Honeywell 3000MkII, 3000MkIII Operating Manual

Technical Manual

Series 3000 MkII Gas Detector

SERIES 3000 MKII TECHNICAL MANUAL S3KMKIIMAN_MAN0878_Issue 8_08/2015

1. Safety

Ensure that this Operating Manual is read and understood BEFORE installing / operating / maintaining the equipment.

Pay particular attention to Warnings and Cautions.

All document Warnings are listed here and repeated where appropriate at the start of the relevant chapter(s) of this Operating Manual.

Cautions appear in the sections / sub-sections of the document where they apply.

Warnings

Series 3000 MkII is designed for installation and use in Zone 1 or 2 or 21 or 22 hazardous

areas in Europe and Class I Division 1 or 2 and Class II Division 1 or 2 area applications

in North America.

Installation must be in accordance with the recognized standards of the appropriate

authority in the country concerned.

Access to the interior of the detector, when carrying out any work, must only be

conducted by trained personnel.

Before carrying out any work ensure local regulations and site procedures are followed.

Appropriate standards must be followed to maintain the overall certication of the detector.

To reduce risk of ignition of hazardous atmospheres, conduit runs must have a seal tting

connected within 18 inches of the enclosure.

To reduce the risk of ignition of hazardous atmosphere, de-classify the area or

disconnect the equipment from the supply circuit before opening the detector enclosure.

Keep assembly tightly closed during operation.

Never attempt to open a junction box / enclosure in potentially hazardous atmospheres.

The detector must be earthed / grounded for electrical safety and to limit the effects

of radio frequency interference. An earth / ground point is provided inside and outside the

unit. The internal grounding shall be used as the primary equipment ground. The external

terminal is only a supplemental bonding connection where local authorities permit or

require such a connection.

The enclosure of the remotely mounted sensor assembly contains Aluminium.

Care must be taken to avoid ignition hazards due to impact or friction when installed

in a Zone 1 location.

Take care when handling sensors as they may contain corrosive solutions.

Do not tamper or in any way disassemble the sensor.

Do not expose to temperatures outside the recommended range.

Do not expose sensor to organic solvents or ammable liquids.

At the end of their working life, sensors must be disposed of in an environmentally

safe manner. Disposal should be according to local waste management requirements

and environmental legislation.

Alternatively, sensors may be securely packaged and returned to

Honeywell Analytics clearly marked for environmental disposal.

Electrochemical cells should NOT be incinerated as they may emit toxic fumes.

SERIES 3000 MKII TECHNICAL MANUAL S3KMKIIMAN_MAN0878_Issue 8_08/2015

2. Information

Honeywell Analytics can take no responsibility for installation and / or use of its equipment if this is not done in accordance with the appropriate issue and / or amendment of the Operating Manual.

The reader of this Operating Manual should ensure that it is appropriate in all details for the exact equipment to be installed and / or operated. If in doubt, contact Honeywell Analytics for advice.

The following types of notices are used throughout this Operating Manual:

WARNING

Identies a hazardous or unsafe practice which could result in severe injury

or death to personnel.

Caution: Identies a hazardous or unsafe practice which could result in

minor injury to personnel, or product or property damage.

Note: Identies useful / additional information.

Every effort has been made to ensure the accuracy of our documents, however, Honeywell Analytics can assume no responsibility for any errors or omissions in our documents or their consequences.

Honeywell Analytics greatly appreciates being informed of any errors or omissions that may be found in the contents of any of our documents.

For information not covered in this document, or there is a requirement to send comments / corrections about this document, please contact Honeywell Analytics using the contact details given on the back page of this document.

Honeywell Analytics reserve the right to change or revise the information supplied in this document without notice and without obligation to notify any person or organization of such revision or change. If information is required that does not appear in this document, contact the local distributor / agent or Honeywell Analytics.

