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Environmental Monitoring & Control Units Types MCU 3 & 4

1. N A LO Document Ref P0102 800 00 June 2012 Page 8 67 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 8 7 Mounting details for FGD3 detector heads The diagram below shows the mounting centres for the Analox Ltd FGD3 detector heads 122 102 gt gt iN 102 122 140 Depth 75mm approx All dimensions are in mm and are approximate only Note The front panel lid of the detector head opens to allow access to the screw terminals situated inside Sufficient space should be allowed around the mounting position so that this action is not restricted Two mounting slots are provided suitable for M6 fasteners Fixings Required 2 off M6 fasteners Rawl bolts or similar dependent on mounting wall construction Document Ref P0102 800 00 June 2012 N A LO Page 8 68 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 8 8 FGD detector head calibration look up table Each time a calibration is performed on a detector head the user will be displayed a zero and a span factor refer to section 5 4 for calibration instructions The values given for these factors should be compared to the table below to determine the serviceability of the sensor Analox Ltd strongly advise that sensors providing zero and span factors that do not corre
2. In addition the input module can re transmit the signals for use by external equipment e g chart recorders The transmitted signal can be configured using jumpers to provide one of three output options e 4 20mA current source proportional to detected signal e 4 20mA current sink proportional to detected signal e 0 5V voltage output proportional to detected signal Up to eight input modules can be located within an MCUS control unit up to sixteen can be located within an MCU4 Situated on each input module are 3 double pole change over relays each relay having contacts rated at 5A 240V AC These relays operate at low intermediate and high alarm levels when enabled Analox Ltd are able to implement modifications to the software to meet a customer s specific requirement Contact Analox for further information Document Ref P0102 800 00 June 2012 NA LO Page 1 10 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 1 4 Distribution board The distribution board is the distribution point for power around the system It allows the connection of external power supplies into the system and the use of external batteries for backup purposes It is located at the left hand side of the main chassis within the MCU control units beneath the common relay module There are two main versions of the distribution board see sections 1 4 2 amp 1 4 3 Note that Issue 3 is fitted in
3. Environmental Monitoring amp Control Units Types MCU 3 amp 4 Supplied by Analox Ltd 15 Ellerbeck Court Stokesley Business Park North Yorkshire TS9 5PT UK T 44 0 1642 711400 F 44 0 1642 713900 W www analox net E info analox net Installation and Hardware User Manual Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual List of Contents 1 lntrod ctign suni cione tee tree ens edn ete reete PUn eese pe pec eet beet 1 3 1 1 The MCUS amp 4 manuals asinina entrent enne nnns nnne nnns 1 4 1 2 Microcontroller miodule critici trc tee eter eee eee 1 8 1 3 Input riodule iei rea ect ude ene ete sapevo eu abeo n tru oro EE nets 1 10 1 4 Distribution Doard iere e aret teret ee oet Ene Dee kon dca EE ERE xr 1 11 1 4 1 Field connections eerte re elis Des et eset edie eo eoe es ede Enea 1 11 1 4 2 Distribution board Issues 1 amp 2 1 12 1 4 3 Distribution board Issues 3 and above ssseeeee 1 12 1 5 Common relay module eric onec nece set eei es iei aaaea EAEE 1 13 1 6 Power supply module iere tree troc enn A Ee ce be aet e 1 15 1 7 Battery backup reet Ee ertet ort pecore nre Le Ende Eun Eo no 1 17 1 7 1 Calculation examples vissa minnast ne aa tende este 1 19 1 7 2 Calculating the backup time for your system srrrannrrnnnnvnnorrnnnnrrrnnnrnnnnnnnrnnr 1 22 1 8 MCU system communications essssss
4. 3 34 4 Input module configuration sse nnns 4 37 AA Input CORTIgUratiOri cii eco ret Eee cer aE keen 4 37 4 1 1 Analox Ltd gas detectors esencan A 4 38 4 1 2 Alternative detector heads rrnnronnnnnnvonnnnnnnvnnnnnnnvnnnnnnavennnnnavnnnnnnnvennnnnnrennnnnne 4 43 4 2 Analogue output configuration essssssseseneeenene enne 4 47 4 2 1 4 20mA Current SOURCE minnene eten 4 48 4 2 2 4 20mA current SINK Lang Ix eerte Eten Re ec Rete ER e Ee ee 4 48 4 2 3 1 5V voltage OUtput rmm cenare ci ee zoe recede eee 4 49 4 3 Input module installation essere 4 50 5 Detector head operation amp calibration 5 51 5 1 Detector head variants esee ecce reine e A eu Eee PR 5 51 SES UCM ECT 5 51 5 2 1 Status INGICAtIONS EE 5 51 5 3 Inspection and maintenance sssssssseeeeene eene eee 5 52 5 3 1 Calibration intervals sesssssssssseseeeeeeene enne nnne 5 52 5 3 2 Routine inspection 0 0 2 eee eeeeeeeeeeeeeeee tees AE A E EEA iaia EE 5 52 MEM T LE 5 52 5 5 Gas detector contaminants nnenen nennen nnn nennen 5 52 5 5 1 Flammable gas detectors osoren ron a EAEN a R 5 52 5 5 2 Oxygen gas delectos edet erect reet aaa Saaai Ea p HE rani aa a nd 5 53 5 5 39 TOXIC GAS delectols cet emet tee peer mee rb enu eu ee E ng 5 54 5 6 Sensor disposal n et tette dude e cepere tU eara ped e P Pug roue 5 54 5 6 1 Oxygen SE ail 5 54 N A L
5. FGD10A Connection procedure Disconnect power from the system Remove the grey protective cover from the associated input module Configure the jumper switches as shown below i e J6 J7 J10 J12 J13 and J14 Switched ON all others OFF BS iB gt J120 gt min between pins 22 V and 24 OV of PL1 lt Connect a voltmeter range 0 to 24 Connect power to the system Adjust VR1 and VR2 until voltmeter reads between 15V and 24V VR1 and VR2 provide fine and coarse voltage adjustment respectively Disconnect power to the system and connect the wires from the detector head to PL1 on the input module observing the following Detector head PL1 pin number PSU 24 PSU 22 Aout 23 Connect power to the system and ensure the detector head operates Verify that the voltage between the PSU and PSU terminals at the detector head are correct Refit grey protective cover Perform software configuration refer to MCU software configuration and system calibration manual Perform system calibration Document Ref P0102 800 00 June 2012 NA LO Page 4 42 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 4 1 2 Alternative detector heads The MCU control units have been designed to accommodate detector heads built by other manufacturers section 4 1 2 shows the relevant diagrams and procedures 4 1 2 1 4 20mA sink to ground using interna
6. They should not be burnt since they may evolve toxic fumes Analox Ltd will accept sensors for disposal by prior arrangement contact Analox Ltd for further details 5 6 1 Oxygen sensors Oxygen sensors contain a 4 molar potassium acetate solution which is corrosive They also contain small amounts of lead lead oxide platinum silver carbon and antimony some of which are toxic and or mutagenic As these sensors contain some highly toxic compounds irrespective of physical condition they should be disposed of according to local waste management requirements and environmental legislation They should not be burned as they may evolve toxic fumes Document Ref P0102 800 00 June 2012 NA LO Page 5 54 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 5 6 2 Toxic gas sensors The majority of toxic gas sensors contain a sulphuric acid electrolyte They also contain platinum ruthenium gold silver and carbon some of which are toxic Several sensors contain a phosphoric acid electrolyte And a select few also contain lithium chloride sodium chloride and iodine which are toxic 5 6 3 Flammable gas sensors Pellistor based flammable gas sensors contain two pellistor beads known as the detector and the compensator The pellistor bead of the detector element contains very small traces of toxic chemicals The amounts involved are so small they do not represent any safety hazard However
7. rrrsrrrrrrnnvvrrrrnnvvrrrrnnvvrrrrnnrverrrnrrerrrnnn 8 67 8 7 Mounting details for FGD3 detector heads sse 8 68 8 8 FGD detector head calibration look up table ssssssseeene 8 69 9 SPOCHICALIONS scsi secte exin tna tare rn teal ee dede suere teta deae ena era at ia aan Te quaa de Fund T 9 70 9 1 MCU3 amp 4 control units sss nnne nnne enne en 9 70 9 2 S barrier type FGDIO nnrnonnvonnnnvnnnnnvnnnnrnnnnnvnnnnnvnnnnnnnnnrnnenavnnnnnennnnrnennrnnssnennnnnennnnn 9 71 9 3 Specification for FGD detector heads sssssssssseeeeeennee 9 72 9 3 1 FGD flammable heads sse nennen nennen 9 72 9 3 2 FGD Os TOXIC heads nte dete eren helene adco etas eiue sh IS 9 72 Document Ref P0102 800 00 June 2012 N A LO Page 1 2 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 1 Introduction The MCU3 amp 4 are environmental monitoring control units MCU that provide facilities to monitor a wide variety of industry standard environmental and other sensors The MCUS provides up to 8 monitoring channels The MCUA provides up to 16 monitoring channels The MCU range has been designed primarily for environmental monitoring However the versatility of the range extends its application to other aspects of industry where monitoring of remotely connected sensors is required The specification allo
8. they should still be disposed of in accordance with guidelines laid down by any relevant safety bodies as well as in accordance with local regulations N A LO Document Ref P0102 800 00 June 2012 Page 5 55 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 6 Trouble shooting The MCU system is supplied fully tested and it is unlikely that any apparent faults are as a result of faulty hardware Most problems encountered are as a result of installation faults or incorrect software hardware configuration 6 1 Common faults Fault The detector head display is blank Ensure the MCU has power connected Ensure the current loop connections are correct at the detector head and at the MCU Ensure all connectors within the detector head are attached Ensure a voltage is present at the loop current connections at the detector head terminal block Unless the detector head is mounted a significant distance from the MCU this voltage should be approaching 20V 7V minimum e Where an I S barrier is fitted check that the barrier fuse is intact Fault A flammable head is attached to channel 1 but the reading on the detector head display is a high negative number e g 60 e Check that the pellistor supply is connected to the head The flammable heads require a separate supply to provide the pellistors with current in excess of the 4 20mA available loop current e Check that th
9. case An eight channel system comprising of 8 flammable channels All system relays are configured as normally energised All analogue outputs are providing signals to external equipment Module and detector heads Qty Current Controller amp display 1 36 36 m A Input module amp toxic head 0 0 0 m A Input module amp oxygen head 0 0 0 m A Input module amp flammable 8 41 328 m A Common relays Energised 4 17 68 m A Input module relays Energised 24 17 408 m A Input module analogue output 4 4 16 m A Total current required under normal conditions DIEI Batteries are 1 2Ahr therefore backup time is 1200 856 1 4 Hrs 1 Hour 24 mins Document Ref P0102 800 00 June 2012 NA LO Page 1 20 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual Example 3 Best case A 4 channel system comprising of 4 toxic channels All system relays are configured as normally de energised No analogue outputs are being provided by the system Module and detector heads Qty Current Contoler amp dispay 1 36 36 ma Input module amp toxic head 4 8 32 mA Input module amp oxygen head 0 17 0 mA Input module amp flammable head 0 41 0 mA Common relays Energised 0 17 0 mA Input module relays Energised 0 17 0 mA Input module analogue output 0 4 0 mA Total current required under normal conditions 68 mA Batt
