FGD3 Flammable Sensor - Analox sensor technology
Contents
1. FGD3 Flammable Sensor User Manual Analox Ltd 15 Ellerbeck Court Stokesley Business Park North Yorkshire TS9 5PT UK T 44 0 1642 711400 F 44 0 1642 713900 W www analox net E infoQanalox net FGD3 Flammable Sensor User Manual List of Contents 1 Introduction oa 1 3 11 Installation 2 tee neldel 1 3 1 1 1 Siting the sensors u ensure ee Balearen 1 3 1 1 2 Wire termina P eege ee AE Eeer Kernen EE 1 3 CEI ele 1 EE 1 3 1 1 4 Cable amp screenng esse rss essns sens dndn rdr ben siresne bensen een eran Nn Ned ER 1 4 2 Installation in a non hazardous location ssseersrsrerssererrrssrrersrrrerssrrarsrera rerna rare arenan resan nn 2 5 2 1 Installation in a hazardous location msnrseersrsrersrsrrrrssssrerssreerssrrersrrra raser rann arr rar nn 2 6 2 2 Installation using proprietary safety barriers nr er nr erna 2 7 3 Menu ModesseleciON EE 3 8 3 1 ZEr SENSOr rs menden nn Eege ee geed 3 9 9 2 SENSIS PANA aane Mest gies teg soe gueeeatst E E E E 3 9 A A O 3 10 34 Setting 4MA level senken dee eege 3 10 3 8 Setting 2OMAM SVS EE 3 11 360 Display e EE 3 11 3 7 Display firmware Version lt ssissimsbesesseskid sees ksss ses Nan d Nasa nonn nn ER nano nc aaas 3 11 EW 3 12 3 9 View engineer diagnostics data 3 12 3 10 Set Cross reference sosoeseeesrresrresrrrsrrrsrrssrrrsnrrenrr enn erna snar re R Ene PEES KRA RKA ARK Enae natnn Ren 3 12 3 11 Positive zero suppression ooooooccciooccccccooccconon2. 0 WARNING STATIC HAZARD DO NOT RUB WITH DRY CLOTH N A LO Document Ref P0102 802 00 April 2012 Page 6 17 FGD3 Flammable Sensor User Manual 7 Mounting details The diagram below shows the mounting centres for the FGD3 detector head enclosure 122 102 Q N 102 122 140 ea Depth 75mm approx Note The front panel lid of the detector head opens to allow access to the screw terminals situated inside Sufficient space should be allowed around the mounting position so that this action is not restricted Fixings required 2 off M6 Fasteners Rawl bolts or similar dependent on mounting wall construction Document Ref P0102 802 00 April 2012 NA LO Page 7 18 FGD3 Flammable Sensor User Manual 8 Declaration of conformity We declare that on the date the equipment accompanied by this declaration is placed on the market the equipment conforms with all technical and regulatory requirements of the directives listed below Description of Equipment The FGD1 3 Series of Fixed Gas Detectors for the detection of Oxygen Toxic or Flammable gases ATEX Certified intrinsically safe for use in Group IIC hazardous locations Directive 94 9 EC ATEX Standards Used EN50014 1997 Amds 1 8 2 Electrical apparatus for potentially explosive atmospheres General requirements EN50020 1994 Electrical apparatus for potentially explosive atmosphere
3. 7 8 Restore 3 8 9 View engineer diagnostics data 3 9 12 Set cross reference 3 10 19 Positive zero suppression 3 11 20 Negative zero suppression 3 12 30 Set password 3 13 Document Ref P0102 802 00 April 2012 N A LO Page 3 8 FGD3 Flammable Sensor User Manual 3 1 Zero sensor This calibration feature allows the instrument to determine the sensor output under zero gas conditions e Apply zero gas to the sensor inlet and allow enough time for the sensor to respond and all the gas to be purged typically 2 minutes minimum dependent upon flow rate e Select menu mode C 1 and press ENTER e Press ENTER to perform the ZERO calibration Note Pressing MENU instead of ENTER aborts any changes the existing ZERO factor will be displayed on exit e Press MENU the display will show the ZERO factor for the instrument before returning to its standard mode of operation The ZERO factor should be recorded on any calibration certificates completed Note The two thermal conductivity sensors CHTC 8 H2TC have been characterised using nitrogen and as such must be zeroed in nitrogen 3 2 Sensor span This calibration feature allows the instrument to determine the sensor output when it is exposed to a know concentration of gas e Apply a known concentration of gas to the sensor inlet and allow enough time for the sensor to respond e Select menu mode C 2 refer to section 3 and press ENTER e Using the UP and D
4. and PREVIOUS buttons select menu option C 19 Press ENTER Using the INCREASE and DECREASE buttons set the required zero suppression value e Press ENTER to store the new value Note Pressing MENU instead of ENTER aborts any changes the existing suppression level is be displayed on exit e Press MENU to close the menu system N A LO Document Ref P0102 802 00 April 2012 Page 3 13 FGD3 Flammable Sensor User Manual 3 12 Negative zero suppression This option is used to allow the user to suppress small amounts of negative sensor zero drift The setting can be set between 0 and 1096 of the sensor range as set by the FSD value Press MENU to open the menu system Using the NEXT and PREVIOUS buttons select menu option C 20 Press ENTER Using the INCREASE and DECREASE buttons set the required zero suppression value e Press ENTER to store the new value Note Pressing MENU instead of ENTER aborts any changes the existing suppression level is be displayed on exit e Press MENU to close the menu system 3 13 Set password Use this menu option to enable disable the password feature Place the FGD in the password menu as follows e Press the MENU to open the menu system e Using the NEXT and PREVIOUS buttons select menu option C 30 Note If the password system is already enabled the user must enter the 6 digit password to get to this menu Press ENTER The display shows either On or OFF Press the U
5. multimeter to 200mV 0 5mV e Press ENTER to store the 20mA calibration data Note Pressing MENU instead of ENTER aborts any changes the existing DAC 20mA factor will be displayed on exit e Press MENU the display will show the DAC 20mA calibration factor for the instrument before returning to its standard mode of operation 3 6 Display mode e Select menu mode C 6 refer to section 3 and press ENTER e Use the UP and DOWN button to move the decimal point to the desired setting e Press ENTER to set the display mode Note Pressing MENU instead of ENTER aborts any changes the existing display mode will be displayed on exit e Press MENU to return the instrument to its standard mode of operation Note Changing the decimal point will not result in a more accurate reading 3 7 Display firmware version The firmware version is displayed as part of the start up procedure but can be viewed without powering down the instrument via menu option 7 e Select menu mode C 7 refer to section 3 and press ENTER e The display will show the firmware version number e Press MENU to return the instrument to its standard mode of operation N A LO Document Ref P0102 802 00 April 2012 Page 3 11 FGD3 Flammable Sensor User Manual 3 8 Restore The firmware for the detector head is common to infrared CO2 HC pellistor oxygen and toxic instruments This feature allows the type of sensor fitted to be selected e Select menu m
6. or propane but use the unit to detect a different gas e g methanol or acetone etc This is achieved by adjusting the cross reference factor according to the difference in signal that is detected for the calibration gas compared to the target gas e Press MENU to open the menu system e Select menu mode C 12 refer to section 3 and press ENTER e Press ENTER Document Ref P0102 802 00 April 2012 NA LO Page 3 12 FGD3 Flammable Sensor User Manual e Using the INCREASE and DECREASE buttons set the required cross reference factor e Press ENTER to store the new value Note Pressing MENU instead of ENTER aborts any changes the existing factor is displayed on exit e Press MENU to close the menu system Ask Analox Ltd for advice on settings Some typical settings for methane calibration gas Target gas Xref Comments Methane 1 00 Propane 1 88 Butane 2 04 Hexane 2 35 Ethane 1 39 Pentane 2 21 Nonane 4 00 Acetylene 1 67 Acetone 2 21 Xylene 3 00 MEK 2 63 Note The cross reference signal is not suitable for either of the two thermal conductivity sensors CHTC amp H2TC and as such must be set to 1 00 3 11 Positive zero suppression This option is used to allow the user to suppress small amounts of positive sensor zero drift The setting can be set between 0 and 10 of the sensor range as set by the FSD value Press MENU to open the menu system Using the NEXT
7. OWN buttons adjust the displayed reading so that it matches the calibration gas concentration e Press ENTER to perform the SPAN calibration Note Pressing MENU instead of ENTER aborts any changes the existing SPAN factor will be displayed on exit e Press MENU the display will show the SPAN factor for the instrument before returning to its standard mode of operation The SPAN factor should be recorded on any calibration certificates completed Note The two thermal conductivity sensors CHTC 8 H2TC have been characterised using nitrogen and as such must be calibrated with a CH4 H2 gas balance nitrogen mix Typical gas levels are 50 of the range N A LO Document Ref P0102 802 00 April 2012 Page 3 9 FGD3 Flammable Sensor User Manual 3 3 Select FSD The FSD value is usually matched to the sensor fitted If the sensor is say a O to 100 LEL sensor then the FSD is set to 100 It is possible to transmit a lower range on the 4 to 20 mA signal by reducing this value to say 50 LEL This function does not affect the sensor calibration but does change the maximum reading that can be measured Note Changing this value outside the sensor s operating range may make the FGD unsuitable for its intended use e Select menu mode C 3 refer to section 3 and press ENTER e Using the UP and DOWN buttons adjust the displayed reading until the desired setting is displayed e Press ENTER to save the setting Note Pressi
8. P button to select the desired setting Press ENTER to accept the setting Note Pressing MENU instead of ENTER leaves the unit without change Press MENU to return the instrument to its standard mode of operation Note If the password is in operation then the user will be prompted with PASS when ever the menu key is pressed Pressing the MENU key again will result in the restricted user access Le only the zero and span options will be available Entering the correct password will give access to the full menu facility Document Ref P0102 802 00 April 2012 N A LO Page 3 14 FGD3 Flammable Sensor User Manual 4 FGD3 head indications 4 1 Normal conditions The FGD3 gas detector head will display a steady reading for gas levels between 0 and FSD 4 2 High gas conditions The FGD3 gas detector head will flash between the gas reading and Hi when the gas reading is above the sensor FSD This will coincide with the head drawing a current of 20 25mA from the control unit thus ensuring the control unit is aware of the high condition 4 3 Fault conditions The FGD3 gas detector head will flash between F xx and the gas reading when the reading falls below 10 of the sensor FSD This will coincide with the head drawing a current of less than 2 5mA from the control unit thus ensuring the control unit is aware of the fault condition Note 1 xx is a number that defines a particular fault as follows 1 Checksum error 2 Zero cal
9. This may restrict the permissible cable length in some applications If in doubt consult Analox Ltd for assistance Document Ref P0102 802 00 April 2012 Page 2 7 NALO FGD3 Flammable Sensor User Manual 3 Menu mode selection In order to gain access to the menu switches and test points release the screw situated between the letters A and T of the chrome STATUS label on the detector head front panel The screw does not need to be completely removed only release it far enough so that the STATUS label can rotate revealing the calibration switches and test points The buttons and test points are designated as follows ee el e UP DOWN TP1 TP2 ENTER MENU Several calibration modes exist in the detector head and these are accessible via the instruments simple menu system To select a menu mode follow this procedure e Press the MENU button and C 1 appears on the display e Press UP or DOWN until the required menu mode is displayed on the screen e Press ENTER to select the menu mode e To exit the menu mode press MENU While the instrument is in a menu mode any data displayed on the screen will alternate between the menu number and the reading The FGD menu system is as follows Cal number Function Section 1 Zero sensor 3 1 2 Sensor span 3 2 3 Select FSD 3 3 4 Setting 4mA level 3 4 5 Setting 20mA level 3 5 6 Display mode 3 6 7 Display firmware version 3
