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1. 2 2 Installing the HF Sensor Assembly 2 4 Chapter 3 Set up and Operation une 3 1 Setting the Operating Point New Sensors 3 1 Check out 3 2 Operation 3 3 Chapter 4 Maintenance and Spare Parts 4 1 Check out 4 1 Sensor Replacement 4 2 Spare Parts 4 2 Chapter 5 Diagnostics and Troubleshooting 5 1 Appendix A Technical Specifications A 1 Performance Specifications A 1 Interface A 1 Environmental A 2 Mechanical2. 2 2 Connecting Wire to the Terminal Strip 2 5 HF Concentration vs Alarm Time A 2 Wiring Schematic Local Power Supply B 1 Wiring Schematic Remote Power B 3 Chapter 1 Getting Started General Description The SHUR SHOT is a reliable cost effective specific detector of high concentrations of hydrogen fluoride HF It is suited for leak monitoring of flanges pumps seals and other components at risk of releasing HF Even pinhole sized leaks in an HF process stream can produce localized concentrations in the 1000s of ppm range before being dispersed in the air SHUR SHOT rapidly detects localized leaks that may not be detected by other HF detectors located several feet away Because the SHUR SHOT is a high concentration detector these leaks are easily differentiated from low ppm ambient levels of HF The sensor assembly is a one shot disposable item that must be replaced after exposure Because low ppm ambient levels of HF affect SHUR SHOT signal output over long periods of time periodic replacement of the sensor assembly is required The electrical components are housed in an explosion proof enclosure with NEMA 4 rating with the following approvals
3. A 3 Electrical A 3 Logistics A 3 Table of Contents Appendix B Signal Line Length vs Resistance Calculations B 1 Wiring Configuration Signal Cabling Requirements B 1 Maximum Signal Loop Length for 24 V Local Power Supply and 4 wire Configuration B 2 Wiring Configuration Power Cabling Requirements B 3 4 wire Configuration and Remote Power Supply B 3 Wiring Check B 4 List of Tables Acceptable Calibration Ambient Temperature Range 3 1 Maximum Signal Loop Resistance for 24 VDC Supply B 2 Line Resistance per 1000 feet of Copper wire B 2 List of Tables This page is intentionally left blank List of Figures Explosion Proof X Proof SHUR SHOT 1 2 System Components 1 3 Wiring Diagram
4. UL CSA and FM for Class 1 Groups B C and D Class II Groups E F and G Class II hazardous locations Pagel 1 Principle of Operation Detection is based on the very specific reaction of HF with a glass like coating on a sensor chip in the sensor assembly This coating in the form of a blue surface on a shiny substrate is etched away during the reaction with HF The surface of the chip is continuously illuminated by light from a red LED through an optical fiber The reflected light is collected by another optical fiber and transmitted back to a photosensor where it is converted to an analog 4 20 mA signal As the HF reacts with and removes the coating the amount of reflected light increases until all of the coating is gone causing the signal to reach a maximum value This increase of light intensity monitored in the form of a current level change provides a positive indication of detection If the sensor assembly is removed or damaged or if the optical path is interrupted for any reason the output signal will decrease to a minimum value indicating a failure or fault condition A porous Teflon membrane protects the sensor from environmental effects such as rain dust and sunlight Figure 1 1 Explosion Proof X Proof SHUR SHOT Page 1 2 System Components HF SENSOR FIBER FTIG SENSORICONNECTION u 5 00 ees TERMINAL BLOCK are MB eres py 0 912 2PL OPTIONAL MOUNTING _ LAA SA
