Crowcon Flamgard Plus Fixed Gas Detector User Manual
Contents
1. 12 J CROWCON Detecting Gas Saving Lives Flamgard Plus 4 OFF M4 X 12MM ALLEN HEAD screns 2 TOP CAP amp SENSOR PCB NEOPRENE GASKET 1 Part No MO4452 GASKET 2 Part No MO4128 MAIN BODY SINTER ASSEMBLY Part No 501781 SINTER Diagram 4 96HD assembly Operation Re assemble the 96HD housing taking time to ensure that the 3 mm Allen head screws are securely fixed into position Fit the 96HD sensor housing to the junction box ensuring that the colour coded wires are terminated correctly m Replace amplifier ensuring the captive screws are fastened securely n Switch on power JCROWCON Detecting Gas Saving Lives 13 Operation o Us Se complete list p Us Se ing a DVM measure Bridge Volts Pot A ing a DVM measure Balance Pot B unti until the DVM read Flamgard Plus he voltage across Test Points A and adjust s correctly see Table 3 for he voltage across Test Points B and adjust the DVM reads 0 mV q Close the junction box remembering to fasten the tamper proof grub Screw into position r Follow the Commissioning Procedure given in 4 1 Sensor Part Element Test point A Comment no voltage mV S01 637 A VQ21T 310 Poison resistant B 300P 280 Poison resistant IC VQ8 350 Lead resistant D VQ16 350 Early model E VQ22 170 Low power F VQ25 310 For Halogens G VQ41 310 Ammonia or aviation fuel H vQ1 310 Early mode2. HW OV he base of the junction box see Diagram 2 The relay contacts are rated 1 A 30 Vdc CONTROL EQUIPMENT SAFE AREA V ov 000 4 20mA Y 0v d 12 30 SOURCE NE D E SINK Diagram 3 Electrical connections to Flamgard Plus JCROWCON Detecting Gas Saving Lives Operation Flamgard Plus 4 Operation WARNING Prior to carrying out any work ensure local regulations and site procedures are followed Never attempt to open the detector or junction box when flammable gas is present Ensure that the associated control panel is inhibited so as to prevent false alarms 4 1 Commissioning Procedure a Open the junction box of the detector by loosening the tamper proof grub screw and removing the lid by rotating it anti clockwise b Remove the amplifier and check that all electrical connections have been made and are correct as per Diagram 3 c Replace the amplifier and close the junction box ensuring that all screws have been re fitted correctly d Apply power to the detector The status LED will show a steady green indicating normal operation e Leave the detector to stabilise for 1 2 hours Zeroing the detector ZERO Mode f Place the end of CRO Mag over the MENU Green Status LED will flash Decimal point above ZERO will illuminate Display backlight will illuminate Decimal point above INHIBIT may
3. a INHIBITED s E O mam Oo ALARM 1 amp 2 2 Lowe ADJUSTMENT S ar POTS ven M STATUS V CROWCON LED LA SN 7 DOWN eT LO 9 R EXTERNAL 4 OFF EARTH POINT FIXING HOLES 6mm Y 1 83 3 HEIGHT 115 4 All dimmensions in mm unless otherwise stated Diagram 1 Flamgard Plus general arrangement JCROWCON 2 Detecting Gas Saving Lives Flamgard Plus Introduction REAR VIEW OF AMPLIFIER GAS RANGE ALARM 000000 agaaaa el YO Test N POINT 40 200mV PUT OPTIONS RELAY CONTACT CONTACT REVERSING LINKS ALARM 2 GND ISOLATE ALARM 1 ahl X FAULT ALARM NOTUSEDON FLAMGARD PLUS SET POTS CONTRO EQUIPMENT YOSNIS s LA 9559 1999 SENSOR INTERNAL TERMINAL LAYOUT E ALARM RELAY VERSION ONLY Diagram 2 Terminal and amplifier layouts 1 3 Status Indication 3 CROWCON 3 Detecting Gas Saving Lives Introduction 1 3 Status Indication Flamgard Plus includes a local display and status LED visible through the junction box window This is shown in Diagram 1 Flamgard Plus The display shows the current flammable gas concentration in the range 0 100 LEL and current mode of operation ie NORMAL ZERO or CAL The LED shows the current alarm state of th
4. Normally energised de energised on fault Contact normally closed NC opening on fault Alarm fault relays automatically reset when alarm or fault has cleared INHIBIT Normally selected ie when CAUZERO selected current output is forced to 2mA and relays are held in normal no alarm state 3 CROWCON 5 Detecting Gas Saving Lives Installation Flamgard Plus 3 Installation WARNING Flamgard Plus is designed for use in Zone 1 and 2 hazardous areas and is certified Ex d IIC T6 AEx d IIC T6 in USA Installation must be in accordance with the recognised standards of the appropriate authority in the country concerned For more information contact Crowcon Prior to carrying out any work ensure local regulations and site procedures are followed 3 1 Location There are no rules which dictate the siting and location of detectors however considerable guidance is available from BS EN 50073 1999 British Standard Code of Practice for the Selection Installation Use and Maintenance of Apparatus for the Detection and Measurement of Combustible Gases or Oxygen In the USA refer to the National Electrical Code NEC 1999 Similar international codes of practice may be used where applicable In addition certain regulatory bodies publish specifications giving minimum gas detection requirements for specific applications The detector should be mounted where the gas is most likely to be present The following points should be noted w
