Detcon PI-700 Manuale utente

INSTRUCTION MANUAL

Detcon Model PI-700

PI-700 VOC Gas Sensors

This manual covers all ranges of PID based VOC Sensors

DETCON, Inc.

4055 Technology Forest Blvd.,

The Woodlands, Texas 77381

Ph.281.367.4100 / Fax 281.298.2868

www.detcon.com

June 05, 2018 • Document #3228 • Revision 3.2

Model PI-700

Model PI-700 ii

This page left intentionally blank

Model PI-700

Model PI-700 iii

Table of Contents

1. Introduction ..................................................................................................................................................1

1.1 Description.......................................................................................................................................... 1

1.2 Sensor Electronics Design .................................................................................................................. 1

1.3 Modular Mechanical Design............................................................................................................... 2

1.4 Intelligent Plug-in PID Gas Sensor..................................................................................................... 3

2. Installation....................................................................................................................................................4

2.1 ATEX Operational Guidelines for Safe Use....................................................................................... 4

2.2 Sensor Placement................................................................................................................................ 5

2.3 Sensor Contaminants and Interference ............................................................................................... 6

2.4 Mounting Installation.......................................................................................................................... 6

2.5 Electrical Installation.......................................................................................................................... 9

2.6 Field Wiring...................................................................................................................................... 10

2.7 Initial Start Up................................................................................................................................... 12

3. Operation....................................................................................................................................................14

3.1 Programming Magnet Operating Instructions................................................................................... 14

3.2 Operator Interface............................................................................................................................. 15

3.3 Normal Operation ............................................................................................................................. 16

3.4 Calibration Mode.............................................................................................................................. 17

3.4.1 AutoZero....................................................................................................................................... 17

3.4.2 AutoSpan...................................................................................................................................... 17

3.5 Program Mode .................................................................................................................................. 20

3.5.1 View Sensor Status....................................................................................................................... 20

3.5.2 Set AutoSpan Level...................................................................................................................... 22

3.5.3 Set Serial ID ................................................................................................................................. 23

3.5.4 Set Range...................................................................................................................................... 23

3.5.5 Set Gas Factor............................................................................................................................... 24

3.5.6 Set Zero Offset.............................................................................................................................. 24

3.5.7 Signal Output Check..................................................................................................................... 25

3.5.8 Restore Factory Defaults .............................................................................................................. 25

3.6 Program Features .............................................................................................................................. 26

3.6.1 Operational Features..................................................................................................................... 26

3.6.2 Fault Diagnostic/Failsafe Features ............................................................................................... 26

4. RS-485 Modbus™ Protocol .......................................................................................................................29

Content Description.............................................................................................................................................29

5. Service and Maintenance............................................................................................................................31

5.1 PID Plug-In Sensor Maintenance...................................................................................................... 31

5.2 Replacement of Intelligent Plug-in Sensor ....................................................................................... 38

5.3 Replacement of ITM......................................................................................................................... 39

5.4 Replacement of PI-700 Sensor Assembly......................................................................................... 39

6. Troubleshooting Guide...............................................................................................................................41

7. Customer Support and Service Policy........................................................................................................44

8. PI-700 Sensor Warranty .............................................................................................................................45

9. Appendix ....................................................................................................................................................46

9.1 Specifications.................................................................................................................................... 46

9.2 Gas Reference Table......................................................................................................................... 48

9.3 Spare Parts, Sensor Accessories, Calibration Equipment................................................................. 55

10. Revision History.....................................................................................................................................56

Model PI-700

Model PI-700 iv

Table of Figures

Figure 1 Typical Sensor Cell................................................................................................................................ 1

Figure 2 ITM Circuit Functional Block Diagram................................................................................................. 2

Figure 3 Sensor Assembly Front View ................................................................................................................ 2

Figure 4 Sensor Assembly Breakaway................................................................................................................ 3

Figure 5 Intelligent Plug-in Sensor....................................................................................................................... 3

Figure 6 PI-700 ATEX Approval Label............................................................................................................... 4

Figure 7 Outline and Mounting Dimensions (Sensor Assembly only)................................................................. 7

Figure 8 Outline and Mounting Dimensions (Stainless Steel Junction Box)....................................................... 7

Figure 9 Outline and Mounting Dimensions (Aluminum Junction Box)............................................................. 8

Figure 10 Outline and Mounting Dimensions (Mini Stainless Steel Junction Box) ............................................ 8

Figure 11 Typical Installation ............................................................................................................................ 10

Figure 12 Sensor Wire Connections................................................................................................................... 11

Figure 13 Magnetic Programming Tool............................................................................................................. 14

Figure 14 Magnetic Programming Switches..................................................................................................... 14

Figure 15 PI-700 Software Flowchart................................................................................................................ 16

Figure 16 UV Lamp Aging Expectation ............................................................................................................ 31

Figure 17 Splashguard Adapter with Integral Filter........................................................................................... 32

Figure 18 Plug-in sensor with Moisture control packet ..................................................................................... 32

Figure 19 Sensor Cell Parts................................................................................................................................ 33

Figure 20 Removal of Filter Cap........................................................................................................................ 33

Figure 21 Removal of Filter Media.................................................................................................................... 34

Figure 22 Removal of Spacer............................................................................................................................. 34

Figure 23 Removal of Cell Assembly................................................................................................................ 34

Figure 24 Removal of Lamp .............................................................................................................................. 35

Figure 25 Lamp cleaning.................................................................................................................................... 35

Figure 26 Polishing the Lamp............................................................................................................................ 35

Figure 27 Lamp installation ............................................................................................................................... 36

Figure 28 Lamp seating...................................................................................................................................... 36

Figure 29 Cell Assembly installation................................................................................................................. 36

Figure 30 Spacer installation.............................................................................................................................. 37

Figure 31 Installing Filter Media........................................................................................................................ 37

Figure 32 Replacing the Cap.............................................................................................................................. 37

Figure 33 Sensor Assembly................................................................................................................................ 38

Figure 34 Sensor Cell and ITM Mating ............................................................................................................. 38

Figure 35 Sensor Cell and ITM Mating ............................................................................................................. 41

List of Tables

Table 1 Wire Gauge vs. Distance....................................................................................................................... 10

Table 2 Maximum and Minimum AutoSpan Settings........................................................................................ 22

Table 3 Modbus™ Registers.............................................................................................................................. 29

Table 4 Modbus™ Special Registers ................................................................................................................. 30

Table 5 Gas Factor Table ................................................................................................................................... 48

Shipping Address: 4055 Technology Forest Blvd., The Woodlands Texas 77381

Mailing Address: P.O. Box 8067, The Woodlands Texas 77387-8067

Phone: 888.367.4286, 281.367.4100 • Fax: 281.292.2860 • www.detcon.com • sales@detcon.com

Model PI-700

PI-700 Instruction Manual Rev. 3.2 Page 1 of 58

1. Introduction

1.1 Description

Detcon Model PI-700 VOC gas sensors are non-intrusive “Smart” sensors designed

to detect and monitor a wide range of VOC and Toxic gasses in air. Ranges of

detection for target gasses are from 0-1ppm up to 0-5,000ppm. The sensor features

an LED display of current reading, fault and calibration status. The Sensor is

equipped with standard analog 4-20mA and Modbus™ RS-485 outputs. A primary

feature of the sensor is its method of automatic calibration, which guides the user

through each step via fully scripted instructions displayed on the LED display.

The microprocessor-supervised electronics are packaged in an encapsulated module

and housed in an explosion proof casting, called the ITM (Intelligent Transmitter

Module). The ITM includes a four character alpha/numeric LED used to display

sensor readings, and the sensor’s menu driven features when the hand-held

programming magnet is used.

Sensor Technology

The sensors are based on plug-in replaceable miniature PID (Photo-Ionization Detector) sensor technology. The

sensor is sensitive to ambient gases that have ionization potentials of < 10.6eV, making it highly sensitive but

extremely non-specific. The sensor responds to most toxic VOC compounds and many other toxic gases as well.

The sensor is comprised of a UV lamp covered by a specific optical filter which projects only radiation in the

10.6eV range. Target gases that diffuse into the sensor chamber with ionization potentials of < 10.6eV, are

ionized by the radiation and give up free electrons. The free electrons are captured by the high voltage collection

grid and provide a current that is directly proportional to the concentration of the target gas.

Figure 1 Typical Sensor Cell

1.2 Sensor Electronics Design

Intelligent Transmitter Module

The PI-700 Intelligent Transmitter Module (ITM) is a fully encapsulated microprocessor-based package that is

universal in design and will accept any Detcon intelligent plug-in PID gas sensor. The ITM design uses an

internal intrinsically safe barrier circuit that lifts the requirement for use of flame arrestors to achieve Class 1,

Division 1 (Zone1) area classification. This facilitates fast response times and improved calibration repeatability

on strongly absorbing gas types. The ITM circuit functions include extensive I/O circuit protection, on-board

power supplies, internal intrinsically safe barrier circuit, microprocessor, LED display, magnetic programming

switches, a linear 4-20mA DC output, and a Modbus™ RS-485 output. Magnetic program switches located on

either side of the LED Display are activated via a hand-held magnetic programming tool, thus allowing non-

Model PI-700

PI-700 Instruction Manual Rev. 3.2 Page 2 of 58

intrusive operator interface with the ITM. Calibration can be accomplished without declassifying the area.

