User Manual - Automatikprodukter
Contents
1. Three wire connection VDC output signal 0 20 mA output signal Relay output LCD display Heating X5 Transmitter Connection field bus and tension Two or three wire connection depending on transmitter type PCB Terminal block Fig 3 Option Manual Addressing Anal Output oO Start Point EM 20 O mm gt ODO y OE 9 DK v Option Manual Calibration a A OU N gt NO KR GON X5 Anal Output EE V DC OX mA Selection analog output signal Fig 4 Not set Not set Set Not set Not set Set Set Set Calibration adapter Fig 5 Type Calibr set 25 Notes and General Information It is important to read this user manual thoroughly and clearly in order to understand the information and instructions The AP transmitters must be used within product specification capabilities The appropriate operating and maintenance instructions and recommendations must be followed Due to on going product development AP reserves the right to change specifications without notice The information contained herein is based upon data considered to be accurate However no guarantee is expressed or implied regarding the accuracy of this data 25 1 Intended Product Application The Cl transmitters are designed and manufactured for control applications and air quality compliance in commercial buildings and manufacturing plants 25 2 Insta2. C to 30 C 41 F to 86 F Storage time Max 6 months Mounting height 0 2m 0 7ft Stability amp resolution 0 1 ppm Repeatability 2 of reading Long term output drift lt 2 signal loss year Response time too lt 90 sec Life expectancy gt 2 years normal operating environment Cross sensitivity Concentration ppm Reaction ppm Cl Carbon monoxide CO 300 Hydrogen H2 300 0 Nitrogen dioxide NO 20 20 Nitrogen monoxide NO 35 0 Sulphur dioxide SO 5 Electrical 18 28 VDC AC reverse polarity protected Power supply 2 wire mode only VDC Power consumption without options Analog mode 22 mA max 0 6 VA DGC 05 Bus mode 12 mA max 0 3 VA Output signal Analog output signal 0 4 20 mA load lt 500 Q Selectable Current tension 0 2 10 V load gt 50 k Q Starting point 0 20 proportional overload and short circuit proof Serial interface Transceiver RS 485 19200 Baud 9600 ModBus Protocol depending on version DGC 05 or ModBus Physical Enclosure Stainless steel V2A Enclosure colour Natural brushed Dimensions H x W x D 113 x 135 x 45 mm 5 35 x 4 5 x 1 8 in Weight Approx 0 5 kg 1 1 Ibs Protection class IP 55 Mounting Wall mounting pillar mounting Cable entry Standard 1 x M 20 Screw type terminal min 0 25 to 2 5 mm Wire connection 24 to 14 AWG Current signal ca 500 m 1500 ft Voltage signal ca 200 m 600 f
3. 22 mA 220 mV Check the wiring Control voltage does not reach Sensor element not calibrated Calibrate sensor element the calculated value Replace sensor element No reaction of the output signal Power voltage not applied Measure tension at X4 in spite of gas concentration Signal Pin 4 not wired correctly Check the wiring 7 2 CGD 05 Bus Mode Yellow LED not shining Power voltage not applied Measure tension at X4 Pin 1 and 2 PCB not plugged in correctly at X4 X5 Replug PCB correctly Check wiring Yellow LED not flashing No communication at the transmitter Transmitter not addressed check bus wiring incl topology and termination Voltage lt 16 V No control voltage at calibration Jumper V A not set Set the jumper Remove it after calibration 8 Cross sensitivity Data The cross sensitivity can be read from the table Technical Data The table doesn t claim to be complete Other gases can have an influence on the sensitivity too The indicated sensitivity data are only standard values referring to new sensor elements 9 Technical Data General sensor performances Gas type Chlorine Cl Sensor element Electrochemical diffusion 0 10 ppm factory set 0 20 ppm optional Measuring range Temperature range 10 C to 45 C 14 F to 113 F Pressure range Atmosphere 15 Humidity 15 95 RH non condensing Storage temperature range 5
4. Cl2 Electrochemical Chlorine Transmitter User Manual May 2008 10 11 General Overview siss sa testes cu dau a adonde scada a san iia BE a a 3 Functional Description rrrnnnnvnnnnnnnnvnnnnnnnvnnnnnnnvnnnnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnr 3 ZA Control Mode e taaan 3 22 SENSOR 3 A ra knee E SEERE SEES BENS SED SEE SE ER SEE SEERE BEDER a te AEA DAS AA Aaaa Si 4 LL Mounting Instructions as ga A na 4 32 Installation sete 4 Electrical Connection a Tn 4 4 1 lt Wiring GONNEG ON sa aaa ka a a a aa saga det ee 4 COMMISSIONING sasssa ansa Fs sa MR Mr He 5 5 Ala aa IA alin Lit ea aa e 5 5 2 Manual Calibration sasssa En Ra gat aaa tes KRR teh la agder alet 6 5 21 LOTO POMO Ate ne 6 52 27 AM Grane 6 5 2 3 Calculation of Control Voltage 6 5 3 Calibration with Service Tool CDG 05 coooccccccnccococonononocnnncnnnnononnnnnnnnnnnnnnnnnnnnnnnnnnnnnn rr 7 5 4 Calibration with CDG 05 Configuration and Calibration Software oooonnnncccnnnnciccnnnaccccnnancccnnn 7 5 5 Addressing only for CDG 05 Bus Mode mrsrrnnnnnvvrnnnnnvvrnnnnnrsrrnnnersrrnnnersrrnneersrreneersrrrrnsersrreneenn 8 5 67 Option Relay UP Us sn annara ak dali Dios tote 8 Inspection and Service rrrnsnnnnnnvnnnnvnnnnnnnnnnnnnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnn 9 6 1 InsPeCtIO SRS AR OR TR SR a 9 6 2 Alan ean kat Slur a ee ad 9 6 3 Exchange of Sens
5. al blocks X4 and X5 Insert the cable and connect cable leads to terminal blocks See fig 1 and 2 Replug the PCB in the terminal blocks X4 X5 with care Replace the cover 5 Commissioning Consider commissioning instructions at any exchange of the sensor element as well Only trained technicians should perform the following e Check mounting location e Select output signal form Current or voltage and starting point 0 or 20 See fig 4 e Check power voltage e Check PCB for correct mounting at X4 and X5 e Check the sensor for proper mounting at the connectors X7 of the PCB e Addressing of the transmitter in the CGD 05 Bus mode e Calibrate the transmitter if not already factory calibrated Required instruments for commissioning calibration of the transmitter e Test gas bottle with synthetic air or Chlorine free ambient air e Test gas bottle with Cl ppm in the range of 30 80 of the measuring range e Gas pressure regulator with flow meter to control the gas flow to 150 ml min e Calibration adapter with tube Calibration set See fig 5 e Digital voltmeter with range 0 300 mV accuracy 1 e Small screwdriver e Calibration tool CGD 05 STL only for calibration with service tool CGD 05 e CGD 05 configuration and calibration software incl USB RS 485 communication set only for software calibration mode Note Prior to calibration the sensor must be connected to the power supply and fully stabilised for at leas
6. e Service Tool or of the Configuration and Calibration Software In the manual addressing version which can be identified by the address switch being equipped there is a maximum of 60 addresses to be selected See fig 3 The jumper is responsible to define the address group and the switch to define the address according to the following table Switch Jumper pos 01 Jumper pos 02 Jumper pos 03 Jumper pos 04 positon address address address address inactive inactive inactive inactive i 2 3 4 5 6 7 8 9 A B C D E F 5 6 Option Relay Output The two relays are activated in dependence of the gas concentration If the gas concentration exceeds the adjusted alarm threshold the corresponding relay switches on If the gas concentration falls below the threshold minus hysteresis the relay switches off again The contact function for relay 2 NC normally closed or NO normally open can be selected via the jumper NO NC See fig 1 and 3 Relay 1 is equipped with a change over contact Via the ModBus interface the two alarm thresholds and the hysteresis are freely adjustable at the PC within the measuring range The procedure can be read from the user manual ModBus Software The following parameters are factory set Alarm threshold 1 Relay 1 5 ppm Alarm threshold 2 Relay 2 8 ppm Switching hysteresis 1 ppm 6 Inspection and Service 6 1 Inspect
7. e for both control modes 5 2 Manual Calibration 5 2 1 5 2 2 5 2 3 Zero point Connect calibration adapter carefully to the sensor element Apply synthetic air 150 ml min 1 Bar 14 5 psi 10 or Chlorine Cl free ambient air Wait 2 minutes until the signal is stable push button Zero for 5 seconds After successful calibration the measuring signal is corrected automatically Depending on the selected signal starting point the measuring signal shows the following values Signal start at 2 V or 4 mA 40 mV 0 ppm Signal start at 0 V or 0 mA OmV 0ppm If the zero point is out of the admissible range gt 20 mV at starting point 0 gt 60 mV at starting point 20 before calibration there is no correction of the measuring signal The sensor has to be replaced Remove calibration adapter carefully by turning lightly Check the sensor for correct mounting Gain Connect calibration adapter carefully to the sensor element Apply calibration test gas Cl 150 ml min 1 Bar 14 5 psi 10 Wait three minutes until the signal is stable adjust control voltage with potentiometer Gain until the signal corresponds to the calculated value 2 mV see Calculation of Control Voltage Remove calibration adapter with a careful light turn Check the sensor for correct mounting By limiting the gain factor calibration will not be possible any more when the sensitivity of the sensor reaches a residual sensiti