10. l l Screen QQQQQQ000Q000 Note Distribution board Link Ji should not be fitted I S Earth Connection diagram for FGD2 amp 3 flammable detectors in a hazardous area I Hazardous area Safe area l Screen I Document Ref P0102 B0 Page 3 34 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual Note The system OV is NOT connected to the earth Ensure J1 on the distribution board is not fitted The I S earth connection on the power distribution PCB must be connected to the installations I S earth point The connection must be made via a conductor of minimum 4mm cross sectional area Refer to EN60079 14 previously BS5345 Part 4 section 16 for further details of earthing requirements N A LO Document Ref P0102 800 00 June 2012 Page 3 35 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 4 Input module configuration The MCU systems have been designed to cater for almost all requirements of available detector heads For this reason many of the options available require either software or hardware configuration The diagram below shows the Input module and the positions of switches etc required during configuration FLNEL2 TERR CEI o N ETIE pige Se eon Oo bows ony Detector head E The relay connections shown are with the relay coil in its de energised sta
11. power fail and duration of power fail 3 Alarm status 4 Relay configuration whether normally energised or de energised 5 External loads placed on the system The table below lists the various modules that can be connected to the MCU system and the load that they place on the system Module and condition Current required Quiescent current of microcontroller module display 36mA Display backlight 244mA Quiescent current of input module 5mA Input module c w toxic head zero gas 8mA Input module c w toxic head full scale 24mA Input module c w oxygen head 20 996 17mA Input module c w flammable head zero gas 41mA Input module c w flammable head full scale 58mA Common relay module with relays energised 17mA per relay Input module relays with relays energised 17mA per relay Input module analogue output zero gas 4mA Input module analogue output full scale 20mA N A LO Document Ref P0102 800 00 June 2012 Page 1 17 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual The time for which the battery will supply power can now be calculated by taking into account the modules fitted to the system and the configuration of alarm relays i e whether normally energised or normally de energised To calculate an approximate time for battery backup we need to make several assumptions 1 No alarm conditions are encountered during the battery backed time 2 Display backl
12. relative humidity at 40 C Installation category over voltage category Il Pollution degree 2 User interface Display Backlit 240 x 64 dot Liquid Crystal Display LCD Keyboard 8 button multifunction keypad LED indications Red Indicates alarm condition Green Indicates power ON flashes when powered from int batteries Yellow Indicates fault condition Input modules Number of channels 8 max 16 max Signal inputs 4 20mA current loop from 24V source 4 20mA current loop sink to OV 3 Wire pellistor systems DC voltage input Analogue output 4 20mA current source proportional to detected signal 4 20mA current sink proportional to detected signal 1 5V voltage output proportional to detected signal 3 Relays 1 relay assigned to each alarm level low medium and high Contacts Double pole changeover contacts voltage free Rating 5A 240V AC Distribution Module 3 Common outputs For specification of common outputs refer to section 1 4 External reset Connection for normally open switch contacts 5V max present at terminals Common Relay Module 4 Common relays 1 Relay assigned to each alarm level low medium high 1 Relay designated as fault relay Double pole changeover contacts voltage free 5A 240V AC Document Ref P0102 800 00 June 2012 Page 9 70 NALO Environmental Monitoring amp Contro
13. 00 00 June 2012 Page 1 9 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual From the rear of the MCU front panel access can be gained to a 9 way D type connector labelled programming and configuration see section 1 8 With the aid of an interconnecting cable supplied by Analox Ltd the following functions can be performed e Programming and configuration of the MCU system via a P C e Networking of MCU control units e Downloading of logged data A reset button is also located on the microcontroller module to allow the system to be reset locally in the event of an irretrievable fault This will reboot the microcontroller but will not erase configuration data or logged data stored within the system 1 3 Input module The input module monitors the status of an externally attached sensor and interfaces the signals that it receives to the microcontroller module The input module is designed to accommodate virtually all sensor configurations currently available It can be connected to any sensor environmental or otherwise that supplies it status signal in any of the following formats Current loop 4 20mA from 24V source Current loop 4 20mA to ground 9 Wire pellistor systems a b c d Voltage input Note Option d requires hardware configuration that should be made at the factory prior to dispatch Please request this option at time of ordering
14. 2 Relay 1 ee D Did D gt RL3a RL3b RL4a RL4b O O CHANNEL 1 CHANNEL 2 CHANNEL 4 4 RL2b RL2a RL1b RL1a Relay 1 Relay 2 Relay 3 1 Relay 1 Relay 2 Relay 3 D000000000000000000Go0000 D0000000000000000003g00000 RED AMBER GREEN SOUNDER The above example shows the MCU being used to control a traffic light unit that for example may be used outside the entry door of a building This configuration uses the common alarm level relay contacts for alarm levels 1 amp 2 such that if any channel reaches an alarm level then either the amber or red light is illuminated and the sounder operated The relays are configured to be energised in the healthy state The green light is illuminated via the normally open contacts of RL1a RL2a and the fault relay contacts RL4a Document Ref P0102 800 00 June 2012 NA LO Page 8 64 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 8 4 Mounting details for MCU3 control unit 475 8 7 458 8 s FT fos E E GC wn c ceo Ny e P v Note The front panels of the MCU control units open to allow access to the screw terminals situated inside Sufficient space should be allowed around the mounting position so that this action is not restricted Four mounting holes are provided each having a diameter of 11mm Fixings re
15. MCU 3 amp 4 Installation and Hardware User Manual 1 2 Microcontroller module Situated within the MCU control unit front panel is the microcontroller module This module communicates with all Input Modules connected to the system via an lC serial bus The microcontroller module also communicates with the distribution board and relay module as well as providing a user interface in the form of a back lit 240 x 64 dot LCD graphical display and an eight button multifunction keypad Note IC is a trademark of Phillips Semiconductors Three LED indications are provided directly by the microcontroller module and these are visible via MCU front panel gt Green LED indication of power on gt Red LED indication of alarm condition Yellow LED indication of fault condition An Audible signal is also provided by a sounder mounted within microcontroller module This provides an audible intermittent tone during alarm or fault conditions Note This sounder is not intended for use as a main indication of alarm conditions It is strongly advised that a more substantial sounder and or beacon be connected to this system e g Analox sounder type SS367 or SS368 The microcontroller module also provides the user with many configuration and interrogation facilities via the LCD display and keypad These facilities include gt Setting of the real time clock The system has a battery backed 24Hr clock as a standard feature gt Sensor config
16. O Document Ref P0102 800 00 June 2012 Page 1 1 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 5 6 2 Toxic gas SENSOrS mmmmenavrvrvvnnvrernannvneenannvnnennneneenenneneenennnneenennnneennnneneennnnnenee 5 55 5 6 3 Flammable gas sensors ssesssseeeeenennnenen nennen nennen 5 55 6 Fro ble shooting EE EE pe RESE AERA 6 56 6 1 Common faults uci prenne E e Fennec diaa aiad oaaae Ropa daa 6 56 TE nel 7 59 n WANI EEE EEE Shape cate aadeieyeae ete 7 59 7 2 Commissioning and service ssssssssssssssseeseeeeeenee nennen nenne 7 59 7 3 Sensor replacement sseesssssssssesesseseeee enne entren enhn ernst entere 7 59 74 Routine Servicing cerro ete sire dr A ae ee 7 60 7 4 1 Routine inspection sesseessseseeseneenenennenen mener nnns 7 60 8 JAppendQlx EE NE En 8 61 8 1 Installation of safe area sounders and beacons sse 8 61 8 2 Installation of intrinsically safe sounders and beacons sseseesssss 8 63 8 3 Example of connection to a Analox Ltd traffic light unit seessssessssss 8 64 8 4 Mounting details for MCUS control unit ssseseseeeeneeen 8 65 8 5 Mounting details for MCU4 control unit ssssseseeeeeeneeneen 8 66 8 6 Mounting details for FGD2 detector heads
17. OV FGD10B Connection procedure Disconnect power from the system Remove the grey protective cover from the associated input module Configure the jumper switches as shown below i e J6 J7 J10 J12 J13 and J14 Switched ON all others OFF NS B 73 gt J120 ARggEE min between pins 22 V and 24 OV of PL1 J100 lt Connect a voltmeter range 0 to 24 Connect power to the system Adjust VR1 and VR2 until voltmeter reads between 15V and 24V VR1 and VR2 provide fine and coarse voltage adjustment respectively Disconnect power to the system and connect the wires from the detector head to PL1 on the input module observing the following Detector head PL1 pin number 0 24 Supp 22 4 20mA out 21 Connect power to the system and ensure the detector head operates Verify that the voltage between the Supp and 0 terminals at the detector head is correct Refit grey protective cover Perform software configuration refer to MCU software configuration and system calibration manual Perform system calibration N A LO Document Ref P0102 800 00 June 2012 Page 4 41 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 4 1 1 5 FGD10A infrared current source The FGD10A is a current source device i e the 4 to 20 mA signal is derived from the detector 24V 9 Variable voltage output 22 Current 23 D sense 24 T circuit Terminals OV
18. allation and Hardware User Manual 1 1 The MCU3 amp 4 manuals The MCUS amp 4 environmental monitoring systems have a range of manuals covering various aspects of their operation e MCU3 amp 4 installation and hardware configuration manual This manual covers all of the hardware aspects of the MCU environmental monitoring systems Each of the component parts of the system is discussed and hardware configuration is explained Dimensional drawings are included e MCU3 amp 4 software configuration and system calibration manual The operation of the MCU system is discussed as well as the software configuration and calibration procedures e Mentor PC operators manual The Mentor PC software is discussed including o Software Installation Hardware configuration to facilitate downloading logged data and configuration via a PC o Displaying and archiving logged data Important Analox Ltd strive to continually improve their products in line with customer s requirements and technological advancement Analox Ltd reserve the right to modify the design of the System at any time Due to continual improvement not all of the features described within this manual may be available on earlier models contact Analox for further details This manual covers all MCU control units containing input boards fitted with jumper switch configurable options If the configuration of the Input Boards is set by the removal or fitting of jumpers then pl
