User Manuals - Honeywell Analytics
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1. es oo co FAULT R OFF OFF FAULT R N A N A mA FAULT R OFF OFF mAFAULT R N A N A source source G N A N A amos G ON PERIODICALLY ON PERIODICALLY amos G N A N A NOTE 1 Dead band from 4 mA to 4 6 mA NOTE 2 No dead band from 0 to 26 mA NOTE 3 Environmental compensation energized for cold temperatures Calibration Mode NOTE 1 Error on output will result in fast blink on red mA FAULT LED 4 ZERO FUNCTION 4 DURING SPAN J DURING4mA FACTORY CALIBRATION INITIATED CALIBRATION OUTPUT CALIBRATION LOST Powe CG lt lt n a system Y N A a CALIBRATE Y N A FAULT R OFF OFF N A N A mAFAULT R OFF OFF OFF N A souRcE G N A N A N A N A amos G N A N A N A N A NOTE 1 Indicates that Zero function is initiated and pushbutton S1 can be released Yellow Calibrate LED will be off after pushbutton is released NOTE 2 Indicates unit lost the factory calibration data Contact Manning Systems Manning AirScan iR Refrigerant Sensor 19100 AirScan iR ind 05 2006 REVA Copyright 2006 Manning Systems Inc All Rights Reserved 10 3 Ope ration continued Figure 7 LED Indicator Summary continued Initiated by button press GreenLED Y YellowLED R Red LED See LED indicators and blink sequence descriptions on page 9 Fault Indicator Error Sequences LOST FACTORY FAILED2. 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 19100 AirScan iR ind 05 2006 REVA Copyright 2006 Manning Systems Inc All Rights Reserved IMPORTANT The AirScan iR sensor is factory calibrated and should require minimal adjustments after installation This sensor was calibrated at an altitude of 1 000 ft above sea level For installations where the altitude is greater than 3 500 feet above sea level it is necessary to recalibrate the sensor span during the initial setup for more accuracy and reliability 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 1 One person exposes each sensor to a small amount of the gas that is being monitored 2 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 r
3. 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 ATMOS equipped enviro adaptive technology option required for condensing conditions or refrigerated areas Operating Temperatures 50 F to 140 F ATMOS equipped enviro adaptive technology option required for refrigerated areas or outdoors 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 in 10 seconds with full scale target calibration gas 75 liters min flow rate Weight 4 4 Ibs Dimensions 9 59 high x 7 71 wide x 4 52 deep Manning AirScan iR Refrigerant Sensor 19100 AirScan iR ind 05 2006 REVA Copyright 2006 Manning Systems Inc All Rights Reserved 4 2 Installation A Locating the Sensor Because each sensor can only report what it is seeing at the moment it is very important that the 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 sens
4. 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 Honeywell Analytics for specific wiring instructions when using AirScan iR sensors with an AirAlert 96d readout unit Cable Recommendation Use 18 3 Belden 8770 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 If sensor is SUPER HEAT equipped contact Manning Systems for cable recommendations Use only the existing punched holes for connections to the sensor Monitoring The AirScan iR Refrigerant Sensor may be monitored by any Manning 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 positive side Black connects to 24 VDC ground side Bare wire wrap connects to case ground at monitoring equipment earth ground DC ground black Shield bare Manning AirScan iR Refrigerant Sensor 19100 AirScan iR in
5. 4 20 mA LOW SIGNAL OR POWER SUPPLY OPERATING TEMPERATURE CALIBRATION OUTPUT FAILED SOURCE OR CIRCUIT VOLTAGE TOO LOW RANGE EXCEEDED SYSTEM N A N A N A N A CALIBRATE Y N A N A N A N A N A FAULT R N A N A oa ee ee mAFAULT R N A e m N A N A N A SOURCE G N A N A N A N A N A amos G N A N A N A N A N A NOTE 1 Indicates Normal Run Mode wthout output filtering where unit lost factory calibration data Contact Manning Systems for technical support NOTE 2 Indicates failed 4 20 mA output signal Load resistance is too high READING DRIFTED SHORTED BELOW 4 mA SOURCE SYSTEM N A N A CALIBRATE N A N A FAULT R c mA FAULT N A N A SOURCE G N A OFF ATMOS G N A N A NOTE 1 Indicates the gas reading drifted below 4 mA and needs to be re calibrated only in non filtered output run mode no dead band Manning AirScan iR Refrigerant Sensor 19100 AirScan iR ind 05 2006 REVA Copyright 2006 Manning Systems Inc All Rights Reserved 1 3 Ope ration continued C Modes of Operation The Manning AirScan iR has various modes of operation and calibration Normal run mode with output filtering Normal run mode without output filtering 4 20 mA loop check 4 20 mA calibration to an external PLC or read out panel Neutral gas resting point or zero calibration mode Span calibration modes Normal Run M
