Honeywell MPD Operating Manual

Operating Manual

Multi-Purpose Detector (MPD)

Table of Contents

Safety......................................................................................................5

1. Introduction .......................................................................................8

1.1.1 Naming Conventions .......................................................8

1.2 Principle of Operation ..............................................................9

1.2.1 Catalytic Bead Sensor MPD-**-CB1 ................................ 9

1.3 Accessories .............................................................................. 9

1.3.1 Collecting Cone .............................................................10

1.3.2 Weatherproof Cap .......................................................... 10

1.3.3 Sample / Calibration Gas Flow Adaptor ........................11

1.3.4 Gassing Point Assembly ................................................ 11

1.3.5 Duct Mount Kit ............................................................... 12

1.3.6 Filters .............................................................................12

2. Installation .......................................................................................13

2.1 Unpacking ............................................................................... 13

2.2 Sensor Orientation ................................................................. 13

2.3 MPD Remote Mount ...............................................................13

2.4 Wiring ...................................................................................... 14

2.4 Cable Connections .................................................................14

2.5 Fitting Sensors ....................................................................... 15

3. Fitting Accessories .........................................................................16

3.1 Collecting Cone ...................................................................... 16

3.2 Weatherproof Cap .................................................................. 16

3.3 Sample/Calibration Gas Flow Adaptor ................................. 16

3.4 Filters ......................................................................................16

3.5 Duct Mount Kit ........................................................................16

4. Maintenance.....................................................................................17

4.1 General .................................................................................... 17

4.2 Cleaning .................................................................................. 17

5. Faults ................................................................................................ 18

6. Functional Gas Test (Bump Test) .................................................. 19

6.1 Sensor without Accessories ................................................ 19

6.2 Sensor with Collecting Cone or Weatherproof Cap ............19

6.3 Sensor with Sample/Calibration Gas Flow Adaptor ...........19

7. Calibration ........................................................................................20

7.1 Zero and Span Calibration for MPD Sensors with XNX

Universal Transmitter ..............................................................20

7.2 Cross Calibration procedure for MPD-CB1 .........................22

7.3 MPD-CB1 Flammable Sensor Operational Life ...................24

7.4 Meter Multiplication Factors for MPD-IF1 ............................ 24

8. Replacement Parts .......................................................................... 25

MPD Operating Manual

8.1 MPD Catalytic Bead and IR Replacement Sensor Cartridges

.......................................................................................................25

8.2 Terminal Housings ................................................................. 25

8.3 Maintenance Spares ..............................................................25

8.4 MPD Calibration Gases..........................................................26

9. Specifications .................................................................................. 26

9.1. General Specifications .........................................................26

9.2 Performance Data ..................................................................26

9.3 MPD-CB1 ................................................................................. 28

9.2.1 MPD-CB1 Cross Sensitivity ...........................................28

9.4 MPD-IV1...................................................................................29

9.5 MPD-IF1 ................................................................................... 30

9.6 MPD-IC1 ..................................................................................31

9.7 MPD Certifications by Part Number Series..........................32

9.7.1 MPD Certification Labels ............................................... 33

10. Warranty ......................................................................................... 34

11. EC Declaration of Conformity ...................................................... 36

MPD Operating Manual

Safety

» Ensure that this Operating Manual is read and understood BEFORE installing, operating,

or maintaining the equipment.

» Pay particular attention to Warnings and Cautions.

» All document Warnings and Cautions are listed here and repeated where appropriate in

the relevant chapter(s) of this Operating Manual.

WARNINGS

» Agency approvals are associated with speciﬁc Sensor/Housing combinations

rohibiting ﬁeld upgrade of sensor types. The MPD part number, serial number, sensor type and target gas should be provided when ordering replacement sensors (See Section 8.1 MPD Catalytic Bead and IR Replacement Sensor Cartridges).

» High off-scale readings may indicate an explosive concentration of gas.

» To maintain safety standards, regular maintenance, calibration and operation of this

equipment by qualiﬁed personnel is essential. Read and understand this manual completely before operating or servicing. If any further details are required which do not appear in this manual contact Honeywell Analytics or their agent.

» The Code of Practice regarding ‘Selection, Installation and Maintenance of Electrical

Apparatus for use in Potentially Explosive Atmospheres’ must be complied with at all times. Refer to the appropriate local or national regulations relative to the installation site. Elsewhere the appropriate local and/or national regulations should be used.

» As some test gases may be hazardous, the Flow Adaptor outlet should exhaust into

a safe area.

» Operators must be fully aware of the action to be taken if the gas concentration

exceeds an alarm level.

» Before installing the sensors, isolate the power supply by disconnecting or removing

the associated control module from the installation.

» Appropriate care should be taken when handling cylinders of compressed ﬂammable

and toxic gases during calibration and bump testing.

MPD Operating Manual

CAUTIONS

» To maintain safety standards, regular maintenance, calibration and operation of the

equipment by qualiﬁed personnel is essential.

» Do not modify or alter the sensor construction as essential safety requirements

may be invalidated.

» When replacing sensors, dispose of used sensors in accordance with local

disposal regulations. For more information on sensor disposal, contact your HA Representative.

» The catalytic detector element is resistant to catalyst poisons, however, abnormally

high concentrations of halogenated hydrocarbons, vapors of heavy metals or compounds, some silicone compounds and sulfur compounds may cause loss of sensitivity.

» The MPD must never be used in conditions where there is insufﬁcient oxygen to

totally oxidize the combustible gas. For most combustible gases, an oxygen level of at least 15% is sufﬁcient.

» The sintered disc on the sensor assembly must be kept free from contaminants;

i.e. oil and dirt.

» The sensitivity of catalytic sensors is impaired by silicone compounds. Do not expose

the sensors to silicones or silicone-based products.

» The relevant site procedures must be obeyed at all times when opening the Terminal

Housing or removing the sensor in a hazardous areas.

» The sensitivity of Catalytic Sensors is impaired by silicone compounds. Do not expose

to silicones or silicone based products.

» Dismantling of a sensor or a sensor installation by other than authorized engineers

invalidates certiﬁcation.

» Upward pressure on the gassing nozzle of the Weatherproof Cap forces the nozzle

against the sinter. Rotation of the nozzle may damage the sinter if a ﬁlter is not ﬁtted.

» Direct gassing of the sensor via the nozzle on the Collecting Cone in wind speeds of

greater than 5 meters per second may cause errors.

» The calibration procedure should only be performed by qualiﬁed personnel.

» Before initial calibration allow the detector to stabilize for 30 minutes after applying

power. When in zero and span calibration mode the current output from the detector is inhibited (e.g. default 2mA) to avoid false alarms.

» Extended or frequent exposure to elevated concentrations of combustible gases

may affect sensor sensitivity. Verify sensor performance by frequent calibration.

» Where the user calibrates any sensor using a different gas, responsibility for dentifying

and recording calibration rests with the user. Refer to the local regulations where appropriate.

» These (meter multiplication) factors only apply to gas concentrations expressed in

% Volume terms.

MPD Operating Manual

» When using a linear cross reference factor the temperature compensation is based

upon propane, and there may be errors at temperatures away from the calibration temperature.

» To maintain safety standards, regular maintenance, calibration and operation of the

equipment by qualiﬁed personnel is essential.

» Do not modify or alter the sensor construction as essential safety requirements

may be invalidated.

» When replacing sensors, dispose of used sensors in accordance with local

disposal regulations. For more information on sensor disposal, contact your HA Representative.

ATEX Temperature Code Ratings

» Component gets no hotter than an operating temperature code of T4 when installed

according to the electrical speciﬁcations of Label ( Sch Drawing 1226E0309)

» Maximum surface temperatures is less than 85°C when measured under normal

operating conditions for the Dust evaluation.

Important Notices

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

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 manual.

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

If further details are required which do not appear in this manual, contact Honeywell Analytics or one of their agents.

MPD Operating Manual

1. Introduction

The MPD (Figure 1) is a serviceable explosion proof housing, offered with either

catalytic bead or infrared sensors for the measurement of ammable and toxic

gases. The assembly is constructed of 316 stainless steel and is supplied in either ¾ inch NPT or M25 thread versions with corresponding approvals (See Section

10 - Specications). The sinter assembly can easily be removed for same sensor

replacement.

WARNING:

Agency approvals are associated with specific Sensor/Housing combinations prohibiting field upgrade of sensor types. The MPD part number, serial number, sensor type and target gas should be provided when ordering replacement sensors (See Section 8.1 MPD Catalytic Bead and IR Replacement Sensor Cartridges).

The MPD can be mounted directly to a transmitter such as the XNX Universal Transmitter or other suitable device in a hazardous area, or remotely mounted to a transmitter located in a non-hazardous area. For remote mounting, the detector is

tted to an optional junction box. The ¾ NPT type is supplied with factory sealed leads eliminating the need for a pour gland between the detector and the junction

box.

Optional accessories such as collecting cone, weatherproof cap or alternative sampling systems can be installed to the MPD via the M40 external thread provided on the sensor retainer. A M40 (female) to M36 (male) adaptor can be ordered, offering additional accessory selections.

The presence of target gas is indicated via a millivolt electrical interface for all sensor types via three wires. Two additional wires provide a digital interface for the infrared version. When appropriately interfaced with a controller, the controller can provide outputs such as display, 20mA, relay, etc.

The MPD detector must be installed in accordance with local and national requirements for the installed area and application. Reference drawing number

1226E0351 for specic installation requirements.

Honeywell recommends periodic bump testing of the sensor to ensure proper operation and compliance with the functional safety rating of the installation.

1.1.1 Naming Conventions

MPD sensor models are in the format MPD-XX-YYY. XX designates agency approval (AM = ATEX/IEC Ex with male M25 thread, UT = UL/CSA or UL with male 3/4“ NPT thread, BT = UL/INMETRO with male 3/4“ NPT thread), YYY designates the sensor Type (CB1 = Catalytic bead % LEL, IF1 = Infrared % LEL, IV1 = Infrared % LEL CH

, IC1 = Infrared CO2).

MPD Operating Manual

3/4” NPT or M25 Threads

Sensor Cell

Sensor Retainer and Locking Screw

2.080

[52.83]

1.875 [47.63]

(All dimensions reference)

Figure 1. Multi-Purpose Detector (MPD)

[76.62]

2.016

[51.21]

3.016

20AWG Stranded Wire

7.5 [190.5] Nominal Length

1.2 Principle of Operation

1.2.1 Catalytic Bead Sensor MPD-**-CB1

The CB1 sensor, catalytic bead type contains two elements which are heated by a

dened constant electrical current from the transmitter. One element is sensitive to

the presence of combustible gas, the second element compensates for changes in temperature. When a combustible gas is present, the sensing element temperature increases due to catalytic oxidation of the gas. The resistance of the element is proportional to temperature and is proportional to a change to gas concentration. The catalytic bead sensor provides the broadest range of combustible detection, widest temperature range and performance approvals.

1.2.2 Infrared Sensor MPD-**-IF1, IV1, IC1

The IF1, IV1and IC1sensors use Non-Dispersive InfraRed (NDIR) Adsorption techniques to detect a gas or family of gases. The sensor cells contain a long life

tungsten lament infrared light source, an optical cavity into which gas diffuses,

a dual temperature compensated pyroelectric infrared detector, and integral semiconductor temperature sensor and electronics to process the signals from the pyroelectric detector.

The IV1 sensor can measure methane concentration in the range of 0-5%Vol or 0-100%LEL. The IF1 sensor can measure propane concentration in the range of 0-100%LEL. The IC1 is used for carbon dioxide monitoring in the rage of 0-5% Vol.

