Combustible Gas Controller R8471A Instructions Manual

Instructions 95-8398Combustible Gas ControllerR8471A6.1 Rev: 12/10 95-8398Section I - General InformationDescription ..........................................................1Features ................................................................1speciFications .....................................................1system operation ..............................................5sensor .................................................................5transmitter ..........................................................5controller ............................................................5Faceplate Description ...................................5setpoints .......................................................6outputs .........................................................6automatic Diagnostics and Fault identification ...........................................7operating modes ..........................................8Section II - System Installationinstallation .......................................................10sensor location ................................................10General Wiring requirements ........................... 11sensor separation ............................................12sensor installation ......................................13Wiring requirements ..................................13sensor Voltage adjustment (model 505) ....14sensor/transmitter Wiring (without sensor separation) .................................................14controller Wiring ...............................................15Field Wiring connector ...............................15controller programming ....................................18normally open/closed relays ...................18latching/non-latching relays ....................18normally energized/De-energized relays .184-20 ma output ..........................................18installation checklist ..................................19Section III - System Startupstartup proceDure ........................................20setpoint aDjustment ......................................20setpoint Display mode ......................................20setpoint adjustment procedure ........................21calibration .........................................................21conversion (k) Factor .......................................22calibration procedure .......................................22setting controller Default Values ................23transmitter calibration procedure (model 505) ..........................................23alternate transmitter calibration procedure (for model 505 transmitters) ................24controller calibration procedure ................25current output calibration ................................26Section IV - System Maintenanceroutine maintenance .....................................27manual check of output Devices .....................27checkout in normal mode ................................27sensor replacement ........................................27controller calibration ..................................27transmitter calibration ...............................27troubleshootinG ............................................28loss oF sensor sensitiVity ..........................28replacement parts .........................................30DeVice repair anD return .............................30orDerinG inFormation ...................................30Table of Contentsii1 95-83986.1Section IGeneral InformationDESCRIPTIONThe R8471A Combustible Gas Controller monitors a 4-20 mA signal generated by a Det-Tronics catalytic sensor based gas detector such as the Model 505 or U9500A Infiniti detector. The single channel system operates in the range of 0 to 100% LFL (lower flam-mable limit). Controller response includes actuation of solid state or optional relay outputs for direct con-trol of field response devices, a full array of faceplate indicators, as well as an optional 4-20 mA output for transmitting system information to other monitoring devices.FEATURES• Controller accepts a 4-20 mA input, ensuring com-patibility with a variety of catalytic gas detectors.• Digital display, bar graph display, and high intensity LEDs indicate important system status information.• AutoCal feature ensures easy and accurate calibra-tion.• Easy programming.• Base model is furnished with solid state alarm and fault outputs.• Premium model is furnished with relay outputs and a 4-20 mA dc output.• Current output is selectable for isolated/non-isolated operation.• Variety of racks available in 4U or 3U height config-uration.SPECIFICATIONSControllerOPERATING VOLTAGE—24 vdc. Can operate in the range of 18 to 32 vdc.MAXIMUM RIPPLE—Ripple should not exceed 5 volts peak-to-peak. The sum of dc plus ripple must be =18 vdc and = 32 vdc.SOLID STATE OUTPUTS (Base model only)—The outputs are open collector transistors with a 100K resistor from the collector to emitter with the emitter grounded, rated 100 mA at 32 volts dc maximum.RELAY CONTACTS (Premium model only)—Selectable normally open/normally closed contacts rated 5 amperes at 30 vdc/250 vac. See Table 1 for selectable relay options.CURRENT OUTPUT (Premium model only)—4-20 mA dc current, with a maximum loop resistance of 600 ohms at 20 to 32 vdc. InStrUCtIonSCombustible Gas ControllerR8471A6.1 ©Detector electronics Corporation 2010 Rev: 12/10 95-83982 95-83986.1POWER CONSUMPTION (CONTROLLER ONLY)—Base model: 0.7 watt nominal, 1.3 watts maximum (25 mA nominal, 50 mA maximum at 24 vdc.)Premium model: 1.2 watts nominal, 3.5 watts maxi-mum (50 mA nominal, 145 mA maximum at 24 vdc.)TEMPERATURE RANGE—Operating: +32°F to +140°F (0°C to +60°C)Storage: –49°F to +185°F (–45°C to +85°C).HUMIDITY RANGE—5 to 99% RH, non-condensing.OPERATING RANGE—0 to 100% LFL.ACCURACY—±3% of full scale over specified temperature range.DIMENSIONS—See Figure 1.SHIPPING WEIGHT (approximate)—2.0 pounds (0.9 kilogram).SYSTEM APPROVAL—The R8471A Combustible Gas Controller, base and premium model in 3U and 4U height, has been tested and approved by FM. It can be used with any FM approved gas sensing device capable of generating a 4-20 mA input.FM approval of the R8471A Combustible Gas Controller, however, does not include or imply approval of input devices such as sensors or transmitters, or devices connected to the controller outputs. To maintain FM system approval, all equipment connected to the controller must be FM approved. Note that while the Det-Tronics combustible gas sensor with K Series transmitter are fully compatible with the R8471A Controller, they have not been FM tested and approved for use with the R8471A Controller.NOTEEnsure sensor hazardous (classified) location rating is applicable for the intended use.The R8471A Combustible Gas Controller must be used only in non-hazardous locations.ATEX: CE Mark, EN 60079-29-1 Compliant. 0539 DEMKO 04 ATEX 134903X FMAPPROVED II (2) G. EN 60079-29-1Special Conditions for Safe Use:The R8471A Combustible Gas Controller is to be placed outside the hazardous area.The R8471A Combustible Gas Controller must be used only in conjunction with the Detector Electronics Corporation Model CGS Combustible Gas Sensor.Performance testing to en60079-29-1The measuring function of the Combustible Gas Controller Model R8471A, according to Annex II paragraph 1.5.5, 1.5.6 and 1.5.7 of the Directive 94/9/EC is, for methane, covered in the EC-Type Examination Certificate in the following configuration: — Controller Model R8471A with Sensor Termination Box Model STB and Infinity Transmitter Model U9500A and Combustible Gas Sensor Model CGS (tested as a gas detection system with methane applied to the CGS). Figure 1—Controller Dimensions in Inches (Centimeters)Table 1—Selectable Relay Options relay Selectable Selectable Selectable normally normally latch/ open/Closed energized/ non-latch De-energizedLow Y Y YHigh Y Y N1Auxiliary Y Y YFault Y N2 N3Y = Yes N = No 1Latching only2Normally energized 3No latching option?? 9.3 (23.6)1.0(2.5) 7.0*(17.8)????A1526 * 4U DIMENSIONS SHOWN, 3U HEIGHT IS 5.2 (13.3)3 95-83986.1MoDel 505 CatalytIC SenSor BaSeD GaS DeteCtorINPUT VOLTAGE—With signal loop impedance option A: 10 to 30 vdcWith signal loop impedance option B: 17 to 30 vdc.Refer to the Model 505 instruction manual (form number 95-8472) for additional information regarding imped-ance option.Linear, regulated, filtered 24 vdc power source is rec-ommended.POWER CONSUMPTION—4.0 watts maximum.PEAK STARTUP CURRENT—Less than 0.5 ampere for < 0.2 second at 10 vdc input, and less than 0.2 ampere for < 0.2 second at 24 vdc input.OUTPUT CURRENT—Linear 4-20 mA.CURRENT LEVEL—Fault: < 2.0 mA.Calibration Mode: 3.4 mA (non-adjustable).LOAD RESISTANCE—Option A: 125 ohms maximum.Option B: 500 ohms maximum.Refer to the Model 505 instruction manual (form number 95-8472) for additional information regarding imped-ance option.TEMPERATURE RANGE—Operating: –40°F to +167°F (–40°C to +75°C).Storage: –67°F to +185°F (–55°C to +85°C).HUMIDITY RANGE—0 to 99% RH, non-condensing.DIMENSIONS—See Figure 2.RFI/EMI IMMUNITY—Less than ± 0.5 mA signal output variation with a 5 watt, 157 Mhz or 451 Mhz walkie-talkie keyed at distances greater than 1 foot from Model 505 with junction box cover installed.Complies with EN50081-1, EN50082-2.CERTIFICATION—ATEX: Refer to Appendix. 0539 DEMKO 02 ATEX 131329X See Model 505 ATEX Certificate 131329X.3.46(8.8)4.7(11.9)2.7(6.9)5.2(13.2)5.86(14.9)A25313.77(9.6)1.28(3.3)Figure 2—Dimensions of Transmitter Junction Box in Inches (CM)4 95-83986.1MoDel CGS CatalytIC SenSorTEMPERATURE RANGE*—–67°F to +302°F (–55°C to + 150°C).*Materials suitable for installation in this range.HUMIDITY RANGE—0 to 99% RH, non-condensing.RESPONSE TIME—50% full scale in < 10 seconds with 100% LFL applied.90% full scale in < 30 seconds with 100% LFL applied.60% full scale in < 10 seconds with 100% methane by volume in air (CSA flooding test).RECOVERY TIME—Less than 30 seconds after exposure to pure methane. ACCURACY—±3% LFL from 0 to 50% LFL,±5% LFL from 51% to 100% LFL.REPEATABILITY—±1% LFL.LONG TERM STABILITY—Zero: < 1% LFL per month.Span: < 1% LFL per month in clean air.TEMPERATURE STABILITY—< ±5% LFL: –13°F to +167°F (–25°C to +75°C).< ±10% LFL: –40°F to –13°F (–40°C to –25°C).TYPICAL SENSOR LIFE—3 to 5 years, when environment is free of substances and conditions known to be detrimental to catalytic sensing elements.STORAGE LIFE—Indefinite if sensor is stored within the specified temper-ature range and remains in unopened original packag-ing.CALIBRATION CYCLE—90 days typical.CERTIFICATION—FM and CSA: Class I, Div. 1, Groups B, C & D. Explosion-proof verified: –-40°F to +257°F (–40°C to +125°C). Performance verified: –40°F to +167°F (–-40°C to +75°C).ATEX: Refer to Appendix. 0539 DEMKO 02 ATEX 131323X See CGS ATEX Certificate 131323X.DIMENSIONS—See Figure 4. 