TVOC Instrument User Manual V3.1
Contents
1. instrument via our website www ionscience com instrument registration To receive your Extended Warranty you need to register within one month of purchase Terms and Conditions apply You will then receive a confirmation email that your Extended Warranty Period has been activated and processed Full details along with a copy of our Warranty Statement can be found by visiting www ionscience com instrument registration Service Ion Science is pleased to offer a number of service options on our TVOC product range that allow you to choose the instrument cover that best suits your needs At Ion Science we recommend that all of our gas detection instruments be returned for service and factory calibration once every 12 months Contact Ion Science or your local distributor for service options in your area Find your local distributor by visiting www ionscience com Page 24 of 29 TVOC MANUAL Ion Science Ltd 10 Diagnostics Below are two conditions your TVOC can be in when it is working correctly Power supplied to the PIG sensor from TVIOC Instrument t Lamp ON OFF gf No fault with instrument Light torm Light controlled by Twi FIO lamp Seneor Power to PID cell ON PID lamp OWN Light sensor Indicates Light sensor Housing Sensor Cap TOG Instrument y No fault with instrument Power to PID cell OFF PID lamp OFF Light sensor Indicates NO Light The two conditions shown below are of the2. 3 1 Addition of F3 and F4 fault 08 09 10 V3 25 ARO9033 to diagnostics section pages 27 28 amp 29 Additional notes in TVOC setup selector pin section page 11 TVOC 3 1 Addition wire C S A areas 06 10 10 V3 25 AR10017 accepted on pages 14 amp 30 Mounting diagram 5 2 1 on page changed to general assembly drawing Page 29 of 29
3. 5 mA or 2 0 mA Jumper A fitted 3 5 mA during an alarm condition Jumper A removed 2 0 mA during an alarm condition Page 9 of 29 TVOC MANUAL Ion Science Ltd 4 TVOC Setup IMPORTANT if the 10ppm range is selected the TVOC will require a calibration using 10ppm Isobutylene before use See the calibration section of this manual NOTE TVOC is shipped with all selector pins fitted as standard TVOC only reads the selector pin settings when power is connected Always ensure power is disconnected from TVOC before changing setting or carrying out maintenance Never place selector pins on the programming port connector Ensure static build up is discharged before touching components IF the jumper selection is not a recognised option then error F4 will occur To recover switch the instrument off perform the correct jumper selection and switch the instrument back on 4 2 Duty Cycle The TVOC has a variable duty cycle whereby the lamp is ON for 5 seconds and then OFF for a user set period between 0 to 5 minutes in 1 second increments The 4 20 mA output is updated at the end of each cycle As standard the TVOC duty cycle is 1 minute the lamp is ON for 5 seconds and OFF for 55 seconds The lamp OFF time is fully adjustable by the user Please see page 16of this manual for full instructions Page 10 of 29 TVOC MANUAL Ion Science Ltd 5 Installation 5 1 Location There are many variables involved in defining
4. Disposal Dispose of TVOC and its components in accordance with all local and national safety and environmental requirements This includes the European WEEE Waste Electrical and Electronic Equipment directive Ion Science Ltd offers a take back service Please contact us for more information Contact Ion Science Ltd UK Head Office USA Office German Office Ion Science Ltd Ion Science Americas LLC Ion Science Messtechnik GMBH The Way Fowlmere 35 Crossroad Laubach 30 Cambridge Waterbury Metmann Neandertal SG8 7UJ VT 05676 40822 UK USA GERMANY Tel 44 0 1763 207206 Tel 1 802 244 5153 Tel 49 2104 14480 Fax 44 0 1763 208814 Fax 1 802 244 8942 Fax 49 2104 144825 Email info ionscience com Email info ionscience americas com Email info ism d de Web www ionscience com Web www ionscience com Web www ism d de Page 5 of 29 TVOC MANUAL Ion Science Ltd 2 Introduction to TVOC TVOC is a fixed continuous monitor for the detection and measurement of total volatile organic compounds which can be dangerous from both a poisoning and explosive perspective Total VOC s are detected using PID Photoionisation Detection technology TVOC has a number of user selectable features which define its operation and will be application dependent The user can define the detection ranges or 0 01 10ppm 0 1 100 ppm or 1 1 000 ppm Default detection units either ppm or mg m and the duty cycle time i e the frequency that the in
5. environment Page 15 of 29 TVOC MANUAL Ion Science Ltd 6 Operation 6 1 Start Up After electrical power is connected TVOC runs through a Start up routine which lasts for approximately 1 minute During this Start up routine TVOC demonstrates the following characteristics The LCD screen displays the software version number The GREEN LED flashes The 4 20 mA output is set to 4 mA 0 0 ppm NOTE If the 0 10ppm range is selected the TVOC will require calibration using 10ppm Isobutylene before user See the calibration section of this manual During this Start up time the user can adjust the lamp OFF time as referred to on page 10 This time can be adjusted from 0 to 5 minutes in 1 second increments 6 2 Cycle times To extend PID lamp life and the time between servicing TVOC includes a variable duty cycle see section 4 2 whereby the lamp is switched ON Display and OFF The length of time between servicing and calibration is update increased where longer OFF times are selected However the length of time between servicing also depend on ambient air quality the higher VOC concentration detected by the instrument then the shorter the time between servicing PID lamp duty cycle 6 2 1 Adjusting the lamp OFF time There are two stages to adjusting the lamp OFF time The first stage adjusts the seconds 0 59 and the second stage adjusts the minutes 0 5 To adjust the lamp OFF time the magnetic switch m