8. formed into a linear output signal Electrochemical processes always lead by and by to a loss of sensitivity Therefore regular calibration of zero point and gain is obligatory See also section 6 Caution There is a small quantity of corrosive liquid in the sensor element If in case of damage persons or objects touch the liquid you have to clean the affected areas as fast and carefully as possible with tap water Out of use sensors must be disposed in the same way as batteries 3 Installation Note Avoid any force e g by thumb on the sensor element during operation or installation Electronics can be destroyed by static electricity Therefore do not touch the equipment without a wrist strap connected to ground or without standing on a conductive floor acc to DIN EN100015 3 1 Mounting Instructions When choosing the mounting site please pay attention to the following The specific weight of Chlorine CL is higher than that of air factor 2 4 Recommended mounting height is 0 2 m 0 7 ft to 0 3 m 1 ft above floor Choose mounting location of the sensor according to the local regulations Consider the ventilation conditions Do not mount the transmitter in the centre of the airflow air passages suction holes Mount the transmitter at a location with minimum vibration and minimum variation in temperature avoid direct sunlight Avoid locations where water oil etc may influence proper operation and where
9. ions Inspection service and calibration of the transmitters should be done by trained technicians and executed at regular intervals We therefore recommend concluding a service contract with AP or one of their authorized partners 6 2 Calibration See section 5 1 and 5 2 e At commissioning and at periodic intervals determined by the person responsible for the gas detection system recommendation every 6 months e After exchange of the sensor e f in case of operational or climatic influences the sensitivity of the sensor falls below 30 in operation calibration will not be possible any more e In this case the sensor has to be changed 6 3 Exchange of Sensor Element Consider static electricity See point 3 Sensor should always be installed without power applied e Unplug basic PCB carefully from the bottom part e Unplug old sensor element from the PCB e Take the new sensor out of the original packing e Plug the sensor element in the PCB at X7 e Replug the PCB in the terminal blocks X4 X5 carefully Calibrate according to section 5 7 Troubleshooting 7 1 Analog Mode Output signal lt 3 mA 1 5 V Jumper 0 20 not set Check jumper position and or control voltage lt 30 mV Measure tension at X4 only for starting signal 2V 4 mA Power voltage not applied Two wire Pin 1 and 4 Three wire Pin 1 and 2 PCB not plugged in correctly at X4 and Replug PCB correctly X5 Output signal gt
10. llers Responsibilities It is the installer s responsibility to ensure that all transmitters are installed in compliance with all national and local codes and OSHA requirements Installation should be implemented only by technicians familiar with proper installation techniques and with codes standards and proper safety procedures for control installations and the latest edition of the National Electrical Code ANSI NFPA70 It is also essential to follow strictly all instructions as provided in the user manual 25 3 Maintenance It is recommended to check the transmitter regularly Due to regular maintenance any performance deviations may easily be corrected Re calibration and part replacement in the field may be implemented by a qualified technician and with the appropriate tools Alternatively the easily removable plug in transmitter card with the sensor may be returned for service to Automatikprodukter 25 4 Limited Warranty Automatikprodukter warrants the transmitters for a period of one 1 year from the date of shipment against defects in material or workmanship Should any evidence of defects in material or workmanship occur during the warranty period AP will repair or replace the product at their own discretion without charge This warranty does not apply to units that have been altered had attempted repair or been subject to abuse accidental or otherwise The warranty also does not apply to units in which the sens