6. absence of target gas in this condition Start Set meter to mV DC place meter leads on Test and Test respectively see Figure 9 Apply pure nitrogen N into the calibration port at a rate of 6 Liter min for at least 3 minutes Check the status of the yellow system LED If this LED is continuous ON place the unit in non filtered output run mode by pressing both the zero S1 and span S2 buttons simultaneously for 1 second or until the system LED begins to blink slowly See example below Wait until output signal has stabilized to within 02 mA of signal deviation change Output should read between 3 9 and 4 1 mA 39 0 to 41 0 mV If this is not the case proceed to the next step Follow the zero procedure above to re zero the unit Follow the simple zero test procedure to ensure the unit is resting at the optimum 4 mA point Simple Zero test NO Dead band mode 0 to 26 mA POWER G system Y CALIBRATE Y OFF FAULT R OFF mAFAULT R OFF source G amos G N A Manning AirScan iR Refrigerant Sensor 19100 AirScan iR ind 05 2006 REVA Copyright 2006 Manning Systems Inc All Rights Reserved Exit Press and hold both the zero S1 and span S2 buttons simultaneously for 1 second or more until system LED is continuous ON Unit should be ready for long term operation 4 20 mA Output
7. be exited by fully calibrating the unit See the following example POWER G system Y CALIBRATE Y OFF FAULT R OFF mAFAULT R OFF source G ATMOS G N A Manning AirScan iR Refrigerant Sensor 19100 AirScan iR ind 05 2006 REVA Copyright 2006 Manning Systems Inc All Rights Reserved 12 3 Ope ration continued 4 20 mA Loop Test 22 mA full scale and 5 mA fault check Start Press S1 5 times within a two to three second period of time The yellow system LED will turn off and the yellow calibrate LED will blink fast See the following example Output should be 21 to 22 5 mA 22 mA Full Scale Output Test LED SEQUENCE POWER G SYSTEM Y OFF CALIBRATE Y FAULT R N A mAFAULT R N A SOURCE G N A amos G N A To proceed to the next step in the mA test press and hold S1 for 1 second or more until the yellow calibrate LED is a medium double blink See the following example The output should be between 4 and 6 mA 5 mA Fault Output Test LED SEQUENCE POWER G system Y OFF CALIBRATE Y FAULT R N A mAFAULT R N A SOURCE G N A amos G N A Exit Press and hold S1 for 1 second or more until the yellow system LED resumes the state before the mA test was initiated and the yellow calibrate LED turns off Manning AirScan iR Refrigerant Sensor 19100 AirScan iR ind 05 2006 REVA Copyrig
8. by Honeywell Analytics for extended exposure to excessive gas con centrations if a claim by the Purchaser is made under this limited warranty Should such inspection indicate that the gas sensor has been expended rather than failed prematurely this limited warranty shall not apply to the Product C This limited warranty does not cover consum able items such as batteries or items subject to wear or periodic replacement including lamps fuses valves vanes sensor elements cartridges or filter elements Warranty Limitation and Exclusion Honeywell Analytics will have no further obligation under this limited warranty All warranty obligations of Honeywell Analytics are extinguishable if the Product has been subject to abuse misuse negligence or accident or if the Purchaser fails to perform any of the duties set forth in this limited warranty or if the Product has not been operated in accordance with instructions or if the Product serial number has been removed or altered Disclaimer of Unstated Warranties THE WARRANTY PRINTED ABOVE IS THE ONLY WARRANTY APPLICABLE TO THIS PURCHASE ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED Limitation of Liability IT IS UNDERSTOOD AND AGREED THAT HONEYWELL ANALYTIC S LIABILITY WHETHER IN CONTRACT IN TORT UNDER ANY WARRANTY IN NEGLIGENCE OR OTHERWISE SH
9. must be considered a high gas concentration Manning infrared sensors are normally long lived 5 years plus unless physically damaged or wetted with water or other liquid System Specifications 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 If sensor is SUPER HEAT equipped 15 F and below contact Honeywell Analytics for cable recommendations NOTE The standard AirScan iR is for use in non classified areas only Sensor 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 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 Type CFC HCFC HFC selective infrared gas sensor transmitter AirScan iR 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 SensorCheck Features Dual channel functionality test