6. to normal operation the previous calibration levels will be used The Yellow zero LED will be illuminated to indicate the failure to set a zero calibration level 7 3 Setting the gas tolerance 1 2 Now again place the calibration magnet over the corner of the logo ir The GREEN or RED LED will be extinguished and the numeric display LIL Will start to flash f If the 0 10ppm range is selected you will be able to adjust between 1 0 ppm and 100ppm for both the 100 ppm and 1000 ppm ranges a tolerance of between 1 and 200 ppm can be selected Leaving the magnet in position will cause the displayed number to cycle through the tolerance remove the magnet when the displayed value matches that stated on the Calibration gas bottle Should you miss the desired reading quickly reapply the magnet to continue scrolling through the numbers and remove the magnet at the desired figure The selected number will be recorded 5 seconds after the removal of the magnet when the display stops flashing The display will initially show 90 should this be the desired figure remove the magnet straight away 7 4 Setting the SPAN 1 2 3 Connect the SPAN gas to the calibration connector then the connector to the adaptor Do not over tighten the Luer fitting only a turn is required Switch on the gas supply and then place the magnet over the logo The SPAN LED will flash and TVOC will display the direct millivolt mV output from the PID sen
7. 100 ppm Isobutylene on the 0 10ppm range 3 Setting the SPAN Using the SPAN gas GREEN STATUS LED ZERO LED SPAN LED FAULT LED 7 2 Setting the ZERO i Place the calibration magnet over the top right hand corner of the Ion Science logo to enter calibration mode 7he ZERO LED will illuminate and the GREEN STATUS LED will extinguish 2 Remove the calibration magnet 35 Insert the calibration adaptor into the sensor cap attach the carbon filter to the calibration adaptor The carbon filter should be attached to the hand aspirator 4 Again place the calibration magnet over the logo 7he ZERO LED will flash during this stage TVOC displays a direct milivolt mV output from the PID sensor Hand Calibration adaptor Carbon filter aspirator Page 18 of 29 TVOC MANUAL Ion Science Ltd 7 5 6 Calibration Slowly and repeatedly squeeze the hand aspirator to push clean air through the carbon filter and past the PID sensor The ZERO LED will stop flashing after approximately 2 minutes Now remove the equipment except for the calibration adaptor NB during the Zeroing process the mV reading on the display must reduce to below 30 mV to pass the ZERO calibration stage An acceptable ZERO calibration level will result in the illumination of the GREEN LED An unacceptable ZERO calibration level will result in the illumination of the RED LED Should this occur the TVOC will not proceed to the gas tolerance setting and return
8. 8 Display lamp life 18 8 Maintenance i l i 20 22 Cleaning and replacing the PID lamp l 20 Fuse rupture and replacement l i l 22 Lamp warranty statement i e i 22 9 Instrument Warranty and Service l 23 10 Diagnostics 24 25 11 Spare parts l j l i 26 12 Technical Specifications i l l l 27 13 Update Log l 28 Page 4 of 29 TVOC MANUAL Ion Science Ltd 1 Statements Responsibility for use TVOC detects a large range of gases which are potentially dangerous from both a poisoning and or an explosive perspective TVOC has a number of selectable features allowing the detector to be used in a variety of applications Ion Science Ltd can accept no responsibility for the incorrect adjustment of features that cause harm or damage to persons or property It is the users responsibility to respond appropriately to the readings delivered Warning 1 Substitution of components may impair intrinsic safety and result in unsafe conditions 2 For reasons of safety TVOC must only be operated and serviced by qualified personnel 3 Please read and understand this user manual fully before installing operating or servicing TVOC Quality assurance TVOC has been manufactured in compliance with ISO9001 2000 which ensures that the equipment supplied to our customers has been designed and assembled reproducibly from traceable components and leaves Ion Science calibrated to stated standards
9. C ATEX Identification amp II 2G Ex ia IIC T4 20 C lt Ta lt 50 C Notified Body Baseefa Ltd 1180 Buxton UK Identification II 3G Ex nL IIC T4 20 C lt Ta lt 50 C Ion Science Ltd Self certified EC Type Examination Certificate s Baseefa05ATEX0277 latest supplement Baseefa05ATEX0277 2 issued 24 November 2008 IECEx BAS 06 0057 latest revision no 1 issued 20 November 2008 Ref Baseefa Cert Report 05 c 0423 06 c 0614 08 c 0578 IonscienceO9ATEX002 Examination certificate issued 3 September 2009 Ref Ion Science Cert Report 849237 849242 Standards BS EN 60079 0 2006 Electrical Apparatus for Potentially Explosive Atmospheres General Requirement BS EN 60079 11 2007 Explosive Atmospheres Equipment Protection by Intrinsic Safety i BS EN 60079 15 2007 Explosive Atmospheres Equipment Protection by other means n BS EN 61010 1 2001 Safety requirements for electrical equipment for measurement control and laboratory use General requirements Directive 2004 108EC Electrical Equipment Electromagnetic Compatibility EMC EN61000 6 3 2007 Class 1 light industrial and domestic Electromagnetic Compatibility EMC Generic standards Emission standard for residential commercial and light industrial environments EN50270 2006 Electromagnetic compatibility Electrical apparatus for the detection and measurement of combustible gases toxic gases or oxygen Other Standards BS EN ISO 9001 2000 Quali