5. TD THORNE amp ED DERRICK INTERNATIONAL CROWCON www thorneandderrick com Detecting Gas Saving Lives Flamgard Plus Flameproof Flammable Gas Detector Flamgard Plu t y NCROWCOr Installation Operation and Maintenance Instructions M07192 Issue 7 March 2015 Flamgard Plus Introduction 1 Introduction 1 1 Product overview Flamgard Plus is a flameproof flammable gas detector suitable for use in zone 1 or 2 hazardous areas It is designed to detect flammable gas present in ambient air at concentrations not exceeding the Lower Explosive Limit LEL of the target gas for which it is calibrated A local display and magnetically operated switches allow non intrusive one man calibration without a hot work permit Powered by 24 V dc nominally Flamgard Plus provides a 4 20 mA signal sink or source proportional to the gas concentration and can also be fitted with optional alarm and fault relays For a list of flammable gases that can be detected please contact Crowcon 1 2 Product description Flamgard Plus comprises four parts 96HD sensor housing junction box amplifier and terminal board Diagram 1 details Flamgard Plus The overall assembly is certified Ex d IIC T6 in Europe and Class 1 Zones 1 amp 2 AEx d IIC T6 in the USA The 96HD sensor housing is a modular stainless steel assembly that dismantles to allow plug in pellistor sensors to be replaced easily see Diagram 4 The assembly screws int
6. flash if the option has been internally selected g With no flammable gas present at the detector place the end of the CRO Mag key over the UP or DOWN arrow pads to make the display read zero Calibrating the detector CAL Mode h Place the end of the CRO Mag over the MENU pad The decimal point above the word CAL will illuminate Other indications remain unchanged i Apply calibration gas to the detector at a flow rate of 0 5 litres min Crowcon recommend 50 LEL gas for calibration purposes contact Crowcon for the supply of calibration gas 10 3 CROWCON Detecting Gas Saving Lives Flamgard Plus Operation j Allow the gas reading to stabilise k Place the end of the CRO Mag over the UP or DOWN arrow pads to make the display read the correct concentration If the control equipment display requires adjustment consult the operating manual for the equipment Returning to normal operation NORMAL Mode n Place the end of CRO Mag over the MENU pad All decimal points will disappear and the backlight will turn off The green status LED will be on steadily assuming no gas is present at the detector o The detector is now operational Note Always return the detector to NORMAL mode to avoid leaving the detector in a permanently inhibited state Note ATEX certified Flamgard Plus flammable gas detectors will be supplied calibrated for compliance with EN60079 20 1 where for examp
7. not collect on the sinter and stop gas entering the detector 3 3 Cabling requirement Cabling to Flamgard Plus must be in accordance with the recognised standards of the appropriate authority in the country concerned and meet the electrical requirements of the detector Crowcon recommend the use of steel wire armoured SWA cable and suitable explosion proof glands must be used Alternative cabling techniques such as steel conduit may be acceptable provided appropriate standards are met Flamgard Plus requires a dc supply of 12 30 V at up to 210 mA Ensure the minimum dc supply of 12 V is observed at the detector taking into account the voltage drop due to cable resistance For example a nominal dc supply at the control panel of 24 V has a guaranteed minimum supply of 20 V The maximum voltage drop allowed is therefore 8 V Flamgard Plus can demand up to 210 mA and so the maximum loop resistance allowed is 38 Ohms A 1 5 mm cable will typically allow cable runs up to 1500 m JCROWCON 7 Detecting Gas Saving Lives Installation Flamgard Plus Table 2 shows maximum cable distances given typical cable parameters CSA Resistance Ohms per km Max distance mm2 awg Cable Loop m ft 1 0 17 18 1 36 2 1000 3280 1 5 15 12 1 24 2 1500 4920 Table 2 Maximum cable distances for typical cables Acceptable cross sectional area of cable is 0 5 to 1 5 mm Table 2 provides guidance only actual cable p