10. of particulate contamination Usually is takes an appreciable amount of time for the particles to pose signal degradation however under long term exposure the filter surface could be dirty causing low thermal readings hence marginal operation for signal analysis LED SEQUENCE POWER G system Y N A CALIBRATE Y N A FAULT R mAFAULT R N A SOURCE G N A amos G N A NOTE 4 20 mA will be set to 0 5 mA Manning AirScan iR Refrigerant Sensor 18908 AirScan iR comm 01 2006 REVA Copyright 2006 Manning Systems Inc All Rights Reserved 22 4 Maintenance Expose each sensor to test gases monthly to verify that the sensor has a normal response This will also check the alarm lights and relay action of the monitoring equipment It is essential that signal voltages be taken and logged on a consistent basis at least monthly Periodically sensors should be exposed to refrigerant sample and the results logged 5 Replacement Parts For proper operation it is essential that the test and calibration schedule be adhered to Honeywell Analytics recommends the following maintenance schedule Calibration should be performed with certified calibration gas every six months Calibration kits are available from Honeywell Analytics All tests and calibrations must be logged It is highly recommended that certified calibration gas be used every six months For replacement parts contact Honeyw
11. this instrument a broad band infrared source emits energy which is then band pass 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 AirScan iR Sensor line is a three wire 4 20 mA sensor for two bands of refrigerants available in a range of O 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 SensorCheck 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
12. ALL NOT EXCEED THE AMOUNT OF THE PURCHASE PRICE PAID BY THE PURCHASER FOR THE PRODUCT AND UNDER NO CIRCUMSTANCES SHALL HONEYWELL ANALYTICS BE LIABLE FOR SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES THE PRICE STATED FOR THE PRODUCT IS A CONSIDERATION LIMITING HONEYWELL ANALYTICS LIABILITY NO ACTION REGARDLESS OF FORM ARISING OUT OF THE TRANSACTIONS UNDER THIS WARRANTY MAY BE BROUGHT BY THE PURCHASER MORE THAN ONE YEAR AFTER THE CAUSE OF ACTIONS HAS OCCURRED Manning AirScan iR Refrigerant Sensor 18908 AirScan iR comm 01 2006 REVA Copyright 2006 Manning Systems Inc All Rights Reserved 24
13. Interference 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 Manning AirScan iR Refrigerant Sensor 19100 AirScan iR ind 05 2006 REVA Copyright 2006 Manning Systems Inc All Rights Reserved Introduction This manual has been prepared to help in the use and installation of the Manning AirScan iR Infrared Refrigerants Sensor This manual will convey the operating 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 Manning AirScan iR Sensor Warranties made by Honeywell Analytics 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 Honeywell Analytics before proceeding Manning AirScan iR Refrigerant Sensor 19100 AirScan iR ind 05 2006 REVA Copyright 2006 Manning Systems Inc All Rights Reserved 3 1 Sensor Description Gas detection by the infrared method is based on the principle that most gases absorb infrared energy ata characteristic frequency In
14. Loop Integrity Check 22 mA High Signal Test STEP 1 Start Set meter to mV DC place meter leads on Test and Test respectively see Figure 9 Press the zero S1 button 5 times The yellow calibrate LED will blink fast and the yellow system LED will turn off The output should be 21 to 22 5 mA 210 to 225 mV If a problem exists on the output signal line or the output load is not within the specified range the mA fault LED will blink either before or upon activation of this test In some cases the 22 mA high signal output will cause incorrect output load resistance values to surface because of the demand on high resistances to produce high currents Low power supply voltages can also be something to investigate if this error surfaces only when the 22 mA high test is initiated During 4 20 mA loop test 22 mA high LED SEQUENCE POWER G SYSTEM Y OFF CALIBRATE Y FAULT R N A mAFAULT R N A source G N A ATMOS G N A 3 Ope ration continued During 4 20 mA loop test 22 mA high w Error on output LED SEQUENCE POWER G system Y OFF CALIBRATE Y lt FAULT R N A mAFAULT RQ SOURCE G N A ATMOS G N A 5 mA Low Signal Output Test for Fault Conditions NOTE The unit must be in the 4 20 mA loop 22 mA high test to proceed with this te
15. Manning AirScan iR Refrigerant Sensor for Industrial Applications Instruction and Installation Manual Rev A Manning AirScan Sens rCheck ATMOS Honeywell Honeywell Analytics 11511 West 83 Terrace Lenexa Kansas 66214 sales manningsystems com 800 444 9935 or 913 894 1185 www gasalarm com 913 894 1296 fax 19100AirScan iR ind 5 2006 REVA 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 iR 5 B Wiring 6 Figure 2 Wiring Diagram for AirScan iR 6 3 Operation A Start up Procedure 7 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 D Calibration 15 Figure 8 Board Component Layout 15 4 20 mA Output Calibration 17 Zero Calibration 17 Figure 9 Board Component Layout 18 Span Calibration 18 E Diagnostic Procedures 19 Simple Zero Test 19 4 20 mA Output Loop Integrity Check 19 F Troubleshooting 21 Electrical