10. ibration error 4 Span calibration error 8 Sensor reference low output 16 Sensor reference high output 32 Sensor detector low output 64 Sensor detector high output Note 2 There may be more than one fault i e F 6 The above fault numbers are simply added together thus Sensor requires zero calibration F2 Sensor requires zero calibration F4 N A LO Document Ref P0102 802 00 April 2012 Page 4 15 FGD3 Flammable Sensor User Manual 5 Sensor replacement Note Applies only to instruments fitted with an integral sensor a Inhibit the channel at the control unit b Disconnect power to the head at the control unit c Release the sensor retainer d Unplug the sensor from the PCB e Push the new sensor into the PCB making sure of the pin alignment f Refit the sensor retainer g Allow the sensor to stabilise for 1 to 2 hours prior to calibration h Calibrate the detector head i Enable the channel at the control unit Document Ref P0102 802 00 April 2012 N A LO Page 5 16 FGD3 Flammable Sensor User Manual 6 Certification The FGD3 flammable gas detectors carry the following markings ANAL X GAS DETECTOR TYPE FGD3 CE 1180 Ex I12G EExiad II C T4 20C lt Ta lt 60C BASEEFA BASO1ATEX2300 SERIAL No MANUFACTURER STATUS SCIENTIFIC CONTROLS LTD MANSFIELD NOTTINGHAM NG18 5ER UK A Ui li Pin Ci Li Termis Sig amp 0 30V 0 15A 0 81W 10nF 0 Termis 80 7 5V 0 75A 14W 9 7uF
11. ng MENU instead of ENTER aborts any changes the existing FSD factor will be displayed on exit e Press MENU the display will show the sensor FSD for the instrument before returning to its standard mode of operation 3 4 Setting 4mA level This calibration feature allows the instrument to simulate a condition of zero gas so that the 4mA output can be set e Attach a multimeter set to measure DC voltage between test points TP1 and TP2 e Select menu mode C 4 refer to section 3 and press ENTER e Using the UP and DOWN buttons adjust the reading displayed on the multimeter to 40mV 0 5mV e Press ENTER to store the 4mA calibration data Note Pressing MENU instead of ENTER aborts any changes the existing DAC 4mA factor will be displayed on exit e Press MENU the display will show the DAC 4mA calibration factor for the instrument before returning to its standard mode of operation Document Ref P0102 802 00 April 2012 N A LO Page 3 10 FGD3 Flammable Sensor User Manual 3 5 Setting 20mA level This calibration feature allows the instrument to simulate a condition of full scale gas so that the 20mA output can be set A control unit connected will indicate full scale gas also and may enter its alarm state e Attach a multimeter set to measure DC voltage between test points TP1 and TP2 e Select menu mode C 5 refer to section 3 and press ENTER e Using the UP and DOWN buttons adjust the reading displayed on the
12. ode C 8 refer to section 3 and press ENTER e Press ENTER to restore the factory default settings Note Pressing MENU instead of ENTER aborts any changes the existing sensor data is left intact e Press MENU to return the instrument to its standard mode of operation Sensor type Range display PELL 0 100 LEL O 100 CHTC 0 100 Volume 0 100 CHA H2TC 0 100 Volume H2 0 100 This feature will erase all the configuration settings of the detector head and replace them with the instruments default values for the sensor selected Following the use of this feature the instrument must have a full calibration including the 4 20mA loop 3 9 View engineer diagnostics data This feature is a view only feature No configuration changes are possible from within this menu This information is for the use of Analox Ltd e Select menu mode C 9 refer to section 3 and press ENTER The display will alternate between the current value and code C 9x where x is 0 Sensor reading 4 Detector A to D counts e The mode of operation can be selected by pressing the UP button e Press MENU to return the instrument to its standard mode of operation Note The diagnostic structure is compatible with other gas types and as such certain features are not available N A 3 10 Set cross reference Menu mode C 12 This option is used to allow the user to calibrate the sensor with a commonly available gas e g methane