5. 25 ohms 215 ohms 50 ohms 190 ohms 100 ohms 140 ohms 200 ohms 40 ohms Table B 2 Line Resistance per 1000 feet of copper wire AWG Size At 0 C At 20 C At 40 C 32 F 68 F 104 F 14 2 33 ohms 2 52 ohms 2 73 ohms 16 3 7 ohms 4 01 ohms 4 35 ohms 18 5 88 ohms 6 39 ohms 6 97 ohms 20 9 36 ohms 10 15 ohms 11 01 ohms 22 14 87 ohms 16 14 ohms 17 52 ohms 24 23 65 ohms 25 67 ohms 27 86 ohms Page B 2 Wiring Configuration Power Cabling Requirements For installations that are a long distance from the power source the resistance of the cable needs to be calculated to ensure that the voltage at the sensor is gt 18V To calculate the longest cable that can be used find the resistance that drops the voltage by 6 V Rcable 6 V 160 mA 37 5 ohms For 20 AWG 40 C this limits cable length to 3406 feet 1703 feet each way 4 wire Configuration and Remote Power Supply asus ee Bst 160 mA F 1 R PHOTO SENSOR Figure B 2 Wiring Schematic Remote Power Supply Page B 3 rs o os Wiring Check Check the power supply voltage at the ShurShot is in the range of 18 24 V Measure total resistance of signal cabling and termination resistor e Disconnect power from unit e Disconnect signal cable from pins 2 and 7 of unit e Using an ohmmeter measure the resistance around the signal cable The resistance should be less that 240 ohms Page B 4
6. Do not readjust the 4 20 mA after initial installation and setting 10 12 mA e A slow rise from 10 12 mA WARNING Sensor indicates that maintenance has assembly may have been not been done and sensor has exposed to high been exposed to a low concentrations of HF concentration of HF Lethal concentrations of e A rapid rise to above 12 mA HF may be present indicates that the sensor has been exposed to a high concentration of HF gt 12 mA High Alarm e See Exposure warning above Replace sensor Follow applicable Safety and Emergency procedures Page 5 1 Blank Page Page 5 2 Appendix A Technical Specifications Performance Specifications Interface Environmental Chemicals Detected Hydrogen Fluoride Concentration Catastrophic releases Alarm Time 30 or less seconds to a catastrophic leak See Figure A 1 HF Concentration vs Alarm Time on page A 2 Interface Ammeter 0 25 mA DC mA Note For reference only The readout may not agree with exact 4 20 mA output For precision readings read voltage across the 10 A calibration resistor 40 mV to 200 mV output provided or any other calibrated load Indicator Lights Not used Adjustments One 1 adjustment potentiometer under the red and green LEDs to set gain Set current can be read through the calibration 10 A resistor Communications Analog 4 20 mA current loop See Appendix B for maximum loop length Environmental 8242540
7. 0 40 Heated 24 VDC 40 C to 50 C 40 to 122 F Humidity 0 to 100 RH Page A 1 Mechanical Configuration The active electrical components are housed in an explosion proof enclosure with NEMA 4 rating Enclosure approvals UL CSA and FM for Class I Groups B C and D Class II Groups E F and G Class III hazardous locations Electrical 18 25 VDC 0 20 mA Logistics Sensor Assembly Life One shot Discard and replace the sensor assembly if the 4 20 mA signal output is greater than 10 mA Page A 2 Appendix B Signal Line Length vs Resistance Calculations Wiring Configuration Signal Cabling Requirements The following diagram shows a SHUR SHOT connected in a four wire configuration 18V MIN PHOTO SENSOR Figure B 1 Wiring Schematic Local Power Supply Page B 1 If the signal loop s total resistance Rt is defined as the loop s line resistance R1 plus load resistor RL then Rt R1 RL or Rt 2r RL where r is defined as line resistance for half of the signal loop s total length The maximum allowable Rt is 240 he cabling length and gage must be sized accordingly Refer to Table B 3 for the resistance of stranded copper wire Maximum Signal Loop Length for 24 V Local Power Supply and 4 wire Configuration In this configuration the power supply is local to the photoelectric sensor Table B 1 Maximum Signal Loop Resistance for 24 VDC Supply