19. ated at 8A 240V AC Each of the relays can be configured as normally energised or de energised The standard configuration for these relays is Any channel incurs a low alarm common relay 1 will operate N A LO Document Ref P0102 800 00 June 2012 Page 1 13 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual Any channel incurs a medium alarm common relay 2 will operate Any channel incurs a high alarm common relay 3 will operate RL4 is designated as a fault alarm relay These relays can be configured to provide alternative features via the software if required Analox Ltd are able to implement modifications to the software to meet a customers specific requirements contact Analox for further information Document Ref P0102 800 00 June 2012 NA LO Page 1 14 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 1 6 Power supply module INT EXT Battery 24V External O P The power supply is situated beneath the main chassis of the control unit and provides the power for the whole system The power supply is a standard item and does not require any modifications regardless of the type and quantity of detector heads being used There are three power source options available to the system 1 220 240V AC mains supply Switch selectable 2 110 120V AC mains supply Switch selectable 3 24V DC supply No switch positio
20. ation and Hardware User Manual 4 2 3 1 5V voltage output 24V Control V Chart recorder ov PL5 terminals ov The SCM1 can provide a voltage output ie zero gas 21V full scale 5V This output is not ideal when transmitting a signal over a large distance The resistance of a cable attached will cause a voltage drop to occur Notes Switch ON J1 J3 and J4 Note Incorrect jumper switch configuration can cause damage to the system N A LO Document Ref P0102 800 00 June 2012 Page 4 49 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 4 3 Input module installation The MCU system supplied by Analox Ltd will normally be delivered correctly configured for the detector heads that have been purchased If an existing MCU system requires the addition of a monitoring channel a kit of parts can be purchased from Analox Ltd This includes Input module Terminal identification label Fitting hardware i e hex spacers screws washers etc Tools Required 5mm A F Spanner Flat blade screwdriver Install the input module as follows 1 Switch OFF the power supply to the MCU system 2 Locate the position within the control unit for the new channel Unscrew the two knurled black thumbscrews that retain the grey protective cover 3 Remove the two hexagonal spacers and associated washers that are revealed beneath the cover 4 Locate the new input modul
21. automatically select the internal batteries in the event of the external AC DC supply failing and will reselect the external supply on its reconnection If it is necessary to disconnect all power to the system mains power should be removed followed by the removal of fuse FS4 Document Ref P0102 800 00 June 2012 NA LO Page 1 16 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 1 7 Battery backup The MCU control units are supplied with a pair of 12V 1 2Ahr maintenance free backup batteries mounted beneath the main chassis MCU4 contains 2 pairs of batteries The batteries are connected in series enabling them to provide the 24V required by the system in the event of an external power failure The power supply for the system provides the charging current required maintaining the batteries in a fully charged state Should the main source of power fail the system will indicate to the users that it is operating from its batteries by flashing the green power LED whilst lighting the yellow fault LED The fault relay RL4 located within the common relay module will also operate and therefore trigger any warning devices added to the system by the user No audible alarm will be generated The backup time provided can not be stated without first considering the configuration of the System The backup time is dependent upon 1 Quantity and type of detector heads used 2 Time since last
22. d may be determined by noting the position of jumper J1 If this not located adjacent to the 4 way connector refer to section 1 4 2 However if the jumper is located adjacent to the 4 way connector refer to section 1 4 3 The jumper position on the distribution board labelled J1 allows connection of chassis earth to the system OV The fitting of J1 is not always required section 3 2 discusses this link and determines whether it should be fitted in a given situation An I S earth point is also provided on the distribution board This is discussed in section 3 3 N A LO Document Ref P0102 800 00 June 2012 Page 1 11 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 1 4 2 Distribution board Issues 1 amp 2 o I S Earth 12 11 10 9 8 7 6 5 4 3 2 1 The lower 4 way connector provides a 24V and OV connection The voltages are always present at these terminals whilst FS2 is intact The remaining two connections must not be used The 24V supply is designed for use by Analox Ltd when powering external equipment The amount of power available from this connector must be determined for each installation based upon the system configuration Pins 1 amp 2 pins 3 amp 4 and pins 5 amp 6 of the 12 Way connector provides three external outputs under software control Outputs 1 and 2 are designated as sounder and beacon control outputs respectively consult section 8 1 for
23. dition There are two methods by which safety barriers can be provided a using an optional Analox Ltd barrier type FGDIO fitted integral to each output channel of the MCU unit b using externally mounted proprietary safety barriers of the correct type in series with each remote detector head When using barriers to create an l S supply certain restrictions are imposed on the parameters of the interconnecting cables used These parameters are defined by the manufacturer of the barrier and limit the maximum capacitance inductance and inductance to resistance ratio of the cable The installation is only intrinsically safe when the combination of the barrier and connecting cables comply with the manufacturer s specification As with a non l S installation the cable length is restricted by the cable loop resistance With the introduction of a barrier the cable loop resistance is reduced because of the internal resistance of the barrier The end to end resistance of the barrier must therefore be subtracted from the overall cable loop resistance when calculating cable lengths Barriers must be selected to restrict the parameters of the I S supply to the gas detectors within the following limits Gas detector FGD2 3 oxygen or toxic FGD2 3 flammable FGD2 3 flammable Terminals Umax lax 0V and SIG 0 15A OV and SIG 0 15A OV and PWR Pin 1 4W When considering the capacitance and inductance allowable acros
24. e pwr supply measures 3 5V to 4 5V at the detector head The voltage supply for the pellistors is regulated within the detector head at a factory pre set level 2 0V for VQ2 type pellistors In order to provide a regulated supply at the correct voltage the detector head pwr connection must receive a minimum of 3 5V Fault Document Ref P0102 800 00 June 2012 NA LO Page 6 56 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual The detector head displays a valid reading however the MCU does not appear to be displaying the same or any valid reading e Ensure that the channel has been enabled within the software e Ensure the channel setup is correct i e gas type range e Check that the jumper switch settings are correct For all Analox Ltd detector heads J6 J7 amp J11 need to be switched ON e Calibrate channel Fault The MCU does not appear to communicate with channels five to eight e Ensure interconnecting cable is correctly attached between upper and lower platforms within the control unit e Ensure relevant channels are enabled within the software N A LO Document Ref P0102 800 00 June 2012 Page 6 57 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 7 Service 7 1 Warranty The quality of design and manufacture included in all Analox Ltd Instruments ensure a long and trouble free life In t
25. e e Configure the jumper switches as shown below i e J6 J7 J11 J13 and J14 switched ON all others OFF Hs B i JeETI d IR ET J12EI J11LEd J100 e Connect a voltmeter range 0 to 24V min between pins 22 V and 24 OV of PL1 e Connect power to the system e Adjust VR1 and VR2 until voltmeter reads 4 5V 0 5V VR1 and VR2 provide fine and coarse voltage adjustment respectively e Disconnect power to the system and connect the wires from the detector head to PL1 on the input module observing the following Detector head label PL1 pin number 4 20mA loop 0 24 22 Sig 21 e Connect power to the system and ensure the detector head operates text on LCD display LED will flash once every six seconds approximately e Measure the voltage between the and 0 terminals at the detector head e f necessary adjust VR1 and VR2 at the Input Module to give 4 5V 0 5V at the detector head 7 0V absolute maximum e Refit grey protective cover e Perform software configuration refer to MCU software configuration and system calibration manual e Perform system calibration N A LO Document Ref P0102 800 00 June 2012 Page 4 39 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 4 1 1 3 FGD10B infrared current sink The electronics for the head derives its power from the current loop A separate supply is provided for the sensor due to the sensor req
26. e of calibration whereas an installation in a particularly dirty environment may require weekly inspections It is the responsibility of the system engineer to assess the installation environment and determine the frequency of routine inspections 5 4 Calibration In order to carry out calibration of the gas detector refer to the relevant instruction manual for the product concerned 5 5 Gas detector contaminants The information provided in section 5 5 and its associated sub sections is taken from the sensor manufacturers Product Data Handbook 5 5 1 Flammable gas detectors Flammable gases can be detected by using either infrared or pellistor type gas detectors Infrared gas detectors have the advantage of being immune to chemical poisoning and providing a long operational life However they will not detect hydrogen Pellistor type gas detectors are relatively low cost but are prone to chemical poisoning as detailed below The following information relates only to flammable gas detectors containing pellistors Document Ref P0102 800 00 June 2012 NA LO Page 5 52 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual Certain substances are known to have a detrimental effect on gas detectors containing pellistors Poisons Some compounds will decompose on the pellistor and form a solid barrier over its surface This action is cumulative and prolonged exposure
27. e over the protruding studs at the appropriate position within the control unit taking care to align the pins of the motherboard header plug with the corresponding circuit board sockets 5 Fit the M3x8 screws with shakeproof washers into the two holes at the front of the circuit board Place a shakeproof washer onto each of the studs that protrude through the input module Replace the hex pillars onto the studs 6 Take the transparent terminal identification label and attach it to the sloping front edge of grey protective cover refer to input modules already installed for correct mounting position 7 Configure the input module jumper switches for the detector head that is to be attached 8 Refit the grey protective cover locating the black thumbscrew threads into the top of the hex pillars 9 Connect the detector head to the output terminals of the input module following the appropriate installation diagrams see section 3 3 1 10 Calibrate the new channel When wiring to the input module connector the use of bootlace ferrules is highly recommended Document Ref P0102 800 00 June 2012 NA LO Page 4 50 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 5 Detector head operation amp calibration For details regarding FGD detector head specifications consult section 0 5 1 Detector head variants Analox Ltd manufacture detector heads for a wide variety of gases The fle
28. e system 14 Calibrate the new channel Document Ref P0102 800 00 June 2012 NA LO Page 3 32 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual Note RHS and LHS apply to modules located in even number channel positions Where the input module is being installed in an odd number channel position these locations must be reversed When wiring to the input module connector ensure that no stray strands of wire exist between the two intrinsically safe I S outputs The use of bootlace ferrules is recommended To comply with the certification of the module ensure there is always at least 50mm between exposed non intrinsically safe module outputs The connection between the system I S earth and the control unit I S earth must be made using at least one conductor with a minimum of 4mm copper Further guidance on the correct installation of I S systems is provided by EN60079 14 1997 which replaces BS5345 parts 1 3 8 N A LO Document Ref P0102 800 00 June 2012 Page 3 33 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 3 3 3 Hazardous area installations using proprietary safety barriers The following diagrams show how proprietary l S barriers from alternative manufacturers can be used barriers manufactured by MTL are shown Hazardous area Safe area Input module 4 I I I I I I l l Screen
29. e the voltage to the appropriate level Connection procedure e Disconnect power from the system e Remove the grey protective cover from the appropriate input module e Configure the jumper switches as shown below i e J9 and J14 switched ON all others OFF d zB EE BH a3 e Remove R16 and R18 located above J13 from the input module e Fit conventional watt resistors to positions SR1 and SR2 using values from the following J12ETI J11ETI J10ETI J7ED Ja ED table Voltage input max SRi SR2 2 5V 18R 470R 5V 390R 330R 10V 1K5 470R 12V 1K8 390R 24V 12K 1K2 For alternative voltage inputs contact Analox Ltd for appropriate resistor values Connect the detector head to PL1 observing the above diagram Connect power to the system Refit grey protective cover Perform software configuration refer to MCU software configuration and system calibration manual e Perform system calibration refer to MCU software configuration and system calibration manual and detector head manufacturers instructions N A LO Document Ref P0102 800 00 June 2012 Page 4 45 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 4 1 2 4 Pellistor only gas detectors Gland plate earth stud Link to cable screen or armour PL1 terminals Compensator 21 D Variable 22 D voltage ions output ad D Signal sensing 24 D circuit ic Control unit gland
30. ease refer to an Issue 2 0 manual available from Analox Ltd Document Ref P0102 800 00 June 2012 N A LO Page 1 4 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual e MCU3 control unit 1C CONTROLS STATUS SCENDE e The MCUS can monitor up to eight channels Channels 1 to 4 are located on a lower platform whilst channels 4 to 8 are located on a hinged upper level This allows easy access to all hardware configurable options whilst maintaining its compact size It is supplied with interchangeable gland plates located on its upper and lower face The lower plate has seventeen holes suitable for 20mm compression glands or 7 NPT conduit entries other gland plate configurations are available on request whilst the upper plate is blank NA LO Document Ref P0102 800 00 June 2012 Page 1 5 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual e MCU4 control unit The MCUA contains two MCU3 systems giving the system the ability to monitor up to Sixteen channels The MCUA is supplied with interchangeable gland plates located on its upper and lower face The lower plate has seventeen holes suitable for 20mm compression glands or 1 NPT conduit entries other gland plate configurations are available on request whilst the upper plate is blank Document Ref P0102 800 00 June 2012 NA LO Page 1 6 Environ
31. ected to the distribution board with the MCU isolated from the mains supply b The maximum number of sounder beacon units that can be connected to the panel outputs is two two sounders and two beacons c Outputs 1 amp 2 of the distribution module are capable of supplying an absolute maximum of 200mA each N A LO Document Ref P0102 800 00 June 2012 Page 8 61 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual Part Numbers SS 367 24V DC sounder SS 368 24V DC Sounder beacon combined SS 369 24V DC beacon Document Ref P0102 800 00 June 2012 NA LO Page 8 62 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 8 2 Installation of intrinsically safe sounders and beacons SAFE AREA I HAZARDOUS AREA Barrier type 728 l Intrinsically safe beacon SS 327 Distribution board Issue 3 Intrinsically safe sounder SS 328 MN C 4 O1 O Oo cO qQaooooooooooo See section 1 4 3 for further details N A LO Document Ref P0102 800 00 June 2012 Page 8 63 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 8 3 Example of connection to a Analox Ltd traffic light unit Traffic light unit MCU control panel Stock No SS366 000000900990000009000900 DD OXDD0000000000000000090 MDODOO OOOO EEEEEISEEEIE rofofofofore I 5005 Relay 3 Relay
32. efer to MCU software configuration and system calibration manual and detector head manufacturers instructions 4 2 Analogue output configuration In addition to providing the connections for various connector types the Input Module can also provide an analogue output This output mimics the signal detected so that it may be used by external equipment e g chart recorders data loggers for a variety of purposes Note It is important to ensure that the analogue output is calibrated if in use refer to MCU software configuration and system calibration manual N A LO Document Ref P0102 800 00 June 2012 Page 4 47 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual The analogue output options available are 4 2 1 4 20mA current source 24V J3 Control PL5 terminals OV The input module sources current proportional to the detected gas level i e zero gas 4mA full scale 20mA The supply is taken from the internal PSU Notes Switch ON J3 and J 4 2 2 4 20mA current sink Control PL5 terminals signal recorder The input module can also sink current proportional to the detected gas level i e zero gas 4mA full scale 20mA The supply is derived from the external equipment Notes Switch ON J2 and J5 Document Ref P0102 800 00 June 2012 NA LO Page 4 48 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Install
33. eries are 1 2Ahr therefore backup time is 1200 68 17 6 Hrs 17 Hours 36 mins N A LO Document Ref P0102 800 00 June 2012 Page 1 21 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 1 7 2 Calculating the backup time for your system Notes for calculation 1 The microcontroller module is always present on a functioning system and therefore its quiescent current must always be included in any calculations 2 f an external load is placed upon the system then the current that the load requires must be added to the table prior to performing the final calculation Consider the system being installed the detector heads being used and the normal status of all relays within the system Enter the quantities in the table below to assist in battery life calculations Module and detector heads Qty Current Controller amp display 1 36 36 mA Input module amp toxic head 8 mA Input module amp oxygen head 17 mA Input module amp flammable head 41 mA Common relays Energised 17 mA Input module relays Energised 17 mA Input module analogue output 4 mA External loads e g Status lamp mA Total current required under normal conditions o Lom The battery life can now be calculated by dividing 1200 by the total current required by the System under normal conditions Document Ref P0102 800 00 June 2012 NA LO Page 1 22 Environmental Mon
34. f about 0 396 of signal per 1 CO The oxygen gas detectors are not suitable for continuous operation in concentrations of CO above 25 Note Gas detectors should not be subjected to prolonged exposure to highly corrosive atmospheres as this will cause premature failure N A LO Document Ref P0102 800 00 June 2012 Page 5 53 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 5 5 3 Toxic gas detectors Toxic gas sensors are known to be cross sensitive to gases other than those for which they have been designed to detect The amount of response observed by a sensor will vary depending upon the sensor type and the interfering gas For example This table shows the cross sensitivity of the H2S sensor fitted to the FGD2 and 3 detector heads The table shows the typical response to be expected from a sensor when exposed to a given test gas concentration Gas Concentration Sensor response Carbon monoxide 300ppm lt 6ppm Sulphur dioxide 5ppm lt 1ppm Nitric oxide 35ppm Oppm Nitrogen dioxide 5ppm 1ppm Chlorine 1ppm 0 1ppm Hydrogen 10 000ppm lt 15ppm Hydrogen cyanide 10ppm Oppm Hydrogen chloride 5ppm Oppm Ethylene 100ppm Oppm Contact Analox Ltd for further details regarding the cross sensitivity of a particular sensor 5 6 Sensor disposal All gas sensors should be disposed of according to local waste management requirements and environmental legislation
35. fer to MCU software configuration and system calibration manual e Perform system calibration Document Ref P0102 800 00 June 2012 NA LO Page 4 46 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 4 1 2 5 3 Wire Connection 4 20mA Current Input and Separate Supply PL1 Terminals Variable Voltage voltage input output Current sensing Current output circuit 0 This configuration allows the connection of a detector head that provides a 4 20mA current output and requires a separate power source between 0 to 24V Connection procedure e Disconnect power from the system e Remove the grey protective cover from the appropriate input module e Configure the jumper switches as shown below i e J6 J7 J10 J12 J13 and J14 switched ON all others OFF eo x d Hz cH Dor 257 1 O J12LEJ J11ETI J10 02 e Connect a voltmeter between pins 22 V and 24 OV e Connect power to the system Adjust VR1 and VR2 until the correct voltage can be measured for the detector head being used Disconnect power to the system Connect the detector head to the input module observing the above diagram Refit grey protective cover Connect power to the system and confirm that the detector head operates Perform software configuration refer to MCU software configuration and system calibration manual e Perform system calibration r
36. for 4 20mA signal for sensor supply 7 to 30vDC 20 to 40 C 0 to 95 RH non condensing Ambient 10 560 ohms at nominal 24v IP66 Intrinsically safe BASO1ATEX2300 EEx ia IIC T4 0 1 or2 for 4 20mA Signal Document Ref P0102 800 00 June 2012 Page 9 72 NALO Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual NA LO Document Ref P0102 800 00 June 2012 Page 9 73
37. he stainless steel sensor housing Unscrew the sensor housing cover Unplug the sensor assembly and ensure the new assembly is identical f Push in the new sensor assembly g Refit the sensor housing cover and tighten the grub screw h Allow the sensor to stabilise 1 2 hours for toxic 1 2 mins for flammable Calibrate the head j Enable the channel at the MCU a0 N A LO Document Ref P0102 800 00 June 2012 Page 7 59 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 7 4 Routine servicing The MCU control unit will provide a reliable and fault free service but they rely upon sensible housekeeping and regular calibrations It is recommended that the system be calibrated at least once every six months This can be arranged with Analox Ltd as part of a maintenance contract 7 4 1 Routine inspection It is advisable to periodically inspect the MCU control unit Installation e Check cables to ensure no damage has occurred e Clean control unit casing using a clean cloth e Clean detector heads using a clean DAMP cloth Note Use of a dry cloth would constitute a static hazard e Inspect detector heads and ensure the sensor housings aperture is not obstructed Note Do not use solvents to clean the LCD display window on the control units or the detector heads The time interval between routine inspections will depend upon the area in which the equipment is i