2.0(5.2)1.5(3.8)1.7(4.4)3/4 INCHSTANDARD PIPE THREADOR M20D1213Figure 4—Dimensions of Sensor in Inches (CM)5 95-83986.1SYSTEM OPERATIONSenSorDet-Tronics CGS Series combustible gas sensors use a catalytic type sensing element and operate in the range of 0 to 100% LFL. With proper calibration, the CGS sensor will accurately detect a wide variety of combustible gases. The CGS sensor is always installed with a transmitter to provide a 4-20 mA sig-nal.tranSMItterThe transmitter functions as the interface between the sensor and the controller. It regulates operating power to the sensor and generates a linear 4-20 mA output signal proportional to 0 to 100% LFL combusti-ble gas concentration. The transmitter is housed in a sealed, explosion-proof metal enclosure.A transmitter output signal of less than 4 mA is dis-played as a negative reading by the controller. The sensor is normally threaded directly to the trans-mitter enclosure. However, the sensor and transmitter can be mounted separately using a Model STB (Sensor Termination Box and Separation Kit) available from Detector Electronics.The sensor, transmitter and termination box are designed for use in hazardous areas, and when prop-erly installed will provide an explosion-proof installa-tion.Detector Electronics offers a variety of transmitter models that operate in the 0 to 100% LFL range and are compatible with the R8471 Controller. Refer to the “Ordering Information” section for more information.ControllerFaceplate DescriptionThe faceplate of the controller provides LEDs for iden-tifying status conditions, a digital display and bar graph display for indicating the sensor input, and pushbuttons for programming, calibrating and reset-ting the system. See Figure 5 for the location of indi-cators and pushbuttons.Figure 5—Controller Front PanelDIGITAL DISPLAYBAR GRAPHCAL LEDFAULT LED????A1384? RESET PUSHBUTTON? SETPUSHBUTTON? LOW LED? AUXILIARY LED? HIGH LED6 95-83986.11. Digital Display—The digital display continuously provides a % LFL reading of the sensor input in both the Normal and Calibrate modes. In the event of a fault, it identifies the nature of the fault using an alpha-numeric code. In other operating modes it shows the alarm setpoints and pro-grammed calibration gas concentration. A nega-tive zero drift condition is indicated by a minus (–) sign in the left hand digit. If an over-range condi-tion occurs, the display flashes and the highest reading latches on. Since this display is always on, it also functions as a power indicator.2. Bar Graph Display—The 20 segment bar graph display provides a reading of sensor input in 5% LFL increments.3. High alarm leD—Flashes in response to a sen-sor signal that exceeds the high setpoint. 4. auxiliary alarm leD—Flashes in response to a sensor signal that exceeds the auxiliary setpoint. 5. low alarm leD—Flashes in response to a sen-sor signal that exceeds the low setpoint. NOTEThe alarm LEDs flash when the setpoint is exceeded and are on steady (until reset) when the gas level drops below the setpoint, whether the corresponding alarm output is latching or non-latching.6. Cal leD—Illuminated while the controller is in the calibrate mode.NOTEIn the Setpoint Display or Setpoint Adjust mode, a flashing alarm LED identifies the particular set-point currently being indicated on the digital dis-play. A flashing Cal LED indicates that the pro-grammed calibration gas concentration in % LFL is currently being shown on the digital display.7. Fault leD—Flashes upon detection of a system fault and is on steady during the power-up time delay.8. reset Pushbutton—Used for various system pro-gramming and calibration functions as well as for resetting the controller.9. Set Pushbutton—Used for various system pro-gramming and calibration functions.SetpointsThe R8471 Controller has independent Low, High, and Auxiliary alarm setpoints, with corresponding out-puts.The programmed calibration gas concentration in % LFL is also displayed and adjusted with the alarm set-points. This value must be equal to the % LFL con-centration of the calibration mixture that is used for the span adjustment.The adjustment range is:Low alarm 5 to 50% LFLHigh alarm 10 to 60% LFLAuxiliary alarm 5 to 90% LFLCalibration gas 30 to 99% LFL.The alarm setpoints and calibration gas concentration can be checked by pressing the Reset pushbutton located on the front panel of the controller. See “Setpoint Adjustment” and “Calibration” sections.outputsThe R8471 Controller is available in a Base version and a Premium version. The differences between the two models are the output configuration and program-ming options.Base Model—The base controller is furnished with open collector transistor outputs (rated 100 mA at 32 volts dc) for the Low alarm, High alarm, Auxiliary alarm, and Fault circuits. The normally de-energized alarm outputs are energized when their correspond-ing setpoints are exceeded. The fault output is nor-mally energized and becomes de-energized upon detection of a system fault.Premium Model—The premium model is furnished with a set of four relays in place of the four solid state outputs. The relays have SPST contacts rated 5 amperes at 30 vdc or 250 vac.This model also includes a selectable isolated/non-isolated 4-20 mA dc current output for transmitting system information to other monitoring devices. The linear 4-20 mA output corresponds to levels from 0 to 100% LFL. If a system fault is detected, the output drops to less than 1.0 mA. The current output can be calibrated in the field to ensure maximum accuracy. (Refer to the “Calibration” section for details.)7 95-83986.1Programming Options (Premium model only)—Each of the four relays is field selectable for either normally open or normally closed contacts using jumper plugs located on the printed circuit board inside the control-ler. (See Table 1.)The alarm relays are also switch programmable for either normally energized or normally de-energized operation. The fault relay is normally energized.The low and auxiliary alarm relays are programmable for either latching or non-latching operation. The high alarm relay is always latching and the Fault relay is non-latching. Latching relays are reset using either the Reset pushbutton on the front panel of the control-ler or an external reset switch. The 4-20 mA circuit is selectable for isolated or non-isolated operation.automatic Diagnostics and Fault IdentificationThe microprocessor based controller features self-testing circuitry that continuously checks for faulty sensor or open sensor wiring, low or high input volt-age, and other problems that could prevent proper system response. When power is applied, the micro-processor automatically tests memory. In the Normal operating mode, it continuously monitors the input signal from the transmitter to ensure proper function-ing. In addition, a “watchdog” timer is maintained to ensure that the program is running correctly. If a fault should occur:— The Fault LED flashes.— The digital display identifies the nature of the fault using an alpha-numeric code. Refer to Table 2.— The normally energized Fault output is de-ener-gized.— The dc current output drops to less than 1 mA.NOTEThe fault code will be shown for about 2 sec-onds out of every 5 seconds. The gas concen-tration at the sensor will be displayed during the remaining time. If more than one fault should occur, the highest priority fault will be displayed. (Table 2 lists the faults in order of priority.) An alarm condition will normally over-ride a fault con-dition unless the fault condition occurred first (except F10, F2X). However, faults that affect the actual func-tion of the controller (F50, F60, F70, F9X) can impair the ability of the controller to maintain an alarm out-put.Table 2—System Status CodesStatus Condition F9X Initialization failure. (Subcodes are as fol-lows.) F91 EPROM sumcheck failure. F92 Sensor failure during startup - current too high or too low (transmitter calibration needed). F93 Watchdog timer failure. F94 RAM failure. F95 Internal 5 volt power supply failure during startup. F96 External 24 volt power supply failure dur-ing startup. F97 Controller type invalid. Error in data from RAM. F98 Watchdog timer reset the controller. F70 External reset button has been activated for 15 seconds or longer. Self clearing when button is released. F60 External 24 vdc power input is not in the 18 to 32 vdc range. F50 Internal 5 volt power supply is not in the 4.75 to 5.25 volt range. F40 Sensor fault (after startup). Input is above 35 mA or below 2 mA. F30 Negative zero drift. Sensor input is –9% full scale or lower. F2X Calibration error. (Subcodes are as fol-lows.) F20 General calibration fault, or calibration aborted due to a higher priority fault. F21 Time ran out while waiting for calibration gas to be applied to the sensor. F22 Sensor input is too low. The sensor cannot generate enough offset to get an accurate calibration. Replace sensor. F23 Sensor is too sensitive for the controller to read 100% full scale. Replace sensor. F24 Zero gas level too high, or sensor zero input over limit. F10 Sensor reaching end of life. Consider replacing the sensor within the next two calibration periods.8 95-83986.1All faults automatically reset except the F9X, F20, and F10 faults. After the fault condition has been correct-ed, the fault output automatically switches to the nor-mal (energized) state, the dc current output returns to normal, and the Fault LED turns off. Clearing F9X faults requires removing operating power from the controller for approximately one second.NOTEA “F92” fault on power-up may be cleared by performing a transmitter calibration after the appropriate warm-up. Refer to the “Calibration” section for details.CAUTIONThe fault detection circuitry does not monitor the operation of external response equipment or the external wiring to these devices. It is important that these devices be checked periodically to ensure that they are operational.operating ModesNOTEThe following section is intended to acquaint the operator with the basic operation of the control-ler. For complete step-by-step programming and calibration procedures, refer to the correspond-ing sections in this manual.The controller can operate in any of the following modes. Operating modes other than Normal are selected by pressing the appropriate pushbutton(s) located on the controller front panel. See Figure 6.NORMALIn the Normal operating mode with no alarm condi-tion:— Digital display is on and indicates the sensor input in % LFL.— Bar graph display reads the same as the digital display.— All LEDs are off.— Alarm outputs are in their normal state (energized or de-energized as programmed).— DC current output signal level corresponds to sen-sor input.— Fault output is energized.Figure 6—R8471 Controller Flow ChartPOWER-UPTIMEDELAYNORMAL RESET< 0.5 SECOND 0.5 SECOND 1.0 SECONDHOLD RESET7 SECONDSSET1.0 SECONDNOYESBASICRESETFORCEDRESETRELEASERESETRELEASERESETRELEASERESETSETPOINTDISPLAYHOLDRESETHOLDRESETHOLDRESETSENSORREPLACESETPOINTADJUSTCURRENTCALIBRATERESETPUSHED WITHSET?CALIBRATE9.0 SECONDSSET*RESET*MUST BE PRESSED BEFORE THE ZEROCALCULATIONS ARE COMPLETED.D13859 95-83986.1In the Normal operating mode with a low and/or auxil-iary alarm condition occurring:— Digital display and bar graph display indicate the sensor input in % LFL.— Low and/or Auxiliary LED flashes.— Low and/or Auxiliary alarm output changes state.— Dc current output signal level corresponds to sen-sor input.— Fault output energized and LED off.When the signal decreases below the low or auxiliary setpoint:— Digital display, bar graph display, and 4-20 mA output continue to track the sensor input.— With latching operation programmed: No change to alarm outputs.