Oldham iTrans 2 Installation And Operation Manual
FIXED POINT
SINGLE OR DUAL GAS MONITOR WITH
DUAL ANALOG OUTPUTS
Installation • Operation • Wiring • Troubleshooting
Part Number: 77036429-EN
Version: 01
Release Date: June 29, 2013
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© 2013 Industrial Scientific - Oldham. All rights reserved.
is a trademark of Industrial Scientific - Oldham.
ModBus® is a registered trademark of Schneider Automation Inc.
ModBus® protocol™ is a trademark of Schneider Automation Inc.
All other trademarks and registered trademarks are the property of their
respective owners.
Although every effort is made to ensure accuracy, the specifications of this
product and the content herein are subject to change without notice.
Industrial Scientific - Oldham
1001 Oakdale Road
Oakdale, PA 15071-1500
USA
Tel: +1 412-788-4353
Toll Free: 1-800-DETECTS (1-800-338-3287)
Fax: +1 412-788-8353
Service: 1-888-788-4353
Web: www.oldhamgas.com
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Warnings and Cautionary Statements
CAUTION: Failure to perform certain procedures or note certain conditions
may impair the performance of the monitor. For maximum safety and
performance, please read and follow the procedures and conditions outlined
below.
Oxygen deficient atmospheres may cause combustible gas readings
that use catalytic LEL sensors to be lower than actual concentrations.
Oxygen enriched atmospheres may cause combustible gas readings
that use catalytic LEL sensors to be higher than actual concentrations.
Calibrate the catalytic combustible gas sensor after each incident where
the combustible gas content causes the instrument to enter in the
OVER-RANGE alarm condition.
The catalytic and IR sensors are factory configured to accurately
monitor the gas for which they are designated. It should be noted,
however, that the LEL sensors WILL respond to other combustible
gases and are not gas-specific.
Silicone compound vapors may affect the catalytic combustible gas
sensor and cause readings of combustible gas to be lower than actual
gas concentrations. If the sensor has been used in an area where
silicone vapors were present, always calibrate the instrument before
continued use to ensure accurate measurements.
Sensor openings must be kept clean. Obstruction of the sensor
openings may cause readings to be lower than actual gas
concentrations.
Sudden changes in atmospheric pressure may cause temporary
fluctuations in the oxygen readings.
Alarms relays are non-latching.
When connecting 4-20 mA outputs to inductive loads, Industrial
Scientific - Oldham recommends using an isolation barrier in line with
the 4-20 mA signal.
Interior grounding terminal is to be used for grounding, the exterior
terminal is only to be used for bonding.
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FOR IR SENSORS:
The output of the IR sensors can be disrupted by sudden changes in
temperature. If there is an excessive change in the ambient
temperatures, gas sample temperature or flow rate, then the output
signal will be momentarily frozen. Correct operation is restored when
the effects of the transient have settled. Rates of change in the ambient
temperature should be restricted to 2 °C/minute and gas flow rates kept
below 0.6 L/minute.
Extreme pressure variations will cause errors in readings. The unit
should be recalibrated if the atmospheric pressure change is greater
than 10% from the original pressure.
Do not expose the sensor to corrosive gases such as Hydrogen
Sulphide.
Do not allow condensation to occur inside the sensor.
CALIBRATION ALERT: Gas detection instruments are potential life-saving
devices. Recognizing this fact, calibration for the toxic and catalytic LEL
sensors should be at least at quarterly intervals, while the infrared sensor
should be calibrated on an annual basis with function test every 6 months.
Further, Industrial Scientific - Oldham recommends prudent testing and/or
includes calibration after a gas alarm. All calibration service to sensors
should be recorded and accessible.
CAUTION: For safety reasons, this equipment must be operated and
serviced by qualified personnel only.
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Our Mission
Preserving human life: on, above and below the earth.
Delivering highest quality, best customer service…
every transaction, every time.
