Manning Systems Airscan IRF9 Operating Manual

Instruction and Installation Manual

AirScan

Refrigerant Sensor for Commercial Applications

MOUNT ENCL OSURE T HIS END UP. DO NOT B LOCK PER FORATE D VENT HOLE S.

AirScan

ha_manning@honeywell.com

405 Barclay Boulevard Lincolnshire, Illinois 60069

www.honeywellanalytics.com

Tel: +1 847 955 8200 Toll free: +1 800 538 0363

Fax: +1 847 955 8208

www.manningsytems.com 18908 AirScan-iR-comm 01/2014 REVC

Contents Serial number:

Section Title Page

1 Sensor Description System Specifications and Sensor Specifications 4

2 Installation A Locating the Sensor 5

Figure 1: Mounting Dimensions for the AirScan

B Wiring 6

Figure 2: Wiring Diagram for AirScan

eration A Start-up Procedure 7

3 Op

iR 6

iR 5

Figure 3: Required LED Status at Start-up 7

B Pushbutton Operation, LED Indicators, Adjustment Pots and Test Points 8

Figure 4: Board Component Layout 8 Figure 5: LED Layout 8 LED Indicators and Blink Sequence 9

Figure 6: LED Blink Sequence 9

Figure 7: LED Indicator Summary 10 Normal Run Modes 10 4/20 mA Loop Test Mode 10

Calibration Mode 10

Fault Indicator Error Sequences 11

C Modes of Operation 12

Normal Run Modes 12 4/20 mA Loop Modes 13 Calibration / Programming Modes 14

Calibratio

n 15 Figure 8: Board Component Layout 15 4/20 mA Output Calibration 17 Zero Calibration 17 Figure 9: Board Component Layout 18 Span Calibratio

Diagnostic Procedures

n 18

19 Simple Zero Test 19 4/20 mA Output Loop Integrity Check 19

Troubleshooting

Electrical Interfer

ence 21

Figure 10: Troubleshooting the AirScan

iR 21

Sensor On-Board Diagnostic System 21 Error on 4/20 mA Output 22 Sensor Output at 0 mA 22 Sensor Output at .5 mA 22 Gas Concentration Indicated with No Refrigerant Present 22 IR Source Failure 22

4 Maintenance 23 5 Replacement Parts 23

6 Limited Warranty 24

nning AirScan-iR Refrigerant Sensor 18908 AirScan-iR-comm 2

Introduction

This manual has been prepared to help in the use and installation of the Manning Systems AirScan principles of the sensor, ensure proper installation, and demonstrate start-up and routine maintenance procedures.

This manual must be carefully followed by all individuals who have or will have the responsibility for using or servicing the AirScan

Manning Systems, Inc. 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 Manning Systems, Inc. before proceeding.

iR (Infrared Refrigerants) Sensor. This manual will convey the operating

iR Sensor. Warranties made by

nning AirScan-iR Refrigerant Sensor 18908 AirScan-iR-comm. 3

1 Sensor Description

Gas detection by the infrared method is based on the principle that most gases absorb infrared energy at a characteristic frequency. In this instrument, a broad band infrared source emits energy which is then bandpass filtered to produce a narrow range of frequencies characteristic of the refrigerants’ (CFC/HCFC/HFC) absorption spectra. Any refrigerant in the gas sample cell selectively absorbs energy reaching the detector. This reduction in energy is detected, amplified and sent to the signal processing portion of the system.

The Manning Systems AirScan

iR Sensor line is a threewire, 4/20 mA sensor for two bands of refrigerants available in a range of 0–3,000 ppm, but can be adjusted for lower ranges, if required. The low-band or R-404a infrared sensor reacts to R-123, R-134a, R-404a and R-507. The high-band or R-22 AirScan

iR sensor reacts to R-22.

Its solid, high-mass metal bench provides structural and thermal stability, greater immunity to vibration, as well as superior EMI/RFI shielding of the detector and source. Internal compensation for environmental changes allows the sensor to automatically adapt to fluctuating temperature and humidity conditions. The unit exhibits extremely high reliability with no moving parts.

Every two seconds SensorCheckTM technology monitors the AirScan

iR source and ensures that the dual channels are functioning properly. A notification signal will be transmitted if any of several performance parameters is not met.

