Refrigerant & Ammonia Leak Monitoring System Model
Contents
1. Each screen will show the sample zone in which the alarm occurred sample reading at the time the alarm occurred The alarm codes displayed are LEAK The unit detected a LEAK alarm SPILL The unit detected a SPILL alarm ZONE The unit detected a ZONE alarm Note If a flow fault was detected the sample reading will be replaced with the word FLOW General system alarms are also recorded in the alarm log when these occur the name of the alarm will be displayed in place of the sample zone The alarm log holds up to 50 alarms when the alarm log becomes full the oldest entry will be removed from the alarm log to make space when a new alarm occurs 25 3 8 Zone setup menu The zone setup menu enables the user to setup the variables associated with each sample zone such as alarm thresholds sample zone names and refrigerants Press to enter the zone setup menu The next screen prompts the user to enter the admin password Note By pressing enter without entering a password variables can be viewed but not edited Next the sample zone that user wishes to setup must be selected The unit will be supplied with zones named numerically ZONE 01 ZONE 02 etc 3 8 1 Change zone name The user is able to change the name of a channel See section 3 1 2 for more details on entering text variable If you do not wish to change the sample zone name press ENTER to proceed No2. 21 3 5 1 Change password enter old password 21 3 5 2 Change admin password cette 21 3 5 3 Change lt 5 cece 21 3 5 4 Change zone output type ccceececeeeeeeceeeeeeeceeeeeeeeaeee esses nenne nnn nennen nennen 21 3 5 5 Change date 22 3 5 6 Change date iie Du eg etra LR EET X ERR LAE NONE XAR EM Fed ER ER ER RED 22 3 5 7 Charge eie EQ rd REO 22 3 5 8 Clear arene deena enact 22 3 5 9 Change alarm relay LED lt 22 3 5 10 Change low reading threshold esee 23 3 5 1T 23 3 5 12 Che ha ARE RAE 23 3 6 Manual override earen yaa nnne nnne nnn nnne tenen 24 3 7 Zone historical data Menu sssssssssssesnrssnrannnennnsssnannnannnennnannnnnnnnnnnannnnnnnnnnannnn nne 25 3 7 1 Zone 25 3 7 2 Zone alartnzl0g Pes ranae rado 25
3. The system will proceed to the next screen following selection Select YES or NO V The system will proceed to the next screen following selection Select Y or N V for each variable Press Press to move to next variable enter to proceed to the next screen The next screen will allow the user to setup the relay and STATUS LED function whenever a spill alarm occurs If you do not wish to change the spill alarm relay and LED settings press ENTER to proceed Select Y A or N for each variable Press gt to move to next variable Press r to proceed to the next screen The next screen will allows the user to setup the relay and STATUS LED function whenever a system fault occurs If you do not wish to change the fault relay and STATUS LED settings press ENTER to proceed Select Y or N for each variable Press gt to move to next variable Press to proceed to the next screen The final screen in the sub menu allows the user to setup the state of the relays following an alarm i e contacts closed or contacts open the relays are normally open when the unit is un powered Select state using V Press ever to proceed to the next screen 3 5 10 Change low reading threshold The user can
4. Note Setting an 8 zone unit to sample 16 zones will result in flow fault alarms 16 2 7 2 Camero Network Mode Settings Network Address DIP switches 1 4 DIP switches 1 4 are used to set the Camero network address Each DIP switch is assigned a value To select the desired address simply set the switches that add up to the address value you require some examples Switch No 1 2 3 4 Value 1 2 4 8 Address 3 ON ON OFF OFF 1 2 3 Address 6 OFF ON ON OFF 4 2 6 Address 14 OFF ON ON ON 8 4 2 14 Watchdog enable DIP switch 5 DIP switch 5 enables and disables the unit watchdog If enabled the unit will reset if a software error occurs ON Disabled OFF Enabled normal operation RS485 speed DIP switch 6 DIP switch 6 sets the baud rate of the RS485 port ON 9600 bps normal operation OFF 19200 bps Number of sample zones DIP switch 8 If the unit is set for Camero network mode DIP Switch 8 selects the number of sample zones to be monitored ON 8 Sample Zones OFF 16 Sample Zones 17 3 User Interface The units operating software includes variables that must be configured by the user in order for the unit to operate correctly The software is configured using the keypad and LCD on the front of the unit the user interface It is also possible to view live and historical sample information and historical alarms using the user interface 3 1 Basic user inte