In practical terms, that means developing both portable instruments and
fixed-point systems for detecting, measuring and monitoring a wide variety
of gases, including toxic and combustible gases, as well as oxygen.
From research and development through final manufacturing, we never
forget that human lives depend on what we do. Workers all over the world
enter confined spaces, face the risk of asphyxiation, poisoning or explosion,
and depend on our instruments to ensure their safety. That's why every one
of our products is designed and manufactured with just one question in
mind:
“Would you bet your life on it?”
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Contents
Chapter 1 | Overview ............................................................ 11
Overview of the Gas Monitor .................................................. 11
Specifications .......................................................................................... 12
Agency Approvals - CSA ......................................................................... 14
Chapter 2 | Hardware Overview ........................................... 15
Main Electronics Unit (Housing) .............................................................. 15
Sensor ..................................................................................................... 16
Display ..................................................................................................... 16
Inputs – Intrusive and Non-Intrusive ........................................................ 17
Electronics Modules ................................................................................ 18
Chapter 3 | Installation ......................................................... 21
Introduction .............................................................................................. 21
Installation Considerations ...................................................................... 21
Wall Mounting .......................................................................................... 21
Column Mounting .................................................................................... 21
Chapter 4 | System Wiring ................................................... 23
Introduction .............................................................................................. 23
Wiring Preparation ................................................................................... 23
Alarm Relay Wiring (J1, J5, and J6) ........................................................ 24
Power and Output Wiring (J1) ................................................................. 25
Sensor Wiring (J3) ................................................................................... 26
Digital ModBus RTU Interface Wiring (J1) .............................................. 32
Wiring Conclusion .................................................................................... 36
Chapter 5 | Operation ........................................................... 37
Initial Start-up .......................................................................................... 37
Warm-up Period ...................................................................................... 37
Normal Operating Mode .......................................................................... 37
Programming Mode Overview ................................................................. 39
Programming Mode – Non-intrusive Operation ....................................... 40
Programming Mode – Push Button Operation ........................................ 44
Chapter 6 | Modbus Interface .............................................. 53
Introduction .............................................................................................. 53
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Sample Gas Reading via ModBus Network ............................................ 54
ModBus Register List ............................................................................... 54
ModBus Resources ................................................................................. 59
Termination .............................................................................................. 59
Chapter 7 | Maintenance ...................................................... 61
Introduction .............................................................................................. 61
Sensor Replacement ............................................................................... 62
Zero and Calibration ................................................................................ 62
Chapter 8 | Troubleshooting ............................................... 63
Introduction .............................................................................................. 63
Diagnosing Common Problems ............................................................... 63
Fault Codes .............................................................................................. 64
Function Codes ........................................................................................ 64
Chapter 9 | Warranty ............................................................ 67
Warranty .................................................................................................. 67
Limitation of Liability ................................................................................ 67
Appendix A | HART Interface .................................................. 69
Introduction .............................................................................................. 69
Hardware Overview ................................................................................. 70
Installation ................................................................................................ 71
System Wiring .......................................................................................... 71
Operation ................................................................................................. 76
HART Interface ........................................................................................ 79
User Commands ...................................................................................... 81
Appendix B | Acronyms and Abbreviations .......................... 87
Appendix C | Decimal, Binary, And Hex Equivalents ............ 91
Appendix D | Ordering Matrix ................................................. 95
Appendix E | Factory Default Settings ................................... 99
Appendix F | Infrared Sensors ............................................. 101
Appendix G | LEL Correlation Factors ................................. 103
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Chapter 1 | Overview
Overview of the Gas Monitor
The fixed gas monitor is an
independent monitor capable of
displaying one or two gas
concentrations as well as sensor or
instrument specific diagnostics.
The comes standard with
independent 4-20 mA outputs for
each channel, making it ideal for
interfacing to control units. A digital
ModBus RTU interface is also
available, allowing the to
interface to digital control systems.