13. onocononnnnnonnnnnncnnnn cnn nennen 3 13 3 12 Negative zero Suppression 3 14 3 13 Set D sewor nen 3 14 4 FGD3 head mdcatons susssrrasrrsseraserareraserssersrerssrersrersrersrrrsrr ennen esse rara RAR RAKA RAR RK rare renen 4 15 NN RS rss rra sansa rar R ar R RAKA AREA rr Erenn ete Ennet 4 15 4 2 High gas conditions esmsossrrsrrerasersr serarassrrenosrrsnsnsrrsrnrsrknno kr ARA RANA RAA RARA RAA A AEA naoin annae anaoa 4 15 A3 Fault condtons oossesseskannsssinansansnksnnsdasssnannadinsksnens nn iin eein R ARME ia LARERE AES 4 15 5 Sensor EI 5 16 A 00 1 67 110 9 cece 6 17 A 7 18 8 Declaration of conforme 8 19 N A LO Document Ref P0102 802 00 April 2012 Page 1 1 FGD3 Flammable Sensor User Manual Document Ref P0102 802 00 April 2012 N A LO Page 1 2 FGD3 Flammable Sensor User Manual 1 Introduction The detectors use the industry standard 4 20mA current loop to convey the gas levels detected to a control unit This means that under zero gas conditions 4mA is drawn from the supply and under full scale gas conditions 20mA is drawn from the supply The current varies linearly for gas levels between zero and full scale The detector heads require a three wire connection see section 1 1 4 While the loop current supplies the power required by the detector head electronics within the detector head a second supply must be provided to power the pellistor sensor and its associated circuitry 1 1 Installation 1 1 1 Si
14. pril 2012 N A LO Page 2 6 FGD3 Flammable Sensor User Manual 2 2 Installation using proprietary safety barriers Hazardous area Safe Area Input module Screen Screen OOO0009 Note The control unit OV is not connected to LS Earth Earth Connection diagram for FGD1 2 Flammable Detector in a Hazardous area l In order to maintain intrinsic safety the capacitance and inductance or inductance to resistance L R ratio of the loads connected to the terminals of the FGDIO barrier must not exceed specified values The capacitance and inductance or inductance to resistance L R ratio of the load connected to terminals 1 and 2 must not exceed the following values GROUP Capacitance Inductan OR L R Ratio in UF ce in uH ohm in mH IIC 0 083 3 44 IIB 0 65 12 177 IIA 2 15 25 355 The capacitance and inductance or inductance to resistance L R ratio of the load connected to terminals 4 and 3 must not exceed the following values GROUP Capacitance Inductan OR L R Ratio in UF ce in uH ohm in mH IC 11 1 0 07 28 IIB 174 0 28 114 IIA 1000 0 56 228 Warning When considering the suitability of an installation in terms of the load capacitance and inductance account must be taken of the interconnecting cable itself The figures in the tables must not be exceeded by the combination of the load parameters and the cable parameters
15. s Intrinsic safety i EN50018 2000 Electrical apparatus for potentially explosive atmospheres Flameproof enclosure d Notified Body for Hazardous Area Certification Notified Body for ATEX Quality Assurance Notification Baseefa Baseefa Rockhead Business Park Rockhead Business Park Staden Lane Buxton SK17 9RZ UK Staden Lane Buxton SK17 9RZ UK Notified Body Number 1180 Notified Body Number 1180 Hazardous Area Certificate Number ATEX Quality Assurance Notification Number Baseefa O1ATEX2300 E II 2 G EEx ia IIC 2056 T4 20 C lt Ta lt 60 C Place of Manufacture ISO 9001 2008 Quality Management System Mansfield Nottinghamshire UK Date mark applied see product Certificate No GB93 1938 2004 108 EC Electromagnetic Compatibility Harmonised Standards Used EN50270 2006 Electromagnetic compatibility Electrical apparatus for the detection and measurement of combustible gases toxic gases or oxygen Authorised Signatory to this declaration on behalf of the manufacturer Name W R Baxter Title Managing Director Address Status Scientific Controls Ltd Hermitage Lane Industrial Estate Kings Mill Way Mansfield Nottinghamshire NG18 5ER United Kingdom Signature Wi Date 15 04 11 LO Document Ref P0102 802 00 April 2012 Page 8 19
