Teledyne 1220 User Manual
Instruction Manual
Model 1220
Multi - Channel
Combustible
Monitor
DANGER
HIGHLY TOXIC AND OR FLAMMABLE LIQUIDS OR GASES MAY BE PRESENT IN THIS MONITORING
SYSTEM.
PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED WHEN SERVICING THIS SYSTEM.
HAZARDOUS VOLTAGES EXIST ON CERTAIN COMPONENTS INTERNALLY WHICH MAY PERSIST
FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED.
ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND/OR SERVICING. BEFORE
CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISOR/
MANAGER.
P/N M68325
ECO: #00-0203
05/25/2000
Teledyne Analytical Instruments
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Copyright © 1999 Teledyne Analytical Instruments
All Rights Reserved. No part of this manual may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any other language or computer
language in whole or in part, in any form or by any means, whether it be electronic,
mechanical, magnetic, optical, manual, or otherwise, without the prior written consent of
Teledyne Analytical Instruments, 16830 Chestnut Street, City of Industry, CA 91749-1580.
Warranty
This equipment is sold subject to the mutual agreement that it is warranted by us free
from defects of material and of construction, and that our liability shall be limited to
replacing or repairing at our factory (without charge, except for transportation), or at
customer plant at our option, any material or construction in which defects become
apparent within one year from the date of shipment, except in cases where quotations or
acknowledgments provide for a shorter period. Components manufactured by others bear
the warranty of their manufacturer. This warranty does not cover defects caused by wear,
accident, misuse, neglect or repairs other than those performed by Teledyne or an authorized service center. We assume no liability for direct or indirect damages of any kind and
the purchaser by the acceptance of the equipment will assume all liability for any damage
which may result from its use or misuse.
We reserve the right to employ any suitable material in the manufacture of our
apparatus, and to make any alterations in the dimensions, shape or weight of any parts, in
so far as such alterations do not adversely affect our warranty.
Important Notice
This instrument provides measurement readings to its user, and serves as a tool by
which valuable data can be gathered. The information provided by the instrument may
assist the user in eliminating potential hazards caused by his process; however, it is
essential that all personnel involved in the use of the instrument or its interface, with the
process being measured, be properly trained in the process itself, as well as all instrumentation related to it.
The safety of personnel is ultimately the responsibility of those who control process
conditions. While this instrument may be able to provide early warning of imminent danger,
it has no control over process conditions, and it can be misused. In particular, any alarm or
control systems installed must be tested and understood, both as to how they operate and
as to how they can be defeated. Any safeguards required such as locks, labels, or redundancy, must be provided by the user or specifically requested of Teledyne at the time the
order is placed.
Therefore, the purchaser must be aware of the hazardous process conditions. The
purchaser is responsible for the training of personnel, for providing hazard warning
methods and instrumentation per the appropriate standards, and for ensuring that hazard
warning devices and instrumentation are maintained and operated properly.
Teledyne Analytical Instruments (TAI), the manufacturer of this instrument,
cannot accept responsibility for conditions beyond its knowledge and control. No statement expressed or implied by this document or any information disseminated by the
manufacturer or its agents, is to be construed as a warranty of adequate safety control
under the user’s process conditions.
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Teledyne Analytical Instruments
Specific Model Information
The instrument for which this manual was supplied may incorporate
one or more options not supplied in the standard instrument. Commonly
available options are listed below, with check boxes. Any that are incorporated in the instrument for which this manual is supplied are indicated by a
check mark in the box.
Instrument Serial Number: _______________________
Options Included in the Instrument with the Above Serial Number:
Dual-Sensor
A second sensor PCB is installed to allow the Channel
Module(s) to monitor two sensors simultaneously.
Teledyne Analytical Instruments
iii
IMPORTANT NOTICE
The 1220 is a safety monitor. However, it is the responsibility of the
user to establish whether or not the total system of instrument, environment, alarm components, and any other relevant devices actually will
assure safety in his particular circumstances.