Monitoring equipment must be configured to indicate a fault if the signal is less than 1.5 mA. All signals over 20 mA must be considered a high gas concentration.

Manning Systems infrared sensors are normally longlived (5 years plus), unless physically damaged or wetted with water or other liquid.

System Specifications

Electrical Power: 24 Volts DC regulated, 1.0 amp.

Output: Linear 4/20 mA output into a load resistor of

500 ohms maximum

Cable Length to Sensor: 1,000 feet maximum

Cable Recommendation: Three conductor, stranded,

shielded cable with drain wire, all enclosed in a vinyl jacket. For cable runs up to 200 feet use, #18 AWG (Belden #8770 or equivalent). For cable runs up to 1,000 feet, use #16 AWG (Belden #8618 or equivalent).

Unit Enclosure: NEMA 4, gasketed, molded fiberglass

reinforced polyester. Non-painted, non-rusting construction appropriate for food areas. UL 508 listed, CSA certified for use with industrial control equipment.

NOTE: The standard AirScan

iR is for use in non-

classified areas only.

Sensor Specifications

Type: CFC/HCFC/HFC selective infrared gas sensor/

transmitter AirScan

Method of Detection: Dual channel infrared energy

absorption (N.D.I.R. Non-dispersive Infrared)

Gases Monitored: Low-Band (R-404a, R-507, R-134a,

and R-123), High-Band (R-22)

Range Available: 0–3,000 ppm (can be rescaled to

0–1,000 ppm, or 0–500 ppm if required)

SensorCheckTM Features: Dual channel functionality test,

source strength evaluation, incoming voltage monitor, IR source integrity check, operating temperature monitor, “zero” down drift monitor, and internal circuitry check.

Accuracy: ± 3% of full scale

Repeatability: ± 1% of full scale

Cross Sensitivity: Not affected by moisture, food odors,

floor cleaners, temperature changes, etc.

Operating Humidity: 0–100% RH (condensing)

Operating Temperatures: –20° F to +140° F

Storage Temperature: –20° F to +140° F

Gas Sampling: Diffusion method with no moving parts

Sampling Frequency: Real time continuous monitoring

of all points

Response Time: T

calibration gas @ .75 liters/min. flow rate

Weight: 4.4 lbs.

in 10 seconds with full-scale target

Dimensions: 9.59" high x 7.71" wide x 4.52" deep

nning AirScan-iR Refrigerant Sensor 18908 AirScan-iR-comm. 4

2 Installation

”

A Locating the Sensor

Because each sensor can only “report” what it is seeing at the moment,

sensor be located where leaks are most likely to occur.

CFC/ HCFC/HFC vapor is heavier than ambient air, so in a room with no air movement it will tend to settle. For quickest detection, mount the sensor about one to two feet from the floor, close to the potential leak source.

If the primary application is the fastest possible leak detection, mount the sensor near the potential leak sources. In doing this, be aware that the indicated concentration may not be representative of personnel exposure and easy access for the required calibration and maintenance could be compromised.

General Mounting Considerations:

• Must be easily accessible for calibration and

maintenance.

Always mount the sensor vertically.

•

• Mount the sensor clos

sour

ce for fastest possible leak detection.

• If personnel protection is the primary

application, moun Protect sensor from water, excessive hu

•

and

wash-dow

Take air movement and ventilation patterns into

•

account.

Figure 1: Mounting Dimensions for the AirScanTMiR Sensor

it is very important that the

e to the potential leak

t in the “breathing zone.”

midity,

•

To prevent electrical interference, keep sensor and wire runs away from mercury vapor lights var

iable speed drives, and radio repeaters.

• Protect sensor from physical damage (fork lifts, etc.).

• Do not mount the sensor over a door in a refrigerated area.

• For highly critical locations more than one

sor should be installed in each room.

sen

Very Important:

• Sensor must be mounted vertically

Never mount sensor flat on a ceiling

•

• E

nter enclosure

bottom of

Always make a drip loop in the conduit

•

Never mount sensor on a vibrating surface.

•

only through existing hole in

enclosur

Mount sensor enclosures through the flange holes as shown in Figure 1, and

Penthouses: Multi-Coil (defrost one coil at a time) –

always mount vertically.

In this case the best location is usually in the center of the penthouse four or five feet above the grate.