8. ON 5 25 BC i 3 PHOTOELECTRIC 4 25 ASSEMBLY a AMP METER lt SENSITIVITY ADJUSTMENT 5 250 Major Assemblies Sensor Assembly This is a disposable item consisting of the following parts e chemical sensor chip e chip holder and environmental shield Fiber Optic Sensor Connector Assembly This assembly consists of the following parts fiber optic sensor connector 1 2 or 3 4 inch NPT adapter Page 1 3 Photoelectric Sensor Assembly This assembly consists of the following parts e photoelectric Sensor 4 20 mA transmitter 0 25 mA DC ammeter Not intended for use as a precision readout e terminal block Allows user electrical connections e 2 piece holder and mounting hardware e calibration resistor 10 ohm 1 metal film Photoelectric Sensor Features LED Indicators Not used Adjustments and Controls e sensitivity adjustment A 4 turn adjuster located beneath the red LED indicator e logic operating point adjustment below the sensitivity adjustment Not used 4 20 mA converter output See Appendix B for line length vs resistance calculation Shur Shot X Proof Manual Page 2 1 Page 1 4 Chapter 2 Installation Safety Requirements of the Installation Area SHUR SHOT s active electrical components are housed in an explosion proof enclosure with NEMA 4 rating and the following approvals UL CSA and FM for Class 1 Groups B C and D Class II Groups E F and G Class III hazardous l
9. Shur Shote X Proof Hydrogen Fluoride Alarm Operations Manual P N 1000006053 Rev E ATB Analytics LIC 733 Dairy Rd Parkton Md 21120 www atbanalytics com 410 733 6365 Table of Contents Chapter 1 Getting Started mmm 1 1 General Description 1 1 Principle of Operation 1 2 System Components 1 3 Major Assemblies 1 3 Sensor Assembly 1 3 Fiber Optic Sensor Connector Assembly 1 3 Photoelectric Sensor Assembly 1 4 Photoelectric Sensor Features 1 4 Chapter 2 Installation 0 0 0 0 0 0 2 1 Safety Requirements of the Installation Area 2 1 Installation Using Conduit and the 3 4 inch NPT Port 2 1 Installation Using Mounting Feet 2 1 Installing Wiring
10. g on the voltmeter is 8 mA 0 2 mA 80 mV 2 mV Check out Use the following steps to verify instrument output when the sensor has been removed or the optical link is interrupted Required tool Precision voltmeter 0 200 mV scale 0 5 accuracy or better and orange red Alarm Test Sensor Assembly provided with ShurShot To verify the instrument s output 1 Connect the precision voltmeter across the 10 ohm resistor and verify that output is 8 mA 0 2 mA 80 mV 2 mV 2 Remove the sensor assembly from the SHUR SHOT chassis by unscrewing it counterclockwise 3 Observe the precision voltmeter s reading It should be less than 4 5 mA but gt 2 5 mA This is the FAULT range reading expected when the sensor has been removed or if the fiber optic link is interrupted 4 Install the Alarm Test Sensor Assembly and observe the precision voltmeter s reading It must be greater than 14 mA 5 Confirm that the AMP meter permanently connected to the far end of the sensor wiring produces the same reading NOTE The Alarm Test Sensor Assembly is reusable Do Not Discard the Alarm Test Sensor Assembly orange red color Save it for future use 6 Remove the Alarm Test Sensor Assembly 7 Replace the sensor assembly 8 Current output should return to the calibration reading 8 mA 0 2 mA 80 mV 2 mV NOTE Output of the unit may stabilize at less than 20 mA After exposure to HF Alarm Page 3 2 Operation The recommended alarm thresh
11. l surface Hand Tighten Only Do Not Over tighten Bo Spare Parts Part or Assembly Part Number X PROOF 82425400 40 heated 24 V Sensor Assembly 6 pack 1000007263 Photoelectric sensor assembly Photoelectric sensor 4 20 mA transmitter 1000012202 0 25 mA current meter 1000006077 Calibration Resistor 10 ohm 1 metal film 1000007484 Fuse 1000006413 Page 4 2 Test Sensor Assembly with etched chip 1000007473 NOTE The Test Sensor Assembly is painted bright orange red to differentiate it from the regular sensor assembly which is white Adaptor 1 2 3 4 inch NPT 1000005438 O ring 1000006258 Thermostat 