10. OC gives a continuous 4 20 mA output which can be integrated into a DCS control system to give an indication of VOC levels in the operating environment In addition to the 4 20 mA output TVOC has an LCD display showing gas concentration and 4 colour LED s LED functions are as follows Green is an indicator of TVOC s working status Red is the fault indicator Yellow x 2 are calibration status indicators Please see page 19Calibration for more information on LED status Page 6 of 29 TVOC MANUAL Ion Science Ltd 2 Introduction to TVOC For installation requirements please refer to Pages 11 and 28 of this manual Before attempting an installation please fully read and understand this user manual and for hazardous area IS installations please also refer to the TVOC ATEX or IECEx certificate for further details The TVOC safety rating permits its deployment in all hazardous areas of the quoted or less demanding rating For detail please refer to the marking on your instrument found on the front main label As of 1 of October units will be manufactured with two protection concepts applied by separate certifications Intrinsic Safety ia and Non sparking nA All units manufactured up to that date will only have intrinsic safety a Intrinsic Safety ia permits the deployment in areas where explosive gases of group IIA IIB and IIC are intermittently present zone 1 with an ambient temp range of 20 C to 50 C Intri
11. TVOC Ingress protection Sensor Ingress protection Range Non IS applications With fence electrode technology 10 6eV Krypton IP65 IP54 0 10 ppm 0 22 8 mg m 0 100 ppm 0 228 mg m 0 1 000 ppm 0 2280 mg m 5 28 Vdc 65 mA 0 5mm to 2 5mm C S A 8 35 Vdc 22 mA 0 5mm to 2 5mm C S A Input power 4 20 mA power ATEX safe approval II 2 G EEx ia IIC T4 40 C lt Ta lt 50 C IS for zone 1 amp 2 Certificate number IS applications Input power 4 20mA power Baseefa05ATEX0277 Entry parameters Ui 18V Ti 800mA Pi 1 2W Ci OuF Li OmMH Ui 30V Ti 200mA Pi 1 2W Ci OuF Li OmMH For information only please see ATEX certificate before installation Zener Barriers Ion Science Ltd suggest using the following Zener Barriers for ATEX IS approved applications Ask your installation engineers for installation and application advice Manufacturer Pepperl Fuchs MTL Stahl Pepperl Fuchs ATEX Non sparking approval Dimensions Height 181mm Width 124mm Depth 72 6mm Display Response Accuracy Linearity Calibration Temperature Humidity Manufacturers part number Z715 7715P 9901 01 158 270 101 KFD2 SD Ex1 17 II 3 G EEx nA IIC T4 40 C lt Ta lt 50 C nA for zone 2 only Weight 7 11 Instrument 1 3kg 2 9 Ib 4 882 Packed 1 47kg 3 2Ib 2 859 7 Segment 4 Digit LCD 4 Colour LED s Sensor T90 lt 5sec TVOC updates the outp
12. TVOC Instrument User Manual V3 1 ppm WARNING DO NOT OPEN WHEN ENERGISED 12 G EEx ia tic T4 BaseefaO5ATEX0277 20 C s Tas 50 C II 3 G ExnNA IIC T4 lonScience09849 ECEx BAS 06 0057 Ex ia IIC T4 U S Patent No 7 046 012 EP 1474681 Other patents pending Refer to manual before Installation ION SCIENCE LTD The Way Fowimere Cambs SG8 7U N 1743 208503 FAX 44 0 1763 208814 www ionscience com j PINKY YES RK n 3 4 EINAR PPLE Hy EEGEN f i yy H P if hs Py Ii ER f f did Bey uid TY di HFT f Py TS yA bese it Wii pees gt LE bi a O oe Advanced Gas Sensing Technologies Registered in England No 2359038 Vat No GB 532 2024 00 Registered office address Lake House Market Hill Royston Herts SGB SIN U K Register your instrument online to receive your Extended 2 Year Warranty See page 24 for details TVOC Instrument User Manual Part Number 849215 lon Science Ltd The Way Fowlmere Cambs SG8 7UJ U K Tel 44 0 1763 208 503 Fax 44 0 1763 208 814 Email info ionscience com Web www ionscience com TVOC MANUAL Ion Science Ltd Page 2 of 29 Declaration of Conformity Manufacturer Ion Science Ltd The Way Fowlmere Cambridge SG8 7UJ UK Product TVOC Product Description An intrinsically safe fixed continuous monitor comprising of a photo ionisation detector for detecting and measuring volatile organic compounds with a 4 20mA output Directive 94 9 E
13. cal Connection Non ATEX ____ __________ie_e i TVOC a Ps pi qe eee EE EE Control equipment O Power mt TY Vase ca oeeaseesessecsesccs v ov I I l l l l l l t ASCREEN LMM M A i tO V i H j 4 20mA E 12 O Lid 1 i gt i I i r oV i ESO mi Rae eee S E Diagram 5 4 1 3 Wire System eee eee ee Electrical Connection Non ATEX ________________e_ l SCREEN Control equipment Page 13 of 29 TVOC MANUAL 5 Installation WARNING Ion Science Ltd The label on the enclosure details the IS and nA certifications The appropriate section of the ATEX label should be covered up or blocked out to reflect the type of installation For Non ATEX applications the label should be covered completely For ATEX zone 2 applications with out safety barriers the ia certification details should be blanked out For Zone 1 or 2 IS applications with safety barriers the nA certification details should be covered This will prevent safety discrepancies and or mis use in the future should the equipment be moved or the site be re defined as a hazardous area 5 4 2 ATEX nA Non sparking applications for Zone 2 areas only Entry parameters Input power 4 20mA power 8 35Vdc 22mA 5 to 24Vdc 80mA max For information only please see ATEX certificate before installation The wiring of ATEX nA systems is identical to the wiring showing for non ATEX applications The only dif
