GM TS420, MANTS420 User Manual

Model TS420

r

Oxygen Deficiency Detector

The information and technical data disclosed in this
document may be used and disseminated only for the
purposes and to the extent specifically authorized in
writing by General Monitors.

Instruction Manual 11/00

General Monitors reserves the right to change
published specifications and designs without prio
notice.

*MANTS420*

Part No. MANTS420
Revision B/11-00

Model TS420

WARRANTY STATEMENT

General Monitors warrants the Model TS420 to be free from defects in workmanship or material
under normal use and service within two (2) years (sensor cells one (1) year) from the date of
shipment. General Monitors will repair or replace without charge any equipment found to be
defective during the warranty period. Full determination of the nature of, and responsibility for,
defective or damaged equipment will be made by General Monitors’ personnel. Defective or
damaged equipment must be shipped prepaid to General Monitors’ plant or the representative
from which shipment was made. In all cases this warranty is limited to the cost of the
equipment supplied by General Monitors. The customer will assume all liability for the misuse
of this equipment by its employees or other personnel. All warranties are contingent upon
proper use in the application for which the product was intended and do not cover products
which have been modified or repaired without General Monitors’ approval or which have been
subjected to neglect, accident, improper installation or application, or on which the original
identification marks have been removed or altered. Except for the express warranty stated
above, General Monitors disclaims all warranties with regard to the products sold, including all
implied warranties of merchantability and fitness and the express warranties stated herein are
in lieu of all obligations or liabilities on the part of General Monitors for damages including, but
not limited to, consequential damages arising out of/or in connection with the use or
performance of the product.

WARNING - THE TS420 DETECTS OXYGEN DEFICIENT ENVIRONMENTS AND
EXPOSURE TO OXYGEN DEFICIENT ENVIRONMENTS MAY RESULT IN SICKNESS OR
DEATH.

The TS420 Toxic Gas Detector contains components, which can be damaged by static
electricity. Special care must be taken when wiring the system to ensure that only the
connection points are touched.

The TS420 is rated intrinsically safe as denoted by the symbol “Ex ia” on the instrument label.
Substitution of electrical components within the TS420 may impair intrinsic safety.

Damage to the TS420 housing such that any internal components or potting can be or is
exposed compromises the intrinsic safety of the device and as such should not be used in a
hazardous environment. Such damage includes complete fracture of the plastic housing or
cracks that may be opened to expose any internal components or potting. Destruction of the
sensor cap will not affect the intrinsic safety of the TS420; however, calibration accuracy and
the watertight nature of the TS420 will be compromised.

WARNING - DO NOT USE A TS420 WITH A DAMAGED HOUSING IN A HAZARDOUS
ENVIRONMENT.

IMPORTANT - Each oxygen sensor cell is shipped separate from the TS420. This ensures that
a fresh sensor cell will be used during initial start-up. DO NOT install the cell into the TS420
until you are ready to apply power to the system. When installing this unit, an initial field
calibration must be completed, since the TS420 is not factory calibrated to the specific cell.

i

System Integrity Verification

General Monitors mission is to benefit society by providing solutions through industry leading
safety products, services and systems that save lives and protect capital resources from the
dangers of hazardous flames, gases and vapors.

The safety products you have purchased should be handled carefully and installed, calibrated
and maintained in accordance with the respective product instruction manual. Remember
these products are for your safety.

To ensure operation at optimum performance General Monitors recommends that certain
maintenance items are performed.

Commissioning Safety Systems

Before power up, verify wiring, terminal connections and stability of mounting for all integral
safety equipment including, but not limited to:

! Power supplies
! Control modules
! Field detection devices
! Signaling / output devices
! Accessories connected to field and signaling devices

After the initial application of power (and any factory specifies warm-up period) to the safety
system, verify that all signal outputs, to and from devices and modules, are within the
manufacturers’ specifications. Initial calibration / calibration checking / testing should be
performed per the manufacturers’ recommendations and instructions.

Proper system operation should be verified by performing a full, functional test of all component
devices of the safety system, ensuring that the proper levels of alarming occur.