5. 4 5 Alarm Buzzer Units are fitted with an alarm buzzer the alarm buzzer will operate with the SPILL ALARM LED Whenever a spill alarm occurs the alarm buzzer will also be switched on 31 5 Unit specification Measurement Method Non dispersive infrared Measured Gases e HCFC and HFC refrigerants e Ammonia Analytical Range 5 to 25 000 ppm depending on the compound of interest Accuracy 5 from 0 to 100 ppm 10 from 100 to 1000 ppm Response Time 75 of peak in less than 10 seconds through 60M 6mm tubing User Interface Front panel LCD display and keypad leak and spill alarm control contact relays high visibility LEDs Buzzer 0 5 Vdc analogue linear output RS 485 input output Sample System High capacity vacuum pump up to 500M sample lines low flow sensor 8 or 16 Sample Points Power Input 110 120 208 240 VAC at 50 60Hz Weight 13 1 kg Size Lx x W 32 7 cm x 37 5 cm x 15 6 cm Operating Environment 329 F to 1159 F 09 C to 479 C 0 to 95 Relative Humidity non condensing Approvals UL CSA and CE 32 6 Technical Drawings Please contact CPC UK for technical drawings 33
6. V Press to proceed to the next screen Input new zone name Press eer to proceed to the next screen Select refrigerant using V Press to proceed to the next screen Select threshold value using V Press eer to proceed to the next screen 3 8 4 Change spill threshold The sample reading from each zone is compared against a spill threshold if the sample reading is above the spill threshold then a spill alarm will be generated immediately The user is able to setup different spill thresholds for each sample zone If you do not wish to change the spill threshold press ENTER to proceed Note Pressing the 4 button will increment the threshold in steps of 150 PPM Pressing the M button will decrement the threshold in steps of 50 PPM 3 8 5 Change sample period The sample time is the duration that each sample zone is sampled for during a sample cycle The duration must be changed according to the length of tubing to the final sample point If you do not wish to change the sample time press to proceed Note Pressing the button will increment the sample time in steps of 10 seconds Pressing the button will decrement the sample time in steps of 10 seconds Note Setting the sample time to 0 seconds will disable that zone 3 8 6 C
7. Zone 6 Output Zone 14 Output get AlamRelay 1i JR Zone 5 Output Zone 13Output Q9 JL e Alarm Relay 2 is ode Zone 4 Output Zone 12 Output Zone 3 Output Zone 11 Output Zone 2 Output Zone 10 Output Zone 1 Output Zone 9 Output Figure 2 7 Connections 2 6 1 Zone Outputs The zone outputs can be configured to give either a digital or analogue signal this is done when setting up the software configuration of the unit see section 3 5 4 If configured to provide digital signal the factory default the terminal for a particular zone will change state 0 VDC No Alarm 5 VDC Zone Active Alarm If configured to provide an analogue signal the terminal will provide a linear voltage signal which represents the actual PPM reading for a particular zone 0 VDC 0 PPM 2 4 VDC 600 PPM 4 8 VDC 1200 PPM 4 9 VDC over 1200 PPM 5 VDC Fault Note Care should be taken not to short a zone output channel to earth or OV as this may damage the unit Note The current rating of devices connected to each zone output must not exceed 40mA Connecting devices that have a higher current rating may damage the unit 14 2 6 2 RS485 Interface The unit provides an RS485 interface enabling the unit to transmit data to building management systems and other central alarm systems There are two RS485 communication protocols supported by the IR em u
8. 3 8 ZONE set p eteliaiecdOenensaceeeealsdvevecisectedececsecede ses 26 3 8 1 Change zone 26 3 8 2 Change refrigerant esse anne nennen nnn nnn nna 26 3 8 3 Change leak threshold eerie eese ater atur nnne aa nine naa 26 3 8 4 Change spill 27 3 8 5 Change sample nennen nennen 27 3 8 6 Change leak alarm delay enne nenne 27 3 8 7 Change zone alarm thresholds eseseeeeeene nnne 27 3 8 8 Change zone alarm delay ssssessssseeseeeneneeeeenen ener nnne 28 3 8 9 Change special handling modes seeeeeeneeeennn enn 28 3 8 10 More changes i e eter teet teu p ente 28 UD D ILE 29 EE 29 4 2 Leak IM 30 4 3 5 TE 30 dala PEPPER 31 ASS iss iet D 31 5 Unit specification 6 Technical Drawings 1 Introduction The IR em unit is designed to detect refrigerant leaks by analysing air samples collected from different locations refrigerant concentrations as low as 15 parts per million PPM can be detected Most commo