— With non-latching operation programmed: Alarm outputs return to their normal state.— Low and Auxiliary LEDs are on steady until reset.In the Normal operating mode and a high alarm con-dition occurring:— Same as low or auxiliary alarm, but High LED is on and high alarm output is actuated.When the signal decreases below the high alarm set-point:— The high alarm is always latching and unaffected by the latching/non-latching programming for the low and auxiliary alarms. High LED is on steady until reset.In the event of a system fault:— The normally energized Fault output is de-ener-gized and the Fault LED is illuminated. RESETThe Reset mode is the first mode that is entered by pressing the Reset button located on the front panel of the controller. (See Figure 6.) When the Reset but-ton is momentarily depressed, all LEDs turn off and all outputs return to their normal condition if no alarms or faults are occurring (basic reset). When the Reset button is held for 0.5 second, the LEDs turn off and the outputs return to their normal condition even if an alarm or fault condition still exists (forced reset). Remote reset capability is also provided. (Remote reset performs a forced reset.)NOTEThe remote reset performs a reset function only. It cannot be used for entering other controller operating modes.SETPOINT DISPLAY MODEIf the Reset button is held for approximately one sec-ond, the digital display sequentially shows the pro-grammed alarm setpoints and calibration gas con-centration. Each value is displayed for approximately 2 seconds. After completing the sequence, the con-troller automatically returns to the Normal operating mode if the Reset button is no longer being depressed.This mode is used only for displaying the setpoints. Use the “Setpoint Adjust” mode for changing setpoint and calibration gas values.CALIBRATEThe R8471 Controller uses a fully automatic calibra-tion procedure that requires no adjustments to be made by the operator. The Calibrate mode is entered by pressing and holding the Reset button until com-pletion of the “Setpoint Display” sequence described above (approximately 9 seconds). The controller per-forms the Zero adjustments, then signals the operator when to apply and also when to remove the calibra-tion gas. Upon completion of a successful calibra-tion, the controller automatically returns to the Normal operating mode.NOTEThe R8471 controller calibration procedure does not adjust zero and span levels of the associat-ed transmitter. The transmitter calibration is an independent procedure, and should be per-formed prior to calibrating the controller.If the operator fails to complete the calibration proce-dure, if an error in calibrating occurs, or if a success-ful calibration cannot be completed, the microproces-sor will automatically return to the Normal mode (after 10 minutes) and continue to use the previous calibra-tion data. A fault indication (“F2X” status) will be dis-played until a reset occurs. If the microprocessor determines that the sensing element is approaching the end of its useful life, “F10” will be indicated on the digital display. Refer the “Calibration” section for complete information regarding calibration.NOTEA “F92” fault on power-up may be cleared by performing a transmitter calibration after the appropriate warm-up. Refer to the “Calibration” section for details.10 95-83986.1While in the Calibrate mode, all controller outputs are inhibited, the CAL LED is illuminated, and the dc cur-rent output goes to a preset level (adjustable from 0 to 20 mA).SENSOR REPLACEMENTThis mode inhibits all controller outputs to allow sen-sor replacement without removing power from the controller. In addition, this mode automatically sets the factory default values for sensor calibration. Other programmed setpoint values are not affected.CAUTIONUpon entering the Sensor Replacement mode, all previously entered sensor calibration informa-tion is lost. Sensor calibration must be per-formed, even if the sensor was not replaced.To enter the Sensor Replacement mode, first enter the Calibrate mode as described above, then press the Set button. To exit this mode, press the Reset button.SETPOINT ADJUSTThe Setpoint Adjust mode is entered by depressing the Set button for approximately one second. In this mode the alarm setpoints and calibration gas level are sequentially displayed on the digital display for approximately five seconds and the corresponding LED flashes. To change the setpoint, depress the Reset button to increase the displayed value or the Set button to decrease the value. If no changes are made for 5 seconds, the microprocessor automatical-ly advances to the next setpoint. At the end of the sequence, the microprocessor automatically returns to the Normal operating mode.DC CURRENT OUTPUT CALIBRATIONThis mode is used to calibrate the 4-20 mA dc output. To enter this mode, hold the Set button, then press Reset. First the 0% LFL value (4 mA) is generated for approximately 7 seconds while the Low LED flashes. Then the 100% LFL value (20 mA) is generated while the High LED flashes. Finally the current output dur-ing calibration is generated while the CAL LED flash-es. The microprocessor automatically returns to the normal operating mode at the end of the sequence. Adjustments to the current output level are made by pressing the Reset (increase) or Set (decrease) but-ton. This procedure requires a dc current meter to monitor the actual controller dc mA output.Section IISystem InstallationINSTALLATIONNOTEThe sensor is not included in the FM approval.NOTERefer to the sensor manual for complete informa-tion regarding sensor installation.SenSor loCatIonIt is essential that the sensor be properly located to enable it to provide maximum protection. The formula for determining the most effective number and place-ment of sensors varies depending on the conditions at the job site. The individual performing the installa-tion must rely on experience and common sense to determine the quantity of sensors and the best sensor locations to adequately protect the area.For additional information on determining quantity and placement for sensors in a specific application, refer to Instrument Society of America (ISA) Transaction Volume 20, Number 2, titled “The Use of Combustible Detectors in Protecting Facilities from Flammable Hazards”.The following factors should be considered for every installation:1. What kind of gas is to be detected? If it is lighter than air (acetylene, hydrogen, methane, etc.), place the sensor above the potential gas leak. Place the sensor close to the floor for gases that are heavier than air (benzene, butane, butylene, propane, hexane, pentane, etc.) or for vapors resulting from flammable liquid spills. However, note that air currents can cause a gas that is heavier than air to rise. In addition, if the gas is hotter than ambient air, it could also rise. 2. How rapidly will the gas diffuse into the air? Select a location for the sensor as close as practi-cal to an anticipated source.11 95-83986.13. Ventilation characteristics of the immediate area must also be considered. Movement of air can cause gas to accumulate more heavily in one area than another. The sensor should be placed in the area where the most concentrated accumu-lation of gas is anticipated. Also consider the fact that many ventilation systems do not operate con-tinuously.4. The sensor should be pointed down to prevent the buildup of moisture or contaminants on the fil-ter and to ensure proper operation.5. The sensor must be accessible for testing and calibration. The use of the Sensor Separation Kit (Model STB) will be required in some installations.6. The sensor should be located in an area where it is safe from potential sources of contamination that can poison the sensing element.7. Exposure to excessive heat or vibration can result in premature failure of any electronic device and should be avoided if possible. Shielding the device from intense sunlight will reduce solar heating and can increase the life of the unit.Remember, the finest gas detector is of little value if the gas cannot readily come into contact with it.General WIrInG reQUIreMentSNOTEThe wiring procedures in this manual are intend-ed to ensure proper functioning of the device under normal conditions. However, because of the many variations in wiring codes and regula-tions, total compliance to these ordinances can-not be guaranteed. Be certain that all wiring complies with applicable regulations that relate to the installation of electrical equipment in a hazardous area. If in doubt, consult a qualified official before wiring the system.In applications where the wiring cable is installed in conduit, the conduit must not be used for wiring to other electrical equipment. The use of shielded cable is recommended for con-necting the transmitter to the controller. If a sensor separation kit is used, shielded cable must be used between the sensor and the transmitter.Since moisture can be detrimental to electronic devic-es, it is important that moisture not be allowed to come in contact with the electrical connections of the system. Moisture in the air can become trapped with-in sections of conduit. Therefore, the use of conduit seals is required to prevent damage to electrical con-nections caused by condensation within the conduit. These seals must be watertight and explosion-proof and are to be installed even if they are not required by local wiring codes. A seal must be located as close to the device as possible. In no case should this seal be located more than 18 inches (46 cm) from the device. When an explosion-proof installation is required, an additional seal may be needed at any point where the conduit enters a non-hazardous area. Always observe the requirements of local codes.When pouring a seal, the use of a fiberdam is required to assure proper formation of the seal. The seals should never be poured in temperatures that are below freezing, since the water in the sealing compound will freeze and the compound will not dry properly. Contamination problems can then result when temperatures rise above the freezing point and the compound thaws. The shielding of the cable should be stripped back to permit the seal to form around the individual leads, rather than around the outside of the shield. This will prevent any siphoning action that can occur through the inside of the shield.It is recommended that conduit breathers also be used. In some applications, alternate changes in temperature and barometric pressure can cause “breathing”, which allows the entry and circulation of moist air throughout the conduit. Joints in the conduit system and its components are seldom tight enough to prevent this “breathing”. Moisture in the air can condense at the base of vertical conduit runs and equipment enclosures, and can build up over a peri-od of time. This can be detrimental to electronic devices. To eliminate this condition, explosion-proof drains and breathers should be installed to automati-cally bleed off accumulated water.Three wire cable is used for connecting the sensor/transmitter assembly to the controller. Three conduc-tor cable with a foil shield is recommended. The shield of the cable should be connected to earth ground at one end only.12 95-83986.1The maximum