SERIES 3000 MKII TECHNICAL MANUAL S3KMKIIMAN_MAN0878_Issue 8_08/2015

3. Table of contents

1 Safety 2 2 Information 3 Table of contents 4 Introduction

4.1 Product overview

4.2 Transmitter

4.3 Smart sensor

4.4 Accessories

4.4.1 Pipe mounting bracket

4.4.2 Sunshade / Deluge Protection

4.4.3 Remote sensor mounting kit

4.4.4 Duct mounting kit

4.4.5 Calibration gas ow housing

4.4.6 Collecting cone 5 Installation

5.1 Mounting and location of detectors 6 Electrical connections

6.1 Detector wiring schematic

6.2 Typical maximum installed cable lengths

6.3 Terminal connections

6.4 Cable and earth / ground connection 7 First time switch on 8 Magnetic switch activation

8.1 Default conguration

8.2 Calibration

8.2.1 Zeroing and span calibration

8.2.2 Zeroing and span calibration of Hydrogen Sulde sensors

8.2.3 Zeroing and span calibration of Ethylene Oxide sensors 9 Display and user interface 10 Monitoring mode 11 Review mode 12 Menu mode

12.1 Menu mode operation table 13 Detector fault / warning message display

13.1 Detector fault / warning operation

13.2 Reex™ cell fault diagnosis

14 General maintenance

14.1 Functional gas test

14.2 Detector operational life 15 Servicing

15.1 Sensor replacement

15.2 Serviceable sensor cell replacement 16 Remote sensor mounting kit installation details

17 General specications

18 Ordering information 19 Warranty / liability statement

20 CE certicates 21 Certication

21.1 UL/CSA control drawing

21.2 Sensor Cartridge and Remote Sensor Accessory control drawing

21.3 Main unit UL/CSA hazardous area nameplate

21.4 Main unit ATEX/IECEx hazardous area nameplate

21.5 Sensor label ATEX/UL/c-UL

21.6 Remote sensor ATEX/UL/c-UL hazardous area nameplate

SERIES 3000 MKII TECHNICAL MANUAL S3KMKIIMAN_MAN0878_Issue 8_08/2015

4. Introduction

The Series 3000 MkII gas detector is designed to detect toxic or oxygen gas hazards in Zone 1 or 2 or 21 or 22 hazardous areas in Europe and North American Class I Division 1 or 2 areas and Class II Division 1 or 2 areas. A local LCD provides gas type and concentration information and when magnetically activated enables non-intrusive one man calibration and operation. The sensor interface to the transmitter is Intrinsically Safe (IS) allowing it to be ‘hot swapped’ without the need for removing power to the detector. The replacement plug in smart sensors are supplied pre-calibrated. A remote sensor mounting kit allows the sensor to be mounted up to 50 feet (15 meters) from the explosion proof transmitter housing. The output from the transmitter is an industry standard 2 wire 4-20mA loop (sink) suitable for connection to a wide range Honeywell Analytics or 3rd party control equipment / PLCs.

4.1 Product overview

The Series 3000 MkII detector comprises of the main parts shown below.

Terminal Module and

IS Barrier

Locking Screw

M20 or 3/4"NPT

cable/conduit entry (x2)

Transmitter Enclosure

Cover

Seal

Display Module

Diagram 1: Series 3000 MkII Exploded View

Smart Sensor

Sensor Retainer

Weatherproof Cover

4.2 Transmitter

The transmitter cover has a glass window which allows use of the magnet to activate the three user interface magnetic switches that are located on the front of the display module. This allows for nonintrusive set up and operation. The display provides both numerical and icon information.

Magnetic

MENU/ENTER Switch

Gas Type Warning/Fault Icon

Calibration Icon

Test Pass Icon

Gas Reading

Magnetic

DOWN Switch

Diagram 2: Series 3000 MkII Display and Magnetic Switches

Inhibit Icon

Measuring Units

UP Switch

Magnetic

SERIES 3000 MKII TECHNICAL MANUAL S3KMKIIMAN_MAN0878_Issue 8_08/2015

The cover can be unscrewed to allow removal of the display module. Beneath the display module is the terminal module and IS barrier where all electrical connections to the detector are made.

Electrical connections are made via 2 x M20 cable entries or 2 x 3/4"NPT conduit entries (certication

dependent). A suitable blanking plug is supplied which must be used to seal any unused entry.

The smart sensor plugs into the bottom of the transmitter and is secured by the sensor retainer.

The weatherproof cover is tted over the top of the sensor and screws onto the bottom of the transmitter

enclosure. The weatherproof cover has a spigot that allows the attachment of tubing for the application of bump test gas.