Proper system operation should be verifies by performing a full, functional test of all component
devices of the safety system, ensuring that the proper levels of alarming occur.

Fault/Malfunction circuit operation should be verified.

Model TS420

ii

Periodic Testing/Calibration of Field Devices

Periodic testing/calibrating should be performed per the manufacturers’ recommendations and
instructions. Testing/Calibrating procedures should include, but not be limited to:

! Verify zero reading
! Apply a known concentration of gas, or a simulated test device provided by the

manufacturer

! Verify integrity of all optical surfaces and devices
! For flame detectors, use the appropriate test lamp

When testing produces results outside of the manufacturers’ specifications, re-calibration or
repair/replacement of the suspect device(s) should be performed as necessary. Calibration
intervals should be independently established through a documented procedure, including a
calibration log maintained by plant personnel or third party testing services.

Periodic System Verification

The following system verifications should be performed at least annually:

Verify wiring, terminal connections and stability of mounting for all integral safety equipment
including, but not limited to:

! Power supplies
! Control modules
! Field detection devices
! Signaling / output devices
! Accessories connected to field and signaling devices

Proper system operation should be verified by performing a full, functional test of all component
devices of the safety system, ensuring that the proper levels of alarming occur.

Fault/Malfunction circuit operation should be verified.

Model TS420

iii

A

1. Mount and Wire the Detector (pages 5 through 9)

There are no standard rules for detector placement since the optimum sensor location is
different for each application. The customer must evaluate conditions at the facility to make this
determination. Generally, the TS420 should be easily accessible for calibration checks. The
TS420 should be mounted pointing down to prevent water build-up on the detector head. The
detector assembly should not be placed where it may be coated by contaminating substances.
Although the Model TS420 is RFI resistant, it should not be mounted in close proximity to radio
transmitters or similar equipment.

Some general guidelines for sensor location:

! The TS420 should be used in locations that are tightly enclosed with poor or no

ventilation, such as utility tunnels or underground storage areas. These areas are likely
to have dangerously low oxygen concentrations.

! Observe the TS420’s environmental specifications when locating the unit.

The environmental specifications covering the electrochemical cell are found in the Appendix,
Section 5.1.4.

Detectors should be mounted in an area that is as free from wind, dust, water, shock and
vibration as possible.

WARNING - Operation above or below temperature limits will provide unstable readings, which
may cause false alarms or failure to alarm. See Section 5.1.4 for guidelines.

General Monitors discourages painting of detector assemblies. If the detector head is painted
over, the gas will not be able to diffuse into the sensor. If the TS420 body is painted over, the
LCD display cannot be read.

The TS420 is shipped without the sensor installed. The sensor must be installed into the
detector and calibrated for proper operation. See Sections 3.3 and 3.4 for installation
instructions and Section 4.3 for calibration instructions.

Once correctly installed, the TS420 requires little or no maintenance other than periodic
calibration checks to ensure system integrity. General Monitors recommends a calibration
check schedule be established and that the complete system, including all alarm circuitry, be
tested at least annually.

The overall and mounting dimensions for the TS420 (Figure Q-A) should be used when making
installation determinations. Mechanical specifications can be found in the Appendix, Section

5.1.2.

Model TS420

Quick Start Guide

4.50"

E
D

Y

L

L

O

N

A

O

M

C

N
E
T
H
G

I
T
D
N
A
H

S

L
A

R

R

O

E

T
I

N

N

E

Ø1.75"

LOOP+ (RED)

LOOP- (WHITE)

FRAME GROUND

(GREEN/YELLOW)

3/4 NPT

1 1/2-20 UN-2

Figure Q-A Outline and Dimensional Drawing

iv

Intrinsically Safe Barriers

In order for the TS420 to be used with classified equipment inside of the hazardous area, it is
necessary for the customer to purchase either a Galvanic or Zener Diode Barrier, which should
be mounted in the non-classified area between the TS420 and the facilities’ control room. A list
of recommended manufacturers and part numbers follows for galvanic barriers:

Stahl - 9303/11-22-11 Elcon - mD323 or mD325
MTL - MTL7206 or MTL5041 Turck - mk33-Li-ExO
Pepperl+Fuchs - KFD2-CR-EX1.30-300

These are recommended active type barriers for intrinsically safe applications. Each application
is different and it is the ultimate decision of the user to determine the appropriate I/S barrier for
their application.