9. thresholds When measured gas concentrations rise above these alarm thresholds further actions can be initiated which can be configured by the user and the unit will generate an alarm Alarm Occurrence Normal Action Initiated Leak Alarm Will occur when a measured gas Leak LED illuminated common alarm concentration rises above the relay 1 changes state entry recording corresponding Leak alarm refrigerant concentration time and threshold zone name in the alarm log Zone Alarm Will occur when a measured gas Status LED will turn red the output for concentration rises above the that channel is raised to 5V entry corresponding Zone alarm recording refrigerant concentration threshold time and zone name in the alarm log Spill Alarm Will occur when a measured gas Spill LED illuminated common alarm concentration rises above the relay 2 changes state entry recording corresponding Spill alarm refrigerant concentration time and threshold zone name in the alarm log Every alarm event including system faults will result in an alarm message being displayed on the units LCD display The filtered air tubes that carry the air sample to the unit are constantly monitored for reductions in air flow which can be caused by a squashed tube or a clogged filter The unit will raise an alarm if low airflow is detected in effect warning the user that refrigerant leaks may go undetected The common alarm relays R1 and R2 pr
10. 4 1 Zone alarm A zone alarm will be generated when a sample zone reading has exceeded the zone threshold variable for that zone continuously for the number of cycles defined the zone alarm delay variable If the zone threshold has been set above the leak threshold and a zone alarm is detected the following occurs e The STATUS LED on the door will flash red e The associated zone output will be activated e The unit will record the alarm the alarm log F e The LCD screen will display ZONE ALARM e PRESS ANY KEY TO CLEAR EIS LEAK SPILL STATUS ALARM ALARM If the zone threshold has been set below the leak threshold and a zone alarm is detected the following occurs e The STATUS LED on the door will flash red e The LEAK ALARM LED on the door will flash red e associated zone output will be activated 2e e The unit will record the alarm in the alarm log ea d 5 LCD screen will display ZONE ALARM LEAK SPILL STATUS PRESS ANY KEY TO CLEAR ALARM ALARM If the user does not clear the alarm after a few seconds the unit will return the Status Overview screen the status section of the screen will show ZONE to indicate a zone alarm has occurred Pressing any key on the keypad will reset the alarm and will switch off the alarm LED s and will de activate the associated zone output If the concentration remains above the zone threshold the alarm will be re initiated 29 4 2 Leak Alarm
11. A leak alarm will be generated when a sample zone reading has exceeded the leak threshold variable continuously for the number of cycles defined the leak alarm delay variable When a leak alarm is detected the following occurs e The STATUS LED on the door will flash red e The LEAK ALARM LED on the door will flash red ly wy e The associated alarm relay be activated e Q 7 e unit will record the alarm the alarm log FIM p LCD screen will display LEAK ALARM LEAK SPILL STATUS PRESS ANY KEY TO CLEAR ALARM X ALARM If the user does not clear the alarm after a few seconds the unit will return the Status Overview screen the status section of the screen will show LEAK to indicate a leak alarm has occurred Pressing any key on the keypad will clear the status message on the status overview screen and will switch off the alarm LED s and will de activate the alarm relay 4 3 Spill Alarm A spill alarm will be generated immediately when a sample zone reading has exceeded the spill threshold variable When a spill alarm is detected the following occurs e The STATUS LED on the door will flash red a e SPILL ALARM LED on the door will flash LEAK SPILL STATUS red ALARM ALARM e associated alarm relay be activated e unit will record the alarm in the alarm log e The LCD screen will display SPILL ALARM PRESS ANY KEY TO CLEAR e If any key is pressed the LCD scree