The is available with an
optional relay board, allowing the
unit to directly control external
devices such as fans, pumps, alarm
horns, or warning lights. Two of the
relays can be programmed for alarm
activation, while the third relay is a
fault protection relay. Calibration,
changing span gas concentration,
and checking the instrument’s
configuration are easily
accomplished using the nonintrusive magnetic wand.
The is powered with a 24
VDC (12-28 VDC) power supply and
provides a 4-20 mA control signal
for each sensor.
Figure 1-1 Typical Gas Monitor
with Single Gas Sensor (Stainless Steel
Option)
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Specifications
Item
Description
Enclosure
Cast aluminum, poly-bonded coating or 316 stainless steel. Both are
explosion-proof, NEMA 4X, IP66 rated.
Dimensions
5.0 × 6.0 × 5.0 inches (127 x 153 x 129 mm)
Sensors
Combustible Gases: Catalytic bead and/or Non-Dispersive Infrared
(NDIR) Oxygen/Toxic Gases: Electrochemical diffusion
Input Voltage
12-28 VDC operating range (24 VDC typical)
Input Current
(Max)
Toxic Gas/Oxygen
150 mA@24 VDC (single gas)
200 mA@24 VDC (single gas + HART)
Combustible
Gases (Catalytic)
250 mA@24 VDC, 0.8 A peak (single gas)
300 mA@24 VDC, 0.8 A peak (single gas + HART)
Combustible
Gases (Infrared)
170 mA@24 VDC, 0.5 A peak (single gas)
220 mA@24 VDC, 0.5 A peak (single gas + HART)
Combined
Catalytic/Infrared
350 mA@24 VDC, 1.2 A peak (two gas)
400 mA@24 VDC, 1.2 A peak (two gas + HART)
Display
Dual-channel split-screen LED display (4-digit, 7-segment
arrangement per channel) provides simultaneous display of one or
two gases.
Signal
Outputs
Digital
ModBus RTU: RS485 digital communication
with ModBus RTU software protocol system
at 9600 baud. Three- or four-wire system
accommodates over 200 devices in bus
configuration. Address selection through
on-board 8-position DIP switch. NOTE:
ModBus is not to be used for CSA C22.2 No.
152 compliance.
Analog
4-20 mA (linear analog)
Alarm Relays
Quantity
3 alarm relays: Two user-programmable
relays, SPST, N.O.; plus one fault relay,
SPST, N.C.
Contact Capacity
5A @ 30 VDC
5A @ 30 VAC
Temperature
Range
-40 ºC ~ +75 ºC (-40 ºF ~ +167 ºF)
Humidity
Range
10% - 90% RH (non-condensing), typical
Pressure
Atmospheric pressure ±10%
Weight
2.9 Kg (6.4 lbs.)
Specifications for the gas monitor are listed in Table 1-1.