14. ference is the requirements to ensure that the power supplied used provides 24v or less in normal operation 5 4 3 Intrinsically Safe IS applications Entry parameters Input power Ui 18V 4 20mA power Ui 30V Ti 800mA Ti 200mA Pi 1 2W Ci OuF Li OmH Pi 1 2W Ci OuF Li OmH For information only please see ATEX certificate before installation Ion Science Ltd suggest using the following Zener Barriers for IS approved applications Use competent installation engineers and ask them for installation and application advice POWER SUPPLY Suggested barriers for INLET power supply Manufacturer Manufacturers pt no Type Cable length estimate Pepperl Fuchs Z 15 Zener barrier 1115 meters Pepperl Fuchs KFDO SD2 EX1 1065 Galvanic isolator 1217 meters MTL 7 15P Zener barrier 772 meters Stahl 9901 01 158 270 101 Zener barrier 500 meters Stahl 9143 10 156 065 10 Galvanic isolator SIGNAL OUTPUT Suggested barriers for 4 20mMA OUTLET Manufacturer Manufacturers pt no Type Pepperl Fuchs Z728 Zener barrier Pepperl Fuchs KFD2STC4 Ex1 Galvanic isolator MTL MTL7787 Zener barrier MTL MTL5042 Galvanic isolator Stahl 9001 01 280 110 141 Zener barrier Stahl 9160 13 11 11 Galvanic isolator NOTE e All cable lengths are estimated for zone 1 IIC installation of the equipment e Using 1mm C S A conductor S T P cables with capacitance per meter of 250pF m L R ratio of 25uH Q conductor resistance at 20 C of 18 4 km e Calcu
15. instrument in an error state with potential checks cures for these faults TWO Insirumeni gt E x F4 Error Power to PID cell ON PID lamp OFF Pio Sensar j Light sensor Indicates NO Light Cause Loose cable between sensor and main pcb Contaminated pellet Lamp failure Cell failure If an F1 error occurs when the instrument is first switched on there may not be an issue The instrument needs to be left on for a few cycles to see if the lamp strikes on its own If F1 is still on screen after 5 minutes then look at the information below The first thing to check is to make sure the red cable between the sensor PCB and the main PCB is securely plugged in If the red cable is gripped inside the case it can be pushed into the sensor housing using the rigidity of the cable to make sure the connector is fully plugged in Then the connector on the main PCB should also be checked The build standard has been improved to pot the senor cable into the sensor housing so that it cannot come loose and provide improved strain relief at the Main PCB connection Where this has been done a an F3 diagnostic has been added to the software see F3 section below that indicates if the sensor cable has become disconnected at any point All instruments built with serial numbers newer than 10 01790 will have this improvement Page 25 of 29 TVOC MANUAL Ion Science Ltd 10 Diagnostics The notes below will require some TVOC spares Next thing
16. k advice TVOC must be calibrated after lamp cell cleaning or general maintenance NOTE Causes of contamination and error in signal Changes in air pressure when detecting ppm concentration Variation in Oxygen and or Argon beyond ambient levels Variation in ambient moisture content Page 20 of 29 TVOC MANUAL Ion Science Ltd 8 Maintenance Cleaning replacing the lamp TVOC has been designed to ensure servicing is quick and easy 1 Before servicing 7VOC disconnect the electrical ee power supply 2 Remove the Locking Screw from the Meta Sensor Cap using the Allen Key supplied within the Calibration tool kit Calibration tool kit part number A 849214 WARNING Failing to remove the locking screw before unscrewing the Sensor Cap will damage the sensor holder Locking Screw 3 Unscrew the sensor Cap to access the PID sensor Sensor Cap 4 Remove the PID Sensor by withdrawing it from the Sensor Housing Only light force is required WARNING Do not twist the PID Sensor while it is within the Sensor Housing PID Sensor Sensor Housing Page 21 of 29 TVOC MANUAL Ion Science Ltd 8 Maintenance 5 The PID Cell s Metal Spring Cover can be pulled off using moderate force The Electrode Stack and PID Lamp can then be removed Electrode by holding the PID Cell Stack upside down WARNING Ensure the Electrode Stack and PID Lamp fall onto a soft surface such as a piece of tiss
17. lation assumes cables are at 50 C WARNING Intrinsically Safe IS applications e Units should not be powered using non IS power supplies prior to installation in an IS application e If non IS power is supplied the unit will require inspection by Ion Science Ltd or an Ion Science Approved Service Centre prior to installation in an IS application TVOC fuses may not be replaced in the field If a fuse is blown TVOC will require inspection by Ion Science Ltd or and Ion Science Approved Service Centre before it is used in an IS application Page 14 of 29 TVOC MANUAL Ion Science Ltd 5 Installation Electrical connection using Zener Barrier ia i a ls a Control equipment SCREEN Qet gt Db Pe fe ee r4 O O O OV Diagram 5 4 3 1 4 wire Control equipment sensing 4 20 mA on return line Notes For intrinsically safe installations the enclosure may be opened while the system is live provided the work is undertaken by competent personal and suitable safety precautions are taken This overrides the warning on the enclosure label 5 5 Initial calibration TVOC is calibrated at Ion Science before dispatch using 100ppm Isobutylene However if you wish to calibrate your TVOC once it is installed Ion Science recommends that the TVOC is left to run on its chosen settings see page 9TVOC Set up for 24 hours before an initial calibration is carried out to allow the instrument to settle into the working