distance between the transmitter and controller is limited by the resistance of the connect-ing wiring, which is a function of the gauge of the wire being used. Refer to the transmitter instruction manu-al for sepecific information regarding wire size and distance limitations.SenSor SeParatIonThe Model STB Sensor Termination Box and Separation Kit is designed for use in applications where the sensor and transmitter must be installed in different locations.NOTEThe illustrations in the following section show the Model STB used with a Model 505 Transmitter. Although the basic wiring scheme is similar for other transmitter models, factors such as wiring distances and wire gauge will be different in each case. Refer to the transmitter manual for information specific to that model.NOTEWhen using a sensor separation kit with Model 505 Transmitters, the CGS sensor operating volt-age will require adjustment. Refer to the Model 505 instruction manual for details.The junction box is designed for use in hazardous areas, and when properly installed will provide an explosion-proof installation. The connector board assembly, mounted inside the junction box, contains the terminals for connecting the sensor and external wiring.See Figure 7 for an illustration of a typical system using the Sensor Separation Kit.NOTES1. SHIELDED SENSOR WIRING CABLE REQUIRED.2. GROUND SENSOR WIRE SHIELD AT ONE END ONLY.3. SHIELDS SHOULD BE STRIPPED BACK WITHIN JUNCTION BOXES.4. P/N 102883-001 TERMINAL CONNECTOR REQUIRED FOR SENSOR CONNECTION 4. (PROVIDED WITH SENSOR TERMINATION BOX).TRANSMITTER LOCATIONSENSOR LOCATIONCONNECT KEYED SENSORPLUG TO PIN CONNECTORBLKWHTREDCONTROLLER4 TO 20 MA24 VDC––++D1939–SIGREDSENSORWHT+BLKFigure 7—Typical Installation Using Model STB Sensor Termination Box with Model 505 Transmitter13 95-83986.1The calibration cup can remain on the sensor after calibration without interfering with normal operation. By connecting a length of tubing from the calibration cup back to the transmitter location, the operator can make calibration adjustments and also control the flow of calibration gas from the same location.IMPORTANTThe operator must frequently inspect the filter on the calibration cup. This filter must be kept clean. If the filter should become clogged by environmental contaminants such as dirt, oil, paint, etc., the flow of gas to the sensing element will be restricted. This can significantly reduce the sensitivity and response time of the sensor, thereby impairing the ability of the system to respond to a hazardous condition. Problems of this nature will not be detected by the system’s diagnostic circuitry or during routine calibration. If the filter becomes dirty and cannot be properly cleaned, the calibration cup must be replaced. Sensor InstallationFor proper operation, the sensor must be oriented with the filter pointing down. Install the sensor in the lower 3/4 inch NPT opening on the junction box. Connect the conduit to the upper opening. The sensor junction box can be mounted to a wall or post, or it can be suspended by the conduit. The junction boxes should be electrically connected to earth ground.Wiring requirementsThree wire cable is used for connecting the sensor to the transmitter and also for connecting the transmitter to the controller. The use of shielded cable is required for connecting the sensor and transmitter, and is highly recommended for connecting the trans-mitter and controller. Three conductor cable with a foil shield is recommended. Shields should be grounded at one end only.The maximum distance between the sensor and transmitter is limited by the resistance of the connect-ing wiring, which is a function of the gauge of the wire being used. Note that maximum wiring distances also vary with the specific transmitter model being used. Table 3 shows the maximum separation dis-tance allowed for a given wire size when using Model 505 transmitters. For other transmitter models, refer to the transmitter manual for specific instructions. Wire Size recommended (aWG) Maximum transmitter to Sensor Distance* Maximum transmitter to Sensor Distance** Feet Meters Feet Meters 20 12 3.6 65 19 18 20 6.1 100 31 16 31 9.4 160 50 14 50 15.2 260 79 12 78 24.0 410 126Table 3—Maximum Separation Distances – Sensor to Model 505 Transmitter* Transmitter voltage adjustment not required.** Transmitter voltage adjustment is required.14 95-83986.1Sensor Voltage adjustment (Model 505 transmitters)The combustible gas sensor is designed to operate at 3.3 volts dc. Voltages greater than this will shorten sen-sor life, while voltages less than this will reduce sensor sensitivity. The sensor supply voltage potentiometer is adjusted at the factory to deliver 3.3 volts when the sen-sor is coupled directly to the transmitter housing. However, if the sensor and Model 505 Transmitter are located separately, and the distance exceeds the rec-ommended distance indicated in Table 3, re-adjustment is necessary. To adjust sensor voltage, connect a digi-tal voltmeter across the white and black sensor wires (at the sensor). Adjust the sensor voltage potentiometer (See Figure 8) to obtain a reading of 3.3 volts dc on the meter. For sensor separation configurations, this is typi-cally a two-person procedure.Always measure the sensor voltage whenever utilizing a sensor separation kit, and any time a Model 505 trans-mitter has been replaced Failure to deliver 3.3 vdc to the sensor will result in loss of system accuracy. CAUTIONThe voltmeter must be suitable for use in a hazard-ous location.SenSor/tranSMItter WIrInG (without Sensor Separation)The following section describes the installation and wiring procedure for Model 505 transmitters. When using other transmitter models, mount and wire the sensor and transmitter as described in the transmitter manual.1. Locate the sensors in positions that are best suit-ed for covering the area to be protected, following the previously discussed guidelines. Whenever practical, they should be placed where they are easily accessible for calibration.NOTEDo not apply power to the system with the junc-tion box cover removed unless the area has been de-classified.2. Remove the cover from the transmitter junction box.NOTEThe transmitter and controller contain semicon-ductor devices that are susceptible to damage by electrostatic discharge. An electrostatic charge can build up on the skin and discharge when an object is touched. Therefore, use cau-tion when handling, taking care not to touch the terminals or electronic components. For more information on proper handling, refer to Service Memo form 75-1005.3. Remove the transmitter module from the junction box.4. The junction box can be mounted to a wall or post, or it can be suspended by the conduit. The junction box should be electrically connected to earth ground. For proper operation, the sensor must be oriented with the filter pointing down. Install the sensor in the lower 3/4 inch NPT opening on the junction box. Connect the conduit to the upper opening. 5. Attach the sensor to the junction box. The sensor should be tight to ensure an explosion-proof installation, however, do not overtighten. Attach the wiring plug at the appropriate terminal loca-tion. (See Figure 9.)ZERO ADJUSTZERO/SPAN SWITCHSENSOR VOLTAGE ADJUSTCAL/NORM SWITCHCALIBRATE LED4 MA ADJUSTSPAN ADJUSTTEST POINTSB1944Figure 8—Location of Switches and Potentiometers on Model 505 Transmitter Circuit Board15 95-83986.1CAUTIONThe sensor threads can be coated with an appropriate grease to ease both the initial instal-lation and future replacement of the sensor. Also lubricate the cover threads. The recommended lubricant is a silicone free polyalphaolefin grease, part number 005003-001, available from Detector Electronics. The use of other lubricants is not recommended, since some materials can cause irreversible damage to the sensing ele-ment. Silicone based lubricants or compounds must never be used.6. Connect the power and current output leadwires to the appropriate screw terminals inside the junc-tion box. When using shielded cable, the shield should be connected to earth ground at one end only.The wiring code is:BLK – = Power supply negative (–)RED CTR = SignalWHT + = Power supply positive (+).7. Check all field wiring to ensure that the proper connections have been made, then pour the con-duit seals and allow them to dry (if conduit is being used).8. Install the transmitter module inside the junction box.9. Place the cover back on the junction box.Controller WIrInGField Wiring ConnectorThe controller is furnished with a field wiring connec-tor backplate that incorporates pressure type screw terminals for connecting the external wiring and a cir-cuit board edge connector for attaching to the con-troller. The use of a mounting rack is recommended for mounting the controller. The backplate is attached to the back of the rack to allow easy removal of the controller without disturbing the wiring. See Figures 10 and 11.The controller is designed for installation in a non-haz-ardous area.Figure 12 shows the terminal configuration for the R8471 Combustible Gas Controller.CONTROLLER4 TO 20 MA24 VDC––++NOTES:1. DO NOT APPLY POWER TO THE TRANSMITTER WITH THE JUNCTION BOX COVER REMOVED UNLESS THE AREA HAS BEEN DE-CLASSIFIED.2. POSITION THE TRANSMITTER WITH THE SENSOR POINTING DOWN.3. THE TRANSMITTER JUNCTION BOX SHOULD BE ELECTRICALLY CONNECTED TO EARTH GROUND.4. ATTACH THE SENSOR TO THE JUNCTION BOX TIGHTLY ENOUGH TO ENSURE AN EXPLOSION-PROOF INSTALLATION, HOWEVER, DO NOT OVERTIGHTEN. LUBRICATE THE THREADS WITH THE CORRECT LUBRICANT TO EASE INSTALLATION AND FUTURE REPLACEMENT. SILICONE BASED LUBRICANTS MUST NEVER BE USED.5. CABLE SHIELDS SHOULD BE CONNECTED TO EARTH GROUND AT ONE END ONLY.6. SHIELDS SHOULD BE STRIPPED BACK FROM CONDUCTORS ONLY WITHIN THE JUNCTION BOX ENCLOSURE.C1938–SIGREDSENSOR WHTBLK+Figure 9—Model 505 Transmitter Wiring without Sensor Separation16 95-83986.1Figure 10—Dimensions of the Mounting Rack(A)(B)(C)1.48 (37.59)(D)B1475ALL CONTROLLER CAGES REQUIREA MINIMUM OF 10.12 INCHES (257.1 MM)DEPTH CLEARANCE(E)Figure 11—Clip Positioning for Mounting Racks1A1476FIRE CONTROLLERS ARE APPROX. TWO INCHESWIDE AND REQUIRE TWO GUIDE RAILS FORINSERTION. PLACE THE RETAINING CLIP BETWEENRAILS TO FORM SETS, LEAVE A GAP BETWEEN SETS.SET SETGAP1 2 3 2THE Q4004 CONTROLLER CAGE HAS BEEN MODIFIEDTO ACCOMMODATE EITHER FIRE OR GAS CONTROLLERSOR ANY COMBINATION OF THE TWO.BY FOLLOWING THE INSTRUCTIONS BELOW, THE CAGECAN BE SET UP TO ANY CONFIGURATION.2TO INSERT A BLANK PANEL, PLACE A CLIP INTHE TOP BRACKET IN LINE WITH THE CLIP IN THEBOTTOM BRACKET.3GAS CONTROLLERS ARE APPROX. ONE INCH WIDEAND REQUIRE ONE RAIL FOR INSERTION. PLACE CLIPSIN LINE WITH GUIDE RAILS, CAGES WILL ACCEPT ASMANY GAS CONTROLLERS AS RAILS PROVIDED.RACK PART NUMBER CONTROLLERTYPE 005269-XXX POSITIONS FOR: HT: DIM. (A) DIM. (B) DIM. (C) DIM. (D) DIM. (E) WEIGHTFIRE GAS INCH MM INCH MM INCH MM INCH MM INCH MM LB KG4U –001 8 16 4U 19.00 482.6 18.30 464.8 17.36 440.9 4.00 101.6 6.97 177.1 9.3 4.24U –002 6 12 4U 15.06 382.6 14.36 364.7 13.42 340.9 7.6 3.54U –003 4 8 4U 11.13 282.6 10.43 264.9 9.49 241.1 5.9 2.74U –004 3 6 4U 9.16 232.7 8.46 214.9 7.52 191.0 5.1 2.34U –005 2 4 4U 7.19 182.7 6.49 164.9 5.55 141.0 4.2 1.94U –006 1 2 4U 5.22 132.6 4.52 114.8 3.58 