38. he unlikely event of a piece of our equipment failing within the first twelve months following delivery Analox Ltd will repair or replace any faulty parts free of charge providing that the equipment has not been misused 7 2 Commissioning and service The MCU and FGD sensor heads are fully tested prior to delivery However after installation we strongly recommend that full system testing and commissioning be carried out Analox Ltd service personnel are best equipped to perform the relevant tests and commissioning and will be able to offer advice regarding installation faults Commissioning involves Testing of all system wiring Software configuration for each channel Calibration of all channels and detector heads Operational checks on all detecting channels used 7 8 Sensor replacement Sensors have a finite life pellistors have an expected life span in excess of two years whilst electrochemical sensors have an expected life span of approximately two years All of the Analox Ltd detector heads have push fit sensors to aid on site replacement The different sensor designs dictate mounting orientations to minimise possibilities of incorrect installation Sensor removal and refitting a Inhibit the channel at the MCU performed from the keypad b Disconnect power to the head by unplugging the screw terminal connector on the input module associated with that channel within the MCU control unit Release the grub screw situated on t
39. ight is off 3 The batteries are fully charged For instances where a longer back up time is required Analox can supply an external battery unit This will connect into the system at the distribution board and consists of its own internal charger Contact Analox for more information Document Ref P0102 800 00 June 2012 NA LO Page 1 18 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 1 7 1 Calculation examples Three examples follow demonstrating how the backup time may be calculated Example 1 Typical configuration A 4 channel system comprising of 3 toxic channels and 1 flammable channel All system relays are configured as normally energised No analogue outputs are being provided by the system Module and detector heads Qty Current Qontoler amp dispay 1 36 36 mA Input module amp toxic head 3 8 24 mA Input module amp oxygen head 0 17 0 mA Input module amp flammable head 1 41 41 mA Common relays Energised 4 17 68 mA Input module relays Energised 12 17 204 mA Input module analogue output 0 4 0 mA Total current required under normal conditions 373 mA Batteries are 1 2Ahr therefore backup time is 1200 373 3 2 Hrs 3 Hours 12 mins N A LO Document Ref P0102 800 00 June 2012 Page 1 19 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual Example 2 Worst
40. itoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 1 8 MCU system communications Located at the rear of the microcontroller module is a 9 way D type socket labelled Programming and configuration This is the systems RS232 communications port This provides the system with three useful communications features Note The PC must be running the Mentor PC software to perform any of communications functions 1 8 1 MCU system configuration and interrogation This provides the ability to perform all of the functions available via the control unit keypad and more using a PC e g Displaying live data on the PC screen MCU system configuration Downloading logged data from MCU View and export downloaded data graphical or tabular format These features may be advantageous if the MCU control unit is located in a dirty environment The system could be remotely monitored from a clean room Note An RS232 cable is usually only suitable for short cable runs e g 10ft however cables having lengths of 30 40ft have been known to provide reliable communications 1 8 2 MCU system networking RS485 network cards are available from Analox Ltd These interface the RS232 signals from the MCU into a more suitable format for transmission over longer distances This provides the MCU System with two powerful features e As section 1 8 1 but with less restriction on the cable lengths between PC and MCU C
41. l PSU 21 D Variable 22 D voltage 23 p Current sensing circuit output Terminals 0 This configuration allows a detector head to be powered directly from the MCU with the loop current sensing components situated in the return path to OV Connection procedure e Disconnect power from the system e Remove the grey protective cover from the associated input module e Configure the jumper switches as shown below i e J6 J7 J10 J12 J13 and J14 Switched ON all others OFF e lt HS sE J9 ELI J8 Q J7 LES Js J12 J11ETI J10 e Connect a voltmeter between pins 22 V and pin 24 OV of PL1 e Connect power to the system e Adjust VR1 and VR2 until the appropriate voltage is observed on the meter typically 22V 2V Consult detector head instructions for recommended supply voltage e Disconnect power from the system e Connect the wires from the detector head to PL1 on the input module observing the following Detector head PL1 pin number 23 22 e Connect power to the system and ensure the detector head operates e Refit grey protective cover e Perform software configuration refer to MCU software configuration and system calibration manual e Perform system calibration Refer to refer to MCU software configuration and system calibration manual and detector head manufacturers instructions N A LO Document Ref P0102 800 00 June 2012 Page 4 43 Environmental M
42. l Units Types MCU 3 amp 4 Installation and Hardware User Manual MCUS MCUA Power supply Fuse 1 mains input T1 0A T1 0A Fuse 2 internal 24V T2A T2A Fuse 3 com outputs F1A F1A Fuse 4 battery fuse F2A F2A Batteries 2 x 12V 1 2AHr 2 x 12V 1 2AHr Sealed lead acid battery type YUASA NP1 2 12 9 2 I S barrier type FGDIO Output terminals 1 amp 2 Output terminals 3 amp 4 28V DC 0 112 Amps 0 8 Watts Internal resistance 2700 5 7 5V DC 0 66 Amps 1 24 Watts Internal resistance 120 5 NALO Document Ref P0102 800 00 June 2012 Page 9 71 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 9 3 Specification for FGD detector heads 9 3 1 FGD flammable heads Operating voltage Temperature Humidity range Operating pressure Cable loop resistance Degree of protection Explosive protection Safety certificate no Approval code Zones 9 3 2 FGD O Toxic heads Operating voltage Temperature Humidity range Operating pressure Cable loop resistance Degree of protection Explosive protection Safety certificate no Approval code Zones 7 to 30vDC 4 to 7 5V 20 to 40 C 0 to 9596 RH non condensing Ambient 10 Signal 560 ohms at nominal 24v Sensor 19 ohms at 7 5V DC IP66 Intrinsically safe circuitry Flameproof sensor protection Exd BASO1ATEX2300 EEx iad IIC T4 10r2
43. life span in excess of two years whilst electrochemical sensors have an expected life span of approximately two years e Ensure the proposed site will not interfere with movement of existing equipment e g cranes doors etc Install all cables neatly and securely Detectors for gases that are lighter than air should be positioned at a high level Detectors for gases that are heavier than air should be located at below head height Avoid siting the gas detectors adjacent to potential sources of radio frequency interference e g radio transmitters control switchgear motors etc e Ensure the detectors are mounted with sufficient space to allow air movement around the sensor section and the opening of the front hinged lid Mounting details for Analox Ltd detector heads are located in section 8 6 within the appendix 3 2 Installation in a non hazardous area Where gas detector heads are to be installed in an area where there is no potential of an explosive gas hazard present the cable lengths are limited solely by the resistance of the cable The FGD2 or FGD3 gas detectors fitted with either oxygen or toxic sensors require a minimum of 6V at its terminals to operate correctly The maximum cable loop resistance is therefore 20 6 25mA i e 5600 Cable resistance values depend upon the size of the cable Typical resistance values are 1 0mm solid core 40Q Km loop 1 5mm solid core 25Q Km loop N A LO Document Ref P0102 800 00 Ju
44. m of 200mA Fuse protection is provided by FS3 situated on the power Supply refer to section 1 6 Jumpers are located on the lower half of the distribution board The jumpers allow the engineer to configure the outputs for either 24V switching or OV switching at installation A label appears on the PCB indicating the correct jumper settings for each option Input Allows the outputs to be configured as inputs in some Cai Consult Analox circumstances Contact Analox Ltd for further details Cm Output Switch 24V OV always present at connector 24V is switched via a relay under processor control m Output Switch 24V Output Switch OV 24V always present at connector OV is Em Output switched via relay under processor control mENE Switch OV The label shown above indicates the correct positioning of jumpers to obtain the specified output configuration It should be noted that the external outputs are not switched via voltage free contacts Depending on the configuration either 24V or OV will be permanently available at the connector with the remaining supply being switched via a relay Under no circumstances must mains supply voltages be connected to any of the distribution board terminals Pins 5 amp 6 provide connection for an external switch 1 5 Common relay module Situated on the relay module are 4 double pole change over relays each relay having contacts r
45. mental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual Fuse FS4 int ext battery Fuse FS3 24V for ext outputs Fuse FS2 24V DDOO0000000000000000 DOOCO bD000000000000000000 DDDODDODODDODO NT T90ordounosow 00000000909 Loo I D Did D D RL3a RL3b RL4a RL4b Common relay module CHANNEL 2 2 CHANNEL 4 RL2b RL2a RL1b RL1a board SETE Dpooooo0o00000000000d0000 PDOOOOODDDDDDDDODDDDODOOOO i Fuse FS1 mains input Mains input to PSU situated beneath main chassis The diagram above shows a pictorial representation of the various module positions within the MCU3 and MCUA Control Units The power supply is situated beneath the main chassis and is not visible when the unit is assembled however the four system fuses FS1 to 4 are easily accessible The mains input connector and FS1 are sited beneath a cover to avoid inadvertent user contact during normal operation The standby batteries are also located beneath the main chassis Channels 5 to 8 are mounted on a hinged platform positioned above channels 1 to 4 This design allows easy access to channel 1 to 4 situated below The microcontroller module and LCD display are not shown on the above diagram These are mounted on the rear of the hinged front panel of the MCU3 and MCUA control units N A LO Document Ref P0102 800 00 June 2012 Page 1 7 Environmental Monitoring amp Control Units Types
46. n change required Options 1 amp 2 are easily selected via an on board switch sited beneath a yellow protective cover Option 3 is provided as an alternative to an AC mains supply and allows the use of an external 24V DC power supply connected via the Distribution Board There are four fuses situated on the power supply PCB These are FS1 T1 0A Mains fuse FS2 T2 0A Internal 24V supply FS3 F1 0A 24V to outputs 1 3 FS4 F2 0A Internal external battery see Note below Note The internal batteries will supply power to the system as soon as FSA is fitted However an external power source will be selected once connected to the system and the internal batteries will charge The internal batteries will not provide backup if FS4 is not fitted or it has blown N A LO Document Ref P0102 800 00 June 2012 Page 1 15 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual The power supply provides the charging current for the internal standby batteries such that in the event of an external power failure the system will continue to operate for sufficient time to allow reconnection of the external supply The backup time provided is dependent upon 1 Quantity and type of detector heads used 2 Time since last mains power fail and duration of power fail 3 Alarm status and other external loads placed upon system Refer to section 1 7 for further details The system will