8. 6HD sensor housing is given in Diagram 4 The following procedure may be followed when servicing a Flamgard Plus detector a Switch off and isolate power to the detector requiring attention b Open the detector Junction box by loosening the tamper proof grub screw and removing the lid by rotating it anti clockwise c Remove the amplifier d Disconnect the 3 sensor wires from the terminal board terminals 4 5 amp 6 e Unscrew the complete 96HD sensor housing from the junction box Note If a spare 96HD sensor housing complete with new sensor is available ignore steps f to and return the old 96HD to Crowcon or an approved service centre for repair f Open the 96HD sensor housing by removing the four Allen head screws from the Top Cap with a 3mm Allen key g Remove the sensor from the Top Cap PCB Flammable sensors have an extra black sleeve which may be separate from the sensor This is normal and the sleeve may be re used h Fit the replacement sensor checking the part number is correct This part number is labelled on the main body of the detector i Inspect the gaskets and replace if necessary j The sinter assembly will only need to be replaced if it has become blocked by dust or oil Such blockage causes the response time of the detector to be slow and may affect sensitivity To remove the sinter a removal tool Part M01614 is required Loctite No 243 must be used on the sinter assembly threads to maintain certification
9. Mag key over the UP or DOWN arrow pads to make the display read the desired alarm level i Using a long instrument screwdriver turn the relevant ALARM SET pot mounted on the terminal board see Diagrams 1 amp 2 to adjust the alarm level Tripping of the ALARM 1 level relay is confirmed by the status LED turning a steady red Tripping of the ALARM 2 level relay is confirmed by the Status LED flashing red j Once the alarm level has been set place end of CRO Mag over the UP or DOWN arrow pads and reset the display to read zero k Place the end of the CRO Mag over the MENU pad to return the detector to normal operation ie No decimal points displayed backlight off and the Status LED indicating steady green 3 CROWCON 15 Detecting Gas Saving Lives Operation Flamgard Plus Check that the detector operates correctly by applying test gas as necessary m Switch off and isolate power to the detector n Reset jumpers which may have been changed in step d above o Replace the amplifier and close the junction box ensuring that all screws have been re fitted correctly p Apply power to the detector and allow to stabilise before checking correct operation q Re calibrate if necessary as per section 4 1 Notes Area Classifications Zone 0 area classified as Zone O will have ignitable concentrations of flammable gases vapours or liquids present continuously or for long periods of time und
10. arameters for each application should be used to calculate maximum cable distances 3 4 Electrical connections All connections are made via the terminal board mounted in the base of the junction box see Diagram 2 The 3 wires from the 96HD are colour coded and should be terminated in the corresponding colour coded terminal terminals 4 5 amp 6 Terminals 1 0 Vdc 2 12 30 Vdc and 3 4 20mA signal are connected to the control equipment Flamgard Plus is factory set as a 4 20 mA source device unless specified otherwise when ordering see Section 2 to change configuration Diagram 3 summarises the electrical connections Note The junction box and cable armour must be earthed at the detector or control panel to limit the effect of radio frequency interference and to maintain electrical safety Note The junction box for the Flamgard Plus is manufactured from marine grade alloy and has a powder coated finish Care should be taken during installation to protect the painted finish as use in saline environments could result in paint flaking off from damaged junction boxes This in no way compromises the performance of the detector as the marine grade alloy junction box is approved for use in offshore environments 8 WCROWCON Detecting Gas Saving Lives Flamgard Plus Installation All electrical connections to the optional relays are made via the 6 way erminal block on the terminal board in CONTROL EQUIPMENT SAFE AREA