90.9 3.1 1.43U –007 16 3U 19.00 482.6 18.30 464.8 17.36 440.9 2.25 57.15 5.22 132.6 9.3 4.23U –008 12 3U 15.06 382.6 14.36 364.7 13.42 340.9 7.6 3.53U –008 8 3U 11.13 282.6 10.43 264.9 9.49 241.1 5.9 2.73U –010 6 3U 9.16 232.7 8.46 214.9 7.52 191.0 5.1 2.33U –011 4 3U 7.19 182.7 6.49 164.9 5.55 141.0 4.2 1.93U –012 2 3U 5.22 132.6 4.52 114.8 3.58 90.9 3.1 1.417 95-83986.1Terminals 1 and 2— 4-20 mA dc output.non-Isolated Current output – If the 4-20 mA cur-rent loop is to be non-isolated, wire the system as shown in Figure 13. Note that terminal 2 is not used with a non-isolated current loop. Program the unit for a non-isolated current loop as described in the “Controller Programming” section.Isolated Current output – If an isolated current loop is desired, wire the system as shown in Figure 14 and program the unit for an isolated current loop as described in the “Controller Programming” section. Note that this wiring scheme requires an external power source for the isolated current out-put. Terminal 3— Chassis ground. Ground the cable shield at this terminal.NOTEIf local wiring codes permit and if a ground fault monitoring system is not being used, the minus side of the dc power source can be connected to chassis (earth) ground. Alternatively, a 0.47 microfarad, 100 volt capacitor can be installed (terminal 5 to ground) for best immunity against electromagnetic interference.Terminal 4— Connect to the positive (+) side of the 18 to 32 vdc power source.Terminal 5— Connect to the negative (–) side of the dc power source.Terminal 6— Make no connections to this terminal.Figure 13—A Typical System with Relay Outputs and Non-Isolated Current OutputCURRENT OUTPUTCHASSIS GROUNDPOWERSENSOREXTERNAL RESETHIGH ALARMHIGH ALARM / OCAUX. ALARMAUX. ALARM / OCLOW ALARMLOW ALARM / OCFAULTFAULT / OC1345678910111213141516–++–+–18 TO 32VDCPOWERSIGNAL2OC = OPEN COLLECTOR OUTPUT(BASE MODEL ONLY) B1390Figure 12—Terminal Configuration for R8471 Combustible Gas ControllerISOLATED OUTPUTCURRENT LOOPCHASSIS GROUNDPOWERSENSOREXTERNAL RESETHIGH ALARMHIGH ALARM / OCAUX. ALARMAUX. ALARM / OCLOW ALARMLOW ALARM / OCFAULTFAULT / OC1345678910111213141516–++–+–18 TO 32VDCGROUNDPOWERSIGNALHIGHALARMAUXILIARYALARMLOWALARMFAULTRESET24VDC+–+–SIGTRANSMITTERSENSOR2 4-20 MAB1382R8471 CONTROLLER***NO CONNECTIONFigure 14—A Typical System with Relay Outputs and Isolated Current OutputISOLATED OUTPUTCURRENT LOOPCHASSIS GROUNDPOWERSENSOREXTERNAL RESETHIGH ALARMHIGH ALARM / OCAUX. ALARMAUX. ALARM / OCLOW ALARMLOW ALARM / OCFAULTFAULT / OC1345678910111213141516–++–+–18 TO 32VDCGROUNDPOWERSIGNALHIGHALARMAUXILIARYALARMLOWALARMFAULTRESET24VDC+–+–SIGTRANSMITTERSENSOR24-20 MAA1391R8471 CONTROLLER**NO CONNECTION24VDC+–18 95-83986.1Terminal 7— 4-20 mA dc signal input from transmit-ter/sensor assembly.Terminal 8— A normally open momentary closure switch can be connected between this terminal and the negative (–) side of the power source for remote reset.Terminals 9 and 10— High Alarm Output.Terminals 11 and 12— Auxiliary Alarm Output.Terminals 13 and 14— Low Alarm Output.Terminals 15 and 16— Fault Output.PREMIUM CONTROLLER – The relay outputs (termi-nals 9 to 16) are programmed for the desired opera-tion using the procedure described in the “Controller Programming” section.BASE CONTROLLER – Connections to open collec-tor transistor outputs are made at terminals 10, 12, 14, and 16. Terminals 9, 11, 13, and 15 are not used. See Figure 15 for an example of a typical connection to an open collector transistor output. NOTEExternal equipment that can generate transients when switching (such as relays) must have a transient suppression device (diode) properly connected across the coil at the time of installa-tion. This will safeguard the output transistors of the controller against possible damage. Figure 15 illustrates an inductive load with a diode used for transient suppression.Controller ProGraMMInGRefer to Figure 16 to determine the location of pro-gramming jumpers and switches. Table 1 shows the selectable options for each relay.NOTEAll of the controller jumper plugs must be installed. The controller outputs will not function properly if a jumper plug is missing.normally open/Closed relaysThe four relays are individually programmed for either normally open or normally closed contacts. This is accomplished by placing a jumper plug on the appro-priate pair of pins. Each relay has a set of three pins. For normally open operation, place the plug on the NO and center pins. For normally closed operation, place it on the NC and center pins. The pin groups are identified as follows:J2 – High AlarmJ3 – Auxiliary AlarmJ4 – Low AlarmJ5 – FaultThe controller is programmed at the factory for nor-mally open relay contacts.latching/non-latching relaysThe Low and Auxiliary alarm relays are programmable for latching or non-latching operation. The High alarm relay is always latching. Latching relay operation is programmed using rocker switch 1 at SW1 (SW1-1). For latching operation, place the switch in the closed position. For non-latching operation, place it in the open position. This switch is set at the factory for non-latching relay operation.normally energized/De-energized relaysThe three alarm relays are also programmable for nor-mally energized (fail-safe) or normally de-energized operation. This is accomplished by setting rocker switch 2 at SW1 (SW1-2). For normally energized alarm relays, place the switch in the closed position. For normally de-energized operation, place it in the open position. This switch is set at the factory for nor-mally de-energized operation.The Fault relay is always normally energized, regard-less of the setting of SW1-2.4-20 ma outputIsolated or non-isolated operation of the 4-20 mA out-put can be selected using a jumper plug at J1. For non-isolated operation, as illustrated in Figure 13, place the jumper plug in the INT (internal power source) position. Place the plug in the EXT position for an isolated circuit, as illustrated in Figure 14. The jumper is set at the factory for non-isolated operation.100KR7484OPEN COLLECTOR OUTPUT1N4004TYPICAL+24 VDC (+60 VDC MAXIMUM)C1289Figure 15—Open Collector Output with Inductive Load and Transient Suppression Device19 95-83986.1INSTALLATION CHECKLISTThe following checklist is provided as a means of double checking the system to be sure that all phases of system installation are complete and have been performed correctly.1. Sensors are pointing down and junction boxes are securely mounted.2. Optional sensor accessories (dust/splash guards, sample draw devices, etc.) are installed, clean, and in good condition.3. If a sensor separation kit is used, interconnecting wiring is correct and shorting plug is installed.4. All cable shields are properly grounded.5. Conduit seals have been installed at all junction box entries (if conduit is being used).6. All transmitter modules are properly installed in their junction boxes.7. All junction box covers are tightly installed.8. Transmitter to controller wiring is correct.9. Power wiring to the controller is installed and power source is operational.10. External loads are properly connected to the con-troller.11. Controller is programmed as desired. Record this information for future reference.12. Controllers are properly installed in the mounting enclosure.13. Proper ventilation is provided to prevent over-heating of the controller.Proceed to System Startup, Setpoint Adjustment and Calibration.A1392SW1-1 CLOSED = LATCHING OPEN = NON-LATCHINGSW1-2 CLOSED = NORMALLY ENERGIZED OPEN = NORMALLY DE-ENERGIZEDJ1 INT = NON-ISOLATED EXT = ISOLATEDHIGH ALARMAUXILIARY ALARMLOW ALARMFAULTNORMALLYOPEN/CLOSEDRELAYCONTACTSFigure 16—Programming Jumper Plugs and Switches20 95-83986.1Section IIISystem StartupSTARTUP PROCEDURE1. Output loads that are normally actuated by the gas detection system should be secured (remove power from all output devices) to prevent unde-sired activation.2. Check all external wiring for proper connection. Be sure that the sensor has been connected properly and that the transmitter module has been installed properly.3. Before installing the controller in the mounting rack, inspect it to verify that it has not been physi-cally damaged in shipment. Check the jumper plugs and rocker switches on the controller for proper programming, then slide the controller fully into the mounting enclosure.4. Apply power to the system.NOTEWhen power is applied to the controller, it enters a time delay mode to allow the sensor output to stabilize before beginning normal operation. During this time the outputs are inhibited, the FAULT LED is illuminated, and the current output indicates a fault condition. This time delay can last up to five minutes, but will end earlier if the sensor output no longer exceeds any alarm set-points.NOTEA “F92” fault on power-up may be cleared by performing a transmitter calibration after the appropriate warm-up. Refer to the “Calibration” section for details.5. If a sensor separation kit and Model 505 Transmitters are being used, adjust the sensor voltage to 3.3 vdc, following the procedure described in the “Sensor Separation” section.6. If desired, controller operation can be tested by manipulating the transmitter output to a level that exceeds the alarm thresholds. This is done by adjusting the Zero potentiometer. [The transmitter Span adjustment may have to be increased (clockwise) to obtain a full scale reading on the controller.] The output of Model 400/405 Transmitters can be adjusted over the entire oper-ating range of the transmitter using the optical calibration meter. Refer to the transmitter manual for details. Note that this test will actuate the con-troller outputs.7. Put the controller in the Setpoint Display mode to determine the present alarm setpoints and cali-bration gas concentration. If changes are required, perform the Setpoint Adjustment proce-dure.8. Perform the calibration procedure.9. Check the 4-20 mA current loop for proper cali-bration and adjust as required.10. Remove mechanical blocking devices (if used) and restore power to the output loads.SETPOINT ADJUSTMENTThe adjustment range for the alarm setpoints and cali-bration gas concentration is as follows:Low alarm 5 to 40% LFLHigh alarm 10 to 60% LFLAuxiliary alarm 5 to 99% LFLCalibration gas 30 to 99% LFLThe factory settings are:Low alarm 20% LFLHigh alarm 50% LFLAuxiliary alarm 50% LFLCalibration gas 50% LFLTo check the present levels, use the “Setpoint Display Mode” described below. To change the values, use the “Setpoint Adjustment Procedure”.SetPoInt DISPlay MoDe1. To enter the Setpoint Display mode, press and hold the Reset button until the Low LED begins to blink (approximately one second). Release the Reset button. The low alarm setpoint will be shown for two seconds on the digital display.NOTEThe Reset button should be released as soon as the controller has entered the Setpoint Display mode (after one second). If the button is still depressed at the end of the Setpoint Display mode (9 seconds), the controller will automati-cally enter the Calibrate mode. If the operator is 21 95-83986.1not prepared to perform a calibration, a calibra-tion fault will occur. Recycle power to the con-troller to exit the calibrate mode without affecting the calibration settings.2. At the end of the two second