Table 1-1 Specifications for the Monitor
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Sensor
Gas
Range/Resolution
Combustible Gases
LEL
0 -100% LEL in 1% increments
Hydrogen
H2
0 - 999 ppm in 1 ppm increments
Oxygen
O2
0 - 30.0% by vol in 0.1% increments
Ammonia
NH3
0 - 200 ppm in 1 ppm increments
Carbon Monoxide
CO
0 - 999 ppm in 1 ppm increments
Carbon Monoxide/H2 Null
CO
0 - 999 ppm in 1 ppm increments
Hydrogen Sulfide
H2S
0 - 500 ppm in 1 ppm increments
Sulfur Dioxide
SO2
0.2 - 99.9 ppm in 0.1 ppm increments
Hydrogen Cyanide
HCN
0.2 – 30.0 ppm in 0.1 ppm increments
Hydrogen Chloride
HCl
0.2 - 30.0 ppm in 0.1 ppm increments
Phosphine
PH3
0 - 1.00 ppm in 0.01 ppm increments
Nitrogen Dioxide
NO2
0.2 - 99.9 ppm in 0.1 ppm increments
Nitric Oxide
NO
0 - 999 ppm in 1 ppm increments
Chlorine
Cl2
0.2 - 99.9 ppm in 0.1 ppm increments
Chlorine Dioxide
ClO2
0.02 - 1.00 ppm in 0.01 ppm increments
Methane (by Vol, IR)
CH4
0 – 100% Vol in 1% Vol increments
Methane (by LEL, IR)
CH4
0 – 100% LEL in 1% increments
Propane (IR)
C3H8
0 – 100% LEL in 1% increments
Propylene (IR)
C3H6
0 – 100% LEL in 1% increments
Pentane (IR)
C5H12
0 – 100% LEL in 1% increments
Butane (IR)
C4H10
0 – 100% LEL in 1% increments
Ethylene (IR)
C2H4
0 – 100% LEL in 1% increments
Ethanol (IR)
C2H6O
0 – 100% LEL in 1% increments
Hexane (IR)
C6H14
0 – 100% LEL in 1% increments
Carbon Dioxide (IR)
CO2
0 – 0.50% Vol in 0.01% increments
Carbon Dioxide (IR)
CO2
0 – 5.00% Vol in 0.01% increments
Carbon Dioxide (IR)
CO2
0 – 100% Vol in 1% Vol increments
Table 1-2 Sensor Ranges
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Agency Approvals - CSA
The is certified by CSA, a NRTL laboratory, to the following US and
Canadian Standards.
UL Std No. 916-Energy Management Equipment
UL Std No. 1203-Explosion-Proof and Dust-Ignition-Proof
o Electrical Equipment for Use in Hazardous (Classified) Locations
UL Std No. 1604-Division 2 Hazardous Location Electrical Equipment
ISA S12.13 Part I-2000-Performance Requirements, Combustible Gas
Detectors (iTrans 2 with catalytic sensors only)
CSA Std C22.2 No.30-M1986-Explosion-Proof Enclosures for Use in
Class I Hazardous Locations
CSA Std C22.2 No.142-M1987-Process Control Equipment
CSA Std C22.2 No. 152-M1984-Combustible Gas Detection
Instruments (iTrans 2 with catalytic sensors only)
CSA Std C22.2 No. 213-M1987-Non-incendive Electrical Equipment
for Use in Class I, Division 2 Hazardous Locations
# # #
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Chapter 2 | Hardware Overview
Main Electronics Unit (Housing)
The body is a cast aluminum housing that contains the electronics
of the gas monitor. Details of a single-gas housing are shown in Figure 2-1.
Figure 2-1 Details of a Single-Gas Gas Monitor
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Sensor
Item
Descriptions
Sensor Housing
Material
Aluminum, Anodized, Explosion-proof: Class I, Divisions 1 and 2
Groups B, C, D, and Ex d IICT6 Gb (China)
Aluminum, Anodized w/Gore-Tex Membrane (Division 2/Zone 2
toxics), Suitable for Class I, Division 2 Groups A, B, C, D
Dimensions
3.0 × 3.0 inches (76 × 76 mm)
Accuracy
< ± 3% Toxic and Oxygen
For Combustibles:
For test gas concentrations up to and including 50% of full scale,
the deviation shall not exceed ±3% of full scale gas
concentration.
For test gas concentrations above 50% of full scale, the deviation
shall not exceed ±5% of full scale gas concentration.
Protection Class
IP 66 or NEMA 4X
Table 2-1 Sensor Specifications
Display
The gas monitor has a 4-digit, 7-segment LED display for each of 2
channels. A dual-gas sensor and sample display are shown in
Figure 2-2.
Figure 2-2 The Display (Dual-Gas Monitor Shown)
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Inputs – Intrusive and Non-Intrusive
The gas monitor can be configured using intrusive and nonintrusive means. Both methods of configuration are accomplished through
physical inputs that are visible behind the glass panel of the gas monitor.
A set of four keys are used when intrusive programming is appropriate (i.e.,
when the enclosure can be removed and when the keys can be manually
pressed). These keys are the mode, increment (+), decrement (-), and enter
keys. Refer to Figure 2-3.
For applications that require non-intrusive manipulation, two magneticallyactivated reed switches are used to accomplish programming without
removing the cover. A magnetic wand is positioned over the appropriate
reed switch (above the glass face plate) without the wand physically
touching the reed switches. The locations of the reed switches are shown in
Figure 2-3.
Figure 2-3 Locations of Input Keys and Reed Switches
Programming the gas monitor in both intrusive and non-intrusive
modes is explained in detail in Chapter 5.
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Electronics Modules
The electronics module of the gas monitor contains connectors and
jumpers for wiring and configuring the device. The electronics module for a
main unit is shown in Figure 2-4. The electronics module for a
remote unit is shown in Figure 2-5. Wiring details are explained in Chapter 4
| System Wiring.
Figure 2-4 Electronics Module for (Main Unit)
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Figure 2-5 Electronics Board for Remote Sensor
# # #
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Chapter 3 | Installation
Introduction
The can be mounted in one of two ways. The unit can be wallmounted using the wall mounting holes in the enclosure, or it can be
mounted onto a column using U-bolts. Each of these options is discussed in
this chapter. Be sure to review the installation considerations before
mounting the gas monitor.
Installation Considerations
Regardless of the installation type (wall mounting or column mounting), the
should be installed at or near the location of a possible leak or the
source of emissions. Installation height depends on the density of the gas
being monitored. Moreover, speed and direction of air flow, and relative
position to potential leaking points should also be considered.
IMPORTANT: The gas monitor must not be installed on vibrating or
heat generating sources.
Wall Mounting
If your application is best addressed using a wall-mounted gas monitor,
then use the four 8 mm mounting holes in the enclosure to secure the
to an appropriate location on the wall. Refer to Figure 3-1.
Column Mounting
If your application is best addressed using a column-mounted gas monitor,
then use the four 8 mm mounting holes and two U-bolts to secure the
to an appropriately located segment of a target pipe or conduit.
Refer to Figure 3-2.
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Figure 3-1 Mounting the Gas Monitor on a Wall
Figure 3-2 Mounting the Gas Monitor on a Column Using U-Bolts
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Chapter 4 | System Wiring
Introduction
This chapter outlines the steps required for wiring the gas monitor.
These steps include the following:
Wiring Preparation
Sensor Wiring
Alarm Relay Wiring
Each of these steps is outlined in the sections that follow.
IMPORTANT: Perform all wiring in accordance with local electrical codes
and local authorities having jurisdiction.
Power and Output Wiring
ModBus Interface Wiring
IMPORTANT: DC signal and AC power should not be run in the same
conduit.
NOTE: All field wiring colors are arbitrary (unless provided by ISC).
Wiring Preparation
1. Collect the appropriate types and lengths of wire.
For control wire, use #18 AWG (0.9 mm²) insulated, shielded
cable.
For analog signal and power wire, use three-conductor (or four-
conductor for dual channel) #18 AWG (0.9 mm²) insulated and
shielded cable.
For digital ModBus signal and power, use a minimum of five-
conductor #18 AWG (0.9 mm²) insulated and shielded cable.
2. Power down the unit.
3. Unthread the windowed top from the housing.
4. Gently pull out the electronics module and place it safely to the side
of the unit.
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5. Thread control, signal, and power wires into the transmitter housing.
6. Shielding from either the controller or remote sensors should be
bonded to the enclosure screw located inside the .
IMPORTANT: Use of this product in areas where it may be subject to large
amounts of electromagnetic interference may affect the reliable operation of
this device and should be avoided.
WARNING: Supply wire with a minimum rating of 90°C must be used for
interconnection to the .