NOTE - To maintain intrinsic safety, wire length and gauge are limited by the capacitance and
inductance of the wire, Ci and Li of the TS420, and the barrier ratings. See Section 5.1.5 for
instructions on calculating these values.

Align the TS420 so that the LCD display is easily viewed. Teflon tape may be used on the
TS420’s threads.

The two wires at the base of the TS420 provide a 4-20mA loop-powered output. The red wire
is the “loop +” lead and the white wire is the “loop -” lead (Figure Q-B). A third green/yellow
wire is provided for frame ground.

Model TS420

Quick Start Guide

JUNCTION BOX

LOOP + (RED)

RED

CONTROL

ROOM

LOOP - (WHITE)

WHITE

GRN/YEL

TS420

Figure Q-B Wiring Diagram

It is recommended that a two wire, shielded cable be used for making power and output signal
connections on the TS420.

Connect the green/yellow frame ground wire to the grounding terminal or lug inside the junction
box being used with the TS420.

Ensure the junction box frame is connected to frame ground or connected to the cable shield,
which is connected to frame ground at the controller.

Connect the red wire to the +24VDC terminal. Connect the white wire to the signal input
terminal on the readout/relay display module, FMD Field Mounted Display, S4100E smart
sensor, industrial analog to digital converter, computer-based monitor, PLC, DCS, etc.

Since the TS420 is designed to operate continuously, a power switch is not included, in order to
prevent accidental system shutdown.

v

NOTE - Power must remain disconnected until all wiring connections are made.

The absolute maximum distance between the TS420 and the power supply is 8000 feet (2438
meters). Depending on the application, general purpose or intrinsically safe, the cable length
will depend on the intrinsically safe barrier chosen and the cable used. See the Appendix,
Section 5.1.5, for the intrinsically safe system requirements. In addition, cable length
specifications can also be found in the Appendix, Section 5.1.3. In all cases, the cable run
should be as short as possible.

2. Apply power to the detector.

Before applying power to the system for the first time, all wiring connections should be checked
for correctness. The sensor should be allowed to stabilize prior to calibration. The stabilization
time should be one (1) hour for all sensors.

Initial Power-up

The TS420 has been shipped un-calibrated, therefore, the first time power is applied, the
TS420 will enter Start-up mode (3.6mA) for a short interval, then may transition to fault mode
(flashing MODE LCD with the CAL LCD off and the analog output current at 3.5mA) until
calibrated (See Section 4.3 for Calibration Procedure).

After calibration is complete, the TS420 will proceed to Operate mode (17.38mA = 20.9% V/V
O

) where any detected oxygen will show as a proportional analog output current between 4

2

and 20mA (4mA = 0% V/V O

, 20mA = 25% V/V O2). The MODE LCD will be on steady and the

2

CAL LCD off with normal atmosphere and both the MODE and CAL LCD's will flash when
oxygen deficiency is detected. (O

level < 19%).

2

General Monitors recommends the TS420 be calibrated again within the first twenty-four (24)
hours after the initial calibration. Calibrations should be performed with new units and units that
have been off power for more than one (1) week. See “Calibration”, Section 4.3, for more
details.

Power-up After Initial Calibration

When the TS420 is powered up, after it has been previously calibrated, the unit will enter a
Start-up mode (3.6mA) for approximately 50 seconds, which allows the sensor to stabilize
before proceeding to the Operate mode (17.38mA). During Start-up, the “MODE” LCD will
flash, the “CAL” LCD will be off and the analog output current will be 3.6mA.

