Honeywell 19546GM1, GM-1 User Manual

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Page 1

Gas Monitoring Alarm System

Manning GM-1

Instruction and Installation Manual

07/09

Release D Draft

Honeywell Confidential & Proprietary

This work contains valuable, confidential, and proprietary information. Disclosure, use

or reproduction outside of Honeywell Inc. is prohibited except as authorized in writing.

This unpublished work is protected by the laws of the United States and other countries.

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Notices and Trademarks

Release D July 2009

While this information is presented in good faith and believed to be accurate, Honeywell disclaims the implied warranties of merchantability and fitness for a particular purpose and makes no express warranties except as may be stated in its written agreement with and for its customers.

In no event is Honeywell liable to anyone for any indirect, special or consequential damages. The information and specifications in this document are subject to change without notice.

Manning is a registered trademark of Honeywell International Inc.

Other brand or product names are trademarks of their respective owners.

Honeywell Analytics 405 Barclay Blvd. Lincolnshire, IL 60069 USA

1-800-538-0363

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About This Document

World Wide Web

The following Honeywell web sites may be of interest.

Honeywell Organization WWW Address (URL)

Corporate www.honeywell.com

Honeywell Analytics www.honeywellanalytics.com

Manning Gas Detection www.manningsystems.com

Telephone

Organization Phone Number

United States Honeywell Analytics Inc. 1-800-538-0363 1-913-712-5576 1-913-712-5580 Fax

Canada Honeywell Analytics Inc. 1-888-749-8878

Europe Honeywell PACE +44 (0)1202 676161

Asia Pacific Honeywell Asia Pacific Inc. +82 (0)2 2025 0307

Middle East Honeywell Analytics Inc. +971 4 3458 338

Sales Information

Symbol Definitions

The following table lists those symbols used in this document to denote certain conditions.

Symbol Definition

ATTENTION: Identifies information that requires special consideration.

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. CAUTION symbol on the equipment refers the user to the product manual for additional information. The symbol appears next to required information in the manual.

WARNING: Indicates a potentially hazardous situation, which, if not avoided, could result in serious injury or death. WARNING symbol on the equipment refers the user to the product manual for additional information. The symbol appears next to required information in the manual.

CAUTION

indicates a situation which, if not avoided, may result in equipment or work (data) on the system being damaged or lost, or may result in the inability to properly operate the process.

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Contents Serial number:

Section Title Page

1 System Description 5

2 Installation 7

3 Operation 10

4 Limited Warranty 13

Introduction

This manual has been prepared to help in the use and installation of the Manning GM-1 Gas Monitoring Alarm System. This manual will convey the operating details of the alarm system, ensure proper installation, and demonstrate start-up and routine maintenance procedures.

ATTENTION: This manual must be carefully followed by all individuals who have or will have the responsibility for using or servicing the Manning GM-1 alarm system. Warranties made by Honeywell

Analytics with respect to this equipment will be voided if the equipment is not used and serviced in accordance with the instructions in this manual. If in doubt about a procedure, please contact Honeywell Analytics before proceeding.

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1 System Description

The Manning GM-1 is designed to accept a single 4/20 mA current input signal, plus provide a regulated 24 VDC supply to operate all sensors manufactured by Honeywell Analytics.

The Manning GM-1 is housed in a rugged 14 gauge gasketed steel enclosure. Behind the clear plexiglass window is a 20-segment vertical LED bargraph display which gives a visual indication of the gas concentration.

The unit has warning and alarm level indications on the front panel, and warning and alarm relays allowing the user to incorporate functions such as ventilation control, remote horns, security system monitoring, and automatic shutdown.

Designed to be highly reliable when properly installed, all relays are energized during normal operation, and a sensor fault monitoring circuit will indicate a fault and trip a dedicated fault relay if the signal falls below

1.4 mA.

The unit has an audible horn which will sound if an alarm or fault condition is detected. The silence switch will silence the horn until the next event. If an alarm condition initiates the horn, the horn will clear automatically when the alarm relay clears.

