Detcon 1000 Manuale utente

Model 1000

H2S E-Chem/ CO2Process Analyzer

SAMPLE

FLOW AIR

FLOW

SAMPLE

FLOW

+ +

24VDC

OUT

2.1A

18-36

VDC

Operator’s Installation and Instruction Manual

Detcon Model 1000 H2S/CO2Analyzer consists of two major assemblies:

1. The Model 1000 Series gas sample-conditioning assembly.

2. The Model DM-624 H2S Electrochemical and Model IR-640/IR642 CO2gas sensors.

DETCON, Inc.

4055 Technology Forest Dr. Suite 100,

The Woodlands, Texas 77387

Ph.281.367.4100 / Fax 281.298.2868

www.detcon.com

December 4, 2018• Document #3208• Revision 0.8

1000 H2S EChem/CO2

Model 1000 H2S E-Chem/CO2 Manual ii

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Shipping Address: 4055 Technology Forest Dr. Suite 100, 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 • [email protected]

 
 
H2S EChem/CO2 
 
Model 1000 H2S E-Chem/CO2 Manual iii 
Table of Contents 
Introduction.............................................................................................................................................. 1 
1 DM-624 Description (Sensor #1)......................................................................................................... 1 
2 IR-640/IR-642 Description (Sensor #2)............................................................................................... 4 
3 Enclosures ............................................................................................................................................ 7 
Specifications............................................................................................................................................ 8 
Installation................................................................................................................................................ 9 
1 Mounting.............................................................................................................................................. 9 
2 Gas Connections and Sampling System............................................................................................... 9 
3 Electrical Connections........................................................................................................................ 12 
4 Relays and RS-485 Setup (DM-624 and IR-640/IR-642).................................................................. 13 
Start Up................................................................................................................................................... 15 
Operating Software ............................................................................................................................... 18 
1 Programming Magnet Operating Instructions.................................................................................... 18 
2 Operating Software (DM-624)........................................................................................................... 18 
2.1 Normal Operation ...................................................................................................................... 18 
2.2 Calibration Mode....................................................................................................................... 19 
2.3 Program Mode ........................................................................................................................... 19 
2.4 Software Flow Chart .................................................................................................................. 21 
3 Operating Software (IR-640/IR-642)................................................................................................. 22 
3.1 Normal Operation ...................................................................................................................... 22 
3.2 Calibration Mode....................................................................................................................... 22 
3.3 Program Mode ........................................................................................................................... 22 
3.4 Software Flow Chart .................................................................................................................. 24 
Calibration.............................................................................................................................................. 25 
1 DM-624 H2S Sensor Calibration........................................................................................................ 25 
2 IR-640/IR-642 CO2Sensor Calibration.............................................................................................. 27 
Programming Alarms............................................................................................................................ 29 
1 Alarm Levels –DM-624 H2S Sensor................................................................................................. 29 
2 Alarm Levels –IR-640/IR-642 CO2Sensor....................................................................................... 29 
3 Alarm Reset (DM-624 and IR-640/IR-642)....................................................................................... 30 
4 Other Alarm Functions....................................................................................................................... 30 
Program Features.................................................................................................................................. 30 
1 DM-624 H2S Sensor........................................................................................................................... 30 
2 IR-640/IR-642 CO2Sensor................................................................................................................. 31 
RS-485 Protocol ..................................................................................................................................... 32 
Display Contrast Adjustment............................................................................................................... 34 
Low Flow Fault Options........................................................................................................................ 34 
Sensor Replacement............................................................................................................................... 34 
1 Electrochemical –DM-624 H2S Sensor............................................................................................. 34 
2 Optical Sensor –IR-640/IR-642 CO2Sensor..................................................................................... 35 
Troubleshooting..................................................................................................................................... 35 
1 DM-624 H2S Sensor........................................................................................................................... 35 
2 IR-640/IR-642 CO2Sensor................................................................................................................. 36 
Spare Parts............................................................................................................................................. 37 
Warranty................................................................................................................................................ 41 
Flow Diagrams....................................................................................................................................... 42 
Wiring Diagram..................................................................................................................................... 45 
Appendix C....................................................................................................................................................... 46 
Revision Log .................................................................................................................................................. 46 
 

 
 