Electrical classifications are Class I, Division 1, Groups A B C D and are ATEX Approved for II 2G Ex d ib IIC

Gb area classifications.

Figure 2 ITM Circuit Functional Block Diagram

Program Switch #1 Program Switch #2

Splashguard Adapter

Locking Set-Screw

LED Display

detcon inc.

VOC

MODEL

PI-700

Figure 3 Sensor Assembly Front View

1.3 Modular Mechanical Design

The Model PI-700 Sensor Assembly is completely modular and is made up of four parts (See Figure 4 for

Assembly Break-away):

1) PI-700 Intelligent Transmitter Module (ITM)

2) Intelligent Plug-in Sensor (varies by range)

3) PI-700 Splash Guard Adapter with Integral Filter

4) Splash Guard.

NOTE: All metal components are constructed from electro polished 316 Stainless Steel in order to maximize

corrosion resistance in harsh environments.

Model PI-700

PI-700 Instruction Manual Rev. 3.2 Page 3 of 58

Housing Bottom

Locking Set-Screw

Splash Guard Intelligent ransmitter Module (ITM)

Microprocessor controlled circuit

encapsulated in an explosion

proof housing

Splashguard

Adapter Plug-In replaceable

Sensor Cell

Magnetic

Programming

Switches

Lens and LCD

Display Interconnect Wiring

O-Rings

detcon inc.

VOC

MODEL

PI-700

Figure 4Sensor Assembly Breakaway

1.4 Intelligent Plug-in PID Gas Sensor

The Detcon range of PID gas sensors are field proven, intelligent plug-in sensors (one type is used for ranges of

20ppm and less, another is used for ranges greater than 20ppm.) The Sensors employ 100% encapsulated

circuitry and over-sized gold-plated connections that eliminate corrosion problems. The intelligent design

provides automatic recognition of gas type, units, full-scale range, and calibrations data when a new sensor is

plugged in. The sensor can be accessed and replaced in the field very easily by releasing the locking setscrew

and unthreading the Splashguard Adapter. The PID Sensor cell can be disassembled so that the lamp used can

be cleaned or replaced. Detcon’s ranges of PID sensors has a long shelf life and are supported by an industry-

leading warranty.

Figure 5 Intelligent Plug-in Sensor

Model PI-700

PI-700 Instruction Manual Rev. 3.2 Page 4 of 58

2. Installation

2.1 ATEX Operational Guidelines for Safe Use

1. Install sensor only in areas with classifications matching with those described on the approval label.

Follow all warnings listed on the label.

Figure 6 PI-700 ATEX Approval Label

2. Ensure that the sensor is properly threaded into a suitable flameproof rated junction box with a

downward pointing female ¾” NPT threaded connection. The sensor should be threaded up at least 5

full turns until tight, with the LED display facing forward (+/- 15°). Minimize use of Teflon Tape, or

any type of non-conductive pipe thread coating on the NPT threaded connection.

3. A good ground connection should be verified between the sensor’s metal enclosure and the junction

box. If a good ground connection is not made, the sensor can be grounded to the junction box using the

sensor’s external ground lug. Also verify a good ground connection between the junction box and earth

ground.

4. Proper precautions should be taken during installation and maintenance to avoid the build-up of static

charge on the plastic components of the sensor. These include the splashguard and splashguard adapter.

5. Do not substitute components that are not authorized by the scope of the safety approval. This may

impair the intrinsic safety rating.

6. Do not operate the sensor outside of the stated operating temperature limits.

7. Do not operate the sensor outside the stated operating limits for voltage supply.

8. The sensor power supply common (black wire) must be referenced to the metal enclosure body (ground)

during installation.

9. These sensors meet EN60079-0:2012, EN60079-1:2007, and EN60079-11:2012.

10. These sensors have a maximum safe location voltage of Um=125V.

11. These sensors pass dielectric strength of 500VRMS between circuit and enclosure for a minimum of 1

minute at a maximum test current of 5mA.