The unit has a power-up delay feature that places all outputs in normal conditions for one minute to allow for sensor stabilization.

The Manning GM-1 will support all of Manning sensors, including oxygen, which requires a downscale alarm.

All components that are in contact with voltages above 40 volts are UL listed, including the enclosure.

Note: The Manning GM-1 is for use in non-classified areas only.

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1 System Description continued

System Specifications

Electrical Power: 120 VAC, 50/60 Hz at 0.35 amp

(230 VAC 50/60 Hz is available as an option)

Signal input: 4/20 mA

DC Power available for sensors: Heavy-duty

internal 24 VDC, 1 amp maximum regulated supply

Display: 20-segment LED bargraph

Light Outputs and Relays:

Alarm Light and Relay

• Setpoint field adjustable

• Alarm Light and Relay independently latchable by board mounted DIP switch

• 10 second on delay, 2 second off delay

Warning Light and Relay

• Setpoint field adjustable

• Warning Light and Relay are NOT latchable

• 10 second on delay, 2 second off delay

Fault Light and Relay

• Setpoint NOT adjustable — all mA signals below

1.4 mA will initiate fault output

• Fault Light and Relay always latch

• 10 second on delay

Note: All relays are normally energized and monitored by individual LEDs for

ease of troubleshooting

Relay Ratings: 3 amps at 24 VDC or 120 VAC

Form C providing NO (normally open) or NC (normally closed) option

Enclosure: 14 gauge steel, gasketed, 10" high x 8" wide x 4" deep, NEMA 1 rated enclosure with plexiglass window

Weight: 11 lbs.

Operating Ambient Temperature range: 0

+120

Operating Humidity: 5-95% Relative Humidity, noncondensing

Options: Down-scale Alarm for oxygen

Push-button Controls:

Silence

Note: The Manning GM-1 is for use only in non-classified areas.

— Silences internal horn

Reset

— Clears signal, latched functions, and relays. If warning, alarm, or fault condition exists, indications will return after a short time delay.

F to

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2 Installation

Locating the Manning GM-1

When unpacking the unit, inspect all boxes and contents for shipping damage. If any screws or other metal parts are missing, these must be found to ensure that the printed circuit boards will not be damaged when power is applied.

Figure 1: Mounting dimensions for the Manning GM-1 Gas Monitoring Alarm System

5/16"

The control unit is designed to be mounted on a solid (non-vibrating) wall through four holes in the two mounting flanges. While the physical location must be determined in part by local conditions, it is important to consider the following:

CAUTION

• Protect the Manning GM-1 from rain, snow, water sprays, cleaning crews, and physical damage.

• Mount the unit on a solid wall (nonvibrating) at eye level for convenience in taking readings, servicing, etc.

• The Manning GM-1 is NOT explosion proof. DO NOT MOUNT in a hazardous atmosphere.

• Operating temperature for the Manning GM-1 is 0

• Pre-punched holes are provided in the bottom of the enclosure for cable access. DO NOT drill holes in the top of the cabinet as this will void the warranty.

F to +120o F.

Gas Monitor

Manning GM-1

10 3/4"

Reset

24 1/4"

Silence

• If hole drilling is required, be sure to remove all metal filings.

• Mounting dimensions are included in Figure 1.

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2 Installation continued

B Wiring

Electrical wiring must comply with all applicable codes. Plant equipment that may be involved and operating conditions should be discussed with local operating personnel to determine if any special needs should be taken into account.

Nearly all start-up problems are due to improper wiring or monitor configuration. Please follow these guidelines carefully. Figure 2 presents a wiring diagram for the Manning GM-1.

AC Power Wiring:

• Use only stranded cable for AC power, relay outputs, and sensor input cables.

• The units must have a proper third wire ground for safety and sensor shielding. Be sure to follow local codes.

• All AC cables must be kept away from the incoming sensor cables, i.e., do not put AC cables inside conduit containing sensor cables.