 1000 H2S EChem/CO2 
 
Model 1000 H2S E-Chem/CO2 Manual iv 
Table of Figures 
Figure 1 DM-624.................................................................................................................................................. 1 
Figure 2 Construction of Electrochemical Sensor................................................................................................ 2 
Figure 3 Functional Block Diagram..................................................................................................................... 3 
Figure 4 DM-624 Control Circuit ........................................................................................................................ 3 
Figure 5 Connector Board Terminals................................................................................................................... 3 
Figure 6 IR-640.................................................................................................................................................... 4 
Figure 7 Sensor Diagram...................................................................................................................................... 5 
Figure 8 Response Curve ..................................................................................................................................... 5 
Figure 9 Principle of operation............................................................................................................................. 6 
Figure 10 Functional Block Diagram................................................................................................................... 6 
Figure 11 Control Circuit..................................................................................................................................... 7 
Figure 12 Connector Board Terminals................................................................................................................. 7 
Figure 13 Enclosures............................................................................................................................................ 8 
Figure 14 Unit Dimensions .................................................................................................................................. 9 
Figure 15 Port Identification .............................................................................................................................. 10 
Figure 16 Port Identification with Dilution........................................................................................................ 11 
Figure 17 Installation Wiring Connections ........................................................................................................ 12 
Figure 18 Alarm Jumpers................................................................................................................................... 13 
Figure 19 RS-485 Dip Switches......................................................................................................................... 14 
Figure 20 Rotameters and Gas Connections ...................................................................................................... 16 
Figure 21 Rotameters and Gas Connections with Air Dilution.......................................................................... 17 
Figure 22 Programming Magnet ........................................................................................................................ 18 
Figure 23 DM-624 Software Flow Chart ........................................................................................................... 21 
Figure 24 IR-640/IR/642 Software Flow Chart.................................................................................................. 24 
Figure 25 DM-624 Replacement Parts............................................................................................................... 37 
Figure 26 IR-640/IR-642 Replacement Parts..................................................................................................... 38 
Figure 27 Analyzer Spare Parts.......................................................................................................................... 39 
Figure 28 Analyzer with Air Dilution Spare Parts............................................................................................. 40 
Figure 29 Unit Flow Diagram............................................................................................................................ 42 
Figure 30 Unit Flow Diagram with dilution....................................................................................................... 43 
Figure 31 Pump Box Flow Diagram .................................................................................................................. 44 
Figure 32 Wiring Diagram................................................................................................................................. 45 
 
 

1000 H2S EChem/CO2

Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 1 of 47

1. Introduction

The Detcon Model 1000 Series H2S/CO2Process Analyzer is a 110/220VAC or 24VDC powered analyzer that

provides a select gas sample mixture to on-board DM-624 H2S and IR-640/IR-642 CO2gas sensor assemblies.

The ranges of analysis are determined at time of order.

When located outdoors, the H2S/CO2Process Analyzer package should be appropriately covered from direct

weather exposure. The Model 1000 Series H2S/CO2Process Analyzer can optionally be ordered with a full

NEMA 4 enclosure.

The “Power Supply” enclosure on the upper right side of the unit houses a 24 VDC power supply, a 24V DC-

DC Converter, and a terminal PCB labeled for all input and output field wiring. The “Pump/Flow” enclosure

located on the upper left houses an air dilution pump, an activated carbon scrubber, and optional air flow fault

and sample flow fault alarm PCB’s.

The analyzer requires a constant, liquid-free, 10±2 psig sample pressure, which is provided by the customer or

may be supplied by Detcon as a separate gas sample handling system.

The on-board gas sample conditioning system includes a stainless steel pressure gauge (0-30 psig), and a Genie

membrane filter to provide the analyzer with absolute condensate liquid protection. On the bypass port of the

Genie membrane filter, a 15 psig over-pressure relief valve and flow control valve are also provided. The flow

control valve can be usedas a sample bypass andliquid exhaust vent. A two part air and one part sample mixture

is maintained and delivered to the Model DM-624 H2S for analysis. The IR-640/IR-642 CO2gas sensor

measures the sample directly, except in units that utilize Air dilution. The IR-640 0-15% range units that utilize

air dilution for the CO2use the same 2 part air and one part sample mixture as the H2S sensor. The H2S sample

flow is maintained by a constant-flow ‘Mass Flow controller’ and an associated rotameter, while airflow is

maintained by a control valve rotameter. The sample for the CO2sensor is set by a control valve rotameter. One

or Two 3-way valves are provided for manually switching between sample monitoring and span calibrations.