Model PI-700

PI-700 Instruction Manual Rev. 3.2 Page 5 of 58

2.2 Sensor Placement

Selection of sensor location is critical to the overall safe performance of the product. Six factors play an

important role in selection of sensor locations:

(1) Density of the gas to be detected

(2) Most probable leak sources within the industrial process

(3) Ventilation or prevailing wind conditions

(4) Personnel exposure

(5) Maintenance access

(6) Additional placement considerations

Density

Placement of sensors relative to the density of the target gas is such that sensors for the detection of heavier than

air gasses should be located within 4 feet of grade as these heavy gasses will tend to settle in low lying areas.

For gasses lighter than air, sensor placement should be 4-8 feet above grade in open areas or in pitched areas of

enclosed spaces.

Leak Sources

The most probable leak sources within an industrial process include flanges, valves, and tubing connections of

the sealed type where seals may either fail or wear. Other leak sources are best determined by facility engineers

with experience in similar processes.

Ventilation

Normal ventilation or prevailing wind conditions can dictate efficient location of gas sensors in a manner where

the migration of gas clouds is quickly detected.

Personnel Exposure

The undetected migration of gas clouds should not be allowed to approach concentrated personnel areas such as

control rooms, maintenance or warehouse buildings. A more general and applicable thought toward selecting

sensor location is combining leak source and perimeter protection in the best possible configuration.

Maintenance Access

Consideration should be given to providing easy access for maintenance personnel. Consideration should also

be given to the consequences of close proximity to contaminants that may foul the sensor prematurely.

NOTE: All installations of the gas sensor should point straight down (refer to Figure 11).

Improper sensor orientation may result in false readings and permanent sensor damage.

Additional Placement Considerations

The sensor should not be positioned where it may be sprayed or coated with surface contaminating substances.

Painting sensor assemblies is prohibited.

Although the sensor is designed to be RFI resistant, it should not be mounted in close proximity to high-powered

radio transmitters or similar RFI generating equipment.

Mount in an area void of high wind, accumulating dust, rain or splashing from hose spray, direct steam releases,

and continuous vibration. If the sensor cannot be mounted away from these conditions then make sure the

Detcon Harsh Environment Splashguard accessory is used.

Model PI-700

PI-700 Instruction Manual Rev. 3.2 Page 6 of 58

Do not mount in locations where temperatures will exceed the operating temperature limits of the sensor. Where

direct sunlight leads to exceeding the high temperature-operating limit, use a sunshade to help reduce

temperature.

2.3 Sensor Contaminants and Interference

PID VOC and toxic gas sensors will respond to any gas with an ionization potential <10.6eV. This is not a

selective measurement technique, and hence can be used to measure a wide range of gases.

Some of the most commonly present gasses that potentially cause PID interference are listed in Table 5 Gas

Factor Table (refer to Section 9). The presence of cross-interference gases in an area does not preclude the use

of this sensor technology, although itis likely that the sensor will experience false high readings should exposure

occur.

Some heavy organic molecules may be polymerized onto, or strongly adhere to, the optical filter of the lamp.

When this occurs, the lamp will require cleaning or replacement.

Relative Response Gas Matrix

Table 5 Gas Factor Table shows the response of the PID sensor to a long list of components. It includes the

compound name, synonyms/abbreviations, and chemical formula. It also lists the 10.6eV Response Factor (the

measure of how strong the signal from the sensor is in reference to Isobutylene gas). Isobutylene gas is the

standard reference used with PID sensors, the lower the Response Factor, the stronger the signal.

2.4 Mounting Installation

The PI-700 sensor assembly is designed to be threaded into a ¾” Female NPT fitting of a standard cast metal,

Explosion-Proof Enclosure or Junction Box. Thread the sensor up until tight (5 turns is typically expected) and

until the display is pointed in the direction that sensor will normally be viewed and accessed.

The PI-700 should be vertically oriented so that the sensor points straight down. The explosion-proof enclosure

or junction box would then typically be mounted on a wall or pole. Detcon provides a standard selection of

junction boxes available as sensor accessories (See Figures 7, 8, and 9 below). Any appropriately rated enclosure

with a downward facing ¾” NPT female connection will suffice.

When mounting on a wall, it is recommended to use a 0.25”-0.5” spacer underneath the mounting ears of the

Detcon standard J-Box to offset the sensor assembly from the wall and create open access around the sensor

assembly. Spacing requirements for other junction boxes may vary.

When mounting on a pole, secure the Junction Box to a suitable mounting plate and attach the mounting plate

to the pole using U-Bolts. (Pole-Mounting brackets for Detcon J-box accessories are available separately.)

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