• Keep all wiring away from variable speed drives and SCR control units to minimize electrical noise exposure.

• Electrical Power: 120 VAC, 50/60 Hz, 0.35 amps.

Relay Wiring:

All three relays have Form C, dry contacts. Any required power source must be within the 3 amp rating and fused or current limited to keep from damaging the contacts.

• Relay wiring must be run in separate conduit from the sensor cable if the relay circuit is AC.

Sensor Wiring:

• See sensor manual for proper sensor cable.

• See sensor manual for proper sensor location.

• Never run AC circuits in the same conduit as the sensor cable.

Note: Relays are energized in a non-alarmed condition so that a power loss in the Manning GM1 will result in an alarm.

• Electrical power ground: The unit must be properly grounded.

Risk of electric shock.

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2 Installation continued

Figure 2: Wiring diagram for the Manning GM-1 Gas Monitoring Alarm System

WARNING

ADJUST

ALARM

ADJUST

GNDTP+20V

FUSE RATING 250V 1.0 AMP

NO NCC NO NCC NO NCCLN

120 VAC

MODEL G/M MAINBOARD REV D

WARNING

RELAY*

WARNING

RELAY

ALARM

C11

+ + +

ALARM RELAY*

*Relay rating 3 amp. User must fuse to protect.

Note: Green wire earth ground must be connected to grounding stud marked

SIG

ALARM RELAY

FAULT

RELAY*

BOT TOP

FAULT RELAY

SHLD GND+24 SIG

TP CURRENT DRAW

Bare wrap— to "SHLD" terminal of sensor

Black— to "GND" terminal of sensor

Risk of electrical shock.

Red— to "+24" terminal of sensor

White— to "SIG" terminal of sensor

Potential hazard.

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3 Operation

A Display Panel C DIP Switch Setting

A 20-segment Bargraph Display indicates the gas concentration level. The bottom LED is always lit to indicate power to the display.

The Warning LED indicates the warning level as determined by the warning setpoint has been exceeded. The Warning LED and Warning Relay operate together and never latch.

The Alarm LED indicates the alarm level as determined by the alarm setpoint has been exceeded. The Alarm LED and Alarm Relay are independently latchable or non-latchable as determined by the DIP switch on the main board. Standard factory settings are to latch the LED and not latch the relay.

The Power LED indicates power to the monitoring unit. This LED will flash during the one minute power up delay indicating that all relays are held in the normal condition to allow for sensor stabilization during power up.

The Fault LED indicates a signal input of less than

1.4 mA (0.14 volts) at TP Sig. The Fault LED and

Fault Relay always latch.

Reset and Silence Switches

Pushing the Reset switch will reset the fault light, fault relay, alarm light, and alarm relay. If either condition still exists, the appropriate light and relay will return to its tripped state after a time delay.

Pushing the Silence switch will silence the horn on the bottom of the Manning GM-1 until the next event occurs. The horn is triggered by a fault or an alarm condition. The horn will clear itself if the alarm and fault relay clear. A warning condition does not trigger the horn.

The two position DIP switch in the center of the bottom board controls the latching of the alarm light and alarm relay. Switch 1 (left) controls the alarm relay. Switch 2 (right) controls the alarm light. Putting the switch in the on (up) position will latch the corresponding function. Putting the switch in the off (down) position will cause the corresponding function to be not latched (see Figure 3).

This allows the alarm condition to remain activated if desired even if the gas concentration goes back to below the setpoint.

Figure 3: Warning adjustment and DIP switch settings

WARNING

GNDTP+20V

ADJUST

WARNING

ALARM ADJUST

WARNING

ALARMTPSIG

RELAY

SW1

1 2

BOT TOP

ALARM

FAULT

RELAY

FUSE RATING 250V 1.0 AMP

NO NCC NO NCC NO NCCLN

120 VAC

MODEL G/M MAINBOARD REV D

WARNING

RELAY*

+ + +

ALARM RELAY*

C11

SHLD GND+24 SIG

FAULT

RELAY*

TP CURRENT DRAW

0.4 - 2.0 V

VDC

Warning adjust pot

DIP switches on bottom of board

Black-Red

Factory set pots

Risk of electrical shock.