1.3 Accessories

The following accessories are available for use with the sensors:

a. Collecting Cone (Figure 3). b. Weatherproof Cap (Figure 4). c. Sample/Calibration Gas Flow Adaptor (Figure 5). d. Remote Gassing Port (Figure 6). e. Duct Mount Kit (Figure 7). f. Filters

MPD Operating Manual

1.3.1 Collecting Cone

(02000-A-1642)

The detection of a lighter than air gas is enhanced by the use of a Collecting Cone.

The cone ts onto the Sensor accessory thread in place of the Filter Housing and retains the lter. The appropriate lter must be tted.

A nozzle on the cone permits gassing of the Sensor with the cone in position. Test gas is applied either direct to the nozzle or via a permanently connected pipe-line when the Sensor is in an inaccessible location.

Figure 2. Collecting Cone

1.3.2 Weatherproof Cap/Housing

(Cap: 02000-A-1640, Housing: SPXCDWP)

The Weather Protection Housing, tted to a sensor installed in an exposed location,

affords protection from driving rain from vertical to 30° below horizontal. When mounted close to the ground, protection is afforded from heavy rain rebounding off the ground. It also reduces contamination from industrial waste and enables

the application of test gas in high wind speeds without signicant error.

Incorporated in the housing is a nozzle to facilitate gassing of the sensor with the Weather Protection Housing in position, either by direct application to the nozzle or via a permanently connected pipeline. On the Weatherproof Cap (02000-A-1640), the nozzle is free to rotate within the housing to allow removal from the sensor without disconnecting a permanently connected pipeline, when changing the Hydrophobic Barrier and cleaning the sensor.

Weatherproof Cap

Sensor Accessory Thread

Figure 3. MPD, Adaptor and Weatherproof Cap

Figure 4. Weatherproof Housing

MPD

MPD Operating Manual

1.3.3 Sample / Calibration Gas Flow Adaptor

(1226A0411)

A Flow Adaptor provides a facility to allow sampling of a closed system by means

of two pipelines. The Flow Adaptor is tted to the sensor accessory thread by a

locking ring that enables the Flow Adaptor to be removed without disconnecting the pipeline. The Filter is retained by the Flow Adaptor and interfaces with a gasket

bonded to the Flow Adaptor. The Flow Adaptor ports are designed to be tted

with 1/4 in (6mm) soft tubing.

The Flow Adaptor is also used to apply calibration gas to the sensor. See Section 7 - Calibration for further details on calibrating the detector.

Figure 5. Flow Adaptor / MPD with Flow Adaptor

1.3.4 Gassing Point Assembly

(1226A0354)

The Gassing Point Assembly assembly can be xed in a convenient position and

permanently connected by suitable tubing to an inaccessible sensor, thus simplifying the application of test gas when checking sensor calibration. A DIN Rail Mounting

Assembly (00785-A-0069) is available to enable ve gassing point assemblies to

be mounted side by side.

Device Adapter

Tube Cap

Figure 6. Remote Gassing Port

1/4 in (6mm) I.D.

Tubing

Teflon

Mounting Bracket

MPD Operating Manual

1.3.5 Duct Mount Kit

The duct mounting kit (S3KDMK), combined with the MPD Interface Adaptor

(1226A0382), can accommodate the MPD to detect ammable gases in a duct

application. The duct mount kit includes the adaptor, gasket and required fasteners. The MPD Interface Adaptor includes only the adaptor and requires the S3KDMKduct mount kit.

1226A0382 MPD Adapter Ring

S3KDMK EC/MPD Duct Adapter Kit

Figure 7. Duct Mount Kit

1.3.6 Filters

In a clean atmosphere, and where no accessories are to be tted, a lter is not needed. It is however mandatory that a lter should be tted to provide protection

appropriate to the environment and to complete the seal when a Weatherproof

Cap or Collecting Cone is tted.

MPD Operating Manual

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