OPERATING MODES INDICATOR ANALOG OUTPUT

CAL MODE

START-UP

❏ ✹

OPERATE
AMBIENT O2 = 20.9%
DEFICIENT ATMOSPHERE, O2< 19%

1

❏ ■
✹ ✹

FAULT
NO POWER
SYSTEM

❏ ❏
❏ ✹

Model TS420

Quick Start Guide

3.6mA

17.38mA

4.0-16.16mA

0.0mA

3.5mA

Figure Q-C Operating Modes, Indicators and Outputs

1. Segment may flash Synchronously or alternating.

Perform a calibration and the TS420 will return to operate mode (17.38mA).

NOTE - The TS420 will not allow you to enter calibration mode during Start-up mode (3.6mA).

vi

3. Calibrate the Detector.

Activating the “CAL” switch will automatically disable the external alarm circuits by fixing the
analog output current to 3.75mA.

General Monitors recommends that the TS420 be calibrated within the first twenty-four (24)
hours after initial start-up, and that calibration be checked at least every ninety (90) days to
ensure the integrity of the system.

NOTE: A calibration check consists of applying a 20.9% V/V O
scale concentration of gas to the sensor and observing the reading on the display device being
used.

General Monitors is not implying that the customer should expect problems with sensor life or
stability. “Frequent” calibration checks merely ensure the integrity of the life protecting
equipment, and are recommended for problem environments (i.e. sensors accidentally being
painted over, etc, see Appendix 5.4).

A calibration schedule should be established and followed. A logbook should also be kept
showing calibration dates and dates of sensor replacement.

Calibration Procedure:

1. If it is suspected that the air is not at “normal” levels (20.9% O
calibrate the sensor with clean air. The 20.9% O

gas cylinder (GMI P/N 1400262-11) can be

2

used. Apply the clean air source prior to entering calibration mode and allow the sensor to
stabilize for at least one (1) minute before proceeding.

2. Place the magnet over the GMI Logo on the body of the unit and hold it there until the “CAL”
LCD indicator appears, then remove the magnet. The analog output current will drop to

3.75mA.

3. The “CAL” and “MODE” LCD indicator will flash, indicating that the unit is now calibrating.

4. After approximately 30 seconds, the display will change from a flashing “CAL” and “MODE”
LCD to a solid “MODE” LCD, indicating that the calibration is complete and the unit has re­entered “OPERATE” mode. Remove any calibration gas.

6. The unit is now calibrated and the new values have been stored in the NOVRAM (non­volatile memory).

Figure Q-D shows a flow diagram of the codes that will appear in the display window during the
calibration procedure.

If there is a problem and the TS420 cannot complete the calibration sequence, a fault indicator
will be displayed, and the analog output current will drop to 3.5mA.

CALIBRATION INDICATOR
CAL MODE
Magnet Applied
Magnet Recognized
Cal Proceeding

Model TS420

Quick Start Guide

(“normal” ambient air) of full-

2

), it will be necessary to

2

❑ ■

■ ❑
✹ ✹

Figure Q-D Flow Diagram

vii

NOTE - If the unit fails to calibrate a flashing “MODE” LCD will be displayed. The sensor must
see “clean” air for at least fifteen (15) minutes before a second calibration is attempted by
reapplying the magnet.

The instrument is now ready to operate! Please consult the manual for more information
on the instrument’s many features.

If you have any problems in the set-up or testing of the detector, please refer to the “Trouble
Shooting Section”, or call the factory direct.

Worldwide Service is available by calling:

Lake Forest, California Phone: [phone]
(24 hr. service) Fax: [phone]

Houston, Texas Phone: [phone]

Fax: [phone]

Ireland Phone: [phone]
Fax: [phone]

Singapore Phone: [phone]
Fax: [phone]

United Arab Emirates Phone: [phone]
Fax: [phone]

United Kingdom Phone: [phone]
Fax: [phone]

Model TS420

Quick Start Guide

viii

Model TS420

Table of Contents

WARRANTY STATEMENT ..........................................................................................i

System Integrity Verification .........................................................................................ii

Commissioning Safety Systems......................................................................................ii

Periodic Testing/Calibration of Field Devices ...............................................................iii

Periodic System Verification ........................................................................................iii