Potential hazard.

Do Not Adjust!

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3 Operation continued

D Signal and Setpoints

The voltage between TP Gnd and TP Sig indicates the current signal received from the sensor. The normal range is 0.4 volts to 2.0 volts, which corresponds with 4/20 mA. This manual will use the voltage at TP Sig to describe the input signal. When this signal exceeds the voltage at TP Warning or TP Alarm, the warning or alarm function will take place. The warning setpoint is user adjustable by looking at the voltage on TP Warning and adjusting the warning adjust pot until the desired setpoint is reached (see Figure 3). The alarm adjust pot and TP Alarm function the same way.

The warning and alarm setpoints are factory adjusted as indicated on the data sheet included with your GM-1. Never adjust these setpoints outside the range of 0.4 to 2.0 volts. Contact Honeywell Analytics if you have any questions or want help in determining setpoints for your particular sensor and application.

After setpoint adjustment always expose sensor to the gas being monitored and verify that the warning and alarm lights trigger at the desired concentration as displayed by the bargraph.

E Start-Up Procedures

F Troubleshooting

The Fault Light and Fault Relay always latch when a fault condition is detected. After the condition is corrected the Reset switch must be pressed to clear the Fault Light and Fault relay.

The unit will indicate a fault if the signal is less than

0.14 volts at TP Sig.

Some Manning sensors are configured to send a signal of 0.05 volts at TP Sig if a sensor fault exists. If TP Sig = 0.05 volts, this indicates a properly wired sensor is in a fault condition. Proceed to investigate the sensor.

If TP Sig = 0.00 volts, this indicates no signal from the sensor. Check for correct wiring or loose connections between the sensor and monitoring unit.

Each relay has a green LED in series with its coil. If this LED is on, this indicates that the relay is energized and contacts will be in the normal position. If this LED is off, the contacts will be in the tripped condition.

Power supply voltages should be checked at TP +20V on the display board and at +24 on the sensor input terminal block (see Figure 4). Both points should be DC Volts as labeled.

Before applying power, make a final check of all wiring for continuity, shorts, grounds, etc. It is usually best to disconnect external alarms and other equipment from the unit until the initial start-up procedures are completed.

After power-up, allow 24 hours for the system to stabilize before testing the sensor. Because sensors are normally located at a distance from the monitoring unit, the test time required and accuracy of the response checks will be improved if two people perform the start-up procedures and use radio contact.

Start-Up Test: One person exposes the sensor to a small amount of the gas that is being monitored. The second person stays at the monitoring unit to determine that the sensor, when exposed to the target gas, is connected to the proper input, responds, and causes appropriate alarm functions.

The total sensor current draw can be checked by looking at the voltage between the two TP Current Draw test points. 1.0mV corresponds to 10 mA, and

50.0mV corresponds to 500mA, etc. Compare this reading with the current draw expected for the sensor you are using (see appropriate sensor manual).

If questions arise, call Honeywell Analytics.

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3 Operation continued

G Maintenance

The Manning GM-1 is designed for long life and high reliability. Honeywell Analytics recommends checking signal voltages monthly and logging them on the data sheet included with your Manning GM-1. Additionally, the sensor being monitored should be exposed to the target gas on a monthly basis while all alarm functions are verified at the Manning GM-1. This will test the sensor and any equipment con-

H Replacement Parts

For replacement parts, contact Honeywell Analytics. Be sure to give serial number and model number of unit.

nected to the relays in addition to the Manning GM-1.

Figure 4: Troubleshooting the Manning GM-1 Gas Monitoring Alarm System

Display power supply voltage

+20V

VDC

Sensor current draw

(1mV per 10 mA)

SENSOR DEPENDENT

mVDC

Black

Red

0.4 - 2.0 V

VDC

Black

Signal from sensor

Red

Risk of electrical shock.