47. ne 2012 Page 3 27 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual Input module Note Distribution board Link J1 must be fitted eO onnection diagram for FGD2 3 oxygen or toxic etector in a non hazardous area Q The correct wiring method for all Analox Ltd FGD2 FGD3 detector heads in a non hazardous location is shown above It is important to note that this drawing shows the wiring connections but does not discuss the input module configuration Prior to connecting the detector ead ensure the input module is correctly configured refer to section 4 1 Note The screens from each cable are connected to the chassis earth of the control unit The connection between the system OV and the earth of the chassis is made by fitting Jumper J1 located on the distribution board For installation diagrams for FGD flammable gas detector heads refer to section 3 3 Document Ref P0102 800 00 June 2012 NA LO Page 3 28 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 3 3 Installation in a hazardous area Where gas detector heads are to be mounted within a potentially explosive atmosphere then electrical safety barriers must be fitted in order to limit the electrical energy that is supplied into the hazardous area This prevents an incendive spark occurring under an electrical fault con
48. nector 1 10 9 8 7 6 5 4 3 2 1 DDODDODODODDDDDOD volun 12 way connector situated on the Distribution Board 2 5 Cable routing Due to the low signal levels generated by gas detectors it is recommended that all wiring to the sensors by segregated away from AC mains or other high voltage power lines to avoid interference 2 6 Cable screening The use of a screened cable is recommended for the installation of all detector heads The screening is used to minimise the effects of electrical interference generated by external equipment e g motors switchgear etc The correct strategy for connecting the screens depends upon the area in which the detector head is to be used i e hazardous non hazardous In all cases the screen should not be connected at the detector head Document Ref P0102 800 00 June 2012 NA LO Page 2 26 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 3 Gas detector head installation 3 1 Siting the detectors Mounting positions for the gas detectors need to be considered individually Analox Ltd will offer advice and assistance with regard to the siting of detectors in varying environments Some initial points for consideration are e Ensure all gas detectors are mounted to allow routine calibration and maintenance to be carried out as required Note The sensors used within the gas detectors have a finite life Pellistors have an expected
49. nstalled A clean laboratory installation may only require inspection at the time of calibration whereas an installation in a particularly dirty environment may require weekly inspections It is the responsibility of the system engineer to assess the installation environment and determine the frequency of routine inspections Document Ref P0102 800 00 June 2012 NA LO Page 7 60 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 8 Appendix 8 1 Installation of safe area sounders and beacons MCU control units have three outputs that are intended for switching alarm sounders and or beacons the MCUA has six outputs These alarms take their power from the MCU system whereas alarms triggered by the various relays are more suited to supply from external power sources Cable specification 1mm conductors should be used between the MCU and sounder beacon Sounder Beacon specification All Analox Ltd sounders and beacons are suitable for internal external use Rated to IP65 Supply voltage 24V SS368 Sounder beacon combined o 8 o 9 o Distribution board Issue 3 le 616 h 516 416 316 18 li 116 Output 1 See section 1 4 3 for further details eid Terminations This wiring diagram shows the interconnection details between the 99367 distribution module situated within an MCU and sounders beacons TF Sounder Notes a The alarms should only be conn
50. nting positions of any input modules which have been modified to comply with an uncommon sensor configuration It is also a convenient time to set the jumper Switches for all the input modules according to the sensor type to be used Note Incorrect input module configuration can cause damage to the system 2 3 System wiring All connections should be made according to the appropriate sensor or loop diagram for the configuration required It is advised that bootlace ferrules or flat blade crimps be used for tidy and reliable connections of wires into the control unit and detector head connectors 2 4 Power supply input An isolating switch should be provided between the power source and the MCU control units to allow the supply to be easily disconnected This should incorporate over current protection or a circuit breaker Alternatively a fused supply would suffice For information regarding the current requirement of the control units refer to the specification located in section 9 1 2 4 1 A C mains connection All mains voltage connectors etc have been positioned beneath a yellow protective cover to prevent inadvertent user contact The power supply board has a three pin screw terminal connector assigned for the connection of an AC supply This is located to the lower left hand side of the MCU shrouded by a yellow protective cover The AC supply can be either 240V or 110V The 110V mains supply can be derived from either a OV 110V AC
51. ol unit alternatively a 24V DC supply can be used The site of installation should be chosen with regard to the following e This equipment should not be located near to known sources of heat e Operating personnel should be within convenient reach of the equipment and within audible distance of alarms e Maximum loop lengths of cable runs and cable inductance to resistance ratios must not exceed limits shown in the relevant loop diagrams refer to section 3 2 e Avoid mounting this equipment near potential sources of electrical interference e g motors switch gear radio transmitters etc Mounting details for the MCU enclosures are located within the Appendix section 8 Document Ref P0102 800 00 June 2012 NA LO Page 2 24 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 2 2 Assembling The MCU control units are supplied with the standby battery fuse FS4 not fitted This fuse should be fitted once the control unit is mounted in position and ready for use It should be noted that once this fuse is fitted power will be connected to all modules and sensor heads connected to the system All wiring tests and commissioning should therefore be performed prior to fitting this fuse Note FS4 is supplied in a plastic bag inside the MCU control unit It is advisable to familiarise yourself with the control unit and its connections before mounting In particular observe the mou
52. onitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 4 1 2 2 4 20mA sink to ground using external PSU 24V PSU PL1 Terminals Current sensing 23 D circuit aD OV This configuration is similar to 4 1 2 1 except an external power supply is used to provide the loop current Connection procedure e Disconnect power from the system e Remove the grey protective cover from the associated input module e Configure the jumper switches as shown below i e J6 J7 J10 J12 J13 and J14 Switched ON all others OFF eo st BS sH J12LEJ EB e Er J9 ELI J8 ELI J7 LES Ja LES Connect the detector head to PL1 observing the above diagram Connect power to the system and ensure the detector head operates Refit grey protective cover Perform software configuration refer to MCU software configuration and system calibration manual e Perform system calibration refer to MCU software configuration and system calibration manual and detector head manufacturers instructions Document Ref P0102 800 00 June 2012 NA LO Page 4 44 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 4 1 2 3 DC voltage input PL1 Terminals 22 D Voltage sensing 23 D circuit ED OV he Input Modules can be configured to accept signal levels in voltage form R1 and SR2 are used to scal
53. ontrol Unit up to 1km possible e The PC can monitor more than one MCU system when utilising network cards All PC s have at least one RS232 COM port to allow communications with external equipment The network cards supplied by Analox Ltd allow the PC to monitor a maximum of 32 MCU Systems via one com port N A LO Document Ref P0102 800 00 June 2012 Page 1 23 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 2 MCU installation The MCU control units and FGD gas detectors are fully tested prior to delivery However after installation we strongly recommend that full system testing and commissioning be carried out Analox Ltd Service personnel are best equipped to perform the relevant tests and commissioning and will be able to offer advice regarding installation faults Warning Installation should be made in accordance with either British Standard BS EN60079 14 which supersedes BS5345 Electrical Apparatus for Explosive Gas Atmospheres or in accordance with the relevant National or Local regulations Caution The MCU control units and associated modules contain no user serviceable parts Refer all module servicing to qualified service personnel 2 1 Siting the MCU The MCU control unit must be sited in a non hazardous location where there is no risk of the presence of potentially explosive gas Either a 110V 120V or a 220V 240V AC supply can be used to power the contr
54. ov Connection procedure e Disconnect power from the system e Remove the grey protective cover from the associated input module e Configure the jumper switches as shown below i e J6 J7 J11 J13 and J14 switched ON all others OFF Hz H Ia UMI J120 J110 J10ETI Jo Js e Connect the wires from the detector head to PL1 on the input module observing the following Detector head label PL1 pin number 4 20mA loop 24 21 e Connect power to the system and ensure the detector head operates text on LCD display LED will flash once every six seconds approximately e Refit grey protective cover e Perform software configuration refer to MCU software configuration and system calibration manual e Perform system calibration refer to MCU software configuration and system calibration manual Document Ref P0102 800 00 June 2012 NA LO Page 4 38 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 4 1 1 2 FGD2 and FGD3 flammable detector heads The electronics for the head derives its power from the 24V current loop A separate supply is provided for the sensor due to the sensor requiring more than the 4 20mA loop current range Current sensing circuit Variable 22 D voltage output Terminals ov Connection procedure e Disconnect power from the system e Remove the grey protective cover from the associated input modul