1.1 DM-624 Description (Sensor #1)

Figure 1 DM-624

1000 H2S EChem/CO2

Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 2 of 47

Detcon MicroSafe™ Model DM-624, toxic sensors are non-intrusive “Smart” sensors designed to detect and

monitor for H2S gas in parts per million (ppm). One of the primary features of the sensor is its method of

automatic calibration, which guides the user through each step via instructions displayed on the backlit LCD.

The sensor features field adjustable, fully programmable alarms and provides relays for two alarms plus fault as

standard. The sensor comes with two different outputs: analog 4-20mA, and serial RS-485. These outputs allow

for greater flexibility in system integration and installation. The microprocessor-supervised electronics are

packaged as a plug-in module that mates to a standard connector board. Both are housed in a condulet that

includes a glass lens window, which allows for the display of sensor readings as well as access to the sensor’s

menu driven features via a hand-held programming magnet.

Electrochemical Sensor

The sensor is an electrochemical cell. Each cell consists of three electrodes embedded in an electrolyte solution

all housed beneath a diffusion membrane. Sensitivity to specific target gases is achieved by varying composition

of any combination of the sensor components. Good specificity is achieved in each sensor type. The cell is

diffusion limited via small capillary barriers resulting in long service life of up to 3 or more years depending on

the application.

NOTE: This particular sensor cell is unique in that it has no cross-sensitivity to alcohol vapors and thus is

a good choice for measuring H2S in natural gas pipelines.

Figure 2 Construction of Electrochemical Sensor

DM-624 Electrochemical Sensor Principle of Operation

Method of detection is by an electrochemical reaction at the surface of an electrode called the sensing electrode.

Air and gas diffuse through the stainless steel filter and the capillary diffusion barrier. The controlling circuit

maintains a small external operating voltage between the sensing and counter electrodes of the proper bias and

magnitude so that no current flows to or from the reference electrode while its potential is maintained at the

correct fixed voltage —usually ground. The electrochemical reaction creates a change in current flow from the

counter electrode to the sensing electrode. This change in current is proportional to the gas concentration and is

reversible. The quick response of the sensor results in continuous monitoring of ambient air conditions.

Microprocessor Control Circuit

The control circuit is microprocessor based, and is packaged as a plug-in field replaceable module, facilitating

easy replacement and minimum down time. Circuit functions include a basic sensor pre-amplifier, on-board

power supplies, microprocessor, back lit alpha numeric display, alarm status LED indicators, magnetic

programming switches, an RS-485 communication port, and a linear 4-20 mA DC output.

1000 H2S EChem/CO2

Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 3 of 47

Figure 3 Functional Block Diagram

Figure 4 DM-624 Control Circuit

Base Connector Board

The base connector board is mounted in the enclosure and includes: the mating connector for the control circuit,

reverse input and secondary transient suppression,input filter, alarm relays, lugless terminals for all field wiring,

and a terminal strip for storing unused programming jumper tabs. The alarm relays are contact rated 5 amps @

250 VAC, 5 amps @ 30 VDC and coil rated at 24 VDC. Gold plated program jumpers are used to select either

the normally open or normally closed relay contacts.

Figure 5 Connector Board Terminals

1000 H2S EChem/CO2

Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 4 of 47

Interference Data

DM-624 series electrochemical sensors are subject to interference from other gases. This interaction is shown

in the following table as the relation between the amount of the interfering gas applied to the sensor, and the

corresponding reading that will occur (in ppm).

Gas Interference

Carbon monoxide 300ppm 1.5ppm

Chlorine 1ppm = -0.2ppm

Ethyl mercaptan 3ppm = 1ppm

Ethylene 100ppm = 0

Hydrogen 1% = < 5ppm

Hydrogen chloride 5ppm = 0

Hydrogen cyanide 10ppm = 0

Nitric oxide 35ppm < 2ppm

Nitrogen dioxide 5ppm = -0.5ppm

Sulfur dioxide 5ppm < 1ppm

Methyl mercaptan 2ppm = 1ppm

1.2 IR-640/IR-642 Description (Sensor #2)

Figure 6 IR-640

Detcon MicroSafe™ Model IR-640 carbon dioxide gas sensors are non-intrusive “Smart” sensors designed to

detect and monitor CO2gas in the 0-5% range. Using air dilution, the IR-640 can be used to measure 0-15%.

The Detcon Model IR-642 is used to measure CO2gas in ranges from 0-10% up to 0-100% without air dilution.