16. R OFF SOURCE G N A Atmos G N A Ensure the output rests between 3 9 and 4 1 mA 39 0 to 41 0 mV If this is not the case perform the zero procedure again Once the output is within the required range with nitrogen flowing apply full scale target gas into the calibration port at a rate of 6 liters min for 3 minutes immediately following the nitrogen flow If the signal is 26 mA or greater adjust the span potentiometer counter clockwise until the signal is near 20 mA Because there is a slight delay in potentiometer movement make small adjustments and wait for the output to change because adjustment response is delayed between source pulses Wait until the output signal has stabilized to within 02 mA of signal deviation change Adjust the span potentiometer again until the output reads around 20 mA Exit Press and hold the span button S2 for one second or more until the yellow calibrate LED turns off The yellow system LED will resume the previous state either filtered or non filtered output mode This indicates the parameters are now programmed into memory Manning AirScan iR Refrigerant Sensor 19100 AirScan iR ind 05 2006 REVA Copyright 2006 Manning Systems Inc All Rights Reserved 18 3 Ope ration continued E Diagnostic Procedures Simple Zero Test This test will ensure the unit is calibrated for a true zero and duly represents an
17. amiliarize yourself with the pushbuttons S1 S2 adjustment pots zero span Test Test and their locations on the main board see Figure 8 Figure 8 Board Component Layout ICSP Programming Port Serial Port Zero Adjust m Pushbutton S1 RxLED TxLED Span Adjust Pushbutton S2 Draw Chamber POWER O SYSTEMO CALIBRATE O FAULT mA FAULT O IR SOURCE ATMOS O ACTIVE Tubing to calibration point In addition the LED indicators and blink pattern meanings are also summarized in this section The calibration procedure will require use and knowledge of the following tools within the sensor 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 function and program the 4 mA output calibration e Pushbutton S2 used to program the span setting In addition there are four LED s used in the calibration procedure Yellow system and calibrate and red fault and mA fault LED s located on the main board are utilized as status indicators during the calibration procedure and as diagnostic and trouble indicators Non calibrate
18. asks surrounding abrupt adverse environmental transients that would cause a small short term anomaly on the 4 mA resting point for a near O ppm reading of the target gas In this mode the yellow system LED will be ON See the following example LED SEQUENCE POWER G SYSTEM Y CALIBRATE Y OFF FAULT R OFF mAFAULT R OFF source G ATMOS G N A Non Filtered Output Mode no signal deadband Start Press and hold both the zero S1 and span S2 buttons simultaneously for one second or until the system LED begins to blink slowly See example below This mode will allow any anomalies to be transmitted from O to 27 mA on the output This mode is also used in the upcoming Simple Zero Test procedure LED SEQUENCE Pow GC system Y CALIBRATE Y OFF FAULT R OFF mAFAULT R OFF source G amos G N A Exit To revert back to dead band mode repeat the same button press procedure above This button press sequence will toggle between modes filtered to non filtered Manning AirScan iR Refrigerant Sensor 19100 AirScan iR ind 05 2006 REVA Copyright 2006 Manning Systems Inc All Rights Reserved 16 3 Ope ration continued STEP 1 STEP 2 4 20 mA Output Calibration This procedure calibrates the 4 20 mA output to match a PLC input converter or various devices that interpret the 4 20 mA signal output to ensure the 4 mA output rests
19. at a true 4 mA even with minor mismatches in load resistance long feed wiring or adverse environmental conditions Start Set meter to mV DC and place meter leads on Test and Test respectively see Figure 9 e Press and hold the zero button S1 for 5 seconds or until the calibrate LED is blinking slowly and the system LED is continuous ON Make sure the mA Fault LED is OFF Adjust the zero potentiometer until the output reads 3 99 to 4 01 mA 39 9 to 40 1 mV This sets the 4 mA resting point Make small adjustments and wait for the output to change because adjustment response is delayed between source pulses 4 mA output programming calibration mode POWER G SYSTEM Y cALIERATE Y _ FAULT R N A mAFAULT R OFF SOURCE G N A ATMOS G N A Exit Press and hold the zero button S1 for one second or more until the calibrate LED turns off The system LED will resume the previous state either filtered or non filtered output mode This indicates the parameters are now programmed into memory Zero Calibration This procedure sets the internal reference that is indicative of O ppm of target gas It MUST be performed before proceeding or every other setting will be offset and inaccurate The zero can be initiated at any time as long as a neutral gas is flowing through the calibration port or the surrounding air is known to be FREE
