (640-
0080) Transformers

4.2.2. Gateway Board Networking

LEFT
R
S
4
8
5
+
R
S
4
8
5
-
0
v
Gateway Board
RS485 -
RS485 +
GND
Side view of double-stack Modbus connector on Gateway
0v
I/O Net
M
O
D
B
U
S
C
O
N
N
E
C
T
O
R
G
r
o
u
n
d
L
e
a
d
A
L
e
a
d
B
RS-485 Terminator Switch
UP (Not Terminated)
DOWN (Terminated)
1
4
23
Termination is set using switch 4 (SM1)
To connect the Gateway to an RLDS, punch out one of the remaining service knockouts to gain access to the interior of the RLDS monitor. Locate the RS485 connector and remove it from the circuit board. Secure the wire leads to the connector orienting them as shown in Figure 4-8. When you are through secur- ing the connections, carefully plug the connector back onto the circuit board.

4.2.2.1. Changing Terminator Switch Settings

The terminator switch is shipped from the factory in the terminated or DOWN position. This is the correct setting if the RLDS is connected to a single device, or it is the last device on the network chain. If the RLDS is to be installed in the middle of a network, the terminator must be moved to the UP position. Locate switch 4 and determine its position. If it needs to be moved, slide the switch to the appropriate position.
Figure 4-8 - RLDS and Gateway Board Wiring
Figure 4-9 - RS485 Connector - RLDS
Figure 4-10 - Positioning the Termination Switch - RLDS

4.2.2.2. RLDS Node Address

The node address is set through the front display of the RLDS unit. Refer to Section 7.16., Node Address for more information.
NOTE: If connecting RLDS units to an Emerson Electronics and Solutions site controller network, you MUST number the
units from 1-3. The Gateway Board will not recognize any RLDS unit with a number that is not 1, 2, or 3.
 
E2, Einstein, and REFLECS Controllers (The RLDS Gateway Board) Connecting Communication Devices • 17
Loading...
+ 57 hidden pages