18. n adaptor 1 3 Calibration connector 1 4 Aspirator 1 5 Carbon filter 1 6 Allen keys 1 3 Calibration 2 Calibration Connector Adaptor 1 Calibration Magnet 6 Allen Keys X 2 5 Carbon Filter 4 Aspirator Page 8 of 29 TVOC MANUAL Ion Science Ltd 4 TVOC Setu 4 1 Selector Pins TVOC has a number of settings that can be selected by the user via a row of 4 selector pins mounted on the reverse side of the main PCB Diagram 4 1 shows the location of the functional selector pins labelled A B C amp D Selector Pins Programming port gr The selector pins absence or presence determines the chosen setting 4 20mA Power F2 4 F1 Screen Screen TVOC is shipped with all 4 selector pins fitted as shown in f Pe diagram 4 2 Diagram 4 1 Diagram 4 2 Diagram 4 3 demonstrates the removal of 1 selector pin JC re 1 s Fi a in 4 f i 5 l ra Diagram 4 3 The following table shows the selector pin combinations and the corresponding function v Selector pin fitted xX Selector pin removed Selector pin A B C D Range Displayed units v v v v 1000 ppm Default v v x v 100 ppm v x Vv v 10 ppm v v v x 2280 mg m v v x x 228 mg m v x v x 22 8 mg m Selector pin B and C selects the ranges 10ppm 100ppm or 1 000ppm Selector pin D selects the units ppm or mg m Selector pin A Fault output range NOTE During an Alarm condition F1 or F2 the output will drop to either 3
19. nsically safe installations will require the use of safety barriers and appropriate wiring b Non sparking nA permits deployment in areas where explosive gases of group IIA IIB IIC are unlikely but possible Zone 2 with ambient temp range of 20 C to 50 C Non sparking installations do not require Safety barriers however the maximum working voltage should be strictly adhered to as a matter of safety As no safety barriers are required there is complete flexibility on the implementation of 3 wire system TVOC does require regular calibration onsite please see page 19 Calibration for information TVOC calibration mode is accessed via a magnetic read switch system Page 7 of 29 TVOC MANUAL Ion Science Ltd 3 Packing List All items of equipment shipped by Ion Science Ltd are packed in suitable containers and enclosed in a shock absorbing filling which affords a considerable degree of protection against physical damage Contents should be carefully removed and checked against the packing list Any discrepancies between the contents and the packing list must be reported to Ion Science Ltd within 10 days of receipt of shipment Ion Science cannot be held responsible for shortages not reported with in the period Standard TVOC instrument Item Description 1 TVOC instrument 1 2 Cable gland M20 ATEX Exe 23 Blanking plug M20 ATEX 1 4 TVOC Manual 1 TVOC Calibration Tool Kit Item Description 1 Calibration magnet 1 2 Calibratio
20. of the Start up routine TVOC will enter the selected monitoring routine Page 16 of 29 TVOC MANUAL Ion Science Ltd 6 Operation 6 3 LED s The GREEN LED indicates TVOC s working status ON Indicates the PID lamp is OFF Flashing Indicates the PID lamp is ON The RED LED indicates Fault status ON Indicates TVOC cannot function correctly The 4 20mA output drops to 3 5mA URGENT attention is required Flashing Indicates the TVOC cannot function but a reading is being attempted The Yellow Zero LED indicates during normal operation ON Last calibration zero level was outside expected limits The instrument will operate normally with the previous calibration The Yellow Span LED indicates during normal operation ON Last calibration zero level was outside expected limits The instrument will operate normally with the previous calibration last calibration carried out was outside expected limits The instrument will continue working but service is required Please see Section 7 Calibration for YELLOW LED status 6 4 Selector pins TVOC has a range of options that are selected via the selector pins on the back of the main PCB please see page 9TVOC Set up The options are shown below with the defaults highlighted in bold 1 1000ppm or 0 01 10 ppm or 0 1 100 ppm ppm units or mg m units 6 5 Calibration mode TVOC calibration mode can be accessed using the calibration magnet supplied in the TVOC calibration tool kit Part numbe
21. pliance Cable screens must be terminated at both ends for them to be effective in achieving electromagnetic compatibility EMC The screens should be terminated to the TVOC enclosure using EMC compatible cable glands It is important for an EMC compatible gland to make electrical contact to the enclosure This is usually done using a serrated washer or EMC lock nut that bites through the paint making electrical contact EMC lock nuts have been provided These locknuts are orientation specific the points should be facing against the case in order to cut through the pain during tightening Two M20 ATEX cable glands and one ATEX blanking plug have been supplied as standard to ease installation in most circumstances These parts will not be appropriate for all applications so they should be used at the discretion of the installation engineer It is recommended that the manufacturer s instructions are followed for the gland and blanking plug installation The M20 blanking plug has been included to enable installations using a single entry cable for example a three wire system to be implemented While ion science can not recommend the cable gland suitable for every application the following information may be useful to the installation engineer for the selection of the appropriate cable gland e For ATEX Ex i intrinsically safe operation using safety barriers the only requirements on the cable glands are that they are better than IP20 rated This may