20. aving at least 100 to 250 ohms across the signal output SIG and ground GND The mA fault LED will stop blinking indicating the load or wiring has a problem Sensor Output at 0 mA Verify 24 VDC at the sensor terminal block see Figure 10 Note 1 on previous page Check signal voltage between Test and Test see Figure 10 Note 2 Voltage should be in the range of 40 to 200 mV corresponding to an actual current flow of 4 to 20 mA If this voltage is O mV the signal has no path to ground Check monitoring equipment connections and configuration Input impedance must be 500 ohms or less Sensor Output at 5 mA Please see Section D on page 15 for possible fault conditions related to 5 mA output Gas Concentration Indicated With No Refrigerant Present The AirScan iR is designed to be quite specific to CFC HCFC HFC s that are colorless odorless gases which can t be sensed by humans at low levels Always double check with another instrument before assuming refrigerants are not present Performing a zero and a span calibration using certified calibration gas will confirm or correct the sensor s reading IR Source Failure If the IR source signal strength drops to the point that the unit can no longer function satisfactorily the fault LED will remain continuous ON and the 4 20 mA output will be set to 0 5 mA See example below This condition can also occur in environments where there is a significant amount
21. bing to calibration point Manning AirScan iR Refrigerant Sensor 19100 AirScan iR ind 05 2006 REVA Copyright 2006 Manning Systems Inc All Rights Reserved Sensor On board Diagnostic System It is possible to have the mA output fail during normal run mode In some instances a mA output circuit that is incorrectly setup can supply 4 mA to the load reasonably well however an incorrect circuit arrangement could not be capable of driving 20 mA to the load when required Therefore the system will place a fault condition out on the mA loop output and flash the mA fault LED indicating the output wiring is not correct or load resistance is too high To properly ensure the load is correct during the 20 mA or high 4 20 mA integrity test the output circuit dynamic range is tested to its fullest extent If the mA fault LED blinks during this test the load resistance is too high or power supply voltage is too low In the case of a mA Failure during Run mode the mA fault LED will blink Fast In the case of a mA failure during the mA output test the mA fault LED will also blink Fast See figure at the top of the next page 21 3 Ope ration continued Error on 4 20 mA output or during 4 20 mA test 20 mA high POWER G system Y N A CALIBRATE Y FAULT R N A mAFAULT R SOURCE G N A amos G N A To resolve this issue Place a resistor h
22. ble 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 only three conductor cable not two cables of two conductor wire see Figure 2 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 If the AirScan iR is to be used with the AirAlert 96d please call Honeywell Analytics for specific wiring instructions Figure 2 Wiring Diagram White connects to signal input of Output white monitoring equipment 24 VDC red Red connects to 24 VDC power supply Ie 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
23. d 05 2006 REVA Copyright 2006 Manning Systems Inc All Rights Reserved 6 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 LED s 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 LED s below are operational as follows see Figure 3 Green Power LED continuous ON Both Fault LED s are OFF Green source
24. d Sensor or Loss of Factory Calibration IMPORTANT Upon power up if the yellow system LED is showing a fast blink pattern the unit hasn t been calibrated yet or has lost the factory calibration and requires a full calibration before it can reliably read the target gas See the following example Should this occur please contact Honeywell Analytics for assistance LED SEQUENCE POWER G SYSTEM Y lt CALIBRATE Y N A FAULT R N A mAFAULT R N A SOURCE G N A amos G N A Manning AirScan iR Refrigerant Sensor 19100 AirScan iR ind 05 2006 REVA Copyright 2006 Manning Systems Inc All Rights Reserved 15 3 Ope ration continued Before continuing with the calibration procedure determine which of the two Normal output modes is best for the control scheme Filtered output holds a stable 4 mA signal within a dead band range while the non filtered output allows the signal to be seen without any output limitations After this output mode choice is made continue through Steps 1 3 of the Calibration Procedure As a first step the 4 mA output is matched to the signal input device being used as a control panel After this is accomplished Step 2 Zero Calibration and Step 3 Span Calibration can be completed in that order Filtered Output Mode Each unit is equipped with a filtered output or dead band output mode which locks the output at 4 mA for signal readings of 4 to 4 6 mA This m