GNDTP+20V

WARNING

ADJUST

WARNING

RELAY

ALARM

ADJUST

ALARM

AC fuse

C11

+ + +

ALARM

RELAY*

120 VAC

MODEL G/M MAINBOARD REV D

FUSE RATING 250V 1.0 AMP

NO NCC NO NCC NO NCCLN

WARNING

RELAY*

Potential hazard.

Black

SIG

ALARM RELAY

BOT TOP

FAULT RELAY

Red

+24V

Black

VDC

Red

FAULT

RELAY*

TP CURRENT DRAW

SHLD GND+24 SIG

Power supply voltage to sensor

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4 Limited Warranty

1. Limited Warranty Honeywell Analytics, Inc. warrants to the original purchaser and/or ultimate customer (“Purchaser”) of Manning products (“Product”) that if any part thereof proves to be defective in material or workmanship within eighteen (18) months of the date of shipment by Honeywell Analytics or twelve (12) months from the date of first use by the purchaser, whichever comes first, such defective part will be repaired or replaced, free of charge, at Honeywell Analytics’ discretion if shipped prepaid to Honeywell Analytics at 405 Barclay Blvd., Lincolnshire, IL 60069, in a package equal to or in the original container. The Product will be returned freight prepaid and repaired or replaced if it is determined by Honeywell Analytics that the part failed due to defective materials or workmanship. The repair or replacement of any such defective part shall be Honeywell Analytics’ sole and exclusive responsibility and liability under this limited warranty.

2. Exclusions

A. If gas sensors are part of the Product, the

gas sensor is covered by a twelve (12) month limited warranty of the manufacturer.

B. If gas sensors are covered by this limited

warranty, the gas sensor is subject to inspection by Honeywell Analytics for extended exposure to excessive gas concentrations if a claim by the Purchaser is made under this limited warranty. Should such inspection indicate that the gas sensor has been expended rather than failed prematurely, this limited warranty shall not apply to the Product.

C. This limited warranty does not cover consum-

able items, such as batteries, or items subject to wear or periodic replacement, including lamps, fuses, valves, vanes, sensor elements, cartridges, or filter elements.

3. Warranty Limitation and Exclusion

Honeywell Analytics will have no further obligation under this limited warranty. All warranty obligations of Honeywell Analytics are extinguishable if the Product has been subject to abuse, misuse, negligence, or accident or if the Purchaser fails to perform any of the duties set forth in this limited warranty or if the Product has not been operated in accordance with instructions, or if the Product serial number has been removed or altered.

4. Disclaimer of Unstated Warranties

THE WARRANTY PRINTED ABOVE IS THE ONLY WARRANTY APPLICABLE TO THIS PURCHASE. ALL OTHER WARRANTIES,

EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A

PARTICULAR PURPOSE ARE HEREBY DISCLAIMED.

5. Limitation of Liability

IT IS UNDERSTOOD AND AGREED THAT HONEYWELL ANALYTIC’S LIABILITY, WHETHER IN CONTRACT, IN TORT, UNDER

ANY WARRANTY, IN NEGLIGENCE OR OTHERWISE SHALL NOT EXCEED THE AMOUNT OF THE PURCHASE PRICE PAID BY

THE PURCHASER FOR THE PRODUCT AND UNDER NO CIRCUMSTANCES SHALL HONEYWELL ANALYTICS BE LIABLE FOR

SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES. THE PRICE STATED FOR THE PRODUCT IS A CONSIDERATION LIMITING

HONEYWELL ANALYTICS’ LIABILITY. NO ACTION, REGARDLESS OF FORM, ARISING OUT OF THE TRANSACTIONS UNDER THIS

WARRANTY MAY BE BROUGHT BY THE PURCHASER MORE THAN ONE YEAR AFTER THE CAUSE OF ACTIONS HAS OCCURRED.

Honeywell 19546GM1, GM-1 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual