Honeywell Analytics VTXVTXM User Manual

Vertex Continuous Gas Monitor

Operating Manual

• Table of Contents

• Introduction

• Installation

• Startup

• Operation

• Maintenance

• Troubleshooting

• Installation Drawings

• Specications

• Detectable Gases

• Replacement/Consumable

• Optional Relay Specs

• Network Interfaces

• LIT Option

• Warranty Statement

Vertex

N OT I C E

Vertex Continuous Monitor Symbols

Symbol Description

Power on

Power off

Potential damage to the device or other property, maintenance procedures, and “refer to manual” instructions.

Lifting instructions, low clearances, slipping/tripping hazards, minor corrosive dangers. Also used when deﬁning personal

CAUTION

WARNING

protective equipment (gloves, dust masks, etc.) Personal injury risk: machinery hazards around guarded

equipment, moving parts, crush/pinch hazards, ﬂying debris, and arc ﬂash hazards.

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72-Point Continuous Monitor

DANGER

V ertex Technical Handbook

The most dangerous or potentially lethal hazards: unguarded equipment, conﬁned space entrances, and lockout labels.

Caution: possibility of electric shock

Caution: hot surface

Protective conductor terminal (ground terminal)

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EMC Considerations

Your Honeywell Analytics continuous gas monitor has been designed to comply with applicable Electromagnetic Compatibility (EMC) standards at the time of manufacture. The design includes ﬁltering, shielding and bypassing techniques. At the time of certiﬁcation, simulated customer Input/ Output (I/O) schemes were tested.

All methods used in your equipment for emission suppression and reduction of susceptibility are interactive. Modiﬁcations to the monitor could result in increased emissions and higher vulnerability to other radiated ﬁelds.

Following the guidelines in this EMC Considerations section will ensure your monitor maintains the highest degree of EMC integrity. The guidelines listed apply only to I/O emissions and do not apply to A.C. and D.C. monitor power connections.

Industry Canada Statement

This device complies with Industry Canada licenceexempt RSS standard(s). Operation is subject to the following tw o conditions: (1) this de vice may not cause interference, and (2) this de vice must accept any interference, including interference that may cause undesired operation of the device.

Le présent appareil est conforme aux CNR d’Industrie Canada applicables aux appareils radio ex empts de licence. L’e xploitation est autorisée aux deux conditions suivantes : (1) l’appareil ne doit pas produire de brouillage, et (2) l’utilisateur de l’appareil doit accepter tout brouillage radioélectrique subi, même si le brouillage est susceptible d’en compromettre le fonctionnement.

FCC Compliance Statement

CAUTION: Changes or modifications

not expressly approved could void your authority to use this equipment.

Th

is device complies with Part 15 of the FCC Rules. Operation to the following two conditions: (1) This device ma y not cause harmful interference , and (2) this device must accept any interference received, including interference that may cause undesired operation.

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Cabling

At a very minimum, all cables should include a braided shield. Ideal results have been obtained with twisted pair cabling which has a foil shield surrounding each pair plus foil and 90% braid shielding around the bundle. In addition, ensure local electrical code requirements are met.

The following cable parameters must be considered:

Braid

Foil

Twisted Pair

Stranded Pair

Shield Termination

Must have a minimum 90% coverage

When used with braid, provides 100% coverage

Do not use foil alone. It has a tendency to break.

Provides for cancelling of magnetic ﬁelds

Provides the greatest surface area

Continuation of the shield to the cabinet earth ground is most important. For discrete wire terminations, pigtails to the cabinet (connector) ground should be extremely short (absolutely no greater than three inches). For multiconductor connector terminations, only 360° shielded shells should be used.

Note:

Honeywell Analytics product testing uses >90% braid with foil (around the bundle); twisted pair; stranded 24 AWG (minimum wiring for all

qualication and certication testing.)

Connectors

All qualification and certification of Honeywell Analytics products were achiev ed with high quality connectors, providing 360° shield cov erage. These connectors generally had metal shells.

Failure to properly secure the connector to the equipment will result in high emission levels. Also, poorly constructed or improperly assembled connectors can be a high source of radiated noise and provide a path for external signals into the monitor.

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Table of Contents

Vertex Continuous Monitor Symbols �� i EMC Considerations Cabling �� ii Connectors �� iii

1 Introduction

1�1 System Overview ��1-2

1�1�1 Manufacturer ��1-2 1�1�2 General Safety ��1-2

1�2 System Components ��1-2

1�2�1 Vertex Front ��1-3 1�2�2 Vertex Back ��1-4 1�2�3 Exhaust and Wiring Ports ��1-5 1�2�4 Module Front - Door Closed ��1-6 1�2�5 Analyzer Side Panel (exterior) ��1-7 1�2�6 Analyzer Side Panel (interior) ��1-8 1�2�7 Sample Tubing Connections (detail) ��1-9 1�2�8 System Controls (behind screen) ��1-10 1�2�9 Analyzer Front ��1-12 1�2�10 Data Acquisition Computer (rear) ��1-13 1�2�11 ChemCam USB Hub ��1-15 1�2�12 Back of Chemcassette® Module ��1-16 1�2�13 Main PLC ��1-17

1�2�14 Relay Option PLC ��1-18 1�3 Menu Map ��1-19 1�4 Analyzer Modules ��1-20 1�5 Sampling System ��1-21 1�6 Chemcassette® Detection System ��1-22

1�6�1 Detector Optics ��1-22

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1�6�2 Stain Pattern ��1-23

1�6�3 Chemcassette® Tapes ��1-25

1�6�4 Optional ChemCam ��1-25

1�6�6 Cooling Fans and Filters ��1-25 1�7 Pyrolyzer Module Detection System ��1-26

1�7�1 Pyrolyzer Fan ��1-26 1�8 Vacuum Pumps ��1-27 1�9 Multiple Gas Monitoring ��1-28 1�10 Control System ��1-29

1�10�1 Data Acquisition Computer ��1-29

1�10�2 Programmable Logic Controller ��1-29

2 Installation

2�1 Introduction ��2-2 2�2 Surveying the Installation Site ��2-3

2�2�1 Placement of the Vertex System ��2-3

2�2�2 Exposure to Dust and Humidity ��2-3

2�2�3 Sample Transport Time ��2-3

2�2�4 Monitor Dimensions ��2-3

2�2�5 Sample Locations ��2-4

2�2�6 Sample Line Particulate Filter Use ��2-4 2�3 Optional Floor Mounting ��2-4 2�4 Installing Sample Lines/ Filters ��2-4

2�4�1 Sample Line Installation Requirements ��2-5

2�4�2 Sample Line Connections ��2-6

2�4�3 Installing Sample Line Particulate Filters ��2-6 2�5 Installing Pump Exhaust Line ��2-7

2�5�1 Exhaust Line Installation Requirements ��2-7

2�5�2 Exhaust Line Connection ��2-7 2�6 Electrical Power ��2-8

2�6�1 Connecting AC Power ��2-8

2�6�2 Verifying Proper AC Power Connection �� 2-9

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2�6�3 Vertex Transformer Installation ��2-11

2�6�4 Power On/Off ��2-16 2�7 Data Acquisition System ��2-17

2�7�1 Optional Keyboard ��2-17

2�7�2 Printer ��2-19

2�7�3 External Network Connection ��2-20

2�7�4 Network Computer Security ��2-20 2�8 Wiring Alarm Relays ��2-21

2�8�1 Relay Contacts ��2-21

2�8�2 Wiring Guidelines ��2-21

Validating the System

3 Startup

3�1 Startup ��3-2

3�1�1 Initial Startup ��3-2

3�1�2 Factory Configuration ��3-2 3�2 Getting Started ��3-3 3�3 Verify Installation ��3-3 3�4 Startup Sequence ��3-4 3�5 Power Up ��3-5 3�6 Start Program ��3-7 3�7 Configuration Utility ��3-9

3�7�1 Define Gas Location ��3-21

3�7�2 Configure Analyzers and Points ��3-23

3�7�3 Set Analyzer Window ��3-24

3�7�4 Configure Point ��3-25

3�7�5 Define and Assign Relays ��3-34

3�7�6 Configure PLC ��3-35

3�7�7 Set Alarm Relays ��3-37

3�7�8 Set Fault Relays ��3-39

3�7�9 Profile Management-File Menu ��3-41

3�7�10 Other Menu ��3-42

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3�7�11 Profile Management Utility ��3-43 3�8 Load Tape ��3-44 3�9 Verify Flow Rates and Supply Vacuum ��3-45

3�9�1 Set Supply Vacuum (Series 2) ��3-45

3�9�2 Verify Flow Rates ��3-45 3�10 Leak Checking Sample Lines ��3-49 3�11 Reconfigure ��3-49 3�12 Moving to a New Site ��3-50 3�13 System Shut Down ��3-51

4 Operation

4�1 Introduction ��4-2 4�2 Monitoring Mode Overview ��4-2 4�3 Main Screen ��4-3

4�3�1 System Display Area ��4-4

4�3�2 Point Detail Display Area ��4-8

4�3�3 Function Buttons ��4-10 4�4 Project Functions ��4-11

4�4�1 Log In and Log Out ��4-12

4�4�2 Changing Password ��4-13

4�4�3 Updating Program ��4-14

4�4�4 Restore OnScreen Keyboard ��4-14

4�4�5 Stopping Project ��4-14 4�5 Review Functions ��4-15

4�5�1 Event History ��4-15

4�5�2 Data Trend ��4-23

4�5�3 Optional ChemCam ��4-24

4�5�4 Event List ��4-26 4�6 Menu Buttons ��4-28

4�6�1 Run Time Options ��4-28

4�6�2 Flow Calibration ��4-34

4�6�3 Maintenance ��4-41

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4�6�4 Diagnostics ��4-44

4�6�5 Service ��4-47

4�6�6 Security Access ��4-51

4�6�7 Configuration ��4-53 4�7 OnScreen Keyboard ��4-54

4�7�1 Restore OnScreen Keyboard ��4-54

5 Maintenance

5�1 Introduction ��5-2 5�2 Maintenance Schedules ��5-3 5�3 Chemcassette® Analyzer Maintenance ��5-4

5�3�1 Air Filter (Series 1 Analyzers only) ��5-4

5�3�2 Remove and Replace Chemcassette® Analyzer Particulate Filters ��5-5

5�3�3 Remove Filters ��5-6

5�3�4 Replace Filters ��5-7

5�3�5 Change Chemcassette® Tape ��5-8 5�4 Replacing an Analyzer ��5-9

5�4�1 Disconnecting Cables ��5-9

5�4�2 Remove Analyzer ��5-11

5�4�3 Install Analyzers ��5-11 5�5 Remove and Replace Pyrolyzer Filters ��5-12

5�5�1 Remove Filters ��5-12

5�5�2 Replace Filters ��5-13 5�6 Remove and Install Pumps ��5-14

5�6�1 Remove Pump ��5-15

5�6�2 Install New Pump ��5-16 5�7 Remove and Install Power Supplies ��5-17

5�7�1 Remove Supply ��5-17

5�7�2 Replace Supply ��5-17 5�8 Clean the Touch Screen ��5-18 5�9 PLC Module Battery Backup Check ��5-19 5�10 File Maintenance ��5-20

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5�11 Optics Cleaning ��5-21

6 Troubleshooting

6�1 Introduction ��6-2 6�2 General System Problems ��6-3 6�3 Maintenance Faults ��6-7 6�4 Instrument Faults ��6-16 6�5 Information Events ��6-26 6�6 Manual Analyzer Override ��6-30

A Installation Drawings

A�1 Introduction ��A-2

B Specifications

B�1 Introduction ��B-2 B�2 Filter Compatibility ��B-3 B�3 Vertex General Specifications ��B-4 B�4 Nominal Transport Times ��B-5

C Detectable Gases

C�1 Detectable Gases ��C-2

D Replacement and Consumable Items

D�1 Consumables ��D-3

D�1�1 Chemcassettes

® ��D-3

D�1�2 End of Line Particulate Sample Filters - See Appendix B ��D-3

D�1�3 Common to all Analyzers (Series 1 or Series 2, Chemcassette® or Pyrolyz-

ers) ��D-3

D�1�4 Common to all Pyrolyzers (Series 1 or Series 2) ��D-3

D.1.4.1 Series 1 Analyzers (Chemcassette

®

or Pyrolyzer) .......................................D-3

D�1�5 Common to all Rack Systems (Series 1 or Series 2) ��D-3

D.1.5.1 Series 2 Rack

..............................................................................................D-3

D�2 Printed Circuit Boards ��D-4

D�2�1 Common to all Pyrolyzers ��D-4

D.2.1.1 Series 1 Pyrolyzers D.2.1.2 Series 2 Pyrolyzers

......................................................................................D-4

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D�2�2 Series 1 Analyzers (Chemcassette® or Pyrolyzer) ��D-4

D�2�3 Series 2 Analyzers (Chemcassette® or Pyrolyzer) ��D-4

D�2�4 Series 2 Power Distribution Module ��D-4 D�3 Components ��D-4

D�3�1 Common to all Analyzers(Series 1 or Series 2, Chemcassette® or Pyrolyzer)

��D-4

D.3.1.1 Series 1 Analyzers (Chemcassette D.3.1.2 Series 2 Analyzers (Chemcassette

®

or Pyrolyzer) .......................................D-4

®

or Pyrolyzer) .......................................D-4

D�3�2 Common to all Pyrolyzers (Series 1 or Series 2) ��D-5

D.3.2.1 Series 1 Pyrolyzers D.3.2.2 Series 2 Pyrolyzers

......................................................................................D-5

D�3�3 Common to all Rack Systems (Series 1 or Series 2) ��D-5

D.3.3.1 Series 1 Rack Systems D.3.3.2 Series 2 Rack Systems

...............................................................................D-5

...............................................................................D-6

D�3�4 Common to all Pump Modules (Series 1 or Series 2) ��D-6

D.3.4.1 Series 1 Pump Module

................................................................................D-6

E Optional Relay Specifications

E�1 Relay Output Contacts ��E-2 E�2 Relay Contact Ratings ��E-3 E�3 Default Relay Assignments ��E-4

E�3�1 Introduction ��E-4

E�3�2 Main PLC ��E-5

E�3�3 Optional Relay PLC ��E-6

E�3�4 Terminal Assignment of 1746-OW16 Relay Module ��E-7

E�3�5 Terminal Assignment of 1746-OX8 Relay Module ��E-14

F Network Interface and Options

F�1 Network Interface and Options ��F-2 F�2 OLE for Process Control (OPC) Interface ��F-3

F�2�1 Setting Up an OPC Client Application ��F-3 F�3 Data Values Common to Fieldbus Networks ��F-7

F�3�1 Alarms and Faults ��F-7

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F�3�2 Concentrations ��F-7

F�3�3 Heartbeat ��F-8 F�4 Data Map ��F-9 F�5 Profibus Option ��F-11 (P/N 1295-0275)

��F-11 F�5�1 Termination ��F-11 F�5�2 Profibus Module Configuration ��F-12

F�6 DeviceNet Interface ��F-13 (P/N 1295-0329)

��F-13

F�7 ControlNet Interface ��F-14 F�8 DF1 Interface (P/N1295-0343) ��F-15 F�9 Modbus Plus Interface ��F-16 (P/N1295-0330)

��F-16 F�10 LonWorks Interface ��F-17 (P/N 1295-0329)

��F-17

F�11 Modbus/TCP (P/N1295-0520) ��F-18

F�11�1 Configuring the IP Address ��F-18

F�12 Ethernet/CIP (P/N1295-0519) ��F-20

F�12�1 Configuring the IP Address ��F-22 F�13 RSView32 Active Display ��F-23 Set-Up Instructions

��F-23 G Line Integrity Test Option H Warranty Statement

Chemcassette Chemcassette

®

Device Warranty Statement ��H-2

®

Warranty ��H-3

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1 Introduction

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1.1 System Overview

The Honeywell Analytics Vertex™ System continuously monitors up to 72 remote locations for toxic gases. It responds to gases that exceed programmed levels by:

• Triggering alarms and opening event windows to warn operators of high or low concentrations

• Triggering relays to external devices

• Displaying the location, gas type and gas concentration

• Storing the alarm information in a database

The V ertex System pro vides fast response to a wide range of gases. Each location may be up to 400 ft (122 m) from the Vertex System. The system uses one or more of Honeywell Analytics’ Chemcassette analyzers, with or without pyrolyzer, to provide a monitoring system tailored to meet the requirements of the facility.

The Vertex System incorporates a range of redundant and protective features for maximum uptime:

• Intelligent analyzer modules allow one to stop monitoring with no effect on the remaining modules

®

• Filters, Chemcassettes® and major components in one of the analyzers can be replaced while the remaining analyzers continue to function

Operation can be through an LCD touch screen or through a local area network (LAN).

Chemcassette® is a registered trademark of Honeywell Analytics, Inc.

1.1.1 Manufacturer

The Vertex System is manufactured by: Honeywell Analytics Inc. 405 Barclay Boulevard Lincolnshire, IL 60069 USA www.honeywellanalytics.com

1.1.2 General Safety

Follow all installation and operational instructions to ensure the safe and reliable operation of this unit.

If this monitor is used in a manner not speciﬁed by Honeywell Analytics Inc., the protection provided by the equipment may be impaired.

1.2 System Components

The following photos illustrate Vertex System components, ports, connections and controls. From the main front and back photos, click on the labels to see the detail photos.