NOTE: For classified locations, a “poured” wire seal must be installed within
18 inches (457mm) of the main unit for both power entry and remote
sensors.
NOTE: Remove power from the before making any wiring
connections.
Alarm Relay Wiring (J1, J5, and J6)
To connect the control wires to the three relay terminals on the relay
board, wire the unit to the connectors shown in Figure 2-4. The low alarm
relay is activated when the low alarm threshold is met. This is a nonlatching, Normally Open (NO) contact. The high alarm relay is activated
when the high alarm threshold is met. This is a non-latching, Normally Open
(NO) contact. The fault alarm relay is activated upon power-up of the
. When the fault condition is met, the circuit opens. This is an
Electronically closed (NC) contact. See Figure 4-1 for relay wiring.
NOTE: It is recommended that on-board relays should not be used to drive
loads directly. On-board relays should be used to drive a secondary, higherpower relay which is connected to the control device (e.g., strobe, siren,
exhaust fan, etc.).
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Figure 4-1 Alarm Relay Connectors J6, J5 and J1
Power and Output Wiring (J1)
Connect the power and signal wires to the appropriate wiring
terminals as follows.
24 V: Connect 24 VDC (12-28 VDC) supply power
CH 1: Channel 1, 4-20 mA output signal
CH 2: Channel 2, 4-20 mA output signal
GND: DC return
Figure 4-2 Power and Signal Connector J1 on the
NOTE: Use supplied green conductor for enclosure ground. Public 485 GND
is to be used for ModBus digital ground.
NOTE: The is a 3- or 4-wire 4-20 mA device. For dual sensor
configuration you must have a second 4-20 mA signal wire pulled to the
unit.
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NOTE: When not using 4-20 mA outputs, use the supplied resistors to
connect CH-1 and CH-2 to GND. If these resistors are not connected and the
4-20 mA outputs are not used, a “P” will appear on the display, indicating an
open loop condition.
Sensor Wiring (J3)
Connect the sensor wires (for on-board, remote or stand-alone) to
the appropriate wiring terminals as follows.
24 V: Red wire from sensor head
485A: Yellow wire from sensor head
485B: Black wire from sensor head
GND: Green wire from sensor head
NOTE: Shielding from either the controller or remote sensors should be
bonded to the enclosure screw located inside the .
NOTE: The 24 V terminal supplies 24 VDC to the sensor for power. This
terminal should not be connected to the output of a 24 VDC power supply.
Figure 4-3 Sensor Connector J3 on the
NOTE: For dual-sensor configurations, place both of the same colored wires
in the appropriate terminal block and firmly tighten.
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NOTE: Use #18 AWG (0.9 mm²) shielded cable for remote sensors. Maximum
distance is 200 meters.
NOTE: When wiring remote sensors to the , “485 B” on J3 should be
connected to “B-” in the remote sensor enclosure, and “485 A” on J3 should
be connected to “A+” in the remote sensor enclosure.
NOTE: For remote or standalone sensors, there are four terminal blocks
located in the remote sensor housing. These terminal blocks are all tied
together and follow the same wiring scheme mentioned above.
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Figure 4-4 Wiring Diagram for a Single On-board Sensor
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J1
Figure 4-5 Wiring Diagram for a Remote Sensor (Stand Alone)
NOTE: When the remote sensor is at distances of 200 meters or further, and
the sensor is not communicating, the jumper J1 may need to be moved to
terminals 1-2.
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NOTE: If using remote sensors and the does not recognize the
sensor upon power up (displays a sensor fault), check the placement of this
jumper. If the jumper J1 is on terminals 1-2, move the jumper to terminals 2-
3.
For digital ModBus signal and power use a minimum of 4 conductors #18
AWG (0.9 mm²) insulated and shielded cable.
Shielding from either the controller or remote sensors should be bonded to
the enclosure screw located inside the .
Figure 4-6 Wiring Diagram for Dual On-board Sensors
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