12. L alarm ZONE The unit has detected a ZONE alarm FLOW The unit has detected a FLOW alarm in one or more zones DATA This indicates that the display is showing historical data for a particular sample zone ALRM Indicates that the display is showing historical alarms FAULT Will be displayed if a system fault has been detected 20 3 5 System setup menu The system setup menu allows the user to change system variables such as passwords relay configuration analogue outputs and the time and date Press to enter the system setup menu 3 5 1 Change password enter old password first The first screen displayed within the system setup menu prompts the user to enter a password To enter the password use the and M buttons to select the character required press E button to proceed to the next character and then the ENTER button when the correct password is displayed Note The factory default password is 00000 Note If the user enters the user password in this screen they will not be able to change the admin password 3 5 2 Change admin password If required the user may change the admin password Initially the existing password will be displayed If you do not wish to change this password press ENTER to proceed Note The user is prompted to enter the admin password before accessing the System setup menu and the Zone setup menu 3 5 3 Change user p
13. ORD REQ SELECT ZONE CHANGE ZONE NAME CHANGE REFRIGERANT TYPE CHANGE LEAK THRESHOLD CHANGE SPILL THRESHOLD CHANGE SAMPLE PERIOD CHANGE LEAK ALARM DELAY CHANGE ZONE THRESHOLD CHANGE ZONE ALARM DELAY SELECT SPECIAL HANDLING MORE CHANGES YES NO BACK TO STATUS OVERVIEW 3 3 Warm up screen After initial power up the unit will display the warm up screen to indicate that the unit is in its warm up cycle This screen also displays the current time and date set within the unit The warm up cycle will last up to 20mins if powered up from cold however during this time the user interface is fully accessible Note Prior to the warm up screen being displayed the unit will briefly display a screen showing the software version of the unit 3 4 Status overview The status overview screen is displayed during normal operation of the unit The screen shows the current reading from last zone sampled and will scroll around each zone in turn the date amp time zone name and operating mode The unit status operating mode options are CON Indicates that the unit is in continuous sample mode from one zone SEQ Indicates that the unit is in sequential sample mode WARMUP Indicates the unit is within its warm up cycle LEAK The unit has detected a LEAK alarm SPILL The unit has detected a SPIL
14. Unit 7 8 UK Heathrow Causeway Estate Ariel Way Hounslow ff Middlesex TW4 6JW 44 0 208 6302270 www cpcuk co uk Refrigerant amp Ammonia Leak Monitoring System Model IR em User Manual Version 3 01 Software version 0 57 All rights reserved The information contained in this manual has been carefully checked and is believed to be accurate However CPC UK assumes no responsibility for any inaccuracies that may be contained herein In no event will CPC UK be liable for any direct indirect special incidental or consequential damages resulting from any defect or omission in this manual even if advised of the possibility of such damages In the interest of continued product development CPC UK reserves the right to make improvements to this manual and the products described herein at any time without notice or obligation Copyright Copyright by CPC UK No part of this manual may be reproduced or transmitted in any Form without express written authorization from CPC UK Trademarks All trademarks are acknowledged and are the property of their respective holders Contents Le egere on o PEL 5 1 1 Overview of unit 6 1 2 Principle of operation erii ee clue savy eee iiie eir terne oret diced en atte 7 2 Installing the unit hardware 9 2 1 Mounting the 10 2 2 Connec
15. aintain the correct time even if the unit is not powered up If you do not wish to change the time format press ENTER to proceed 3 5 8 Clear logs The user may clear the historical alarm logs and data log information stored within the unit Note Clearing the alarm logs and data logs will remove all historical data for ALL sample zones 3 5 9 Change alarm relay LED setup The user may access a sub menu from the system setup menu the sub menu allows the user to change the configuration of the alarm relays and the STATUS LED If the user selects NO the system will proceed to the Change low threshold screen If the user selects YES the system will display a screen enabling the user to setup the relay and STATUS LED function whenever a leak alarm occurs Setting a variable to Y will mean that the relay as indicated above the variable will be switched on and STATUS LED will turn red when a leak alarm occurs If you do not wish to change the leak alarm relay and LED settings press ENTER to proceed 22 Select date format using V Press to proceed to the next screen Select new date using V and gt Press enter to proceed to the next screen Select new time using V and gt Press enter to proceed to the next screen Select YES A or NO V