22. r A 845214 To enter calibration place the magnet over the top right of the Ion Science Logo until the state changes i e an LED illuminates and or the display changes Ensure the magnet is withdrawn away from the magnetic switch by at least 1 cm once a change has occurred 6 6 Calibration gases TVOC has three 3 ranges that can be selected however the 0 10ppm range requires the instrument is calibrated by the user before use The 0 100ppm and the 0 1000ppm ranges can initially run using the Factory calibration carried out during the instruments manufacture however because the 0 10 ppm range is more sensitive and more susceptible to environmental and system tolerances the instrument must be calibrated before use If the 0 10 ppm range is selected TVOC will display the following screen to indicate that a calibration is required before it can be used E E Follow the calibration instructions before use Page 17 of 29 TVOC MANUAL Ion Science Ltd 7 Calibration 7 1 Calibration routine Ion Science recommends calibrating TVOC after any maintenance or lamp cleaning is carried out and on a 3 monthly basis to ensure TVOC is working to specification NOTE Please read this entire calibration procedure before attempting a calibration TVOC calibration has 4 stages 1 Setting the ZERO Using clean gas via carbon filter 2 Setting the gas tolerance 1 200 ppm Isobutylene on 0 100 ppm and 0 1000 ppm ranges 1
23. r if the cable is disconnected an F1 error will be displayed instead and the diagnostics associated with F1 errors above should be performed If an F3 error occurs then check the cable is properly connected to the main PCB If not push it fully home F4 errors The F4 error occurs when a jumper selections without a functional meaning has been implements Review the jumper selection in conjunction with section 4 TVOC set up Page 26 of 29 TVOC MANUAL Ion Science Ltd 11 Spare parts Part Description Part number Calibration tool kit Flow adaptor Fixed bump adaptor PID Lamp cleaning kit Span Gas kit 100ppm Span Gas kit 10ppm PID Cell Carbon filter Calibration magnet Electrode stack PID lamp Calibration magnet Calibration adaptor Calibration connector Zero gas aspirator Carbon filter 2 x Allen keys Replaces the standard Sensor Cap Allows an external pump to be fitted Replaces the standard Sensor Cap Allows an external pip connection Alumina powder and cotton buds 100ppm Isobutylene 103Liters and Flow Regulator in a carry case 10ppm Isobutylene 103Liters and flow Regulator in a carry case Replacement PID Sensor User for ZERO span User to step through calibration Page 27 of 29 A 849214 849218 849217 A 31063 A 845213 849230 1 EO 2 A 31057 A 849219 1 EA 02 A 833227 TVOC MANUAL Ion Science Ltd 12 Technical Specifications PID Sensor Lamp type
24. ronic Pins Cell The PID Cell should insert into the connectors easily if significant resistance is felt remove the cell and check alignment before reinserting WARNING Irreparable damage will be caused by forcing the PID into the Sensor Holder if not correctly aligned NOTE Always calibrate TVOC after servicing is carried out Fuse rupture and replacement TVOC has a 125 mA BASEEFA certified fuse to provide intrinsically safe protection when the unit is installed in hazardous areas This fuse may ruptures for example due to over voltage or a current surge if this is the case replacement is different depending upon the application being Intrinsically Safe or not For Intrinsically Safe IS applications the unit must be inspected and have the fuse replaced by Ion Science Ltd or an Ion Science Approved Service Centre The intrinsically safe rating is not maintained if the fuse is simply replaced For Non Intrinsically Safe Non IS applications the fuse may be replaced by an equivalent rated fuse and operation tested by qualified engineering personnel Lamp Warranty Statement Please note The standard warranty period for a 10 6 PID lamp is one year providing that the default duty cycle for lamp pulsing is used 55 seconds lamp off 5 seconds lamp on Page 23 of 29 TVOC MANUAL Ion Science Ltd 9 Instrument Warranty and Service Warranty Standard Warranty can be extended to up to 2 years on the TVOC when registering your
25. seem extraordinary however where the power is safely limited to the TVOC it is intrinsically safe so does not rely on the prevention of dirt or moisture into the enclosure e For ATEX Ex n the Cable glands must be ATEX rated Ex e Ex n or Ex d and at least IP54 Page 11 of 29 TVOC MANUAL Ion Science Ltd 5 Installation 5 2 Mounting Dimensions for mounting TVOC and connector locations are given in General Assembly drawing 5 2 1 below 5 5mm 0 22in 3 OFF 2 96in 4 92in FIXING POSITIONS FOR M5 75mm i _ 0 98in EE 125mm o E 25mm cie 0 79in 20 0mm ce AE OO Ww o T a TE a8 amp iti iai E E LID S 9 F M5 SCREW x 4 4mm ALLEN KEY CASE SENSOR 4 09in HOUSING 104mm LID OPENED BY PCB MOUNTED REMOVING M5 SCREWS TO REAR OF LID SENSOR amp EARTH CABLE REMAIN CONNECTED TO CASE LID MUST BE ROTATED SENSOR CABLE DOWN OR TO ONE CONNECTION SIDE AND HANGS IN POSITION SHOWN PROGRAMMING PORT SELECTOR PINS Fl POWER POWER CONNECTION 4 20MA CONNECTION F2 4 20mA Diagram 5 2 1 Page 12 of 29 TVOC MANUAL Ion Science Ltd 5 Installation NOTE The TVOC case can be used as a template when marking out fixing holes but do not drill through the fixing holes 5 4 Power requirements 5 4 1 Non ATEX applications Input power 5 28Vdc 80mA max 0 5mm to 2 5mm C S A 4 20mA power 8 35Vdc 22mA 0 5mm to 2 5mm C S A 4 Wire System Electri
26. sor Now remove the magnet Calibration adaptor SPAN gas Calibration connector The SPAN LED will stop flashing after approximately 2 minutes Turn off the gas and disconnect the equipment Page 19 of 29 TVOC MANUAL Ion Science Ltd 7 Calibration NB during the span measurement process the mV reading of the span must be greater than the zero level to pass the ZERO calibration stage An acceptable SPAN calibration level will result in the illumination of the GREEN LED An unacceptable SPAN calibration level will result in the illumination of the RED LED Should this occur the previous calibration levels will be used when the instrument returns to normal operation The Yellow span LED will be illuminated to indicate the failure to calibrate the span Now place the magnet over the logo corner to return to normal monitoring routine The GREEN LED will start flashing as TVOC starts its cycle with a lamp ON cycle If either the ZERO and or SPAN levels where outside acceptable levels the RED LED will flash until an acceptable calibration has been carried out Unacceptable calibration levels will NOT be used TVOC will default to the previously stored acceptable calibration factor NOTE T Always check the accuracy of your calibration by checking readings from TVOC when it is running normally using the ZERO filter and SPAN gas Accuracy of calibration is the responsibility of the person carrying out the calibration If in doubt see
27. strument takes a measurement Duty cycles are explained in more detail on page 10 TVOC set up and page 16 Operation IMPORTANT TVOC can be calibrated on alternative gases to Isobutylene however to ensure TVOC remains within specification the correct concentration for the alternative gas must be chosen Example Benzene gas has a response factor of 0 5 which means only half as much concentration is required to produce the equivalent to Isobutylene The ideal gas concentrations used to set the calibration SPAN are shown below Lower limit Upper limit 10 ppm range 8 ppm 12 ppm Isobutylene equivalent 100 ppm range 90 ppm 110 ppm Isobutylene equivalent 1 000 ppm range 90 ppm 110 ppm Isobutylene equivalent How to calculate alternative concentration of gases for gases other than Isobutylene Ideal response Response factor Ideal calibration gas for Isobutylene concentration Benzene 100 X 0 5 50 ppm Isoprene 100 X 0 7 70 ppm Isobutylene 100 X 1 0 100 ppm Carbon Disulphide 100 X 1 4 140 ppm Ethyl Acrylate 100 X 2 0 200 ppm For other gas response factors please refer to the Ion Science web site or contact Ion Science Ltd http www ionscience com GasSearch tabid 87 Default aspx WARNING Ignoring these guide lines may result may result in calibration failure loss of resolution or loss of range The default settings of TVOC are Detection range 0 1 1000 ppm Units ppm Duty cycle 5 seconds ON 55 seconds OFF TV
28. the optimum location for a gas detector Obvious though it may sound the most important rule is e A detector will not detect gas unless gas actually reaches the detector TVOC should be mounted in the location most likely to detect gas TVOC must be mounted vertically with the sensor underneath the case This avoids dust and debris blocking the access to the detector cell Mount TVOC higher if detecting VOC gases that are lighter than air or lower if detecting VOC gases that are heavier than air but never on the floor This should maximise detection Mount TVOC in an area that has good air circulation Restricting natural air current may result in delayed detection Never mount TVOC in direct sunlight or over a heat source such as a radiator This may cause TVOC to exceed its certified working range Do not mount TVOC where it s subjected to rain fall water aerosols mist or heavy condensation Mount TVOC s in areas that are easily accessible for servicing e Percentage variations in the composition of air 78 Nitrogen 21 Oxygen and 1 Argon may affect the detected signal Please refer to the technical specifications of the instrument in page 28 of this manual before beginning a TVOC installation 5 3 Cable and gland requirements The Screw terminal sockets for connecting wires in the TVOC accept wires of 0 5mm to 2 5mm C S A Screened cables for both power and signal out are necessary to achieve EMC com
29. to try is to replace the pellet with another one if available and switch the instrument on to check remembering that the instrument should be left on for a few minutes if F1 appears straight away If the instrument still shows this error then the lamp should be replaced if available and then the PID cell should be replaced after if it is still not cured If you do not have any spare pellets lamps or PID cells then you will need to contact Ion Science for some assistance if the problem remains after the instrument has completed a few minutes of run cycles and the cable has been checked Or alternatively if the problem remains after you have tried replacement parts THe Instrument x F2 Error Power to PID cell OFF PID lamp OFF but appears ON Light sensor Indicates Light Cause Ambient light on sensor l T OC switched on with PID cell removed The F2 error occurs when the lamp appears to be illuminated yet power is removed from the PID cell TVOC checks the PID lamp status using a light sensor Running TVOC with the sensor or the sensor cap removed will result in an F2 error Light reflecting on to the PID sensor from shiny surfaces can also cause the F2 error to occur TVOC Instrument BE x F3 Power to PID cell ON PID lamp OFF Cause Cable disconnected The F3 error occurs in current build standard instruments when the cable is disconnected Instruments with serial numbers earlier than 10 01790 will not indicate an F3 erro