Single Coil (or when all coils defrost at the same time) In this case high moisture conditions can occur and the sensor should be mounted one foot above the grate.

Engine Rooms: The AirScan

iR sensor should be mounted in a cool part of the room, if possible. Keep the sensor away from hot air exhausting from electric motors or other machinery.

–

MOUNT ENCLOSURE T HIS END UP. DO NOT BLO CK PERFOR ATED VEN T HOLES.

AirScan

9.19”9.59”

3.68”

SIDE VIEWFRONT VIEW

nning AirScan-iR Refrigerant Sensor 18908 AirScan-iR-comm 5

1”

7.71”

4.52

5.01”

TOP VIEW

2 Installation continued

Ceiling Hung Evaporators: When mounting AirScan

iR sensors near evaporators, mount the sensor no higher than two feet below the top of the evaporator coil.

Do not mount in high air flow (1,200 feet/minute

maximum).

Never mount the sensor on evaporators as

vibration can damage the sensor.

Other Locations: When mounting AirScan

iR sensors in locations such as roof top air units, ductwork, attic spaces, makeup air intakes, etc., contact Manning Systems for application assistance and recommendations.

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 considered.

Nearly all start-up problems are due to improper wiring or monitor configuration. Please follow these guidelines carefully.

Always use three conductor, insulated, stranded, shielded copper cable. Use

not two cables of two conductor wire (see Figure 2).

If the AirScan

iR is to be used with the AirAlertTM96d,

please call Manning Systems for specific wiring instructions.

Do not pull sensor wiring with AC power cables. This will

cause electrical interference. Be sure there are no breaks or splices in sensor wiring runs. If cable runs cannot be made without a splice, all connections must be soldered. Soldering should be done using a rosin flux to tie the connecting ends of sensor wires to ensure a positive and long-lasting contact.

only three conductor cable,

Ground the shield at the main control panel. Connect the shield wire in the sensor terminal block labeled shield. Tape all exposed shield wire at the sensor to insulate it from the enclosure.

All penetrations into a refrigerated room should be sealed to prevent condensate from forming in the conduit and dripping into the sensor enclosure.

Make drip loops for cables going into sensor housings (see Figure 1). Follow the special mounting instructions on the enclosure (…This End Up).

Electrical Power: 24 VDC regulated, 1.0 amp.

Output: Circuit board mounted sensor provides a linear

4/20 mA output. Monitoring equipment may have a maximum input impedance of 500 ohms.

Contact Manning Systems for specific wiring instructions when using AirScanTMiR sensors with an AirAlert

Cable Recommendation: Use #18/3 (Belden #8770)

96d readout unit.

for cable runs up to 200 feet. Use #16/3 (Belden #8618) for cable runs up to 1,000 feet. Use only the existing punched holes for connections to the sensor.

Monitoring: The AirScan

iR Refrigerant Sensor may be monitored by any Manning Systems Readout/Alarm unit or other appropriately configured system. Monitoring equipment must be configured to indicate a fault if the signal is below 1.5 mA. All signals above 20 mA must be considered a high gas concentration. A failed sensor will output a 0.5 mA signal.

Figure 2: Wiring Diagram for the AirScanTMiR Sensor

White connects to signal input of monitoring equipment

Red connects to 24 VDC power supply positive side

Black connects to 24 VDC ground side

Bare wire wrap connects to case ground

at monitoring equipment (earth ground)

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Output (white)

+24 VDC (red)

DC ground (black)

Shield (bare)

JP1

TEST +

TEST -

SIG

+24

GND

SHLD

3 Operation

The AirScan

iR has several modes of operation,

including two normal run modes, two 4/20 mA loop check modes and five calibration modes. These will be explained in Operation, Section C, Modes of Operation. Modes are entered by properly activating pushbuttons located on the circuit board, shown in Figure 4.

Sensor operation status is indicated by the blink pattern of seven LEDs located in a vertical row on the right side of the sensor circuit board (see Figure 4). LED status is differentiated by color and duration/ pattern of blink(s). LED Indicators and Blink Sequences are shown in Figure 6, followed by an explanation of blink patterns.

A Start-Up Procedure

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 sensor until the initial start-up procedures are completed.

Check the power supply voltage to the sensor with a digital volt meter set to VDC. Place the black lead on sensor terminal GND and the red lead on +24 (see Figure 4, Note 1). Voltage should be between 21 and 28 VDC. If voltage is outside this range, check power supply and wiring.

After power-up, ensure the LEDs below are operational as follows (see Figure 3):

IMPORTANT: The AirScan

iR sensor is factory

calibrated and should require minimal adjustments after installation.

CARB Compliance: To ensure continued compliance with CARB performance guidelines, calibrate the unit in the environment in which it will be used. Frequency of calibration can improve accuracy; Honeywell Analytics recommends calibration every 6 months. Environmental factors such as temperature, humidity, and pressure can affect accuracy. Consider these factors when establishing a maintenance program .

Allow the sensor to operate for 12 hours with the enclosure sealed prior to testing the sensors. This will give the sensor time to reach thermal equilibrium to the external and internal temperatures while in operation. Because sensors are normally located at a distance from the main 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 each sensor to a small amount of the gas that is being monitored.

The second person stays at the control unit to determine that each sensor, when exposed to the gas fumes, is connected to the proper input and responds, causing appropriate alarm functions.

• Green “Power” LED continuous ON

• Both Fault LED’s are OFF

• Green “source” LED is blinking once every

2 seconds

NOTE: For cold/humid adverse environmental conditions

the “ATMOS” LED may be turning on and off periodically. In addition, the “system” LED may be blinking or continuous ON, also described in later sections.

Manning AirScan-iR Refrigerant Sensor 18908 AirScan-iR-comm

Figure 3: Required LED Status at Start-up

LED

POWER

SYSTEM

CALIBRATE

FAULT

mA FAULT

SOURCE

ATMOS

WITH OUTPUT

FILTERING

OFF

ON PERIODICALLY

WITHOUT OUTPUT

FILTERING

OFF

ON PERIODICALLY

3 Operation continued

Draw

B Pushbutton Operation,

LED Indicators, Adjustment Pots and Test Points

The AirScanTMiR has two internal pushbuttons, and two adjustment pots that are utilized for navigation of test functions, calibrations, and operating modes. In addition, a pair of test points is also provided that assist in the connection to standard meter leads for use in the upcoming calibration and diagnostic procedures (see Figure 4).

Figure 4: Board Component Layout

Serial PortICSP Programming Port

Zero Adjust

Span Adjust

Note 1: Checking voltage to sensor at +24 and GND

VDC

Black-Red

Note 2: Reading signal at TEST+ and TEST-

40-200

mVDC

JP1

TEST +

TEST -

ZERO

SPAN

SIG

+24

GND

SHLD

Pushbutton S2

JP3

Chamber

Draw

Rx LEDPushbutton S1

Tx LED

JP2

CALIBRATE

mA FAULT

IR SOURCE

POWER

SYSTEM

FAULT

ATMOS ACTIVE

“Zero” adjustment pot – adjusts output calibration

•

of the 4 mA nominal resting point

• “Span” adjustment pot – adjusts the 20 mA

concentration level or unit span/sensitivity.

• Pushbutton S1 – used to initiate the auto-zero

unction, program the 4 mA output calibration,

and initiate the 4/20 mA loop test.

• Pushbutton S2 – used to program the span setting.

• Test(+) and Test(–) for connection to a DC Volt

ter (see Figure 4, Note 2)

IMPORTANT: The pushbutton(s) must be pressed the

correct number of times and at the correct rate.

• When a multi-press sequence must be performed, the button must be pressed rapidly and evenly, lifting one’s finger completely from the actuator for each consecutive press.

• For press and hold activations, one’s finger must always be applying a down pressure withou

ruption for the sp

dis

ecified time in order to

activate the desired mode.

•

See complete details of each operation in other parts of the manual.

The AirScan

iR also has a group of LED’s (see Figure 5) that blink in specific sequences (see Figure 6 on next page) to indicate sensor operation and programming modes. A summary of sensor operation and programming modes with corresponding LED blink sequences is shown in Figure 7 on page 10.

Figure 5: LED Layout

Chamber

POWER

Black-Red

nning AirScan-iR Refrigerant Sensor 18908 AirScan-iR-comm 8

Tubing to calibration point

SYSTEM

CALIBRATE

FAULT

mA FAULT

IR SOURCE

ATMOS ACTIVE

+ 16 hidden pages