16. assword The user may change the user password Initially the existing password will be displayed If you do not wish to change this password press ENTER to proceed Note The user password enables the user to reset alarms but will not allow the user to change settings on the unit Press enter to proceed to the next screen Input password Press ENTER to proceed to the next screen Input new admin password Press ENTER to proceed to the next screen Input new user password Press ENTER to proceed to the next screen Note If your password has been lost contact CPC UK for the date sensitive override password 3 5 4 Change zone output type The user may setup whether the zone outputs operate in digital or analogue mode see section 2 6 1 21 Select output type using V Press enter to proceed to the next screen 3 5 5 Change date format The user can change the system date format between U K and U S A format If you do not wish to change the date format press ENTER to proceed 3 5 6 Change date The date maybe changed by the user Once setup the units real time clock will maintain the correct date even if the unit is not powered up If you do not wish to change the date press ENTER to proceed 3 5 7 Change time The time maybe changed by the user Once setup the units real time clock will m
17. ct threshold value using V Press ENTER to proceed to the next screen 3 8 8 Change zone alarm delay If a sample reading is above the zone threshold the unit will ensure the sample reading has been above the zone threshold for a specified number of sample cycles before generating a zone alarm If you do not wish to change the zone alarm delay press ENTER to proceed Setting the zone alarm delay to 0 will result in the leak alarm being disabled for that sample zone Note The zone threshold cannot be set higher than the spill threshold 3 8 9 Change special handling modes The special handling option allows the user to setup how the unit determines a valid 0 PPM reading The variable can be set to one of three settings NORMAL When set to this mode after each sample cycle the sample zone with the lowest PPM reading will be referred to as the reference zone On the next sample cycle all other zones will be referenced to this zone NO REF When set to NO REF this sample zone will ignore the reference zone In addition this sample zone will never be used as the reference zone NO ZERO When set to this mode this zone will never be used as the reference zone If you do not wish to change the special handling mode press ENTER to proceed 3 8 10 More changes The last screen in the zone setup menu asks the user if they would like to make more changes to the zone
18. following selection Select zone using V Press ENTER to proceed to the next screen Select YES The system will proceed to the next screen following selection 3 7 Zone historical data menu The historical data menu allows the user to view historical sample readings and alarms for a particular zone Press M to access the historical data menu 3 7 1 Zone data log The first screen shows the last logged sample reading for zone one The user can change the time of the sample displayed and also the sample zone for the data using the Change time of sample using A arrow buttons older samples 2 newer samples increment zone lt decrement zone Change sample zone using lt VIIJ Each screen will show the zone name sample reading and date and time of when the sample was recorded The unit will record the sample reading obtained from each sample zone during each cycle A 16 channel unit will store a maximum of 125 hours of data 3 7 2 Zone alarm log If the user presses ENTER whilst in the zone data log menu the zone alarm menu will be displayed showing the last alarm that has occurred The user can scroll through the alarm log using the arrow buttons older alarms newer alarms Scroll through alarms using V
19. ghout the site including suggested sampling points types of filters and remote manifolds available is available from CPC UK Sample tubes should be connected to the manifold intake nozzles at the bottom of the unit Each nozzle is identified with a number the sample zone number 8 Channel units Blanking plate 01 O2 04 05 O6 Front of unit 16 Channel units Q001 012013014015016 O01 O2 O3 O4 O5 O7 Os Front of unit Figure 2 1 Manifold nozzles To connect a tube first ensure the end of the tube has been cut off at right angles to the tube then simply push the tube into the nozzle The tube should travel approximately 10mm into the nozzle A Figure 2 2 Connecting tube to nozzle Note On early models the tube must be pushed over the outside of the nozzle a barb on the nozzle holds the tube in place 11 2 4 The liquid separator The unit is normally supplied with the liquid separator not fitted to the unit this is to prevent damage to the liquid separator during transit To fit the liquid separator Push tubes onto nozzles over barbs as indicated Align snap fit lugs Front of unit Figure 2 3 Fitting the liquid separator Note The tubes for the separator are labeled 1 and 2 it maybe necessary to feed these tubes to the outside of the unit before it is possible to fit the liquid separator Over time the liquid separator may fill with liquid To drain the liqu
20. hange leak alarm delay If a sample reading is above the leak threshold the unit will ensure the sample reading has been above the leak threshold for a specified number of consecutive before generating a leak alarm If you do not wish to change the leak alarm delay press ENTER to proceed Note Setting the leak alarm delay to 0 will disable all leak alarms 3 8 7 Change zone alarm thresholds The sample reading from each zone is compared against a zone threshold if the sample reading is above the zone threshold and has been so for number of sample cycles specified in the Zone Alarm Delay variable then a zone alarm will be generated The user is able to setup different zone thresholds for each sample zone If you do not wish to change the leak threshold press ENTER to proceed If the zone outputs are set to operate in digital mode the corresponding zone output will be switched ON Note Pressing the button will increment the threshold in steps of 25 PPM Pressing the button will decrement the threshold in steps of 5 PPM 27 Select threshold value using V Press ENTER to proceed to the next screen Select sample time value using V Press ENTER to proceed to the next screen Select the number of samples using A Press ENTER lt to proceed to the next screen Sele
21. id separator power off the unit unscrew the liquid separator bowl by turning it in an anti clockwise direction and empty the bowl When finished simply re attach the bowl and power up the unit Figure 2 4 Removing separator bowl Note When refitting the separator bowl be careful not to over tighten the bowl finger tight is adequate as this may break the separator bowl seal 12 2 5 Exhaust tube The exhaust tube is located at the top left hand side of the unit The exhaust tube expels the air that has been sampled by the unit Note The exhaust tube must not be blocked or crimped in anyway a blocked or crimped exhaust tube will cause pressure build up within the unit possibly resulting in damage to the unit If desired the exhaust tube maybe extended so that sampled air is pumped outside When doing this ensure that tubing one size larger than the exhaust tube is used the tube length should not exceed 10m Exhaust tube Figure 2 5 The exhaust tube 2 6 Connection Terminals The unit provides connection terminals for interfacing with external equipment All connection terminals are located behind a removable cover plate on the left hand side of the unit Cable entry through holes provided on bottom of unit Figure 2 6 Gland plate 13 Note All cables must enter the unit through holes provided on the bottom of the unit Zone 8 Output Zone 16 Output Zone 7 Output Zone 15 Output
22. ight position to a wall using the mounting brackets at the top and bottom of the unit see figure 2 1 for mounting dimensions Allow at least 150mm on the left and right hand sides of the unit for access to terminals and ventilation Allow at least 200mm underneath the unit for access to manifold connections and so that the liquid separator can be emptied Note The unit must be mounted in an upright vertical position for the liquid separator to function correctly Note Do not mount the unit on a refrigeration pack or other apparatus that produces excessive vibrations Excessive vibrations may cause serious damage to the units IR detector Note It is advised that the unit should be mounted so the LCD is slightly above average eye level 145mm 145mm 400mm 5mm 12mm EN 145mm 145mm Fig 2 1 Mounting dimensions 10 2 2 Connecting power to the unit The unit is supplied with three wires protruding from the right hand side of the unit These wires should be connected to the 240VAC power supply Brown Live Blue Neutral Yellow Green Earth the unit MUST be earthed Note Qualified personnel should only connect the unit to the 240VAC power supply Note The unit should be supplied from a fused switch spur fuse rating 5A 2 3 Connecting sample tubes and filters Note This manual explains the final connection of sample tubing to the unit A separate manual detailing installation of tubing throu
23. lengths The detector provides a voltage output the level of the voltage depends on the amount of IR light detected The actual gas concentration is determined by measuring the difference in the amount of IR light received by the IR detector after passing the IR light beam through the gas IR optical filter and separately through another reference optical filter an optical filter allows through a certain IR wavelength which will not be absorbed by any gas likely to be present in the sample The differential measurement technique provides long term stability which prevents any accuracy drop due to long term degradation of the IR source as the IR detector will be see the same drop in IR light level after it has been passed through both IR optical filters Figure 1 0 illustrates the basic principle of an IR gas detection system 1 seb MI Jo Aq paqiosqe 0 seu euios ule s ea Jaye 14677 JI ye 34617 Auew Jo 14617 Figure 1 0 Principle of operation diagram a 2 Installing the unit hardware The unit is normally mounted in a plant room corridor or office typically in a location that is not accessible to the general public The unit must be connected to a 240VAC mains supply from an un switched fused spur which is normally provided by q
24. n will prompt the user to enter a password in order gt e to accept the alarm LEAK SPILL STATUS ALARM ALARM If the user does not clear the alarm after a few seconds the unit will return the Status Overview screen the status section of the screen will show SPILL to indicate a spill alarm has occurred Pressing any key on the keypad will prompt the user to enter a password When a valid user or admin password has been entered the unit will switch off the alarm LED s and will de activate the alarm relay 30 4 4 Flow Fault The unit constantly measures the airflow from each sample zone if a drop in airflow is detected a flow fault will be generated When a flow fault is detected the following occurs The STATUS LED on the door will turn red e The associated alarm relay be activated O O e The unit will record the alarm in the alarm log LEAK SPILL e The LCD screen will display LOW FLOW STATUS PRESS ANY KEY TO CLEAR ALARM ALARM If the user does not clear the alarm after a few seconds the unit will return the Status Overview screen the status section of the screen will show FLOW to indicate a flow alarm has occurred the sample reading for zone where the flow fault was detected will also show Pressing any key on the keypad will clear the status message on the status overview screen and will switch off the alarm LED s and will de activate the alarm relay
25. nctions on the unit The unit can operate in two RS485 network modes Woodley Network or Camero Network this is done by changing the setting of JP5 changing this setting also defines the operation of the other jumper links and DIP switches Woodley Mode DIP Switch Designation JP6 ON 8 Sample Zones JP6 OFF 16 Sample Zones Note This example show the unit address set as 1 i e switch 1 is ON JP5 ON Woodley Network ii Camero Mode DIP Switch ignat Un Designation OFF Camero Network NOT USED Back of door Note This example show the unit address set as 1 i e switch 1 is ON Figure 2 8 Jumper links and DIP switches 2 7 1 Woodley Network Mode Settings Network Address DIP switches 1 8 The DIP switches are all used to set the Woodley network address Each DIP switch is assigned a value To select the desired address simply set the switches that add up to the address value you require some examples Switch No 1 2 3 4 5 6 7 8 Value 1 2 4 8 16 32 64 128 Address 21 ON OFF ON OFF ON OFF OFF OFF 16 4 1 21 Address 67 ON ON OFF OFF OFF OFF ON OFF 64 2 1 67 Address 200 OFF OFF OFF ON OFF OFF ON ON 128 64 8 200 Number of sample zones JP6 If the unit is set for Woodley network mode JP6 selects the number of sample zones to be monitored ON 8 Sample Zones OFF 16 Sample Zones