30. ty Management Systems Requirements BS EN 13980 2002 Potentially Explosive Atmospheres Application of Quality Systems On behalf of Ion Science Ltd I declare that on the date this product accompanied by this declaration is placed on the market the product conforms to all technical and regulatory requirements of the above listed directives Name Mark Stockdale Position Technical Director Signature Date 20 November 2009 Advanced Gas Sensing Technologies Registered in England No 2359038 Vat No GB 532 2024 00 Registered office address Lake House Market Hill Royston Herts SG8 SJN U K TVOC MANUAL Ion Science Ltd Contents Page 1 Statements A i 5 2 Introduction to TVOC l l 6 7 3 Packing List l l i l l 8 4 TVOC Set up i 9 10 Selector pins 9 Cycle times i l 10 5 Installation i i i l i 11 14 Location i i l l 11 Cable requirements l 11 Mounting i l 12 Power requirements i 12 Non Intrinsically Safe IS applications l 12 Intrinsically Safe IS applications l i 13 Initial calibration 14 6 Operation l l l i l 15 16 Start up i 15 Cycle times l i 15 LED S i 16 Selector pins i l 16 Calibration mode i l 16 7 Calibration l l i l 17 19 Calibration routine l l l 17 Setting the zero i 17 Setting the gas tolerance i l 18 Setting the span i 1
31. ue This will avoid damaging the parts as they fall out and avoids finger contact with the PID Lamp window PID Lamp 6 Clean the PID Lamp using Alumina Powder loaded onto a cotton bud Rub the Cotton Bud Metal Spring Alumina power on the Cover PID Lamp Window using a circular motion until a Cotton Bud Alumina light audible squeak can Podat Alumina Powder be heard NOTE Contamination of the Lamp Window can considerably reduce the detection capability of the PID Cell even when the contamination is not visible Cleaning of the lamp should be carried out on a regular basis depending on the duty cycle of the PID Lamp and the environment Page 22 of 29 TVOC MANUAL Ion Science Ltd 8 Maintenance The amount of humidity and quality of the ambient air will directly affect the time between servicing WARNING Leaving contamination on the lamp window can cause irrecoverable damage to the PID Lamp 7 The Electrode Stack should be inspected for visible signs of contamination if contamination can be seen the Stack it must be replaced The Electrode Stack part number 1 EA 02 Reassembly 8 Place the clean PID Lamp into the PID Cell avoiding finger contact with the Window 9 Refit the Electrode Stack with the electrical pin holes and electrode wire racing down 10 Refit the Meta Spring Cover E 11 Ensure the E ectronic Pins of the PID Cell are at the 12 o clock position before inserting the P D Elect
32. ust be activated during the Start up time NOTE Please read this entire procedure before attempting to adjust the lamp OFF time 1 During the 1 minute Start up routine place the calibration magnet over the top right hand corner of the Ion Science logo 7wo numbers on the LCD screen will flash m 4 j Ad 2 This indicates the lamp OFF time in seconds 3 Placing the calibration magnet back over the logo will cause the number to role between 0 and 59 seconds Remove the magnet when the desired time is displayed 4 After 5 seconds the display will show another two numbers and flash 5 This indicates the lamp OFF time in minutes 6 Again place the calibration magnet over the logo to rotate the numbers between 0 i and 5 minutes Remove the magnet when the desired time is displayed f 7 After 5 seconds the entire output frequency is displayed 8 After a further 5 seconds the set frequency will be set in the a TVOC memory E i 4 ft 9 TVOC then continues through the standard start up routine If you are unhappy with the update frequency you have set you can adjust the time by placing the calibration magnet over the logo during the 5 seconds after the total time has been shown point 8 above NOTE The total duty cycle time includes the 5 seconds lamp ON time Therefore if you wish your total duty time to be approximately 2 minutes set the lamp OFF time to 1 minute 55 seconds At the end
33. ut once every 2 minutes 5minutes or 10 minutes 0 100 ppm or 0 10 ppm 2 100 1 000 ppm 5 0 100 ppm gt 98 Magnetically accessed ZERO Carbon canister SPAN 100 ppm Isobutylene 10 Operation 20 C to 50 C 4 F to 122 F 0 95 RH non condensing EMC Screened cables are required to achive the light industrial immunity levels Page 28 of 29 TVOC MANUAL Ion Science Ltd Update Lo Firmware page 11 TVOC V2 2 Diagram updated on page 15 21 4 08 V3 09 TVOC 2 3 Declaration on conformity 27 11 08 V3 09 change onl TVOC 2 4 Log added to back of manual 09 01 09 V3 09 TVOC 2 5 Diagnostics added and P amp F 20 02 09 v3 09 barrier changed TVOC 2 6 TVOC firmware modified to 22 07 09 V3 10 N A allow customers to calibrate using an alternative concentration Aldo improved the description of the F2 fault condition P6 P17 P24 TVOC 2 7 TVOC ATEX certification to 1 09 09 V3 10 N A without safety barriers P12 P13 P26 TVOC 2 9 Inclusion of Cable gland in 23 3 10 V3 10 kit so addition of details AR90024 regarding cable gland selection and use Change to EMC details as result of testing TVOC 3 0 Warranty Cover updated 22 07 10 V3 10 AR10008 Declaration of Conformity AR90024 updated Contents page updated Instrument Warranty and Service updated TVOC 3 1 Addition of fault output level 07 08 10 V3 25 AR1i0053 on page 9 Calibration fault LED indication changed on Page 20 22 23 TVOC
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