55. plate Screened armoured cable Q f Exe enclosure If EARTH continuity is not maintained via gland e g plastic gland then connect cable screen or armour to EARTH terminal as shown Earth continuity plate This configuration allows the direct connection of Exd flammable 9 i gas sendri pellistors no electronics to the input module Connection procedure Note For use in hazardous areas the pellistors must be housed in an Exd enclosure mounted on an Exe terminal housing e DO NOT connect the pellistors at this time e Remove the grey protective cover from the appropriate input module e Configure the jumper switches as shown below i e J8 amp J9 switched ON all others OFF b cH T T gt 7 aga ET J12EI Jie JI0 EO e Connect a voltmeter between pins 22 V and 24 OV e Adjust VR1 and VR2 until the correct voltage can be measured for the pellistors being used SSCL pellistors require 2 0V 0 01 V VR1 amp VR2 provide coarse and fine output voltage adjustment respectively Note Connecting a voltage of greater than 2 2V will cause irreparable damage to the pellistors e Connect the pellistors to the input module observing the above diagram e Check that the voltage across the pellistors remains at 2 0V 0 01V adjust if necessary Note Measure the voltage at the pellistors not at the input module terminals e Refit the grey protective cover e Perform software configuration re
56. power source or a 55V 0 55V AC power source In all cases ensure the safety earth E is connected To connect AC power to the system it is necessary to unplug the three terminal connector PL1 from the power supply PCB The screw terminals are connected as shown Recommendation for mains input cable 3 Core Conductors having cross sectional area of 0 75mm minimum 24 0 2 LNE N A LO Document Ref P0102 800 00 June 2012 Page 2 25 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 2 4 1 1 Selecting mains input voltage 1 Ensure AC mains supply is disconnected from the MCU control unit 2 Rotate the screw located centrally on the yellow cover anti clockwise until the cover is released It is not necessary to completely remove the screw from the cover assembly 3 Slide the voltage selector switch into the appropriate position dependent upon the AC mains voltage to be used Note that the 115V setting is used for 110 120V supplies and the 230V setting is used for 220 240V supplies 4 Refit yellow cover before connecting AC mains supply Note FS1 located to the right of the mains input connector is a T1 0A fuse 2 4 2 24V DC connection The MCU system can be powered from an external power supply The external PSU must provide a fused 24V 2A min supply The fuse should be F2A rated The diagram below shows the 24V and OV connections to the distribution board con
57. put barrier module assembly and pull the barrier cover away from the input module circuit board 5 Locate the new input module over the protruding studs at the appropriate position within the control unit taking care to align the pins of the motherboard header plug with the corresponding circuit board sockets 6 Fit the M3x8 screws with shakeproof washers into the two holes at the front of the circuit board Replace the LHS hexagonal pillar and fit the M3x14 pillar and shakeproof washer on the RHS Connect a multimeter set to measure voltage between pins 24 0V and 22 V Connect power to the control unit Determine the type of detector head to be used with the FGDIO module o ON O Toxic detector head Rotate VR1 and VR2 fine and coarse adjust respectively until the voltage indicated by the multimeter reads 2 0V 0 5V Flammable detector head Adjust VR1 and VR2 fine and coarse adjust respectively until the voltage indicated by the multimeter reads 8 0V 0 1V 10 Switch off the power supply to the control unit 11 Take the grey cover incorporating the FGDIO module and refit this over the input module Ensure the FGDIO connector locates into its mating half correctly Secure the cover in position using an M3x16 countersunk head screw on the RHS of the barrier cover 12 Connect the detector head to the output terminals of the FGDIO barrier following installation diagrams see section 3 3 1 13 Reconnect power to th
58. quired 4 off M10 fasteners Rawl bolts or similar dependent on mounting wall construction N A LO Document Ref P0102 800 00 June 2012 Page 8 65 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 8 5 Mounting details for MCU4 control unit 500CRS s T 00000000 00000000 400CRS 530 Four mounting holes are provided each having a diameter of 11mm Fixings required 4 off M10 fasteners Rawl bolts or similar dependent on mounting wall construction Document Ref P0102 800 00 June 2012 NA LO Page 8 66 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 8 6 Mounting details for FGD2 detector heads The diagram below shows the mounting centres for the Analox Ltd FGD2 detector heads 122 8 182 0 KK S amp N e m SN i ag m V Depth 75mm approx N 9 All dimensions are in mm and are approximate only Note The front panel lid of the detector head opens to allow access to the screw terminals situated inside Sufficient space should be allowed around the mounting position so that this action is not restricted Two mounting slots are provided suitable for M6 fasteners Fixings required 2 off M6 fasteners Rawl bolts or similar dependent on mounting wall construction
59. ring the suitability of an installation in terms of the load capacitance and inductance account must be taken of the interconnecting cable itself The figures in the tables must not be exceeded by the combination of the load parameters and the cable parameters This may restrict the permissible cable length in some applications If in doubt consult Analox Ltd for assistance N A LO Document Ref P0102 800 00 June 2012 Page 3 31 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 3 3 2 FGDIO intrinsically safe output module installation Where an MCU system has been purchased with the FGDIO barriers already fitted it will be delivered correctly configured for the specified detector heads If an existing MCU system requires the addition of an FGDIO barrier a kit of parts can be purchased from Analox Ltd This includes Input module Grey protective cover incorporating the FGDIO barrier Fitting hardware i e hex spacers screws washers etc Tools required 5mm A F spanner Flat blade screwdriver Multimeter Install the input module and the FGDIO barrier as follows 1 Switch OFF the power supply to the MCU system 2 Locate the position within the control unit for the new channel Unscrew the two knurled black thumbscrews that retain the grey protective cover 3 Remove the two hexagonal spacers and associated washers that are revealed beneath the cover 4 Take the new in
60. s MCU 3 amp 4 Installation and Hardware User Manual The I S earth connection on the power distribution PCB must be connected to the I S earth point for the installation The connection must be made via a conductor of minimum 4mm cross sectional area Refer to EN60079 14 previously BS5345 Part 4 section 16 for further details of earthing requirements The barrier has two outputs having the following electrical parameters Channel 1 output terminals 1 amp 2 28V DC 0 112 Amps 0 8 Watts Internal resistance 2700 5 Channel 2 output terminals 3 amp 4 7 5N DC 0 66 Amps 1 24 Watts Internal resistance 120 5 In order to maintain intrinsic safety the capacitance and inductance or inductance to resistance L R ratio of the loads connected to the terminals of the FGDIO barrier must not exceed specified values The capacitance and Inductance or inductance to resistance L R ratio of the load connected to terminals 1 and 2 must not exceed the following values GROUP CAPACITANCE INDUCTANCE OR L R RATIO in uF in mH in wH ohm IIC 0 083 3 44 IIB 0 65 12 177 IIA 2 15 25 355 The capacitance and inductance or inductance to resistance L R ratio of the load connected to terminals 4 and 3 must not exceed the following values GROUP CAPACITANCE INDUCTANCE OR L R RATIO in uF in mH in wH ohm IIC 11 1 0 07 28 IIB 174 0 28 114 IA 1000 0 56 228 Warning When conside
61. s the barrier output terminals note e There is zero capacitance and zero inductance between terminals OV and SIG on any model of FGD detector head e There is an equivalent of 1 4uF capacitance and zero inductance between terminals OV and PWR on the FGD2 and FGD3 flammable gas detectors N A LO Document Ref P0102 800 00 June 2012 Page 3 29 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 3 3 1 Hazardous area installation using barrier type FGDIO An Analox Ltd barrier type FGDIO can be fitted to each output channel module within the MCU unit The following diagrams show the connections between FGD detector heads and an input module fitted with an FGDIO intrinsically safe barrier Safearea TI gt Q Pe re MCU input module Hazardous area I l I Connection diagram for FGD 2 amp 3 oxygen or toxic detectors in a hazardous area I l S barrier terminals i Type FGDIO I Sig Note Distribution board Link Ji should not be fitted Hazardous area Safe area n cT i JU Connection diagram for MCU FGD2 amp 3 flammable detectors in input module a hazardous area l S barrier terminals Type FGDIO Sig l I I Note Distribution l board Link J1 should not be fitted I I I Document Ref P0102 800 00 June 2012 NA LO Page 3 30 Environmental Monitoring amp Control Units Type
62. sounder and beacon installation details and output 3 is spare Each output is capable of switching a maximum of 200mA Fuse protection is provided by FS3 situated on the power supply refer to section 1 6 It should be noted that the external outputs are not switched via voltage free contacts 24V is always present at pins 2 4 and 6 and the OV line is switched via an open collector transistor Note In certain circumstances outputs 1 2 and 3 can be configured as inputs Contact Analox Ltd for further information 1 4 3 Distribution board Issues 3 and above END 55 o I S Earth ov External 24V DC supply ov O P1 The lower 4 way connector provides two 24V screw terminals and two OV screw terminals The voltages are always present at these terminals whilst FS3 is intact This supply is taken from the 24V supply of the system and is used by Analox Ltd when powering external equipment The amount of power available from this connector must be determined for each installation based upon the system configuration Pins 1 amp 2 and pins 3 amp 4 of the 12 Way connector provides two external outputs under software control Output 1 is designated as the sounder output whilst output 2 is designated as the beacon Document Ref P0102 800 00 June 2012 NA LO Page 1 12 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual output Each output is capable of switching a maximu
63. spond to those listed as acceptable must not be used A new sensor MUST be fitted in the detector to allow continued accurate and reliable readings to be made refer to section 7 3 for sensor replacement instructions Sensor Zero Span Min Typ Max Min Typ Max LEL CH 50 300 600 200 320 960 O 0 5 20 350 450 1300 H2S 350 500 600 100 n d 1500 CO 350 500 600 100 n d 1500 CL 350 500 600 100 n d 1500 NO 350 500 600 100 n d 1500 n d no data This data is unavailable at time of printing Please contact Analox Ltd for updated table Note Contact Analox Ltd for details regarding any sensor not listed N A LO Document Ref P0102 800 00 June 2012 Page 8 69 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 9 Specifications 9 1 MCU3 amp 4 control units Note MCU1 and MCU2 now obsolete MCUS MCU4 Size nominal mm 475 x 300 x 208 475 x 538 x 208 Weight approx 16Kg 30Kg Operating temp 10 C to 50 C Storage temp 20 C to 50 C Humidity range 0 to 95 R H Non condensing Input voltage 24V DC or 120 230V AC 50 60 Hz Tolerance 10 Environmental ating IP65 Note For compliance with UL3101 1 and CSA22 2 No 1010 1 the following environmental conditions apply Indoor use altitude up to 2000m Temperature 0 to 40 C Maximum relative humidity 80 decreasing linearly to 50
64. ssssseeeeee ennemis 1 23 1 8 1 MCU system configuration and interrogation sse 1 23 1 8 2 MCU system networking sssssssssese eene nennen nennen 1 23 2 MCU installati n EE 2 24 2 Siting the MG coi ics ses eens erts ea annaa a re eiae erp Reden 2 24 2 2 Assembling ertet rre reete remit t Fes ir evigted ue oie tender 2 25 2 9 System WINO iecit itf ener keine Det en teen cedat uer Ra Eon aeu aed bu dea as 2 25 24 Powersupply InpUt niece enne skadene nn etu ne sende eanet de ranket raster 2 25 2 4 1 A C mains connection esssssssssssseseeeee eene enne enne nennt nen 2 25 2 4 2 24V DC connection esssssssssssseseeseeeene entrent enses 2 26 25 Cable TOUTING PERPE 2 26 2 6 Cable screening cess itin rtr aab edere ue raa D a re AERE dr educ ded kaien ae 2 26 3 Gasdetector head installation sssssssssssseeeenenenenen nennen 3 27 9 1 Siting the detectors oir teet Rx XR HERBA KXERER MEE X RE a E aeaaeae 3 27 3 2 Installation in a non hazardous area ssssssseeeee enn 3 27 3 3 Installation in a hazardous area sese enne 3 29 3 3 1 Hazardous area installation using barrier type FGDIO s 3 30 3 3 2 FGDIO intrinsically safe output module installation sssssse 3 32 3 8 8 Hazardous area installations using proprietary safety barriers