interval, the Low LED goes out, the High LED begins to blink, and the digital display shows the high alarm setpoint.3. Two seconds later the High LED goes out and the Auxiliary LED blinks. The digital display now shows the programmed auxiliary alarm setpoint.4. Two seconds later the Auxiliary LED goes out and the CAL LED blinks. The digital display now shows the programmed calibration gas concen-tration.5. After displaying the calibration gas concentration for two seconds, the controller automatically leaves the Setpoint Display mode and returns to the Normal operating mode.6. If adjustments to the setpoints are required, per-form the Setpoint Adjustment procedure. When the setpoint levels are acceptable, record this information for future reference and perform the Calibration procedure.SetPoInt aDJUStMent ProCeDUre1. Determine the required alarm setpoint levels and calibration gas concentration. If the system will be used to detect a gas other than the type being used for calibration, a conversion (“K”) factor must be used to determine the correct value to be programmed into the microprocessor in step 5 below. Refer to the “Calibration “ section.2. Press and hold the Set button for one second. The digital display indicates the present low alarm setpoint and the Low LED blinks. Press the Reset button to increase the reading or the Set button to decrease the reading. (Holding the button will cause the reading to change rapidly.)3. When no changes to the setpoint level have been made for 5 seconds, the Low LED goes out, the High LED blinks, and the digital display shows the high alarm setpoint. Press the appropriate button (detailed in step 2 above) to obtain the desired reading on the digital display.4. When no changes to the setpoint level have been made for 5 seconds, the High LED goes out, the Auxiliary LED blinks, and the digital display shows the auxiliary alarm setpoint. Press the appropriate button to obtain the desired reading on the digital display.5. When no changes have been made for 5 sec-onds, the Auxiliary LED goes out, the CAL LED blinks, and the digital display indicates the cali-bration gas concentration. Press the appropriate button to change the calibration gas concentra-tion as required.6. When no changes have been made for 5 sec-onds, the controller automatically returns to the Normal operating mode.7. Record the new values for future reference.NOTEThe alarm setpoints, calibration gas concentra-tion, and calibration data are stored in non-volatile memory and are retained in the event of a power loss. However, if power is interrupted while per-forming the Setpoint Adjustment or Calibration procedure, the entire procedure must be repeat-ed when power is restored.CALIBRATIONVarious factors affect the time interval between peri-odic recalibrations. Exposure of the sensing element to contaminants in the air, exposure to a high concen-tration of combustible gas, or an extended period of normal operation can cause changes in sensitivity. Since each application is different, the length of time between regularly scheduled recalibrations can vary from one installation to the next. In general, the more frequently a system is checked, the greater the reli-ability. The sensor must be calibrated:— Before a new system is initially put into service — If the sensor is replaced — If the transmitter is replaced— If the controller is replaced— If the sensor is exposed to a high level of combus-tible gas.CAUTIONExposure to a high level of gas can have an adverse effect on the sensitivity of the sensing element. If the level of gas at the sensor should reach 100% LFL, it is important that it be tested and recalibrated if required. In some cases, it may be necessary to replace the sensor.If an over-range condition should occur, the digi-tal display flashes and the highest reading latch-es on until reset. The user must exercise caution 22 95-83986.1if an over-range reading is indicated, since a highly explosive condition could exist. The haz-ardous area should be checked with a portable detection instrument to determine the actual level of combustible gas present.For best calibration results, allow a new sensor to operate for several hours to ensure a stable output before performing calibration. For the highest degree of accuracy, perform a second calibration after 24 hours.When a sensor is exposed to a different or new envi-ronment, calibration should be checked frequently to determine the proper interval between periodic cali-brations.NOTELoss of sensitivity can be caused by various fac-tors. One common cause is by clogging of the sensor filter by water, dirt, oil, paint, etc. Problems of this nature are capable of totally incapacitating the sensor, but it is only during calibration that the problem will be discovered. To assure the greatest level of reliability, calibra-tion should be performed at regularly scheduled intervals.Before performing calibration, the operator should examine the sintered metal filter of the sensor (flame arrestor) to be sure that it is not missing or damaged. If the filter is defective or missing, the sensor must not be operated, since the exposed sensing element can act as an ignition source. It should also be noted that a dirty cover can significantly reduce the sensitivity of the sensor.ConVerSIon (K) FaCtorThe output of the sensor to different types of gases can vary considerably. To assure calibration accura-cy, it is recommended that calibration be performed using a gas/air mixture of the gas that is intended to be detected. If several different combustible gases can be present, calibrate to the least detectable gas. If a calibration mixture of the gas to be detected is not available, the system can be calibrated using a stan-dard calibration gas and an appropriate “K” factor. The “K” factor is used to calculate the calibration gas setting that is entered into the controller in place of the standard (typically 50%) calibration gas % LFL concentration. The “K” factor represents the relation-ship between the gas to be detected and the best gas type to be used for calibration. A “K” factor value of “1” is optimum.To calculate the calibration gas setting that will be programmed into the microprocessor, use the follow-ing formula:S = C x KS = Calibration gas settingC = LFL percentage of gas being usedK = Conversion factor.For example, assume that 50% LFL methane will be used for calibrating a system that will detect a gas with a “K” factor of 1.2. Using the above formula, 50% (C) is multiplied by 1.2 (K) to arrive at a calibra-tion gas setting of 60% (S). The value “60” must then be used when programming the controller for the cali-bration gas.IMPORTANTAccurate calibration depends on the use of the correct K factor. The process of determining the correct K factor involves considering the type and LFL percentage of the calibration gas being used, as well as the type of gas to be detected. In addition, since K factors can vary from one sensor model to the next, the type of sensor must also be considered. Contact Detector Electronics to determine or verify the correct K factor to be used. If a K factor for a specific compound is not available, a K factor can be established using a sample of the material to be detected. Contact the factory for details.CalIBratIon ProCeDUreThe gas detection system can be calibrated using either of two methods:1. transmitter Calibration (if a transmitter is used). This method of calibration can be performed by one person. All adjustments are made at the trans-mitter. Calibration of certain transmitter models requires removing the enclosure cover, therefore, the hazardous area must be de-classified. When transmitter calibration is performed, the controller must also be calibrated. Two options are available:A. The controller can be set to use factory default calibration values. This will ensure accuracy when used in conjunction with a properly cali-brated transmitter. Since these default values do not change, the procedure does not need to be repeated with subsequent transmitter recali-brations. This controller calibration is accom-plished by momentarily entering the Sensor Replacement mode. Upon entering the Sensor 23 95-83986.1Replacement mode, the controller automatical-ly sets the factory default controller calibration values. (Follow the procedure described in the “Setting Controller Default Values” section.)B. Calibrate the controller independently from the transmitter. (Always calibrate the transmitter first.)2. Controller Calibration. This method of calibra-tion typically requires two people, one person at the controller and another at the sensor. All adjustments are made automatically by the con-troller. The controller calibration procedure is typically used when the system involves a sensor that gen-erates an uncalibrated output signal (no transmit-ter calibration is possible). However, if the controller calibration procedure will be used with a transmitter that can be cali-brated, the transmitter must be calibrated first, fol-lowed by the controller calibration. (The controller calibration compensates for errors in sensor/transmitter output. If the transmitter is calibrated following a controller calibration, the controller must be recalibrated.) In most cases, the controller calibration proce-dure can be used for all subsequent recalibra-tions, with no need to repeat the transmitter cali-bration.NOTEIf the controller calibration method is used for calibrating a new sensor in a system using a transmitter that can be calibrated, the most accu-rate calibration for the new sensor will be achieved if a transmitter calibration is performed initially (the controller must be placed into the Sensor Replacement mode to set the controller default calibration values), followed by a control-ler calibration (24 hours later for maximum accu-racy). The controller calibration procedure can then be used for all subsequent calibrations.NOTEIf a “F92” status is indicated on power-up, it can normally be cleared by performing a transmitter calibration, followed by a controller calibration.Setting Controller Default Values(Required for Transmitter Calibration)IMPORTANTThis procedure must be performed in addition to transmitter calibration.The controller must be set for the factory default cali-bration values as follows:1. Press and hold the RESET button for approxi-mately 9 seconds until the digital display begins flashing and the CAL LED is illuminated. Release the RESET button.2. Press the SET button. The FAULT LED comes on.3. Press the RESET button. The controller returns to the normal operating mode after a time delay (up to five minutes).4. The controller is now set for the factory default values. The above procedure does not need to be performed with each recalibration unless a controller calibration (described below) is per-formed.Calibrate the sensor/transmitter using the procedure recommended in the appropriate sensor/transmitter manual.transmitter Calibration Procedure (Model 505)The Model 505 Transmitter can be calibrated using either of two procedures. The standard calibration procedure can be performed by one person using a digital volt meter. In addition to calibrating the sensor, this procedure tests sensor sensitivity.The alternate calibration procedure uses the