25. d band Red mA Fault LED attempts to output 5 mA fault signal Fast blink indicates 4 20 mA loop failure or load resistance too high Green Source LED e One blink every 2 seconds indicates when source is energized and also that the source is not short circuited Green ATMOS LED e Continuous ON indicates ATMOS circuitry is active or adjusting the enclosure s internal environmental conditions for the sensor to function reliably NOTES If the Source LED isn t blinking do not proceed until the condition is corrected If a Fault LED is lighted immediately refer to Fault Indicator Error Sequences page 11 to determine potential problem Do not attempt calibration if a Fault is indicated e All status LED s are subordinate to Fault indicators e If an LED is indicated as OFF it must actually be OFF for proper sensor operation If an LED status is N A not applicable that LED indication may vary depending on other operational factors 3 Ope ration continued Figure 7 LED Indicator Summary Initiated by button press G GreenLED Y YellowLED R Red LED See LED indicators and blink sequence descriptions on page 9 Normal Run Mode 4 20 mA Loop Test Mode WITH OUTPUT WITHOUT OUTPUT LED 4 20 mA LOOP TEST 4 20mA LOOP TEST FILTERING FILTERING 2 22 mAHIGH 5mALOW POWER G POwRR system VY system Y OFF OFF CALIBRATE Y OFF OFF CALIBRATE Y
26. ell Analytics Be sure to give serial number of unit and model number Manning AirScan iR Refrigerant Sensor 18908 AirScan iR comm 01 2006 REVA Copyright 2006 Manning Systems Inc All Rights Reserved 23 11 Limited Warranty Limited Warranty Honeywell Analytics Inc warrants to the original purchaser and or ultimate customer Purchaser of Manning products Product that if any part thereof proves to be defective in material or workmanship within eighteen 18 months of the date of shipment by Honeywell Analytics or twelve 12 months from the date of first use by the purchaser whichever comes first such defective part will be repaired or replaced free of charge at Honeywell Analytics discretion if shipped prepaid to Honeywell Analytics at 11511 W 83rd Terrace Lenexa Kansas 66214 in a package equal to or in the original container The Product will be returned freight prepaid and repaired or replaced if it is determined by Honeywell Analytics that the part failed due to defective materials or workmanship The repair or replacement of any such defective part shall be Honeywell Analytics sole and exclusive responsibility and liability under this limited warranty 2 Exclusions A If gas sensors are part of the Product the gas sensor is covered by a twelve 12 month limited warranty of the manufacturer B If gas sensors are covered by this limited warranty the gas sensor is subject to inspection
27. esponds causing appropriate alarm functions Figure 3 Required LED Status at Start up LED WITH OUTPUT WITHOUT OUTPUT FILTERING FILTERING POWER G SYSTEM Y CALIBRATE Y OFF OFF FAULT R OFF OFF mAFAULT R OFF OFF source G amos G ON PERIODICALLY ON PERIODICALLY 3 Ope ration continued B Pushbutton Operation LED Indicators Adjustment Pots and Test Points The Manning AirScan iR has two internal push buttons 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 ICSP Programming Port Serial Port Zero Adjust r Pushbutton S1 RxLED TxLED Span Adjust 5 Pushbutton S2 Note 1 Checking voltage to sensor at 24 and GND Draw Chamber POWER SYSTEMO CALIBRATE O FAULT O mA FAULT O IR SOURCE ATMOS O ACTIVE Note 2 Reading signal at TEST and TEST Tubing to calibration point Zero adjustment pot adjusts output calibration of the 4 mA nominal
28. ht 2006 Manning Systems Inc All Rights Reserved 13 3 Ope ration continued Calibration Programming Modes Refer to Calibration Section D before proceeding Auto ZERO Program Function Start Press and hold S1 for 1 second or until the yellow calibrate LED turns continuous ON Release S1 and the yellow calibrate LED will turn off This indicates the unit zero is now programmed to a neutral or 4 mA resting state for 0 ppm of target gas LED SEQUENCE POWER G SYSTEM Y N A CALIBRATE Y FAULT R OFF mAFAULT R OFF SOURCE G N A amos G N A Span Calibration Programming Mode Start Press and hold S2 for 1 second or until the yellow system LED blinks slowly and the yellow calibrate LED blinks fast Once in this mode the span pot can be adjusted to determine the 20 mA full scale concentration LED SEQUENCE POWER G system Y CALIBRATE Y FAULT R OFF mAFAULT R OFF SOURCE G N A ATMOS G N A Exit To program the span setting and exit this mode press and hold S2 for 1 second or until the yellow system LED resumes the state before the calibration mode was initiated and the yellow calibrate LED turns off 4 mA Output Calibration Programming Mode Start Press and hold S1 for 7 seconds or until the yellow system LED turns continuous ON and the yellow calibrate LED b
29. links slowly See the following example Once in this mode the zero pot can be adjusted to calibrate the 4 mA output to a PLC SCADA system panel etc LED SEQUENCE POWER G system Y CALIBRATE Y FAULT R N A mAFAULT R OFF SOURCE G N A ATMOS G N A Exit To program the 4 mA calibration point and exit this mode press and hold S1 for 1 second or until the yellow system LED resumes the state before the calibration mode was initiated and the yellow calibrate LED turns off Manning AirScan iR Refrigerant Sensor 19100 AirScan iR ind 05 2006 REVA Copyright 2006 Manning Systems Inc All Rights Reserved 14 3 Ope ration continued D Calibration Before calibrating the unit ensure the startup procedure was followed and unit was powered on for a minimum of 12 hours with the enclosure door closed in the operating environment IMPORTANT NOTE For environments where the ambient temperature is less than 10 F during the calibration procedure the door must be closed as far as possible This will ensure the sensor temperature will not drop below the minimum operating temperature which could adversely affect the programmed calibration parameters There are only two adjustment pots and two pushbuttons on the main board that are used for programming the calibration parameters See Section B Pushbutton Operation LED Indicators Adjustment Pots and Test Points Use Section B to f