• Power supplies are redundant

• Pumps are redundant

• The system powers up in the same state as when powered down

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1.2.1 Vertex Front

Sample Tubing

Connections (detail)

Pyrolyzer Analyzer

Module Front Door Closed

(detail)

Analyzer Side Panel

(exterior)

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72-Point Continuous Monitor

Exhaust and Wiring

Ports

System Controls

(behind screen)

Universal

®

Chemcassette

Analyzer

Analyzer Front

Analyzer Side Panel

(interior)

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1.2.2 Vertex Back

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Relay Wire

Raceway

Data Acquisition

Computer (rear)

ChemCam USB

Hubs

Rear Main

Power

Main PLC

Relay Option

PLC

Back of

Chemcassette®

Module

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1.2.3 Exhaust and Wiring Ports

System Exhaust

0.5 in (12.7 mm) tubing

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AC Input

0.75 in pipe thread

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Alarm Wiring Conduit

Plates - 4 in (101.6 mm) x 2

1-5

1.2.4 Module Front - Door Closed

Protective panel over

touch screen.

Open to use.

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72-Point Continuous Monitor

Slot

Pyrolyzer Analyzer

Analyzer Status LED

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Tier 1

Tier 2

1-6

1.2.5 Analyzer Side Panel (exterior)

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Slide Latch

Access Screws

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1.2.6 Analyzer Side Panel (interior)

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Analyzer CPU

ChemCam Option

Sample Pressure

Transducers

Sample Flow

Transducers

Proportional Valve Filters

Sensor Interface PCB

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1.2.7 Sample Tubing Connections (detail)

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Tier 1

Tier 2

Tier 3

4 - Port Manifold

for multiple gas sampling

See Section B.4, Nominal Transport Times

for tubing length limitations

Slot 1 Slot 2

Slot 3

Points - 1 thru 8

Left to Right

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1.2.8 System Controls (behind screen)

Series 2 Units

Set Supply Vacuum

Power

Distribution

Module

Rack Power

Switch and

Circuit Breaker

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Analyzer DC and Pyrolyzer AC Power Switches with Indicators

Data Acquisition Computer (DAq)

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24 VDC Power

Supplies

DVD

Drive

1-10

Hot Swap

Hard Drives

Analyzer

Communications

Hub (Ethernet)

Series 1 Units

Power

Distribution

Module

Rack Power

Switch and

Circuit Breaker

Analyzer

Communications

Hub (Ethernet)

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Analyzer DC and Pyrolyzer AC Power Switches with Indicators

Data Acquisition Computer (DAq)

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24 VDC Power

Supplies

1-11

CD-RW

Drive

1.2.9 Analyzer Front

Analyzer Status LED

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Mounting Slot for Optional Keyboard

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Product Label

location of

RoHS sticker

1-12

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1.2.10 Data Acquisition Computer (rear)

Series 2 Units

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Serial Interface for

Touch Screen (COM 1)

Keyboard Connection

Note:

Touchscreen Video

Mouse Connection

LCD Video

(white cable)

Serial Connection to

the PLC, COM8

External Ethernet

Port

USB Ports

USB

Connection to

the Hosting

Device

This photo shows a typical port conguration. Port and slot locations on your monitor may vary.

Caution:

Restrict access to the USB port to reduce the risk of malicious software being introduced.

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Series 1 Units

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Serial Interface for

Touch Screen (COM 1)

External Ethernet Network

Serial to PLC

(COM2)

Modem

Parallel Printer Port

Keyboard Connection

USB Port

Internal Ethernet

Network

LCD Video

Mouse Connection

Note:

This photo shows a typical port conguration. Port and slot locations on your monitor may vary.

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1.2.11 ChemCam USB Hub

ChemCam USB Hubs

(3)

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1.2.12 Back of Chemcassette® Module

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ChemCam USB

Connection (option)

Analyzer

Communications

(Ethernet)

Circular Tubing

Harness

V ertex Technical Handbook

Cable Carrier

Analyzer 24V

Power Supply

Multifunction

Connector

Note:

Connection secured by slide latch. Push up to open. Push down to close.

1-16

1.2.13 Main PLC

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DH485 Link

Coupler

Advanced Interface

Converter

PLC Power

Supply

Optional Relay

Modules

Connection to optional

4-20mA System

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PLC

Processor

Module

1-17

DH485/RS232

Interface Module

Expansion slot

for optional

Communications

Interface

1.2.14 Relay Option PLC

Power Supply

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Relay Module (up to seven) cards

1-18

Honeywell Analytics VTXVTXM User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual