NetSafety UNI-TRAN P-SIR100-BV Premium IR Gas Transmitter Manuals & Guides

MODEL: Premium
UNI-TRAN-P-SIR100-BV
INFRARED GAS TRANSMITTER
Part Number: MAN-0030-00 Rev 1
Copyright © 2003 Net Safety Monitoring Inc. Printed in Canada
This manual is provided for informational purposes only. Although the information contained in this manual is believed to be accurate, it could include technical inaccuracies or typographical errors. Changes are, therefore, periodically made to the information within this document and incorporated without notice into subsequent revisions of the manual. Net Safety Monitoring Inc. assumes no responsibility for any errors that may be contained within this manual.
This manual is a guide for the use of a Infrared Combustible Gas Detector and the data and procedures contained within this document have been verified and are believed to be adequate for the intended use of the detector. If the detector or procedures are used for purposes other than as described in the manual without receiving prior confirmation of validity or suitability, Net Safety Monitoring Inc. does not guarantee the results and assumes no obligation or liability.
No part of this manual may be copied, disseminated or distributed without the express written consent of Net Safety Monitoring Inc.
Net Safety Monitoring Inc. products, are carefully designed and manufactured from high quality components and can be expected to provide many years of trouble free service. Each product is thoroughly tested, inspected and calibrated prior to shipment. Failures can occur which are beyond the control of the manufacturer. Failures can be minimized by adhering to the operating and maintenance instructions herein. Where the absolute greatest of reliability is required, redundancy should be designed into the system.
Net Safety Monitoring Inc. , warrants its sensors and detectors against defective parts and workmanship for a period of 24 months from date of purchase and other electronic assemblies for 36 months from date of purchase.
No other warranties or liability, expressed or implied, will be honoured by Net Safety Monitoring INC
Contact Net Safety Monitoring Inc. or an authorized distributor for details.
Table of Contents
Unit I - GENERAL INFORMATION
DESCRIPTION ..................................................................... 1
FEATURES ........................................................... 1
SPECIFICATIONS ...... ... ...... ...... ... ...... ... ...... ... ...... ...... ... ...... ... . 2
Unit II - SYSTEM INSTALLATION
INSTALLATION ..................................................................... 3
Location of Sensors ........................................................... 3
Figure 1 - Dimensions for Adalet Enclosure ................................. 3
Unpacking .................................................................. 3
Mounting .................................................................... 3
Wiring ...................................................................... 4
Sensor Separation ............................................................ 5
Initial LED Status ............................................................. 5
TERMINAL CONNECTIONS ........................................................... 7
Figure 2 - Uni-Tran Terminal Arrangements ........................................ 7
Figure 3 - Uni-Tran Terminal Connections for Non-Isolated current output . . . . . . . . . . . . . . . . . 7
Figure 4 - Uni-Tran Term inal Connections for Isolated Current outputs . . . . . . . . . . . . . . . . . . . . 7
Figure 5 - Uni-Tran Jumper setting for isolated current output . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 6 - Uni-Tran Jumper setting for non-isolated current output . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 7 - Uni-Tran Wiring with sensor separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Analog Output .............................................................. 10
Sensor Life ................................................................. 10
Test Jacks ................................................................. 10
Unit II - SYSTEM CALIBRATION
CALIBRATION ..................................................................... 10
Figure 8 - Magnet Reed Switch Activation ......................................... 11
SENSOR POISONS AND INHIBITORS ................................................. 12
Table 1 (Detector Responses) .................................................. 12
IMPORTANT INFORMATION
Appendix A ....................................................................... 14
Appendix B ....................................................................... 15
Unit I
GENERAL INFORMATION
DESCRIPTION
The UNI-TRAN-P-SIR100-BV is a sophisticated gas detector which is based on the absorption of infrared energy by a hydrocarbon gas. The sensor measures the amount of gas as a percentage of gas by volume (BV). The detector is composed of two components, the transmitter and the sensor. The components may be coupled as a whole device or more commonly separated for convenience. W hen separated, the sensor is mounted near the sample point and the transmitter is located (transmitter located at eye level for convenient use) up to 2000 feet away. The transmitter (Uni Tran) is a micro-controller based system which transfers information from the IR (Infrared) sensor to its LED display (four character alphanumeric that scrolls full text messages in several languages) and to a 4-20mA current output. The digital infrared combustible gas sensor (SIR-100) detects the hydrocarbon gas and transmits the data to the Unitran for display and control.
For accurate performance, UNI-TRAN-P-SIR100-BV must be set-up and calibrated to the specific gas specie of concern. The concentration of gas corresponding to 100% v/v is converted to a linear 4 to 20mA output signal which can be powered by an isolated external supply or from the primary DC supply to the instrument.
Calibration is automatic after manual initiation. The operator begins the calibration sequence by magnetic activation of the reed switch or by pressing the internal push-button and is then guided by text-based instructions and current loop signals to apply clean air then 50% of span calibration gas while Uni-Tran automatically sets zero and span. The entire procedure requires about three minutes to complete. If the procedure is not followed correctly then the program automatically returns to normal operation using the previous calibration data and the failure is indicated by LED readout.
FEATURES
< Full text, alphanumeric LED display. < Non-intrusive simplified one-person calibration. < No manual adjustments. < Explosion-proof housing with viewing window. < Selectable Isolated or Non-isolated Current Output (4-20mA) < Wide operating voltage range. 10.5 to 32Vdc. < Temperature compensation circuitry. < 0 to 20 mA analog output.
1
SPECIFICATIONS
< Operating Voltage:
10.5 to 32Vdc measured at the transmitter terminals with sensor and current loop active.
< Power Consumption:
2.8 Watts nominal, 78mA nominal
3.4 Watts maximum, 110mA maximum
< Operating Temperature:
<Range of Detection:
< Accuracy:
< Response Time to 90% (100% applied):
< Response Time to typical low alarm (100% GAS applied):
< Current Output:
< Linearity:
< Repeatability:
ooo o
-40 C to +75 C (-40 F to +167 F).
0 to 100% of methane or propane.
+ 3% or better.
< 30 seconds.
3 seconds
4 to 20 mA into a maxim um loop impedance of 800 O hm s at 32Vdc. 4 to 20 mA into a maxim um loop impedance of 150 O hm s at 10.5Vdc. Term inals for isolated or non-isolated loop supply.
+ 3%
+ 2%
< Zero Drift:
< 1% per month.
< Dimensions:
Refer to Figure 1.
< Weight:
Window enclosure 5.28 pounds (2.4 kilograms).
< Approvals and Certifications:
CSA and NRTL/C & Nema 4X certified for hazardous locations, Class 1, Division 1, Groups B, C and D .
< Warranty:
3 years on electronics and sensor
2
Figure 1 - Dimensions for Adalet Enclosure
Unit II
SYSTEM INSTALLATION
INSTALLATION
Location of Sensors
This is governed by convenience and proximity to the sample.
Unpacking
The UNI-TRAN-P-SIR100-BV is made up of two primary components. T he housing and terminal board are a single assembly to which the sensor is wired. The control module is a separate plug-in assembly. Since all modern electronic equipment can be damaged by static electricity discharge it is important to take precautions. Discharge static electricity from your body by touching a grounded metal object before handling the module. Loosen the retaining screws, then remove the module carefully from the housing by grasping the centre (pull) knob and pull straight away, then temporarily store it in a clean and safe place until field wiring is connected to the terminal strip located in the base of the housing.
Mounting
The housing should be oriented so that the sensor is on the under-side of the housing. Use a conduit seal and conduit loop or trap on the field wiring side to prevent water or condensation from entering the housing through the conduit or its threaded connection.
3
Sample System
WARNING: Dangerous levels of gas may be present in the sample. Take precautions to avoid personnel injury.
The UNI-TRAN-P-SIR100-BV comes equipped with a gas sample system. Surrounding the SIR 100 sensor is a metal cell which sample gas flows through. Connected to the cell are gas sample and gas vent ports. The sample port
1
( / " Swagelock Stainless Steel fitting) is located on the side of the sample chamber. The vent port ( / " Swagelock
42
®
Stainless Steel fitting) is located on the bottom of the sample chamber. Plumb tubing from the sample port to an appropriate location in the process. Plumb tubing from the vent port to atmosphere (there can be no pressure within the sample system). Leak check all tubing with an appropriate leak detection fluid (Snoop).
Wiring
NOTE
The control module (CPU board and Display Board) with cable should never be totally removed from the Relay board and housing. If it is removed there are bright red alignment markings on the cable and on the Relay board for you to use when re-inserting the cable into the Relay Board connector.
NOTE
Since all modern electronic equipment can be damaged by static electricity discharge it is important to discharge static electricity from your body by touching a grounded metal object before handling the module.
Refer to figure 3 and 4
The transmitter is made up of two assemblies. The enclosure / relay board are a single assembly to which the input is wired. The control module (CPU board and Display Board) is a separate assembly. To conduct wiring unscrew the two retaining screws from the front of the display board. (The control module is attached to the relay board by a cable. Do not detach the cable during wiring). Detach the module from the housing by grasping the centre (Pull Here) knob and pull straight away. Gently hang the module from the cable while you conduct wiring.
NOTE:
The wiring procedures in this manual are intended to ensure proper functioning of the device under normal conditions. However, because of the many variations in wiring codes and regulations, total compliance to these ordinances cannot be guaranteed. Be certain that all wiring complies with applicable regulations that relate to the installation of electrical equipment in a hazardous area. If in doubt, consult a qualified official before wiring the system.
The use of shielded cable is highly recommended for any signal wires to protect against interference caused by extraneous electrical “noise”. This includes power and current outputs; relay outputs do not require shielded cable. In applications where the wiring cable is installed in conduit, the conduit must not be used for wiring to other electrical equipment.
The maximum distance between the sensor and controller is limited by the resistance of the connecting wiring, which is a function of the gauge of the wire being used. Refer to the manuals on the sensors used (and transmitters if used) for maximum wiring distances and wiring instructions.
4
NOTE:
The controller contains semiconductor devices that are susceptible to damage by electrostatic discharge. An electrostatic charge can build up on the skin and discharge when an object is touched. Therefore, use caution when handling, taking care not to touch the terminals or electronic components. For more information on proper handling, refer to Appendix A.
Water-proof and explosion-proof conduit seals are recommended to prevent water accumulation within the enclosure. Seals should be located as close to the device as possible and not more than 18 inches (46 cm) away. Explosion-proof installations may require an additional seal where conduit enters a non-hazardous area. Always conform to local wiring codes.
When pouring a seal, use a fibre dam to assure proper formation of the seal. The seals should never be poured at temperatures below freezing.
The jacket and shielding of the cable should be stripped back to permit the seal to form around the individual wires. This will prevent air, gas and water leakage through the inside of the shield and into the enclosure.
It is recommended that explosion-proof conduit drains and breathers be used. In some applications, alternate changes in temperature and barometric pressure can cause 'breathing' which allows moist air to enter and circulate inside the conduit. Joints in the conduit system are seldom tight enough to prevent this 'breathing'.
Refer to applicable wiring codes when installing and wiring. After the field wiring has been carefully connected, check that the correct wires are connected to the corresponding terminals and that voltage levels do not exceed the specifications. When the wiring and voltages have been verified remove power form the system. Set the Display board back in place and tighten the two retaining screws.
It is necessary that reliable monitoring and indicating devices or systems be connected to the transmitter. These devices must be designed to produce clear visual and audible danger signals when high signal levels occur. Operating personnel must consider the area to be dangerous until a careful survey of the area has been conducted with a separate and reliable gas indicating device.
NOTE If the 4-20 mA signal is not used, connect a jumper between the 4-20 terminal and the Common terminal.
Sensor Separation
The SIR100-BV sensor can be installed and wired directly to the Uni-Tran housing and terminal board as per the wiring diagram or it may be remotely mounted using a sensor separation kit (CB4) which is composed of a junction box and terminal strips. The wiring includes two wires for power and two for the digital signal. The sensor and kit are then connected to the Uni-Tran. Use two individually shielded pairs of 18AWG, shielded copper instrument wire for separations up to 2000 feet. Consult factory if greater separations are required (See figure 7).
Initial LED Status
With power applied, check that the green POWER LED is ON and the FAULT/ CAL LED is showing a slow red flash during the first 90 seconds which will then change to a short green flash every two seconds (confidence blip). During the first 90 seconds the analog output will be at 3.0 mA and then change to
4.0mA. If after the 90 seconds warm-up the current is at 2.5mA or any value other than 4.0mA then the sensor requires calibration and the calibration procedure must be initiated. Observation of the LED status
5
signals and output current levels aid the operator when calibrating the sensor/transmitter as described below under CALIBRATION.
The Premium version with alphanumeric display provides a variety of English language(other languages available) commands scrolled across the display to supplement the LED sequences and aid the operator. Please refer to the following list and see Table of Responses.
START DELAY: power up delay in progress SWITCH ON: magnetic reed switch is activated SENSOR FAULT: fault present, sensor or sensor wiring failure SETTING ZERO: calibration zero gas setting in progress APPLY 50% : apply 50% of full span calibration gas SETTING SPAN: span gas detected, automatic span setting in progress REMOVE GAS: remove calibration gas FAIL CAL: calibration span setting failed TIME-OUT: calibration failed, no gas detected in calibration SENSOR FAIL: sensor or sensor connections failed NEG DRIFT: excessive negative sensor drift
6
7
JUMPER LOCATION FOR NON-ISOLATED/ISOLATED CURRENT OUTPUT
The UNI-TRAN Premium models are capable of providing an isolated current output. A jumper must be moved to select between isolated, or non-isolated current output on the terminal board.
UNI-TRAN REMOTE MOUNTING USING SENSOR SEPARATION
Figure 5 - Jumper Setting for
Isolated Current Output
( Premium)
Figure 6 - Jumper Setting for Non-Isolated Current Output
( Premium)
8
Figure 7 - Wiring with Sensor Separation
9
ANALOG OUTPUT
The analog output is precisely controlled by the internal micro-controller and digital-to-analog converter. The standard 4 to 20mA signal is proportional to gas concentration of 0 to 100% v/v. Additional stepped levels below 4mA provides various diagnostic signals.
SENSOR LIFE
Sensor life of the SIR100 can be expected to exceed 5 years.
Sensor response may deteriorate very slowly over a period of years, depending on exposure to environmental factors. If calibration becomes impossible for any reason, the analog output will switch repeatedly between 3.0mA and 3.3mA mA. The status LED flashes red/green. Install a new SIR100-BV sensor and re-calibrate. The calibration function automatically adjusts span amplifier gain across a broad range without any need for manual adjustment of potentiometers or jumpers.
TEST JACKS
The UNI-TRAN-P-SIR100-BV is equipped with test jacks to facilitate convenient current loop measurements without opening the external current loop. To make measurements use the following procedure;
1. Attach the current meter leads to the test jacks.
2. Apply test gas and take meter readings. Set external controller to Bypass if necessary to avoid unwanted alarm response.
3. Remove meter leads from test jacks.
NOTE: The UNI-TRAN-SIR100-BV's 4 to 20 mA current output must be connected to a load
device in order to facilitate the use of the test jacks (ie. 100 Ohm resistor must be connected between the 4 to 20mA signal output and the common terminal if the unit is being bench tested prior to field installation).
UNIT III
SYSTEM CALIBRATION
CALIBRATION
CAUTION: FOR SAFETY REASONS THIS EQUIPMENT MUST BE OPERATED AND
SERVICED BY QUALIFIED PERSONNEL ONLY. READ AND UNDERSTAND THE INSTRUCTION MANUAL COMPLETELY BEFORE OPERATING OR SERVICING.
The UNI-TRAN-P-SIR100-BV was calibrated before shipping from the factory and may not require adjustment, however, accurate response to gas must be verified prior to using the device in service.
When used with an external Net Safety controller/monitor it may not be necessary to calibrate the UNI­TRAN analog output since system calibration can be accomplished at the controller which accepts and adjusts to a range of deviations in a nominal 4 to 20mA signal.
10
System response should be checked on a 3 to 6 month interval and if necessary calibration can be performed.
If it is necessary to calibrate the UNI-TRAN-P- SIR100-BV or if it is used as a stand-alone device connected to other monitoring equipment requiring a precise 4 to 20 mA signal then the following calibration procedure should be followed to ensure an accurate correlation between the 4 to 20 mA signal and the gas concentration at the sensor.
CALIBRATION PROCEDURE (use 50% v/v Methane balanced with nitrogen, certified calibration gas).
The Uni-Tran Premium gives exact Calibration instructions which are scrolled across a bright LED alphanumeric display.
During Calibration, the Uni-Tran Premium tells you:
# Setting Zero (3mA output current level) # Apply 50% (3.3mA output current level) # Setting Span (3.3mA output current level) # Cal Complete (3.6mA output current level) When sensor response level falls
to about 12% (6.0mA), the output current is restored to normal operation)
< Be sure the UNI-TRAN-P-SIR100-BV is powered-up and is not indicating a fault; FAULT/CAL
LED is showing a short green flash every 2.0 seconds (Confidence blip).
WARNING: Dangerous levels of gas may be present in the sample. Take precautions to avoid personnel injury.
< Block in the sample port from the process.
< Flow zero air (2-3Litres/minute) through the
sample system tubing to clean it out.
< Place the curved side of the magnet on the side of
the enclosure at the 10 O’clock position (Fig 8) where marked (Orient the “cylinder”
shape of the magnet perpendicular to the “cylinder” shape of the housing) to actuate the
reed switch or press the internal Reset switch and hold it there for 10 seconds to begin the CALIBRATION sequence. The output current will drop to 3.0mA, the FAULT/CAL LED will be GREEN steady. Remove the magnet or release the Reset switch and the micro-controller immediately begins its calibration sequence. When zero readings are complete the output current rises to 3.3mA and the LED will flash fast RED to indicate readiness to start the flow of Calibration gas.
11
< At 3.3mA and a fast RED flash rate, begin flowing 50% span of the correct calibration gas (span
gas) at 2.0 to 3.0 litres per minute through the sample system tubing. Within 3 minutes the FAULT/CAL LED stops flashing and is steady green. The output current rises to 3.6mA indicating the micro-controller has completed setting the current output level to 12mA representing 50% for the applied span gas.
< When the status LED is solid green and the analog output switches to 3.6 mA span setting is
complete. Stop the flow of calibration gas. When the sensor response level falls to 12% (6.0mA), the output current is restored to normal operation and the LED is returned to it normal confidence blip; fast red flash every two(2) seconds changing to fast green when sensor response returns to zero (4mA).
< Flow zero air (2-3Litres/minute) through the sample system tubing to clean it out.
< Open up the sample system to the process.
NOTE:
If calibration becomes impossible for any reason, the analog output will switch repeatedly between 3.0mA and 3.3mA.
SENSOR POISONS and INHIBITORS
Conventional catalytic sensor systems must be re-calibrated whenever the sensor is exposed to gas concentrations in excess of 100% LEL due to damage that can be caused by the high concentration of gas. The UNI-TRAN-P SIR100 BV is resistant to this type of damage even when exposed repeatedly to high concentrations of combustible gas.
All catalytic LEL sensors require oxygen to be present in order to respond. The Net Safety SIR100-BV digital infrared sensor does not require oxygen to detect combustible gas.
TABLE 1 Detector Responses
CONDITION Current O/P (mA) Status LED
RED
Start-up delay 3 Slow Flash START DELAY
Excess drift (>10%) 2.5 Blip/ blink NEG DRIFT
Auto Zero set 3 Solid SETTING ZERO
Apply calibration gas 3.3 Fast Flash APPLY 50%
Span is set, remove gas 3.6 Solid REMOVE GAS
Return to normal operation 3.6 Solid CAL COMPLETE
Normal 4 Blip/ blink 00%
Status LED
GREEN
Alphanumeric display
Premium model
12
Gas Present 4.4 - 20.0 Blip/ blink 00% to 100%
Calibration Failed Current output
toggles between
3.0mA & 3.3mA
Flashes
between Red &
Green
Solid FAIL CAL
13
Appendix A
Net Safety Monitoring Inc.
Electrostatic Sensitive Device Handling Procedure
With the trend toward increasingly widespread use of microprocessors and a wide variety of other electrostatic sensitive semiconductor devices, the need for careful handling of equipment containing these devices deserves more attention than it has received in the past.
Electrostatic damage can occur in several ways. The most familiar is by physical contact. Touching an object causes a discharge of electrostatic energy that has built up on the skin. If the charge is of sufficient magnitude, a spark will also be visible. This voltage is often more than enough to damage some electronic components. Some devices can be damaged without any physical contact. Exposure to an electric field can cause damage if the electric field exceeds the dielectric breakdown voltage of the capacitive elements within the device.
In some cases, permanent damage is instantaneous and an immediate malfunction is realized. Often, however, the symptoms are not immediately observed. Performance may be marginal or even seemingly normal for an indefinite period of time, followed by a sudden and mysterious failure.
Damage caused by electrostatic discharge can be virtually eliminated if the equipment is handled only in a static safeguarded work area and if it is transported in a package or container that will render the necessary protection against static electricity. Net Safety Monitoring Inc. modules that might be damaged by static electricity are carefully wrapped in a static protective material before being packaged. Foam packaging blocks are also treated with an anti-static agent. If it should ever become necessary to return the module, it is highly recommended that it be carefully packaged in the original carton and static protective wrapping.
Since a static safeguarded work area is usually impractical in most field installations, caution should be exercised to handle the module by its metal shields, taking care not to touch electronic components or terminals.
In general, always exercise all of the accepted and proven precautions that are normally observed when handling electrostatic sensitive devices.
A warning label is placed on the packaging, identifying those units that use electrostatic sensitive semiconductor devices.
*Published in Accordance with E1A
standard 471
14
Appendix B Wire Resistance In Ohms
Distance (Feet) AWG #20
100 1.02 0.64 0.40 0.25 0.16 0.10 0.06
200 2.03 1.28 0.08 0.51 0.32 0.20 0.13
300 3.05 1.92 1.20 0.76 0.48 0.30 0.19
400 4.06 2.55 1.61 1.01 0.64 0.40 0.25
500 5.08 3.20 2.01 1.26 0.79 0.50 0.31
600 6.09 3.83 2.41 1.52 0.95 0.60 0.38
700 7.11 4.47 2.81 1.77 1.11 0.70 0.44
800 8.12 5.11 3.21 2.02 1.27 0.80 0.50
900 9.14 5.75 3.61 2.27 1.43 0.90 0.57
1000 10.20 6.39 4.02 2.53 1.59 1.09 0.63
1250 12.70 7.99 5.03 3.16 1.99 1.25 0.79
1500 15.20 9.58 6.02 3.79 2.38 1.50 0.94
1750 17.80 11.20 7.03 4.42 2.78 1.75 1.10
2000 20.30 12.80 8.03 5.05 3.18 2.00 1.26
AWG
#18
AWG
#16
AWG
#14
AWG #12 AWG #10 AWG #8
2250 22.80 14.40 9.03 5.68 3.57 2.25 1.41
2500 25.40 16.00 10.00 6.31 3.97 2.50 1.57
3000 30.50 19.20 12.00 7.58 4.76 3.00 1.88
3500 35.50 22.40 14.10 8.84 5.56 3.50 2.21
4000 40.60 25.50 16.10 10.00 6.35 4.00 2.51
4500 45.70 28.70 18.10 11.40 7.15 4.50 2.82
5000 50.10 32.00 20.10 12.60 7.94 5.00 3.14
5500 55.80 35.10 22.10 13.91 8.73 5.50 3.46
6000 61.00 38.30 24.10 15.20 9.53 6.00 3.77
6500 66.00 41.50 26.10 16.40 10.30 6.50 4.08
7000 71.10 44.70 28.10 17.70 11.10 7.00 4.40
7500 76.10 47.90 30.10 19.00 12.00 7.49 4.71
8000 81.20 51.10 23.10 20.20 12.70 7.99 5.03
9000 91.40 57.50 36.10 22.70 14.30 8.99 5.65
10 000 102.00 63.90 40.20 25.30 15.90 9.99 6.28
NOTE: RESISTANCE SHOWN IS ONE WAY. THIS FIGURE SHOULD BE DOUBLED WHEN DETERMINING CLOSED LOOP RESISTANCE.
15
2721 Hopewell Place NE Calgary, Alberta, Canada, T1Y 7J7 Telephone: (403) 219-0688 Fax: (403) 219-0694
www.net-safety.com
E-mail: netsafe@netsafety.com
DISTRIBUTED BY:
Loading...