16. s Refer to manufacturer if an alternative control unit is used N A LO Document Ref P0102 802 00 April 2012 Page 2 5 FGD3 Flammable Sensor User Manual 2 1 Installation in a hazardous location When used in a hazardous area the FGD3 detector requires an intrinsically safe I S power supply This can be achieved by using proprietary safety barriers Hazardous area Safe Area na re ee I Connection diagram for an FGD l flammable detector in a l l l l Input module hazardous area I S barrier terminals Type FGDIO l l l 8 Note The control unit OV is not connected to Earth I I The use of barriers to create an I S supply imposes certain restrictions on the parameters of the interconnecting cables used Consult the barrier manufacturers data for further information Barriers must be selected to restrict the I S supply to the gas detectors within the following parameters Terminals Umax Imax Pin Ci Li OV and SIG 30V 0 15A 10nF 0 OV and 7 5V 0 75A 1 4W 9 7u 0 F When considering the capacitance and inductance allowable across the barrier output terminals note There is 10nF and zero inductance between terminals OV and SIG on the FGD3 detector head There is an equivalent of 9 7uF capacitance and zero inductance between terminals OV and on the FGD flammable gas detector Document Ref P0102 802 00 A
17. ting the screens depends upon the area in which the detector head is to be used i e hazardous non hazardous In all cases the screen should not be connected at the detector head Refer to the connection diagrams on the following pages for further information The FGD3 flammable detector head requires a three wire connection to the control unit Terminal Function Voltage Current Sig Current loop to head 8 0 to 28V 25mA max 0 OV return to control unit Supply for sensor 4 0 to 7 0V 200mA approx Document Ref P0102 802 00 April 2012 N A LO Page 1 4 FGD3 Flammable Sensor User Manual 2 Installation in a non hazardous location When a detector head is installed in an area where there is no potential of an explosive gas hazard present the cable lengths to the detector are limited solely by the resistance of the cable The FGD3 gas detector requires a minimum of 8V between the Sig and 0 terminals to allow it to operate correctly Input module A Sei et el Se Ae Z Seet SE ee Ge hae Screen a A lt Note The control unit OV is connected to Earth For systems operating at 24V the maximum cable loop resistance is therefore 24 8 25mA i e 6400 The diagram above shows connections for FGD3 detector head in a non hazardous location The pin numbers shown at the control unit refer to pin numbers on the Analox Ltd input modules within the MCU control unit
18. ting the sensors Mounting positions for sensors need to be considered individually some points for consideration are a Ensure all sensors are mounted to allow routine calibration and maintenance to be carried out as required b Ensure the proposed site will not interfere with movement of existing equipment e g cranes doors etc c Install all cables neatly and securely d Sensors for detecting gases that are lighter than air should be positioned at a high level e Sensors for gases heavier than air should be located at below head height f Avoid siting the sensors adjacent to potential sources of radio frequency interference e g radio transmitters control switchgear motors etc 1 1 2 Wire termination All connections should be made according to the appropriate sensor or loop diagram for the configuration required It is advised that bootlace ferrules or flat blade crimps be used for tidy and reliable connections of wires into the detector head connectors 1 1 3 Cable routing Due to the low signal levels generated by gas detectors it is recommended that all wiring to the sensors be segregated away from AC mains or other high voltage power lines to avoid interference N A LO Document Ref P0102 802 00 April 2012 Page 1 3 FGD3 Flammable Sensor User Manual 1 1 4 Cable amp screening The use of a screened cable is recommended for the installation of all detector heads The correct strategy for connec
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