11. mechanical damage might be possible Provide adequate space around the sensor for maintenance and calibration work Duct mounting 3 2 Mount only in a straight section of duct with minimum air vortex Keep a minimum distance of 1 m 3 5 feet from any curve or obstacle Mount only in a duct system with a maximum air velocity of 10 m s 2000 ft min or less Mounting must be performed so that the probe openings are in line with the airflow Installation Open the cover Unplug basic PCB carefully from the bottom part Fix bottom part by screws vertically to the wall terminal blocks to the ground Replug the basic PCB at X4 and X5 with care Replace the cover 4 Electrical Connection Consider static electricity See 3 Mounting Installation of the electrical wiring should only be executed by a trained specialist according to the connection diagram without any power applied to conductors and according to the corresponding regulations Avoid any influence of external interference by using shielded cables for the signal line but do not connect the shield Recommended cable for analog mode J Y St Y 2x2x0 8 LG 20 AWG max resistance 73 Q km 20 8 0 1000 ft Required cable for RS 485 mode J Y St Y 2x2x0 8 LG 20 AWG max res 73 Q km 20 8 Q 1000 ft It is important to ensure that the wire shields or any bare wires do not short the mounted PCB 4 1 Wiring Connection Open the cover Unplug basic PCB carefully from termin
12. o the analog output the transmitter is equipped with a serial interface RS 485 for the connection to the CDG 05 system Analog mode The analog output can be selected as current signal with 0 4 20 mA or as voltage signal 0 2 10 V In the 4 20mA mode and without any supplementary options the Cl2 also works in the 2 wire technique CDG 05_Bus mode The transmitter can be connected to the CDG 05 system via the RS 485 interface In this mode there is an analog input for the connection of an additional 4 20 mA transmitter The two measuring values are transmitted via the RS 485 interface to the gas controller The cable topology for the RS 485 bus can be taken from the Guidelines for wiring and commissioning of the CDG 05 hardware The two control modes are available in parallel 2 2 Sensor The sensor portion of the transmitter is a sealed electro chemical cell with three electrodes sensing counter and reference The ambient air to be monitored diffuses through a membrane filter into the liquid electrolyte of the sensor The chemical process of the measurement is one of reduction where one molecule of the target gas is exchanged for one molecule of oxygen The reaction drives the oxygen molecule to the counter electrode generating a DC microampere signal between the sensing and reference electrodes This signal is linear to the volume concentration of the sensed gas The signal is evaluated by the connected amplifier and trans
13. or Element tdci 9 Troubleshooting ccoo 9 TA Analog Modena a a E 9 12 CDG 05 BUS Mode e o edo 10 Cross sensitivity Data rnsnrnnnvnnnnnvnnnnnvnnnnnnnnnvnnnnnvnnnnnnnnnnvnnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnenn 10 Technical Data ivonne liinda 11 US dd ida 13 Notes and General Information rss rnnnnvnnnnvnnnnnvnnnnnnnnnnvnnnnvnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnenn 15 11 1 Intended Product Application ccccccccceceeceeceeceeeeeeeeeeeneaeeeeeeeeeccaeaeeeeeeeeeesensisaeeeeeeeeetene 15 11 2 Installers Responsibilities rornnnnonnnrnnn nr nr rrnrrnrnr eeeeeeaeeeeeeeee cea ceaaaeeeeeeeeesessncieeeeeeeeneeeiaes 15 11 3 MaintenanGe a isle nde evita eine oie us A A is hae 15 11 4 Limited WA dai 15 Electrochemical Chlorine Transmitter 1 General Overview The Cl analogue gas transmitter with digital processing of the measuring values and temperature compensation is used for the continuous monitoring of the ambient air to detect the presence of Chlorine gas Main application ranges are waterworks sewage plants swimming pools etc The intended sites are all areas being directly connected to the public low voltage supply e g residential commercial and industrial ranges as well as small enterprises according to EN50 082 The Cl analogue transmitter must not be used in potentially explosive atmospheres 2 Functional Description 2 1 Control Mode In addition t
14. or element has been overexposed or gas poisoned The above warranty is in lieu of all other express warranties obligations or liabilities This warranty applies only to the AP transmitter AP shall not be liable for any incidental or consequential damages arising out of or related to the use of the transmitters
15. t Wire distance The table doesn t claim to be complete Other gases too can have an influence on the sensitivity The mentioned cross sensitivity data are only reference values valid for new sensors Indications only for option stainless steel for further types see datasheet AT DT Enclosure Guidelines EMC Directive 2004 108 EWG CE Warranty 1 year on material without sensor Options Relay output Alarm relay 1 switching threshold 5 ppm 30 VAC DC 0 5 A potential free SPDT Alarm relay 2 switching threshold 8 ppm 30 VAC DC 0 5 A potential free SPNO SPNC Power consumption 30 mA max 0 8 VA Warning buzzer Acoustic pressure 85 dB distance 300 mm 1 ft Frequency 3 5 kHz Power consumption 30 mA max 0 8 VA LCD display LCD Two lines 16 characters each not illuminated Power consumption 10 mA max 0 3 VA Heating Temperature controlled 3 C 2 C 37 5 F 35 5 F Ambient temperature 30 C Power supply 18 28 VDC AC Power consumption 0 3 A 7 5 VA Analog input 4 20 mA overload and short circuit proof input Only for RS 485 mode resistance 200 Q Power supply for external transmitter 24 DC max 50 mA 10 Figures Application Analog mode Fig 1 Transmitter Two wire connection 4 20 mA output signal without options Application DGC 05_Bus mode Fig 2 R2 Transmitter Connection analog transmitter