11. e detector This is summarised in Table 1 Operational LED 4 20mA Relay states Comment state indication outputs Normal Steady green 4 to 7 2mA AL1 Off 0 to 20 LEL operation AL2 Off FAULT On Normal Steady red 7 2 to 10 4mA AL1 On 20 to 4096 LEL operation AL2 Off ALARM 1 FAULT On Normal Flashing 10 4 to 20mA AL1 On 40 to 10096 operation AL2 On HELE ALARM 2 FAULT On Over range Flashing red 24mA clamp AL1 On gt 100 LEL AL2 On Display back FAULT On light flashes Zero Flashing Configuration Configuration Latched until calibration green dependent dependent reset via mode see section 2 see section 2 MENU Detector fault Steady OmA AL1 Off amber AL2 Off FAULT Off As standard AL1 2096LEL and 12 4096LEL Relay version only Table 1 LED status indicator summary 4 JCROWCON Detecting Gas Saving Lives Flamgard Plus Detector configuration 2 Detector configuration 2 1 Standard configuration As standard Flamgard Plus is factory set as follows Current source with Fault 2mA Inhibit ie Zero Cal mode 4 20 mA Normal operation 24 mA Over range clamp AL1 relay Alarm level 1 set to 2096LEL Normally de energised energising on alarm Contact normally open NO closing on alarm AL2 relay Alarm level 2 set to 40 LEL Normally de energised energising on alarm Contact normally open NO closing on alarm FAULT relay
12. er normal operating conditions Zone 1 An area classified as Zone 1 is likely to have ignitable concentrations of flammable gases vapours or liquids present under normal operating conditions Zone2 An area classified as Zone 2 is not likely to have ignitable concentrations of flammable gases vapours or liquids present under normal operating conditions 16 J CROWCON Detecting Gas Saving Lives Flamgard Plus Spare parts and accessories 5 Spare parts and accessories Description Part number M20 to 1 2 inch NPT adaptor M02125 M20 to 3 4 inch NPT adaptor M02281 Gasket 1 M04452 Gasket 2 M04128 Sinter removal tool M01614 Collector Cone C01051 Ceiling Mounting Bracket M01401 Weatherproof Cap C01442 Replacement CRO Mag C01697 96HD sensor housing complete with sensor S01749 1 Replacement sensor 501673 1 Sinter assembly 501781 Amplifier 501865 Terminal board 501846 Relay board 501847 Loctite No 243 Contact Crowcon Calibration gas Contact Crowcon 1 Flamgard Plus may be fitted with a range of pellistor sensors depending on the specific application The correct spare sensor part number is itemised on the sensor housing label JCROWCON Detecting Gas Saving Lives 17 Specifications 6 Specifications Flamgard Plus Dimensions 200 x 115 x 115 mm 8 x 41 2 x 41 2 Weight 2 2 kg 4 8 lbs Material 96HD sensor housing 316 Stainless steel Ju
13. hen locating flammable gas detectors To detect gases which are lighter than air eg methane detectors should be mounted at high level and Crowcon recommend the use of a collector cone Part No C01051 To detect heavier than air gases eg butane detectors should be mounted at low level When locating detectors consider the possible damage caused by natural events e g rain or flooding For detectors mounted outdoors Crowcon recommend the use of a Weatherproof Cap Part No C01442 Consider ease of access for functional testing and servicing 6 WCROWCON Detecting Gas Saving Lives Flamgard Plus Installation Consider how the escaping gas may behave due to natural or forced air currents Mount detectors in ventilation ducts if appropriate Consider the process conditions Butane for instance is normally heavier than air but if released from a process line which is at an elevated temperature and or under pressure the gas may rise rather than fall The placement of detectors should be determined following advice of experts having specialist knowledge of gas dispersion the plant processing equipment as well as safety and engineering issues The agreement reached on the locations of sensors should be recorded 3 2 Mounting The mounting detail of Flamgard Plus is given in Diagram 1 Flamgard Plus should be installed at the designated location with the detector pointing down This ensures that dust or water will