4.3 Smart sensor

The smart sensor is manufactured from stainless steel and is supplied 100% tested and calibrated (refer to section for start up procedure). The sensor is serviceable, allowing replacement of the sensor cell (see section 15 for details of sensor or cell replacement).

The sensor can be ‘hot swapped’ without the need to remove power to the detector (subject to local regulations and procedures).

4.4 Accessories

Series 3000 MkII has various accessories available as detailed below:

4.4.1 Pipe mounting bracket

The optional pipe mounting bracket (part number SPXCDMTBR) allows mounting of the Series 3000 MkII transmitter to a mounting pipe (horizontal or vertical) of diameter 20.0-80.0mm (0.8"-3.1").

4.4.2 Sunshade / Deluge Protection

The Sunshade / Deluge Deluge Cover (P/N:SPXCDSDP) is an optional accessory that may be tted to

the integral mounting plate. This accessory is designed to protect Series 3000 MkII from overheating in exposed hot and arid climates, particularly offering additional protection from thermal shock in Tropical Environments.

4.4.3 Remote sensor mounting kit

The remote sensor mounting kit (part number S3KRMK) allows the sensor to be remotely mounted via an IS cable kit, up to 50 feet (15 meters) from the transmitter. The kit includes 50 feet of screened cable, cable glands and remote terminal box. The cable can be cut to the required length and then terminated at the remote terminal box. See section 16 for further installation details.

4.4.4 Duct mounting kit

The duct mounting kit (part number S3KDMK) can be used to allow detection of O2, CO, H2 and H2S gases in ducts. Refer to manual part number MAN0639 for further details.

4.4.5 Calibration gas ow housing

The calibration gas ow housing (S3KCAL) is used to apply calibration test gas to the sensor. It push ts onto the bottom of the sensor and can be tted without removing the weatherproof cover. See section

8.2 for further details on calibrating the detector.

SERIES 3000 MKII TECHNICAL MANUAL S3KMKIIMAN_MAN0878_Issue 8_08/2015

Note: The spigot on the side of the weatherproof cover is supplied for bump test purposes only (see section 14.1 for further details).

4.4.6 Collecting cone

The collecting cone (part number S3KCC) can be used to assist in the detection of ‘non-sticky’ gases

that are lighter air (i.e. Hydrogen only). It is simply tted in place of the weatherproof cover.

SERIES 3000 MKII TECHNICAL MANUAL S3KMKIIMAN_MAN0878_Issue 8_08/2015

5. Installation

Prior to installation refer to the transmitter control drawing 3000E3160 and remote sensor control drawing 3000E3157 shown in section 21.

Warnings

Series 3000 MkII is designed for installation and use in Zone 1 or 2 or 21 or 22 hazardous

areas in Europe and Class I Division 1 or 2 and Class II Division 1 or 2 area

applications in North America.

Installation must be in accordance with the recognized standards of the appropriate

authority in the country concerned.

Access to the interior of the detector, when carrying out any work, must only be

conducted by trained personnel.

Before carrying out any work ensure local regulations and site procedures are

followed. Appropriate standards must be followed to maintain the overall

certication of the detector.

To reduce risk of ignition of hazardous atmospheres, conduit runs must have a seal

tting connected within 18 inches of the enclosure.

To reduce the risk of ignition of hazardous atmosphere, de-classify the area or

disconnect the equipment from the supply circuit before opening the detector

enclosure. Keep assembly tightly closed during operation.

Never attempt to open a junction box / enclosure in potentially hazardous

atmospheres.

The detector must be earthed / grounded for electrical safety and to limit the effects

of radio frequency interference. An earth / ground point is provided inside and

outside the unit. The internal grounding shall be used as the primary equipment

ground. The external terminal is only a supplemental bonding connection where

local authorities permit or require such a connection.

Take care when handling sensors as they may contain corrosive solutions.

Do not tamper or in any way disassemble the sensor.

Do not expose to temperatures outside the recommended range.

Do not expose sensor to organic solvents or ammable liquids.

At the end of their working life, sensors must be disposed of in an environmentally

safe manner. Disposal should be according to local waste management

requirements and environmental legislation.