One of the primary features of the sensors is its method of automatic calibration, which guides the user through

each step via instructions displayed on the backlit LCD. The sensor features field adjustable, fully programmable

alarms, and provides relays for two alarms plus fault as standard. The sensor comes with two different outputs:

analog 4-20mA, and serial RS-485. These outputs allow for greater flexibility in system integration and

installation. The microprocessor-supervised electronics are packaged as a plug-in module that mates to a

standard connector board. Both are housed in an condulet that includes a glass lens window, which allows for

the display of sensor readings as well as access to the sensor’s menu driven features via a hand-held

programming magnet.

1000 H2S EChem/CO2

Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 5 of 47

The sensor technology is a field proven “plug-in replaceable” non-dispersive infrared (NDIR) optical type.

NDIR optical sensors show an excellent response to CO2. The NDIR type sensor is characteristically stable for

both span and zero and is capable of providing reliable performance with low maintenance requirements for

periods approaching 5 years in most industrial environments.

Figure 7 Sensor Diagram

Non-dispersive infrared (NDIR) optical sensor

The Detcon NDIR sensor is designed as a miniature single piece “plug-in replaceable” component, which can

easily be changed out in the field. The NDIR sensor consists of an infrared lamp source, two pyroelectric

detectors, and an optical gas sample cavity. The lamp source produces infrared radiation, which interacts with

CO2as it travels through the optical gas sample cavity. The infrared radiation contacts each of two pyroelectric

detectors at the completion of the optical path. The “active” pyroelectric detector is cove red by a filter specific

to the part of the IR spectrum where CO2absorbs light. The “reference” pyroelectric detector is covered by a

filter specific to the non-absorbing part of the IR spectrum. When CO2is present, it absorbs IR radiation and

the signal output from the “active” pyroelectric detector decreases accordingly while the “reference” detector

output remains unchanged. The ratio of the “active” and “reference” detector outputs is then used to compute

CO2concentration.

Figure 8 Response Curve

Infrared Sensor Principal of Operation

CO2in the sample stream diffuses through a sintered stainless steel flame arrestor and into the volume of the

sample gas optical cavity. A lamp source provides a cyclical IR radiation source, which travels through the

optical gas sample cavity and terminates at two pyroelectric detectors. The “active” and “reference” pyroelectric

1000 H2S EChem/CO2

Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 6 of 47

detectors each give an output, which measures the intensity of the radiation contacting their surface. The “active”

pyroelectric detector is covered by an optical filter specific to the part of the IR spectrum where CO2absorbs

light. The “reference” pyroelectric detector is covered by a filter specific to the non-absorbing part of the IR

spectrum. When present, CO2absorbs a fraction of the IR radiation and the signal output from the “active”

pyroelectric detector decreases accordingly. The signal output of the “reference” detector remains unchanged

in the presence of CO2. The ratio of the “active” and “reference” detector signal outputs is then used to compute

CO2concentration. By using the ratio of the active/reference signal outputs, measurement drift caused by

changes in the intensity of the lamp source and changes in the optical path are negated.

Figure 9 Principle of operation

Characteristics

The NDIR optical sensor element maintains strong sensitivity to CO2, as shown in the Figure 9. Typical zero

calibration intervals would be quarterly and typical span calibration intervals would be quarterly to bi-annual.

However, actual field experience is always the best determination of appropriate calibration intervals.

The NDIR optical sensor readings can be adversely affected by dust, dirt and oil mist accumulation as well as

severe corrosion. These deposits may reduce the optical reflectivity inside the sensor, and although accurate

readings are continually maintained, excessive loss in useable signal eventually gives way to noise and unstable

readings. The optical sensor may, over a long period of time (3-7 years), lose its IR lamp source filament, and

in this case, an optical sensor modular replacement is required. The IR-640/IR-642 has an extensive list of Fault

Diagnostics to alert and pinpoint operational problems. See section 13 Troubleshooting,

Microprocessor Control Circuit

The control circuit is microprocessor based and packaged as a plug-in field replaceable module, facilitating easy

replacement and minimum down time. Circuit functions include a basic sensor pre-amplifier, sensor temperature

measurement, on-board power supplies, microprocessor, back lit alpha numeric display, alarm status LED

indicators, magnetic programming switches, an RS-485 communication port, and a linear 4-20mA DC output.

Figure 10 Functional Block Diagram

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