1000006708 Heater 24 VDC 1000005937 Page 4 3 Blank Page Page 4 4 Chapter 5 Diagnostics and Troubleshooting Current System Condition Recommended Action Output 0 2 45 mA System Failure e Check power to the photoelectric sensor e Check the photoelectric sensor and the 4 20 mA e loop connections 2 5 6 0 mA Sensor Fault e Check sensor assembly unit out of adjustment Check the fiber optic link e Inspect the fiber optic cable for bends e Verify that the photo sensor is operating within the e specified temperature range Inspect the sensor assembly replace if damaged 7 5 10 mA Normal operation e Replace sensor if above 10 mA 10 mA should be set as a e A slow rise above 8 mA maintenance alarm indicates that the sensor has been exposed to a relatively low concentration of HF Warning
12. ocations Installation Using Conduit and the 3 4 inch NPT Port Seal the conduit within 18 inches 46 cm of the instrument enclosure For European applications an ATEX approved cable entry must be used Installation Using Mounting Feet The enclosure may be installed using the mounting feet See Figure 1 2 System Components on page 1 3 The mounting feet have two 312 inch diameter holes located on a 5 25 inch bolt circle The structure to which SHUR SHOT is mounted must be strong and rigid enough to support the enclosure as well as the enclosed device and wiring Before installation determine the safety requirements for the area where SHUR SHOT will be installed and select an appropriate hub and compound Page 2 1 Installing Wiring YA 3 N A 5 aes RETURN BLU 6 F MPER Pre eects 7 LT oar BLK g TEMP SWITCH RETURN R 10 OHMS GAN GRN CHASSIS EARTH GND GND Figure 2 1 Wiring Diagram To install 4 20 mA and power wiring 1 See Appendix B Signal Line Length vs Resistance Calculations and calculate the wire gauge that must be used 2 Remove the SHUR SHOT chassis cover by unscrewing it counterclockwise until it can be removed Locate the screw that holds the terminal block retainer on the rail Loosen the screw and remove the terminal block retainer 5 Carefully pull the terminal block toward the end of the rail until terminal 7 can be accessed 6 Feed the 4 20 mA
13. old point is 12 mA During normal operation with no HF present the SHUR SHOT will continue to read 8 mA when set up as described above Slight fluctuations may be noted due to changes in temperature and humidity In locations where there is high humidity and sudden temperature changes the signal output may drift up to 9 mA The presence of HF is indicated by an increase in the 4 20 mA loop signal A slow increase over several hours or days is an indication of relatively low concentrations of HF A rapid signal increase is an indication of a high concentration of HF SHUR SHOT output is expected to level off above 13 mA after a large HF exposure further exposure to HF has no effect on the output After a large HF exposure the sensor assembly must be replaced The sensor assembly should also be replaced when low level HF concentrations produce a slow rise to above 10 mA This will assure that a false alarm is not triggered by low level releases Page 3 3 Blank Page Page 3 4 Chapter 4 Maintenance and Spare Parts Warning Keep the sensor assembly free of ice oil bird droppings and other material that may impair normal diffusion of HF vapors into the sensor assembly Check out Use the following steps to verify instrument output when the sensor has been removed or the optical link is interrupted Required tool Precision voltmeter 0 200 mV scale 0 5 accuracy or better To verify the instrument s output 1 Connec