Table of Contents ........................................................................................ix

Table of Figures .........................................................................................x

1.0 Introduction .........................................................................................1

1.1 General Description...................................................................................1

1.2 Features and Benefits ...............................................................................1

1.3 Applications .........................................................................................1

2.0 Detector Assembly .........................................................................................3

2.1 Sensor Assembly.......................................................................................3

2.2 Control Electronics ....................................................................................4

3.0 Installation .........................................................................................5

3.1 Receipt of Equipment ................................................................................5

3.2 Detector Location Considerations .............................................................5

3.3 Installation Instructions ..............................................................................6

3.3.1 Intrinsically Safe Barriers..............................................................6

3.3.2 Maintenance .................................................................................6

3.4 Wiring Connections ...................................................................................7

4.0 Operation .........................................................................................8

4.1 Applying Power .........................................................................................8

4.2 Operating Modes .......................................................................................9

4.3 Calibration .........................................................................................9

4.4 Calibration Equipment .............................................................................10

4.5 Sensor Replacement Procedure .............................................................11

4.6 Sensor Care and Maintenance................................................................13

5.0 Appendix .......................................................................................14

5.1 Specifications .......................................................................................14

5.1.1 System Specifications ................................................................14

5.1.2 Mechanical Specifications ..........................................................14

5.1.3 Electrical Specifications..............................................................14

5.1.4 Environmental Specifications .....................................................15

5.1.5 Intrinsically Safe System Requirements.....................................16

5.1.6 Sample Calculation.....................................................................16

5.2 Engineering Documentation ....................................................................17

5.2.1 Outline & Dimensional Drawing..................................................17

5.2.2 Control Drawing ..........................................................................18

5.2.3 Sample Installation .....................................................................19

5.2.4 Junction Boxes ...........................................................................20

5.2.5 Splash-Guards............................................................................21

5.2.6 Accessories ................................................................................22

5.2.7 Calibration Accessories ..............................................................22

5.3 Ordering Information................................................................................23

5.4 Calibration Schedule for Problem Environments.....................................24

5.5 Spare Parts & Accessories......................................................................25

ix

Table of Figures Page

Figure Q-A Outline and Dimensional Drawing ......................................................................iv

Figure Q-B Wiring Diagram................................................................................................... v

Figure Q-C Operating Modes, Indicators and Outputs..........................................................vi

Figure Q-D Flow Diagram .................................................................................................... vii

Figure 1 Model TS420 ...................................................................................................... 1

Figure 2 Oxygen Deficiency Sensor Assembly ................................................................ 3

Figure 3 LCD Display Location......................................................................................... 4

Figure 4 Wiring Diagram................................................................................................... 7

Figure 5 Operating Modes, Indicators and Outputs.......................................................... 8

Figure 6 Flow Diagram ................................................................................................... 10

Figure 7 Calibration Cup................................................................................................. 10

Figure 8 Calibration Plug ................................................................................................ 10

Figure 9 Change in % Oxygen in the atmosphere

with Relative Humidity at constant Temperature................................. 11

Figure 10 Sensor Alignment ............................................................................................. 12

Figure 11 Calibration Kit with Bottle.................................................................................. 13

Figure 12 Outline and Dimensional Drawing .................................................................... 17

Figure 13 Control Drawing................................................................................................ 18

Figure 14 Sample Installation ........................................................................................... 19

Figure 15 10252 Round Aluminum Junction Box ............................................................. 20

Figure 16 31305-2 Aluminum Junction Box...................................................................... 20

Figure 17 45160-1 Plastic Junction Box, NPT; 45160-2 Plastic Junction Box, M20 ........ 21

Figure 18 70631-2 Splash - Guard ................................................................................... 21

Figure 19 45170-1 Flow Block.......................................................................................... 22

Figure 20 45147-1 Flow Block Retainer ........................................................................... 22

Figure 21 914-152 Calibration Plug .................................................................................. 22

Figure 22 1400152-1 Calibration Cup .............................................................................. 22

Calibration Schedule for Problem Environments........................................................................ 24

Model TS420

x