Alternatively, sensors may be securely packaged and returned to

Honeywell Analytics clearly marked for environmental disposal.

Electrochemical cells should NOT be incinerated as they may emit toxic fumes.

All cable entry devices and blanking elements shall be certied in type of explosion

protection ameproof enclosure “d”, suitable for the conditions of use and correctly

installed and have an ingress protection rating of at least IP6X.

Unused apertures shall be closed with suitable blanking elements.

SERIES 3000 MKII TECHNICAL MANUAL S3KMKIIMAN_MAN0878_Issue 8_08/2015

5.1 Mounting and location of detectors

Caution: The location of the detectors should be made in accordance with any relevant local and national legislation, standards or codes of practice.

Always replace detectors with a detector of the same type.

The detector should be mounted where the gas is most likely to be present. The following points should be noted when locating gas detectors.

• When locating detectors consider the possible damage caused by natural events e.g. rain or ooding.

• Consider ease of access for functional testing and servicing.

• Consider how escaping gas may behave due to natural or forced air currents.

Note: The placement of detectors should be determined following the advice of experts having specialist knowledge of gas dispersion, experts having knowledge of the process plant system and equipment involved, safety and engineering personnel. The agreement reached on the location of detectors should be recorded.

Mount the Series 3000 MkII with the sensor pointing downwards. Integral mounting lugs (suitable for M8 bolts) are provided on the Series 3000 MkII transmitter housing for mounting the detector to a wall. An optional pipe mounting bracket (part number SPXCDMTBR) is available for mounting to a pipe / pole of diameter 20.0¬-80.0mm (0.8" to 3.1").

Diagram 3: Pipe Mounted Diagram 4: Wall Mounted

SERIES 3000 MKII TECHNICAL MANUAL S3KMKIIMAN_MAN0878_Issue 8_08/2015

201mm (7.9”)

164mm (6.4”)

130mm (5.1”)

Diagram 5: Pipe Mounting Outline Dimensions

164mm (6.4”)

99mm (3.9”) 108mm (4.2”)

99mm (3.9”)

201mm (7.9”)

Diagram 6: Wall Mounting Outline Dimensions

SERIES 3000 MKII TECHNICAL MANUAL S3KMKIIMAN_MAN0878_Issue 8_08/2015

6. Electrical connections

Prior to installation refer to the transmitter control drawing 3000E3160 and remote sensor control drawing 3000E3157 shown in section 21.

Warnings

Series 3000 MkII is designed for installation and use in Zone 1 or 2 or 21 or 22 hazardous

areas in Europe and Class I Division 1 or 2 and Class II Division 1 or 2 area applications in

North America.

Installation must be in accordance with the recognized standards of the appropriate

authority in the country concerned.

Use copper wiring only.

Access to the interior of the detector, when carrying out any work, must only be

conducted by trained personnel.

Before carrying out any work ensure local regulations and site procedures are

followed. Appropriate standards must be followed to maintain the overall

certication of the detector.

To reduce risk of ignition of hazardous atmospheres, conduit runs must have a seal

tting connected within 18 inches of the enclosure.

To reduce the risk of ignition of hazardous atmosphere, de-classify the area or

disconnect the equipment from the supply circuit before opening the detector

enclosure. Keep assembly tightly closed during operation.

Never attempt to open a junction box / enclosure in potentially hazardous

atmospheres.

The detector must be earthed / grounded for electrical safety and to limit the effects

of radio frequency interference. An earth / ground point is provided inside and outside the unit. The internal grounding shall be used as the primary equipment ground. The external terminal is only a supplemental bonding connection where

local authorities permit or require such a connection.

Take care when handling sensors as they may contain corrosive solutions.

Do not tamper or in any way disassemble the sensor.

Do not expose to temperatures outside the recommended range.

Do not expose sensor to organic solvents or ammable liquids.

At the end of their working life, sensors must be disposed of in an environmentally

safe manner. Disposal should be according to local waste management

requirements and environmental legislation.

Alternatively, sensors may be securely packaged and returned to

Honeywell Analytics clearly marked for environmental disposal.