Location of the equipment and sensors to insure proper operation is
responsibility of the user.
The safety checklist outlined here should be treated only as a guide. It
is up to the user to establish practical safety precautions. It is vital that the
operator understand and test the operation of the total system.
Safety Checklist:
❑ Verify that the instrument is powered correctly.
❑ Verify that the instrument works (all functions).
❑ Verify that alarm indications give the intended results.
❑ Verify that unauthorized personnel cannot tamper with the
instrument or its auxiliary equipment.
iv
❑ Institute routine test/calibration procedures.
❑ Identify and handle any sampling or location problems.
❑ Provide all necessary warning labels and verify that the
labels are on the equipment.
❑ Train all operators to understand all operations and func-
tions of the analyzer and the system.
❑ Identify and handle any environmental or other influences
that could affect the operation of the instrument.
Teledyne Analytical Instruments
Table of Contents
Introduction
1.1 Overview........................................................................... 1-1
1.2 Description........................................................................ 1-1
1.2.1 System Chassis ............................................................ 1-2
1.2.2 Control Unit ................................................................... 1-2
1.2.3 Channel Modules .......................................................... 1-2
1.2.3.1 Main Featuress of the Channel Module............... 1-2
1.2.4 Detector......................................................................... 1-2
1.2.5 Terminal Strip Housing .................................................. 1-2
Operational Theory
2.1 Introduction .................................................................... 2-1
2.2 System Chassis ............................................................. 2-1
2.3 Control Unit .................................................................... 2-1
2.4 Channel Module............................................................. 2-3
2.5 Combustible Sensors..................................................... 2-3
2.5.1 Response of Combustibles to Various Gases .............. 2-7
Installation
3.1 Unpacking the Analyzer ................................................. 3-1
3.2 System Chassis ............................................................. 3-2
3.2.1 Location ................................................................ 3-2
3.2.2 Power .................................................................... 3-2
3.2.3 Electrical Connections .......................................... 3-2
3.3 Control Unit .................................................................... 3-5
3.3.1 ControlUnit Fuses........................................................ 3-5
3.3.2 Control Unit Jumper Settings ...................................... 3-6
3.4 Channel Modules ........................................................... 3-8
3.4.1 Removing the Channel Module Cover......................... 3-8
3.4.2 Changing the Fuse ...................................................... 3-8
3.4.3 Adding or Removing the Second Sensor PCB ............ 3-9
3.4.4 Configuring the Internal Jumper Connections ............. 3-9
3.5 Combustible Sensors................................................... 3-10
Operation
4.1 Introduction .................................................................... 4-1
4.2 Control Unit Operation ................................................... 4-2
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4.2.1 System Power Switch and LED ................................... 4-2
4.2.2 Audible Alarm Switch and Bypass LED....................... 4-2
4.2.3 Fuses .......................................................................... 4-2
4.2.4 RS485 Port.................................................................. 4-2
4.3 Channel Module Front Panel Controls & Indicators ....... 4-4
4.4 Calibration Procedures .................................................. 4-7
4.4.1 Zero Calibrating a Single Sensor Ch. Module ............. 4-7
4.4.2 Span Calibrating a Single Sensor Ch. Module ............ 4-8
4.4.3 Zero Calibrating a Dual Sensor Ch. Module................ 4-9
4.4.4 Span Calibrating a Dual Sensor Ch. Module............... 4-9
4.4.5 Using the "1MAN" Calibration Option. ....................... 4-10
4.4.5.1 Zero & Span Calibrating a Single Sensor Ch. M. ... 4-10
4.4.5.2 Zero & Span Calibrating a Dual Sensor Ch. M....... 4-10
4.5 Alarm Configuration Procedures .................................. 4-11
4.5.1 Defining the Setpoint for the High or Caution Alarm .. 4-11
4.5.2 Configuring Alarm Relay Settings ............................. 4-11
4.5.2.1 Setting the Fail-safe or Non Faile-safe Mode .. 4-11
4.5.2.2 Setting the Latching or Non-Latching Mode ... 4-12
4.6 Setting the ID Code ..................................................... 4-12
4.7 Enabling/Disabling the Pass Code ............................... 4-12
4.8 Setting the Sensitivity Gauge....................................... 4-13
4.9 Routine Operation........................................................ 4-13
4.10 FAIL Alarm Conditions ................................................. 4-14
4.11 Calibration of Combustible Gas Detectors to the LEL of
Gases other than Methane .......................................... 4-14
Failure and Error Codes
5.1 Failure Codes................................................................. 5-1
5.2 Error Codes ................................................................... 5-2
Appendix
A-1 Specifications................................................................. A-1
A-2 Recommended Spare Parts List .................................... A-2
A-3 Drawing List ................................................................... A-3
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Teledyne Analytical Instruments
Multi-Channel Combustible Monitor Introduction 1
Introduction
1.1 Overview
The Teledyne Analytical Instruments (TAI) Model 1220 is a multichannel system that can be used for determining the concentration of combustible gases in an atmosphere at a number of remote locations, and provide alarm information when the combustible gas level exceeds predetermined limits at any one or all of the remote locations.
The combustible gas content of the atmosphere is determined by a
number of remotely located detectors that may be strategically placed to
monitor the atmosphere surrounding their location.
The system is designed to provide indications of the state of each
detector and to actuate individual external alarm indicators as well as alarms
common to all channels. The alarms are user-configurable.
Channel Modules
System
Chassis
1.2 Description
The 1220 system is comprised of a System Chassis, Control Unit,
Channel Modules, and Remote Sensors. Each System Chassis contain one
Control Unit and up to eight Channel Modules. Each Channel Module
monitors up to two remote sensors. Since the sensors are designed for
installation in hazardous locations and are suitable for use in NEC Class I,
Division I, Groups B, C and D areas, they are (generally) located in an area
away from the 1220 System.
Control Unit
Model 1220 System
Teledyne Analytical Instruments
1-1
1 Introduction Model 1220
1.2.1 System Chassis (19” Rack)
The System Chassis provides structural support and electrical interconnection for the Control Unit and Channel Modules (up to eight Channel
Modules may be installed). These latter plug into the sockets of the system
chassis. Terminal strips at the rear of the System Chassis provide for
external electrical connections.
1.2.2 Control Unit
The Control Unit handles power distribution to the entire system. The
main power is controlled by a switch on the front panel and the system fuses
are accessible from the front. The Control Unit also contains common
alarm relays, which indicate alarm conditions whenever any of the Channel
Modules alarm.
1.2.3 Channel Modules
Each channel module is a complete, self-contained instrument including
integral power supply, and requires only external AC power. A channel is
operational simply when plugged into the System Chassis.
Because a channel module plugs into the control module, channels can
easily be added after installation to monitor additional locations on any
control module originally supplied with less than eight channels. Channel
Modules in the same System Chassis may still be configured independently.
1.2.3.1 Main Features of the Channel Module
The main features of the Channel Module Include:
• High resolution 0-100% LEL LCD display readout
• Drop in replacement for Model 122 instruments
• 1MAN calibration capability
• Membrane switch control
• Rugged sensor design
• 2 sensors per channel option
• Microprocessor based electronics
1-2
• Two concentration alarms with adjustable set-points
• Sensor failure alarm
• User friendly touch key controls
• Passcode protection
Teledyne Analytical Instruments
Multi-Channel Combustible Monitor Introduction 1
Model 1220 Combustible Monitor Front Panel
Teledyne Analytical Instruments
1-3
1 Introduction Model 1220
• Failure codes and testpoints
• Two selectable analog outputs (0-10VDC or negative ground
4-20mADC)
• Extensive, automatic self-test diagnostic testing during operation
• Compact and versatile design: Small footprint with accessible
internal PCBs
1.2.4 Detector
The detector is a low temperature, catalytic oxidation, diffusion type
sensor. Each detector contains two beads: a catalytically active bead and a
thermally identical inert bead. Each bead is integrated onto a platinum
heating coil and is mounted on a stainless steel support bar. With this
rugged mounting system the detector is extremely vibration and shock
resistant. The detectors are installed near the potential source of leaks in
the region expected to be first exposed to the gas.
Combustible Gas Detector
1.2.5 Terminal Strip Housing
The terminal strip housing and probe mounts provided for this system
are junction boxes having two hubs with 3/4” pipe treads. The sensor
screws into one hub and the other hub will accommodate standard conduit.
A three-point terminal strip is installed within the housing for connection of the probe.
1-4
Teledyne Analytical Instruments
Multi-Channel Combustible Monitor Operational Theory 2
Operational Theory
2.1 Introduction
The Model 1220 combustible gas analyzer is composed of four com-
ponents:
1. System Chassis
2. Control Unit
3. Channel Modules
4. Combustible Sensors
The System Chassis provides structural support and electrical interconnection for a Control Unit and up to eight Channel Modules. Each
Channel Module can monitor one or two sensors (dual-sensor option).
2.2 System Chassis
All electrical connections are located on the rear of the system chassis.
The nine terminal strips constitute one each for the Channel Modules and
one for the Control Module.
2.3 Control Unit
The Control Unit provides control of electrical power to the channel
module, audio alarms and external alarms through the common alarm
relays.
Alarm signals from any Channel Module trigger the corresponding
relays in the Control Unit. For example, “high” alarm signals from any
channel trigger the “high” alarm relay in the system control module. There
are three such relays in the Control Unit, one each for high, caution and
failure alarms. The failure alarm relay in the Control Unit is operated
“fail-safe”; however, the gas level alarm relays can be optionally connected
Control Unit - Front Panel
Teledyne Analytical Instruments
2-1
2 Operational Theory Model 1220
PRIMARY
POWER
SIGNALS FROM
CHANNEL MODULES
*HIGH
*CAUTION
FAILURE
DRIVERS
POWER
SWITCH
RELAYS
AUDIBLE
ALARM BYPASS
INTERNAL
BUZZER
Control Unit - Block Diagram
for operation in the “non fail-safe” mode by setting the configuration
jumpers as indicated in the installation section 3.3.2. Each of these relays
provides SPDT contacts for operation of external devices.
POWER TO
CHANNEL
MODULES
POWER FOR
EXTERNAL
AUDIBLE
ALARMS
RELAY
CONTACT
ACTUATION
HIGH
CAUTION
FAILURE
An audible alarm is actuated when any alarm state occurs. This
audible alarm may be disconnected by switching the AUDIBLE ALARM
control switch to the BYPASSED position. When this is done, the red
lamp on the system module is illuminated as an indication that the audible
alarm is not functioning.
The Control Unit is the power entry and distribution point. The 1220
system contains universal power supplies that operate on 100-240 VAC,
50/60Hz. The power switch on the Control Unit switches power for the
entire system. The line is protected by two 3 Amp fuses, accessible from
the front panel.
A 1/8 A fuse is furnished for the electronic circuitry of the Control
Unit. The green power LED indicates that the Unit is ON.
Alarm switch S2 has two positions. Normally, the switch is set to the
ACTIVE position which provides for audible alarm when any of the
Channel Modules goes into the alarm state. When set to the BYPASS
position, the local audible alarm is turned off.
2-2
Teledyne Analytical Instruments
Multi-Channel Combustible Monitor Operational Theory 2
2.4 Channel Module
The Model 1220 Combustible Gas Analyzer uses an Intel Microcontroller with on-board RAM and ROM to control all signal processing,
input/output, and display functions for the analyzer. The channel power is
supplied from two separate universal power supply modules (100-240
VAC), designed to be compatible with most international power sources.
The first power supply (triple outputs) supplies the voltages for logic
devices. The second power supply (dual outputs) supplies voltage for the
detector(s).
The power supply for the detector is provided with a stable current of
300mA.
Each detector is connected in a bridge circuit with the output signal
feeding an operational amplifier.
A block diagram of the functional relationships of the Channel Module is
shown in Figure 2-3.
2.5 Combustible Sensors
The basic elements of the combustible gas detector are shown in
Figure 2-1. The two beads each consist of a small coil of wire coated with
an appropriate material. The measuring bead coating is a mixture of a
catalytic material with an inert binder. This catalytic material is selected to
enhance the oxidation of combustible gases. The reference bead coating is
an inert material having similar thermal properties to the other bead.
BLACK
REFERENCE
REFERENCE
BEAD
WHITE
MEASURING
BEAD
COMMON
RED
MEASURING
Figure 2-1 Combustible Gas Detector
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2-3
2 Operational Theory Model 1220
When exposed to a mixture containing gases and oxygen, the measuring bead coating allows the oxygen and combustibles to combine at its
surface. The energy produced by this reaction heats the measuring bead.
The rise in temperature changes the bead’s resistance and is related to the
concentration of the combustible gas. The reaction rate is dependent upon
the nature of the particular combustible gas. Raising the temperature of the
bead increases the reaction rate, which increases the sensitivity of the
sensor and reduces the observed differences of various gases. This rise in
temperature is generated by a constant-current supplied to the sensor.
The temperature of the measuring bead will be influenced by other
factors such as initial gas temperature, gas thermal conductivity, flow rates
and the temperature of its housing. The reference bead, having similar
electrical and thermal properties and being heated by the same current, but
lacking the catalytic material will be similarly affected by these extraneous
factors but not significantly affected by oxidation of the combustible gas.
These two beads are placed in close proximity to one another so that
they are affected by the same environmental factors. Thus the differences
between the changes in resistance of the two coils are directly related to the
concentration of combustible gases.
For area monitoring applications, these two beads are installed in a
metal housing as shown in Figure 2-2. Wires connected to the beads are
brought out the back of the detector through potting which provides mechanical retention of the wires and provides a gas-tight seal. A stainlesssteel flashback arrestor screen at the front of the detector covers the beads
and is held in place by a retaining cylinder pressed onto the housing. This
retaining cylinder is threaded internally to accept a flow-through adapter
for calibration.
INTERNAL THREAD FOR
CALIBRATION ADAPTER
RED
WHITE
BLACK
2-4
3/4 NPT
15/16” WRENCH FLAT
Figure 2-2 Remote Combustible Probe
Teledyne Analytical Instruments
PROBE SENSING
SURFACE
Multi-Channel Combustible Monitor Operational Theory 2
The response of a catalytic bead detector to a number of gases is
shown in Table 1.
For lighter than air gases, the detectors are generally installed above
the source; for heavier than air gases, detectors are generally installed
below the source.
Table 1
Detector Response to Gases
COMPOUND LEL* RESPONSE FACTOR
Methane 5.0 1.00
Hydrogen 4.0 0.86
Carbon Monoxide 12.5 0.32
Ethane 3.0 1.20
Ethylene 2.7 1.26
Acetylene 2.5 1.39
Propane 2.2 1.42
Propylene 2.0 1.33
Butane 1.9 1.54
Hexane 1.1 1.50
Cyclohexane 1.3 1.44
Heptane 1.05 1.59
Benzene 1.3 1.50
Toluene 1.2 1.48
Ethylene Oxide 3.6 0.76
Methyl Ethyl Ketone 1.8 0.96
Methyl Acrylate 2.8 0.59
* Taken from Fire Hazard Properties of Flammable Liquids, Gases
and Volatile Solids, National Fire Protection Agency.
Teledyne Analytical Instruments
2-5
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