65. te Jumper switches J1 J5 select the chart recorder output configuration whilst jumper switches J6 J12 configure the input card for the detector head to be used 4 1 Input configuration Section 4 1 1 discusses the most common configuration options These are also the configurations adopted by Analox Ltd for use with FGD detector heads manufactured by Analox Ltd Section 4 1 2 discusses less common configurations These configurations allow alternative manufacturers detector heads to be used Note The input configurations shown are for detector heads located in non hazardous environments I S barriers are required when mounting in areas where there is a flammable gas hazard refer to section 3 3 N A LO Document Ref P0102 800 00 June 2012 Page 4 37 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 4 1 1 Analox Ltd gas detectors Analox Ltd design manufacture and distribute a variety of fixed gas detectors The detector head used for monitoring oxygen or toxic gases using conventional sensors requires a 2 wire connection whilst detector heads incorporating infrared sensors or pellistors require a 3 wire connection 4 1 1 1 FGD2 and FGD3 O and toxic detector heads 24V The detector head is loop powered and sinks a current directly proportional to the gas levels that it detects Current sensing circuit Variable 22 D voltage output Terminals
66. th a range of 0 100 LEL 10 of full scale is 100 10 10 If the reading goes above fsd by 10 i e 110 LEL HI will flash on the display This condition will coincide with the head drawing a current of greater than 22mA thus indicating to the MCU control unit of a HI condition N A LO Document Ref P0102 800 00 June 2012 Page 5 51 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 5 3 Inspection and maintenance 5 3 1 Calibration intervals Analox Ltd advise that calibrations should be performed at no longer than six monthly intervals this can be arranged with Analox Ltd as part of a maintenance contract If a pellistor based sensor is known to have been exposed to a poison refer to section 5 5 1 it must at least be recalibrated However Analox Ltd strongly advise sensor replacement in these circumstances 5 3 2 Routine inspection The detector heads will provide accurate fault free service but they rely upon sensible housekeeping and regular calibrations It is advisable to periodically inspect the detector head installation e Check cables to ensure no damage has occurred e Clean detector heads using a DAMP cloth e Inspect detector heads and ensure the sensor housing apertures are not obstructed The time interval between routine inspections will depend upon the area in which the head is installed A clean laboratory installation may only require inspection at the tim
67. to all new equipment 1 4 1 Field connections Located on the top edge of the distribution board is a 12 way connector This is used to provide connections for inputs outputs and external buttons Pins 7 amp 8 These pins allow the connection of an external normally open switch This switch will allow the muting of alarms from a remote location the control unit is the only location from which alarm conditions can be accepted or cleared This button can be configured to perform other functions if required Contact Analox Ltd for further details Pins 9 amp 10 External 24V batteries may be connected to the system via these pins This is only required if it is anticipated that the main power source will be disconnected from the system for long periods of time in excess of the internal battery capabilities Note that any external batteries must be independently charged Pins 11 amp 12 An external 24V DC supply may be used instead of having a mains input Refer to section 2 4 2 for further details regarding connection of an external DC supply The internal batteries will still maintain power in the event of the external 24V power supply failing In order to meet all the power supply requirements of the system the external supply must be rated at 24V DC 2A minimum Pins 1 to 6 The function of the remaining pins on the 12 way connector depends upon the issue of the distribution board fitted Note The issue of the distribution boar
68. uiring more than the 4 20mA loop current range 24V Current sense circuit 21 D Variable 22 D voltage 23 D output 24 PL1 Terminals OV FGD10B Connection procedure Disconnect power from the system Remove the grey protective cover from the associated input module Configure the jumper switches as shown below i e J6 J7 J11 J13 and J14 switched ON all others OFF aS 73 gt Connect a voltmeter range 0 to 24V min between pins 22 V and 24 0V of PL1 Connect power to the system Adjust VR1 and VR2 until voltmeter reads between 15V and 24V VR1 and VR2 provide fine and coarse voltage adjustment respectively Disconnect power to the system and connect the wires from the detector head to PL1 on the input module observing the following Detector head PL1 pin number 0 24 Supp 22 4 20mA out 21 Connect power to the system and ensure the detector head operates Measure the voltage between the and 0 terminals at the detector head Refit grey protective cover Perform software configuration refer to MCU software configuration and system calibration manual Perform system calibration Document Ref P0102 800 00 June 2012 NA LO Page 4 40 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual 4 1 1 4 FGD10B infrared current source 24V Variable voltage output 21 D 22 Current 23 D sense 24 D circuit Terminals
69. uration Allows adjustment of sensor type and range e g flammable 100 LEL Calibration of the system This allows each channel to be calibrated independently The sensor zero point and span can both be set via this function Calibration of the retransmitted output for each channel gt Common relay configuration There are four relays situated on the relay module These relays can be configured as normally energised or de energised and they have several triggering options dependent on the application Input module relay configuration Each Input Module contains three relays These relays can be configured normally energised or de energised as required The levels at which the relays operate are also engineer configurable gt Changing of display modes The LCD has a variety of display modes dependent on the application or maybe the personal preference of the engineer Interrogation of logged data The data for any channel can is displayed numerically and graphically Document Ref P0102 800 00 June 2012 NA LO Page 1 8 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Installation and Hardware User Manual The microcontroller module contains all of the software required to communicate with up to eight detecting channels The addition of extra input modules therefore requires only a simple software configuration change to monitor the additional channels N A LO Document Ref P0102 8
70. will result in an irreversible decrease in sensitivity The most common of these substances are e lead or sulphur containing compounds e silicones phosphates It may be possible to recalibrate a sensor that is known to have been exposed to a poison However Analox Ltd strongly advise sensor replacement in these circumstances Inhibitors Certain compounds especially HS and halogenated hydrocarbons are absorbed or form compounds that are absorbed by the pellistor This absorption is so strong that reaction sites within the pellistor become blocked and normal reactions are inhibited The resultant loss of sensitivity is temporary and in most cases a sensor will recover after a period of operation in clean air Pellistors will detect numerous flammable gases The level at which they respond varies depending upon the flammable gas Contact Analox Ltd for details regarding the cross sensitivity of flammable gases 5 5 2 Oxygen gas detectors At very high levels i e levels highly oxidising gases e g ozone and chlorine will interfere to the extent of their oxygen equivalent but most other commonly occurring gases will have no effect For example Methane100 0 Hydrocarbons 100 0 Hydrogen 100 lt 2 Carbon monoxide 20 lt 0 5 Acid gases such as CO and SO will be slightly absorbed by the electrolyte within the oxygen sensor and tend to increase the flux of oxygen to the electrode This gives an enhanced oxygen signal o
71. ws the use of any sensor that can produce a voltage or current output within a specified range The versatile design allows a monitoring system to be initially installed using the minimum number of required channels and then as the monitoring environment changes more channels can be added or alternative detector heads can be used as required Data logging is provided as a standard function Data is stored within the systems non volatile memory thereby providing reliable storage without the risk of losing data in the event of total power loss mains and battery backup failure Logged data can be viewed via the LCD display situated on the front panel in either numerical or graphical form or alternatively the data may be transferred to a P C running the Mentor PC Software via the RS232 output This provides the system with an unlimited storage and data logging medium Care has been taken with the design of the MCU housings and internal chassis to facilitate ease of connection and wire termination All on site wiring to the system is via removable screw terminal connectors A monitoring system consists of as a minimum an MCUS Control Unit and 1 detector head The MCU Control Unit houses all of the components required to implement a sophisticated and reliable monitoring system battery back up alarm relays etc N A LO Document Ref P0102 800 00 June 2012 Page 1 3 Environmental Monitoring amp Control Units Types MCU 3 amp 4 Inst
72. xibility of the MCU Systems has led to alternative heads being designed to monitor alternative parameters e g temperature thermocouples fire smoke etc Analox Ltd can manufacture detector heads allowing the MCU system to monitor almost any measurable level not necessarily related to environmental monitoring Contact Analox Ltd for further details 5 2 Operation The FGD2 amp FGD3 detector heads do not require user intervention during normal operation however periodic inspection is advised consult section 5 3 The front panel LCD will always show the current levels of gas that the head is detecting A confidence LED located on the lower edge of the casing will flash periodically to indicate that the head is powered and the internal microcontroller is running 5 2 1 Status indications 5 2 1 1 FLT The flammable gas detector heads incorporating pellistors will flash FLT if they sense a fault with the pellistors fitted This will coincide with them drawing less than 2 5mA from the control unit thus ensuring the control unit is aware of the fault condition All other detector heads will flash FLT if they sense a gas concentration less than 1096 of FSD below zero 5 2 1 2 Calibration mode When the detector head is placed in calibration mode the display will flash the appropriate information 5 2 1 3 HI HI will flash on the display if the head detects a gas concentration greater than FSD 10 e g A flammable head wi

Environmental Monitoring & Control Units Types MCU 3 & 4

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Environmental Monitoring &amp; Control Units Types MCU 3 &amp; 4

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Environmental Monitoring & Control Units Types MCU 3 & 4