16. t 6 hours without interruption Please observe proper handling procedures for test gas bottles regulations TRGS 220 CL calibration gas is toxic never inhale the gas Symptoms Chemical burn dizziness headache and nausea Procedure if exposed Take the victim into fresh air at once call a doctor 5 1 Calibration Depending on the version and the control mode there are three different possibilities to calibrate the transmitter Manual calibration Manual calibration is only possible if the transmitter is equipped with the push button Zero and the potentiometer Gain version for manual calibration Manual calibration is possible both in analog mode and in CGD 05_Bus mode In the CGD 05 Bus mode the jumper V A has to be set before manual calibration Only by doing so the control voltage is available at the test pins X6 Remove the jumper after calibration Calibration with the Service Tool CGD 05 In the standard version equipped with the communication connector X12 the transmitter is delivered for tool and or software calibration In the analog mode the service tool calibration is only possible with the 3 wire technique of the transmitter In the CGD 05 Bus mode calibration is always possible Software calibration via PC In the standard version equipped with the communication connector X12 calibration can also be done by means of the configuration and calibration software Software calibration is possibl
17. vity of 30 Then the sensor has to be replaced Calculation of Control Voltage Signal start 2 V 4 mA Control voltage MV 160 MV x test gas concentration Cl ppm 40 mV measuring range Cl ppm Signal start 0 V 0 mA Control voltage mV 200 mV x test gas concentration Cl ppm measuring range Cl ppm Example Measuring range 20 ppm Test gas concentration 10 ppm Cl Control voltage Signal start 2 V 4 mA 120 mV Control voltage Signal start O V 0 mA 100 mV Signal start 2 V 4 mA Signal start 0 V 0 mA 160 MV x 10 ppm 40 MV 120 mV 200 MV x 10 ppm 100 mV 20 ppm 20 ppm 5 3 Calibration with CGD 05 Service Tool Connect the CGD 05 Service Tool to the transmitter open menu Calibration Enter measuring range and test gas concentration Connect calibration adapter carefully to the sensor element Apply synthetic air 150 ml min 1 Bar 14 5 psi 10 or Chlorine Cl gt free ambient air Wait until the measuring value is stable and then perform automatic zero calibration Apply calibration test gas Cl 150 ml min 1 Bar 14 5 psi 10 Wait until the measuring value is stable and then perform automatic gain calibration Remove calibration adapter carefully by turning lightly Check the sensor for correct mounting By limiting the gain factor calibration will not be possible any more when the sensitivity of the sensor reaches a residual sensitivit
18. y of 30 In this case the sensor has to be replaced Further information can be taken from the user manual of the CGD 05 Service Tool 5 4 Calibration with CGD 05 Configuration and Calibration Software Connect the PC via USB RS 485 communication set to the transmitter open menu Calibration Enter measuring range and test gas concentration Connect calibration adapter carefully to the sensor element Apply synthetic air 150 ml min 1 Bar 14 5 psi 10 or Cl free ambient air Wait until the measuring value is stable and then perform automatic zero calibration Apply calibration test gas Cl 150 ml min 1 Bar 14 5 psi 10 Wait until the measuring value is stable and then perform automatic gain calibration Remove calibration adapter carefully by turning lightly Check the sensor for correct mounting By limiting the gain factor calibration will not be possible any more when the sensitivity of the sensor reaches a residual sensitivity of 30 In this case the sensor has to be replaced Further information can be taken from the user manual of the DGC 05 Configuration and Calibration Software 5 5 Addressing only for CGD 05 Bus mode In the CGD 05_Bus mode each transmitter gets its communication address In the standard version with the communication connector X12 addressing is done by means of the CGD 05 Service Tool or by the CGD 05 Configuration and Calibration Software See user manual of th
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