SERIES 3000 MKII TECHNICAL MANUAL S3KMKIIMAN_MAN0878_Issue 8_08/2015

Diagram 8: Wiring Schematic Type 2

6.1 Detector wiring schematic

Caution: All electrical connections should be made in accordance with any

relevant local or national legislation, standards or codes of practice.

Detector Supply V

• 17Vdc (+/-10%) < Vd < 32Vdc (max)

Maximum Detector Signal I

• Im = 22mA (over range)

Cable Resistance R

• Subject to cable type

Diagram 7: Wiring Schematic Type 1

Controller

+VE

Signal

-VE

Detector

+VE

-VE

• Typical values are:

Load Resistor of Control Panel R

• Assumed 33Ω (min) / 250Ω (max)

Controller Supply Voltage V

• Subject to controller manufacturer

• Assumed nominal of 24Vdc

6.2 Typical maximum installed cable lengths

(20AWG*) = 36.8Ω/km (59.2Ω/mi)

0.5mm

1.0mm

(17AWG*) = 19.5Ω/km (31.4Ω/mi)

1.5mm

(16AWG*) = 12.7Ω/km (20.4Ω/mi)

2.0mm

(14AWG*) = 10.1Ω/km (16.3Ω/mi)

*nearest equivalent

The formula for calculating the maximum installed cable length between a controller and detector D (meters) is given below.

D = ( ( ( Vc - Vdmin - ( Im * RL ) ) / ( 2 * Im * Rc ) ) ) * 1000

Typical cable data Cable distance km (mi)

Cable size Cable resistance

Rc Ω/km (Ω/mi)

Example 1 Input

impedance RL = 33Ω

Example 2 Input

impedance RL = 250Ω

0.5mm2 (20AWG*) 36.8 (59.2) 3.9 (2.4) 0.9 (0.6)

1.0mm2 (17AWG*) 19.5 (31.4) 7.3 (4.5) 1.7 (1.1)

1.5mm2 (16AWG*) 12.7 (20.4) 11.2 (7.0) 2.7 (1.7)

2.0mm2 (14AWG*) 10.1 (16.3) 14.1 (8.8) 3.4 (2.1) *Nearest equivalent

Notes:

• Distance km=kilometres, mi=miles.

• Assuming Vc=24Vdc, Vdmin=17Vdc, Im=22mA For the value of RC, use the data supplied by the manufacturer of the cable to be used for the specic installation.

SERIES 3000 MKII TECHNICAL MANUAL S3KMKIIMAN_MAN0878_Issue 8_08/2015

6.3 Terminal connections

All electrical connections are made at the terminal module. To access the terminal module follow the procedure below:

1. Remove the detector’s cover by unscrewing it in a counter-clockwise direction.

2. Remove the display module by pulling it rmly away from the enclosure without twisting it.

Internal Earth/

Conduit/Cable Entry

Ground Connection

Supplementary External Earth/

Display Module

Ground Connection

Plug in Socket

Note: Nominal tightening torque of 6.9lb-in. to be applied to the terminal clamping screws.

Terminal number

Detector Terminal

Controller

Connection 1 + +VE 2 - Signal

6.4 Cable and earth / ground connection

Between the Controller and Transmitter use 2 core (plus screen 90% coverage), suitably mechanically protected copper cable with a suitable M20 explosion-proof gland, or ¾ in. NPT steel conduit, with 0.5 to 2.0mm2 (equivalent approx. 20 to 14AWG) conductors. Ensure the cable gland is installed correctly and fully tightened.

To ensure good EMC/RFI immunity bond the system to ground / earth as shown in the diagram below.

Transmitter

Controller

Bonded Point

Earth Point

Transmitter

Cable Screen

Metal Conduit

Sensor

Notes:

• No two ‘Earth Points’ should be connected via screen and / or conduit so as to avoid ‘ground loops’. (Except between the sensor and transmitter which is a digital link).

• Where multiple ‘Earth Points’ are unavoidable (e.g. transmitter mounted on metal superstructure which is earthed then screen and / or conduit to controller should be isolated appropriately).

• ‘ Bonded Points’ (continuity of screen) may be achieved using appropriate glands / cable or conduit;

internal and external ‘Earth Points’ in the transmitter are provided.

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