14. l Storage Instructions The sensor used in thi s detector should be stored in a dry environment and protected from exposure to silicones sulphides chlorines and lead Exposure to these compounds will significantly reduce the sensitivity of the sensor and render the sensor warranty void 14 3 CROWCON Detecting Gas Saving Lives Flamgard Plus Operation 4 4 Changing Alarm Levels Relay Version Only WARNING This work should be carried out by Crowcon or an approved service centre unless suitable training has been received Before attempting to change alarm levels ensure the detector is in fresh air and no flammable gas is present As standard the AL1 and AL2 alarm levels are factory set at 20 LEL and 40 LEL respectively To change either alarm level a Switch off and isolate power to the detector requiring attention b Open the junction box of the detector by loosening the tamper proof grub screw and removing the lid by rotating it anti clockwise c Remove the amplifier from the terminal board d Ensure that the INHIBIT link is set to N e Re fit the amplifier to the terminal board ensuring that all screws have been secured correctly f Apply power to the detector and allow the detector to stabilise g Place the end of CRO Mag over the MENU pad The decimal point above the word ZERO will illuminate h With no flammable gas present at the detector place the end of the CRO
15. le 10096 LEL methane 4 496 volume UL certified detectors will be supplied calibrated for compliance with North American standards where 10096 LEL methane 596 volume 4 2 Routine maintenance The operational life of the pellistor sensor depends on the application for which it is being used Such a device should work satisfactorily for up to 5 years in ideal conditions Site practices will dictate the frequency with which detectors are tested Crowcon recommend that detectors be gas tested at least every 6 months and re calibrated as necessary To re calibrate a detector follow steps given in 4 1 Pellistors can suffer from loss of sensitivity when there is a presence of poisons or inhibitors such as silicones sulphides chlorine lead or halogenated hydrocarbons Flamgard Plus uses poison resistant pellistors to maximise the operational life In applications where such compounds are present continuously we recommend the use of Xgard IR or IRmax Crowcons fixed point infrared flammable gas detectors which are immune to such poisons and inhibitors D CROWCON 11 Detecting Gas Saving Lives Operation Flamgard Plus 4 3 Sensor replacement servicing of detectors WARNING This work should be carried out by Crowcon or an approved service centre unless suitable training has been received Flamgard Plus uses the 96HD sensor housing which allows the user to replace the sensors gaskets and sinter if necessary An exploded view of the 9
16. nction box Marine grade alloy Temperature range 10 C to 55 C 14 F to 131 F Humidity range 0 99 RH non condensing Ingress protection P65 Explosion protection Flameproof Approval codes E Il 2 G Ex d IIC T6 Gb 4 55 c UL Class 1 Zones 1 amp 2 AEx d IIC T6 Safety Cert No Sira03ATEX1124 Standards EN60079 0 EN60079 1 2007 UL2279 Zones Certified for use in Zone 1 or Zone 2 areas see area classifications section Gas groups IA IIB IIC Operating voltage 12 30 Vdc Operating current Relay version 210 mA maximum Non relay version 160 mA maximum Detector output 4 20 mA source or sink selectable 0 mA Fault 2 mA Inhibit 4 mA option 4 20 mA 0 100 LEL 24 mA Over range Relays outputs 2 x Alarm relays SPNO SPNC option 1 x Fault relay SPNC SPNO option Contact rating 1 A 30 Vdc 18 J CROWCON Detecting Gas Saving Lives A HALMA COMPANY THORNE amp DERRICK INTERNATIONAL www thorneandderrick com
17. o an M20 entry on the junction box The junction box is manufactured from marine grade alloy and is supplied with 2 x M20 1 2 NPT for USA cable entries for customer use Alternative cable entries are available from Crowcon The amplifier plugs into the terminal board and is held in place by two captive screws The amplifier provides power to the pellistor sensor local display and controls and a 4 20 mA signal proportional to the gas concentration for connection to a control panel To remove turn screws anti clockwise and use them to pull amplifier out of the enclosure All electrical connections are made via the terminal board mounted in the base of the junction box see Diagram 2 Optional alarm relays AL1 amp AL2 and one fault relay FAULT are mounted on the terminal board which may be used to drive local warning devices or connect Flamgard Plus to a control panel D CROWCON 1 Detecting Gas Saving Lives Flamgard Plus Introduction 415 411 7 SET BRIDGE SET BALANCE UNITS T YOLTS POTA POTR TAMPER PROOF au TEST GRUB SCREW M20 NTP POINTS A POINTS B 1 5mm ALLEN KEY CABLE ENTRY i LOCAL Q DISPLAY M20 NTP STEADY ON CABLE ENTRY INDICATES Sl fs FLASHING ZERO CAL Flamgard Plus INDICATES MODE 4 20mA RELAYS ACTIVATED I
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