30. nd GND Draw Chamber POWER O SYSTEMO CALIBRATE O FAULT mA FAULT Q IR SOURCE O ATMOS O ACTIVE Note 2 Reading signal at TEST and TEST FAX Tubing to calibration point STEP 3 Span Calibration This procedure sets the span or concentration level that would depict a 20 mA reading for full scale target gas on the 4 20 mA output The lower the target gas concentration is for a span of 20 mA the more sensitive or responsive the unit would be to lower ppm readings NOTE This procedure should only be performed if the zero and 4 20 mA procedures are successfully completed Start Set meter to mV DC place meter leads on Test and Test respectively see Figure 9 Apply pure nitrogen N into the calibration port at a rate of 6 Liter min for at least 3 minutes OR until output signal has stabilized to within 02 mA of signal deviation change If N is currently flowing from previous zero calibration disregard the additional flow time Press and hold the span button S2 for 1 second or more until the yellow calibrate LED blinks fast and the yellow system LED is blinking slowly See the following example LED SEQUENCE POWER G system Y CALIBRATE Y FAULT R OFF mAFAULT
31. odes Normal run mode with output filtering This mode outputs a signal from 4 to 27 mA with a dead band from 4 to 4 6 mA This dead band masks small environmental anomalies that could facilitate output signal fluctuations or transients around the 4 mA resting point when the unit is not sensing target gas Start If the system LED is blinking slowly press and hold both S1 and S2 simultaneously for 1 second or more until the system LED is continuous ON then release both buttons If the system LED is blinking fast this mode cannot be engaged and the factory needs to be contacted See the following example LED SEQUENCE POWER G system Y CALIBRATE Y OFF FAULT R OFF mAFAULT R OFF source G amos G N A Normal run mode without output filtering This mode outputs a signal that nominally rests at 4 mA and can range continuously from O to 27 mA Any subtle changes in sensor response will be sent to the mA loop output This mode is entered automatically when the calibration modes are activated Some users may wish to see the subtle anomalies in the signal near the nominal 4 mA rest area Start If the system LED is continuous ON press and hold both S1 and S2 simultaneously for 1 second or more until the system LED is blinking slowly then release both buttons to enter this mode If the system LED is blinking fast this mode is always engaged and can only
32. of any target gas down to 1 ppm Start Apply pure nitrogen N into the calibration port at a rate of 6 liter min for at least 3 minutes OR until output signal is within 02 mA of signal deviation change Press and hold the zero button S1 for approximately 1 second or until the yellow calibrate LED is continuous ON When yellow calibration LED is continuous ON release the zero button The calibrate LED will turn off and the unit will be zeroed See example below Zero programming calibration mode LED SEQUENCE PowER CG system Y N A CALIBRATE Y FAULT R OFF mAFAULT R OFF SOURCE G N A amos G N A Exit System will automatically resume previous mode either normal or no dead band mode This indicates the parameters are now programmed into memory Place multi meter leads on Test and Test and ensure the output is steadily resting between 3 9 to 4 1 mA see Figure 9 on next page If this isn t the case initiate the auto zero procedure once again Manning AirScan iR Refrigerant Sensor 19100 AirScan iR ind 05 2006 REVA Copyright 2006 Manning Systems Inc All Rights Reserved 17 3 Ope ration continued Figure 9 Board Component Layout ICSP Programming Port Serial Port Zero Adjust Pushbutton S1 RxLED TxLED Span Adjust Pushbutton S2 Note 1 Checking voltage to sensor at 24 a
33. or 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 close to the potential leak source for fastest possible leak detection If personnel protection is the primary application mount in the breathing zone Protect sensor from water excessive humidity and wash down Take air movement and ventilation patterns into account To prevent electrical interference keep sensor and wire runs away from mercury vapor lights variable speed drives and radio repeaters e 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 sensor should be installed in each room Very Important e Sensor must be mounted vertically Never mount sensor flat on a ceiling Enter enclosure only through existing hole in bottom of enclosure Always make a drip loop in the conduit Never mount sensor on a vibrating surface Mount