digital display on the controller instead of the digital volt meter to indicate sensor response. In most applica-tions, two people are needed to perform this calibra-tion. No sensor sensitivity test is possible.For information regarding calibration of other transmit-ter models, refer to the appropiate instruction manual.24 95-83986.11. Verify that the area is safe for entry (no dangerous levels of either toxic or combustible gas are pres-ent).CAUTIONA portable instrument should be used to ensure that the area is clear of any combustible gases. If there is any indication of the presence of com-bustible gas at the sensor, calibration or mainte-nance should not be performed.The location must be de-classified prior to cali-bration.2. Remove the cover from the transmitter.NOTEIf a dust cover or splash shield is used, it should be checked to ensure that it is not dirty or plugged. A plugged dust cover can restrict the flow of gas to the sensing element, seriously reducing its effectiveness. For optimum perfor-mance, sensor covers/filters should be replaced at each calibration to ensure that they have not been degraded or plugged.3. A digital voltmeter with probes, a screwdriver for adjusting potentiometers, and calibration gas are required for calibrating the Model 505 Transmitter. Refer to Figure 8 to locate the potentiometers and test points on the transmitter circuit board. Calibrate the transmitter following the procedure described in Table 4.alternate Calibration Procedure for Model 505 transmittersThis method of calibrating the Model 505 Transmitter uses the digital display on the controller for indicating sensor output, eliminating the need for the digital volt meter. Two people are normally needed to perform the calibration.1. The sensor location must be de-classified prior to calibration.CAUTIONThis calibration procedure involves placing the controller in the sensor replacement mode. Upon entering the sensor replacement mode, the fault output will be de-energized. Be sure to secure any output devices connected to the fault output to prevent unwanted actuation of these devices.2. Place the controller in the sensor replacement mode by pressing and holding the RESET button on the controller faceplate for approximately 9 seconds until the digital display begins flashing and the CAL LED is illuminated. Release the RESET button.3. Press the SET button. The FAULT LED comes on. The controller is now in the sensor replacement mode.CAUTIONUpon entering the sensor replacement mode, all previously entered sensor calibration information is lost. The calibration procedure cannot be aborted at this point. Sensor calibration must be performed.4. Remove the sensor junction box cover.5. Adjust the Zero control with a screwdriver until the controller display shows 0% LFL. If the possibility of background gases exists, purge the sensor with clean air to ensure accurate calibration.6. Apply the calibration gas to the sensor. 7. When the controller display shows a stable read-ing, adjust the Span control until the display shows the same % LFL as indicated on the cali-bration gas tank (typically 50%).8. Remove the calibration gas from the sensor. 9. When the reading on the digital display returns below the low alarm setpoint level, the controller can be returned to the normal operating mode by pressing the RESET pushbutton. The controller enters the normal operating mode after a time delay (up to 5 minutes).CAUTIONAll alarm outputs are inhibited when the control-ler is in the sensor replacement mode. The con-troller does not automatically return to normal operation, but remains in the sensor replacement mode until the RESET button is pressed or power to the controller is cycled. Be sure to press the RESET button at the end of the cali-bration procedure to return the controller to nor-mal operation.10. Replace the junction box cover.25 95-83986.1Controller Calibration Procedure1. Be certain that the controller is properly pro-grammed for the gas/air mixture being used for calibration. (See “Setpoint Adjustment” section.) Reprogram the controller if required. Failure to do so will greatly impair system response.2. Be sure that only clean air (0% LFL) is present at the sensor. (The microprocessor begins taking Zero readings immediately upon entering the Calibrate mode.) If the possibility of background gases exists, purge the sensor with clean air to assure accurate calibration.WARNINGBefore removing the junction box cover, verify that no dangerous levels of gas are present. Step Switch Position operator action 1 CAL/NORM switch in the CAL position. 1. LED turns on. 2. Connect a digital voltmeter to the transmitter test jacks. 3. Set the meter range to 2 vdc. 2 ZERO/SPAN switch in the ZERO position. 1. Adjust the ZERO potentiometer to read 0.000 vdc on the voltmeter. See Note 3 below. 3 ZERO/SPAN switch in the SPAN position. 1. Adjust the 4 mA potentiometer to read 0.167 vdc on the voltmeter. 2. Apply the 50% LFL calibration gas to the sensor. When the output has stabilized, adjust the SPAN potentiometer for a reading of 0.500 on the voltmeter. 4 ZERO/SPAN switch in the ZERO position. 1. Sensitivity test. The meter must read greater than 0.015 vdc. See Note 4 below. 2. Remove the calibration gas. 3. When the meter reads 0.002 vdc or less, remove the test probes. 5 CAL/NORM switch in NORM position. 1. The LED turns off. 2. The calibration is complete. 3. Replace the junction box cover.NOTES:1. When the CAL/NORM switch is in the CAL position, the yellow LED turns on and the 4-20 mA output signal goes to 3.4 mA.2. The voltmeter must be suitable for use in a hazardous location.3. If the possibility of background gases exists, purge the sensor with clean air prior to the zero adjustment to assure accurate calibration. 4. A typical sensitivity reading with 50% LFL gas applied to the sensor is 35 to 50 millivolts for a new sensor. Sensor replace-ment is recommended when the sensitivity reading is less than 15 millivolts.5. If a dust cover or splash shield is used, inspect it to be sure that it is not dirty or plugged. A plugged dust cover can restrict the flow of gas to the sensing element, seriously reducing its effectiveness. For optimum performance, sensor covers/filters should be replaced frequently to ensure that they are not degraded or plugged.Table 4—Model 505 Calibration Procedure26 95-83986.1NOTEThe practice of placing your hand over the sen-sor during the zero portion of the calibration pro-cedure is not recommended.3. Depress and hold the Reset button until the CAL LED is illuminated and the digital display starts to flash (approximately 9 seconds).4. When the Zero calculations are complete (30 sec-onds minimum), the digital display stops flashing and reads “00”.5. Apply the calibration gas to the sensor. The digi-tal display starts to flash, and the value indicated on the display rises. The bar graph display also indicates the level of gas at the sensor, but does not flash. (Be sure that the pressure gauge on the calibration gas bottle indicates that there is enough gas in the tank to complete the calibra-tion.)6. When the microprocessor has completed the Span adjustments (30 seconds minimum), the digital display stops flashing. 7. Remove the calibration gas. When the gas level falls below the lowest alarm setpoint, the control-ler automatically exits the Calibrate mode. All out-puts and indicators return to normal operation.If the operator fails to complete the calibration proce-dure or if the sensitivity of the sensor has deteriorated to the extent that calibration cannot be successfully completed, a calibration fault (“F2X” status) will be generated and the system will automatically revert back to the former calibration settings (after 10 min-utes). If a successful calibration cannot be accom-plished, replace the sensor and recalibrate.If the microprocessor determines that the sensing ele-ment is approaching the end of its useful life, “F10” will be indicated on the digital display. This does not indicate a system malfunction, but is intended simply to make the operator aware of this condition. A suc-cessful calibration can still be performed. Press Reset after completing calibration to clear this fault.CUrrent oUtPUt CalIBratIonThe 4-20 mA output is calibrated at the factory to pro-vide a degree of accuracy that is satisfactory for most applications. However, the highest level of accuracy can be obtained by performing the following proce-dure.1. A dc current meter capable of measuring 4-20 mA must be connected to the current loop output. This can be accomplished by disconnecting all loads and connecting a dc ammeter between the two 4-20 mA terminals, by connecting a dc ammeter in series with the load, or by connecting a digital dc voltmeter across a known load resis-tance and calculating the current flow using the formula:I = voltage/load resistance.2. Press and hold the SET button, then immediately press the RESET button. (The Reset button must be pressed within one second of pressing the SET button.) Release both buttons. The Low LED should flash slowly. The flashing Low LED indi-cates that the system is now generating a 4 mA output.3. Press the RESET (increase) or SET (decrease) button to obtain a 4 mA reading on the meter. (Holding the button will cause the output to change rapidly.)4. When no adjustments have been made for 7 sec-onds, the controller automatically switches to a 20 mA output. This is indicated by a flashing High LED. Press the appropriate button to obtain a 20 mA reading.5. When no adjustments have been made for 7 sec-onds, the controller generates the current output level for the calibrate mode. This is indicated by a flashing CAL LED. Press the appropriate button to obtain the desired current output level for the calibrate mode.6. When no changes have been made for 7 sec-onds, the system automatically returns to the Normal operating mode and saves the data in non-volatile memory.7. Remove the meter from the system output.27 95-83986.1Section IVSystem MaintenanceROUTINE MAINTENANCEThe gas detection system requires virtually no routine maintenance, except for periodic checks to assure proper system function and calibration. The frequen-cy of these checks is determined by the requirements of the particular installation.ManUal CHeCK oF oUtPUt DeVICeSFault detection circuitry continuously monitors for an open sensing element, excessive negative zero drift, open sensor wiring, and various other problems that could prevent proper response to a dangerous level of gas. It does not monitor external response equip-ment or the wiring to these devices. It is important that these devices be checked initially when the sys-tem is installed, as well as periodically during the on-going maintenance program.CHeCKoUt In norMal MoDeThe system must be checked periodically in the Normal mode to ensure that those items not checked by the controller diagnostic circuitry are functioning properly.CAUTIONBe sure to secure all output devices that are actuated by the system to prevent unwanted activation of this equipment, and remember to place these same output devices back into ser-vice when the checkout is complete.SenSor rePlaCeMentThe area must be de-classified or power must be removed prior to replacing the sensor. To replace the sensor:1. Press and hold the Reset button for approximately 9 seconds until the digital display begins flashing and the CAL LED is illuminated. Release the Reset button.2. Press the Set button. The FAULT LED comes on. The controller is now in the Sensor Replacement mode.NOTEThe remainder of this procedure assumes that Model 505 Transmitters are being used. Refer to the transmitter manual for information regarding sensor replacement for other transmitter models.3. Remove the cover from the sensor junction box. 4. Unplug the sensor from the connector board and unscrew it from the junction box.5. Coat the threads of the new sensor with the appropriate grease (part number 005003-001), then screw the sensor into the junction box and plug it into the connector board. Controller CalibrationIf the system is being calibrated using the “Controller Calibration” method, the most accurate calibration for a new sensor will be achieved if a transmitter calibra-tion is performed first (as soon as the sensor output has stabilized). Then perform the “Controller Calibration” procedure described in the “Calibration” section (24 hours later for maximum accuracy). The controller calibration procedure can then be used for all subsequent calibrations.transmitter Calibration1. Allow the sensor output to stabilize (several hours for maximum calibration accuracy), then perform the Transmitter Calibration Procedure described in the “Calibration” section.2. When the calibration is complete, place the cover back on the transmitter enclosure.3. Press the controller RESET button. The controller returns to the normal operating mode (after a time delay).For the highest degree of calibration accuracy, per-form a second calibration after 24 hours.A Recommended Test Form is supplied at the back of this manual for recording maintenance performed on the system.28 95-83986.1TROUBLESHOOTINGTable 5 is intended to serve as an aid in locating the cause of a system malfunction.NOTERecord all faults on the Fault Record Sheet sup-plied with this manual.LOSS OF SENSOR SENSITIVITYThere are a variety of factors that can cause a decrease in the sensitivity of catalytic type combusti-ble gas sensors. Interfering or contaminating sub-stances that can adversely affect the response of the sensor to combustible gases are as follows: Problem Possible CauseNo faceplate indicators 1. Wiring to external power source.illuminated. 2. Input power failure.FAULT LED on, digital 1. Power-up time delay (up to 5 minutes).display blank. 2. If condition continues after 5 minutes, repeat power-up. If problem continues, replace controller.F91 to F98 Status 1. Initialization failure. Repeat power-up. If successful, re-program and re-calibrate. If not, replace controller.F92 Status 1. Sensor failure (during startup) - current is over 35 mA or below 2 mA. Status may be cleared by calibrating the transmitter.F94 Status 1. RAM failure. Repeat power-up. If not successful, return to factory for repair. Do not press RESET button. If RESET is pressed, recalibrate and check setpoints.F96 Status 1. Input power problem (should be18 to 32 volts). Check operation of power source and power wiring.F97 Status 1. Controller type invalid. Error in data from RAM. Repeat power-up. If not successful, return to factory for repair. Do not press RESET button. If RESET is pressed, recalibrate and check setpoints.F70 Status 1. External reset activated for over 15 seconds. Check external switch and wiring.F60 Status 1. Input power out of tolerance. Check operation of power source and power wiring.F50 Status 1. Internal power supply problem. Replace controller.F40 Status 1. Sensor output (after startup) is over 35 mA or below 2 mA. Check sensor/ transmitter wiring and calibration. 2. Faulty sensor. Replace and calibrate. 3. Faulty transmitter. Replace and calibrate.F30 Status 1. Negative zero drift. Calibrate sensor. 2. Faulty sensor. Replace and calibrate. 3. Faulty transmitter. Replace and calibrate.F20, F21 Status 1. Calibration error. Re-calibrate.F22, F23 Status 1. Sensor sensitivity out of tolerance. Calibrate transmitter.If problem continues, replace sensor and calibrate.F24 Status 1. Wrong gas for zero calibration. 2. Background gas affecting the zero calibration. 3. Sensor zero input over limit, re-calibrate transmitter.F10 Status 1. Sensor reaching end of life - no problem at present time. Be prepared to replace sensor at next calibration (calibration attempt may fail).Table 5—Troubleshooting Guide29 95-83986.1A. Materials that can clog the pores of the sintered metal flame arrestor and reduce the gas diffusion rate to the sensor are:1. Dirt and oil.A dust cover should be installed to protect the flame arrestor whenever these conditions exist.The dust cover can be cleaned as part of rou-tine maintenance. This can be accomplished using an organic solvent and an ultrasonic bath.2. Corrosion products.This occurs when substances such as Cl2 (Chlorine) or HCl are present. A dust cover provides some protection. The dust cover should be replaced as part of routine mainte-nance.3. Flame arrestor clogged as a result of painting or house cleaning.The routine maintenance procedure should include covering the sensor with a plastic bag when painting or cleaning. The bag should be removed as soon as possible when the pro-cedure is complete.4. Polymer formation in the flame arrestor.This can occur where monomer vapors such as 1-3 butadiene, styrene, isoprene, etc. are present.B. Substances that cover or tie up the active sites on the catalytic surface of the active sensing ele-ment.This occurs in the presence of volatile metal organics, gases, or vapors of hydrides, and vola-tile compounds containing phosphorous, boron, silicone, etc.Examples: RTV silicone sealants Silicone oils and greases Tetraethyl lead Phosphine Diborane Silane Trimethyl chlorsilane Hydrogen fluoride Boron trifluoride Phosphate estersC. Materials that remove the catalytic metals from the active element of the sensor.Some substances react with the catalytic metal forming a volatile compound. This erodes the metal from the surface. With sufficient exposure, most or all of the metal catalyst can be removed from the surface of the active element of the sen-sor.Halogens and compounds containing halogen are materials of this nature.Examples: Chlorine Bromine Iodine Hydrogen Chloride, Bromide or Iodide Organic halides: Trichloroethylene Dichlorobenzene Vinyl chloride Freons Halon 1301 (Bromotrifluoromethane)A brief exposure to one of these materials can temporarily increase the sensitivity of the sensor. This results because the surface of the active ele-ment is increased due to etching. Prolonged exposure continues the etching process until the sensitivity of the sensor is degraded, resulting in shortened sensor life. D. Exposure to high concentrations of combustible gases.Exposure of the sensor to high concentrations of combustible gases for extended periods of time can introduce stress to the sensing element and seriously affect its performance. After exposure to a high concentration of combustible gas, recal-ibration should be performed and, if necessary, the sensor should be replaced.The degree of damage to the sensor is deter-mined by a combination of the type of contami-nant, its concentration in the atmosphere, and the length of time the sensor is exposed. When a sensor has been exposed to a contaminant or a high level of combustible gas, it should be cali-brated at the time, followed by an additional cali-bration a few days later to determine whether a significant shift in sensitivity has occurred.30 95-83986.1REPLACEMENT PARTSThe R8471 Controller is not designed to be repaired by the customer in the field. If a problem should develop, first carefully check for proper wiring, pro-gramming and calibration. If it is determined that the problem is caused by a defect in the controller’s elec-tronics, the device must be returned to the factory for repair.NOTEWhen replacing a controller, be sure that the jumper plugs and rocker switches of the replacement are the same as the original. Remove power before removing the device from the mounting cage or plugging in the replace-ment unit.The sensing element is mounted in a sealed housing and is not intended to be repaired. When calibration can no longer be properly performed, the sensor must be replaced. The frequency of replacement will be determined by the amount and type of contamina-tion present at the particular installation.An adequate supply of spare sensors should be kept on hand for field replacement. For maximum protec-tion against contamination and deterioration of the sensing element, the sensor should not be removed from the original protective packaging until the time of installation. Always calibrate after replacing the sensor.Refer to the “Ordering Information” section for a list of parts.DEVICE REPAIR AND RETURNPrior to returning devices, contact the nearest local Detector Electronics office so that a Service Order number can be assigned. A written statement describing the malfunction must accompany the returned device or component to expedite finding the cause of the failure.Pack the unit properly. Use sufficient packing materi-al in addition to an antistatic bag or aluminum-backed cardboard as protection from electrostatic discharge.Return all equipment transportation prepaid to the factory in Minneapolis.ORDERING INFORMATIONSensors and transmitters must be ordered separately from the controller. When ordering please specify:R8471A Combustible Gas ControllerSpecify base or premium model, 3U or 4U height.NOTESensors and accessories are not tested and approved by FM.MoUntInG raCKSA mounting rack is required for controller installation. 3U racks are used with gas controllers only. 4U racks can house gas or flame controllers in any combina-tion. See Figures 10 and 11. Rack sizes are available to handle up to 8 flame controllers or up to 16 gas controllers.For assistance in ordering a system to meet the needs of a specific application, please contact:Detector Electronics Corporation6901 West 110th StreetMinneapolis, Minnesota 55438 USAOperator: (952) 941-5665 or (800) 765-FIRECustomer Service: (952) 946-6491Fax: (952) 829-8750Web site: www.det-tronics.comE-mail: det-tronics@det-tronics.com31 95-83986.1recommended test Form Detector Detector Date Date Date Number Location Installed Checked Calibrated Remarks32 95-83986.1Fault record Sheet Date Time Detector System Status Operator Comments Affected33 95-83986.1APPENDIXCE MARKFigure A-1 (Drawing 008940-001) Detector Electronics Corporation6901 West 110th Street Minneapolis, MN 55438 USAT: 952.941.5665 or 800.765.3473F: 952.829.8750W: http://www.det-tronics.comE: det-tronics@det-tronics.com Det-Tronics, the DET-TRONICS logo, Eagle Quantum Premier, FlexVu and Eclipse are registered trademarks or trademarks of Detector Electronics Corporation in the United States, other countries, or both. Other company, product, or service names may be trademarks or service marks of others.© Copyright Detector Electronics Corporation 2010. All rights reserved.X3301 Multispectrum IR Flame DetectorPointWatch Eclipse® IR Combustible Gas DetectorEagle Quantum Premier® Safety SystemFlexVu® Universal Displayw/ GT3000 Toxic Gas Detector 95-8398 95-8398 Cover 95-8398 ToC 95-8398-6.1 (R8471A)