14. t the precision voltmeter across the 10 A resistor and verify that output is 8 mA 0 2 mA 80 mV 2 mV 2 Remove the sensor assembly from the SHUR SHOT chassis by unscrewing it counterclockwise 3 Observe the precision voltmeter s reading It should be less than 4 5 mA but gt 2 5 mA This is the FAULT range reading expected when the sensor has been removed or if the fiber optic link is interrupted 4 Install the Alarm Test Sensor and observe the precision voltmeter s reading It must be greater than 14 mA NOTE The Alarm Test Sensor is reusable Do Not Discard the Alarm Test Sensor orange color Save it for future use 5 Remove the Alarm Test Sensor 6 Replace the sensor assembly 7 Current output should return to the calibration reading 8 mA 0 2 mA 80 mV 2 mV NOTE Output of the unit may stabilize at less than 20 mA Page 4 1 Sensor Replacement No special tools are needed To replace the sensor assembly 1 Ensure that a replacement sensor assembly and O ring are available 2 Ensure that the area is safe to work in See Figure 1 1 Explosion Proof X Proof SHUR SHOT on page 1 2 and Figure 1 2 System Components on page 1 3 Unscrew the sensor assembly Visually inspect the O ring seal Replace it if is cracked or deformed 5 Screw the sensor assembly onto the fiber optic sensor connector assembly so that its plastic base is in contact with the fiber optic sensor connector assembly s stainless stee
15. tening when the plastic base touches the stainless steel surface Page 2 3 ES O LLL LL LLL Lhd is gt gt gt gt gt gt 0 19 1N Figure 2 2 Connecting Wire to the Terminal Strip Page 2 4 Chapter 3 Set up and Operation Setting the Operating Point New Sensors Required instrument Precision voltmeter 0 200 mV scale 0 5 accuracy or better WARNING Ensure that the area is certified as non hazardous or that adequate protective devices exist before turning power ON or removing the instrument cover Verify that all electrical connections have been made and that the installation complies with all local State and Federal laws regulations and codes Verify that the sensor assembly has been installed Required instrument Precision voltmeter 0 200 mV scale 0 5 accuracy or better To set the operating point 1 Turn on power 2 Allow a one hour minimum warm up time 3 Verify that the 4 20 mA loop is closed 4 Use the table below to verify that the ambient temperature is within the required range for instrument calibration Remove the instrument cover by turning it counter clockwise Connect the voltmeter across the 10 Ohm calibration resistor on the terminal block resistor R1 Figure 2 1 on page 2 2 ou Page 3 1 7 Adjust the gain sensitivity potentiometer located on the front of the photoelectric sensor underneath the red and green LEDs until the 4 20 mA output readin
16. wires through the NPT port and pull them through until the ends can be connected to the terminal block 7 Connect wires to the terminals 7 and 2 as show in Figure 2 2 Connecting Wire to the Terminal Strip on page 2 5 Bo Page 2 2 8 Feed the power wires through the NPT port and pull them through until the ends can be connected to the terminal block at terminals 3 and 6 9 Connect the power wires to the terminal block 10 Replace the terminal block and the terminal block retainer 11 Tighten the terminal block retainer screw 12 Screw the chassis cover onto the chassis Hand tighten only Installing the HF Sensor Assembly The sensor assembly must be installed to make the SHUR SHOT functional NOTE Install the HF Sensor Assembly only after the SHUR SHOT chassis has been installed in the location it will be monitoring To install the Sensor Assembly 1 Locate the Sensor Assembly 2 Remove the shipping cap from the exposed end 3 Install the sensor assembly on the stainless steel fiber optic sensor connector assembly so that its plastic base is in contact with the stainless steel surface as shown in Figure 1 2 System Components on page 1 3 e To ensure safe performance the user shall install operate and maintain SHUR SHOT per National Electrical Code NEC Articles 500 504 e The user must comply with national regulations and may use EN60079 14 as an installation guide CAUTION Hand tighten only Stop tigh
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