34. ous state either filtered or non filtered output mode NOTE In addition to test procedures initiated manually every 2 seconds SensorCheck technology monitors several performance parameters of the AirScan iR A notification of 5 mA on the output signal is transmitted if any of these parameters is not met Manning AirScan iR Refrigerant Sensor 19100 AirScan iR ind 05 2006 REVA Copyright 2006 Manning Systems Inc All Rights Reserved 20 3 Ope ration continued F Troubleshooting Electrical Interference This sensor has been designed to be highly resistant to EMI RFI using multiple stages of filtering and protection However in extreme environments some noise pickup can occur directly through the sensor Insure that the bare shield wire of the instrument cable is properly connected at the readout unit See Figure 10 Note 2 for AirScan iR meter test points Figure 10 Troubleshooting ICSP Programming Port Serial Port Zero Adjust Pushbutton S1 RxLED TxLED Span Adjust Pushbutton S2 Note 1 Checking voltage to sensor at 24 and GND Draw Chamber POWER O SYSTEMO CALIBRATE O FAULT mA FAULT Q IR SOURCE O ATMOS O ACTIVE Note 2 Reading signal at TEST and TEST FAX Tu
35. resting point Span adjustment pot adjusts the 20 mA concentration level or unit span sensitivity Pushbutton S1 used to initiate the auto zero function 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 meter 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 without disruption for the specified 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 POWER SYSTEMO CALIBRATE O FAULT O mA FAULT IR SOURCE CQ ATMOS ACTIVE Manning AirScan iR Refrigerant Sensor 19100 AirScan iR ind 05 2006 REVA Copyright 2006 Manning Systems Inc All Right
36. s Reserved 8 3 Ope ration continued LED Indicators and Blink Sequence Figure 6 LED Blink Sequence SEQUENCE 1sec 2sec 3sec SOURCE BLINK SLOW BLINK MEDIUM DOUBLE BLINK m m FAST BLINK EES GED IEN ER EEA SES AD ED E Ea ET EE CONTINUOUS ON Green Power LED Continuous ON when power is applied Yellow System LED Continuous ON during normal filtered output run mode dead band from 4 to 4 6 mA Slow blink during normal non filtered output run mode Fast blink indicating unit lost calibration data e OFF during 4 20 mA loop check Yellow Calibrate LED Continuous momentary ON for auto zero mode activation e Slow blink for 4 mA output calibration mode Medium double blink indicates 4 20 mA loop check 5 mA low Fast blink for span calibration mode and 4 20 mA loop check 22 mA high Manning AirScan iR Refrigerant Sensor 19100 AirScan iR ind 05 2006 REVA Copyright 2006 Manning Systems Inc All Rights Reserved Red Fault LED all scenarios produce a 5 mA output e Continuous ON indicates a failed source low signal or circuit failure Slow blink indicates the power supply DC 24V input voltage is too low Medium double blink indicates sensor is outside the operating temperature range e Fast blink indicates the signal drifted below 4 mA and needs to be re calibrated only in non filtered output run mode no dea
37. sensor enclosures through the flange holes as shown in Figure 1 and always mount vertically Penthouses Multi Coil defrost one coil at a time 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 Manning 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 Figure 1 Mounting Dimensions 5 16 diameter Honeywell Manning AirScan iR Refrigerant Sensor 19100 AirScan iR ind 05 2006 REVA Copyright 2006 Manning Systems Inc All Rights Reserved 5 2 Instal lation continued Ceiling Hung Evaporators When mounting Manning 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 Honeywell Analytics for application assistance and recommendations B Wiring Electrical wiring must comply with all applica
38. st STEP 2 Start Press and hold the zero S1 button for at least one second or until the yellow calibrate LED shows medium double blink The yellow system LED will remain off and the output should change to 4 to 6 mA 4 to 6 mV If a problem exists on the output signal line or the output load is not within the specified range the mA fault LED will blink either before or upon activation of this test If an error surfaces during this test only the possibility of cross talk can exist on the signal line This is caused by resistive shorts to power or other voltage sources that can raise the 5 mA target current on the line Moisture in the connector can cause stray voltage to migrate from the 24V DC pin over to the 4 20 mA signal line Check connectors or refer to the troubleshooting section or error code analysis section for assistance During 4 20 mA loop test 5 mA low LED SEQUENCE POWER G system Y OFF CALIBRATE Y FAULT R N A mAFAULT R N A source G N A ATMOS G N A During 4 20 mA loop test 5 mA low with Error LED SEQUENCE POWER CG SYSTEM Y OFF CALIBRATE Y FAULT R N A mA FAULT Q mmm SOURCE G N A atmos N A STEP 3 Exit Press and hold the zero S1 button for at least one second or until the yellow calibrate LED turns off The yellow system LED will resume the previ
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