26. nit Camero and Woodley The Camero protocol is used to communicate to the Viewpoint and Einstein 1 amp 2 system managers Woodley is a third party open communication protocol used within the refrigeration industry Connection between the unit and the remote system should be made using Belden cable 8761 or equivalent the cable should be connected as follows Black RS485 White RS485 Screen Screen The characteristics of the RS485 interface such as address protocol and baud rate must be configured using the units DIP switches see section 2 7 2 6 3 Alarm Relays The alarm relays may each be configured to provide a signal to another device in the event of a spill alarm leak alarm or system fault It is also possible to configure each relay to operate as Normally Open NO or Normally Closed NC providing failsafe operation The exact operation of alarm relays is selected when setting up the software configuration of the unit see section 3 5 9 The factory default operation of the alarm relays Alarm relay 1 Relay contacts will close in the event of a Spill Alarm NO operation Alarm relay 2 Relay contacts will close in the event of a Leak Alarm NO operation Note The alarm relay contacts are rated at 240VAC 3A Connecting devices that exceed this rating may damage the unit 15 2 7 Jumper links and DIP switches The unit includes a number of jumper links and DIP switches that configure certain fu
27. nly used HFC and HCFC refrigerants together with Ammonia can be accurately detected without nuisance alarms from other contaminant gases and substances This is achieved by passing an infrared beam of a certain wavelength depending on the gas to be detected through a sample of air the strength of the beam will become less if the gas to be detected is present in the sample The unit can be supplied to detect many refrigerants R404a R134a R22 R410a R407c and Ammonia NH3 and can be supplied to detect other refrigerants upon request Figures 1 0 and 1 1 show a basic overview of the main components of the unit Liquid Crystal Display Status Alarm indicator LED s Alarm buzzer later models Power Switch on side of unit Liquid Separator Power supply Figure 1 0 Overview of exterior of unit Cooling fan IR Bench Main processor board Power Relay board Figure 1 1 Overview of interior of unit 1 1 Overview of unit operation Air samples are taken sequentially from up to 16 different locations 8 locations on some models via filtered sample tubes To accommodate different sample tube lengths the user can setup how long each location is sampled during the sample cycle Each sample is passed through the IR bench and the gas level within the sample is determined For each location being sampled there are three different alarm thresholds called Leak Zone and Spill
28. nu allows a user to force the unit into continuous sampling of a certain zone or force the unit into sampling a particular zone next interrupting the normal sample cycle This can be useful when finding leaks on site Press ENTER to access the manual override menu The user is first prompted to enter the admin password The next screen asks the user to select continuous or sequential sampling Selecting sequential sampling will interrupt the sample sequence and force the unit to sample the zone selected in the following screen That zone will be sampled for the normal period before the unit proceeds to the next zone Selecting continuous sampling will force the unit to continuously sample the zone selected in the following screen until the user switches the unit back into sequential sampling mode Next the user must select the zone to sample The last screen in the manual override menu asks the user if they would like to make more changes Selecting YES returns the user to the Select Sample Mode screen Selecting NO returns the user to the Status overview screen Note Operating the unit in continuous sampling mode should not be carried out over pro longed periods Doing so may result in a drift in reading accuracy 24 Input password Press ENTER to proceed to the next screen Select sample mode using V The system will proceed to the next screen
29. ovide volt free contacts rated at 230 2A These relays provide open contacts when the unit is not powered The user can setup normal or failsafe relay actions In normal operation the relay contacts will close only when a fault or alarm occurs In fail safe mode the relay contacts will close as soon as the unit is powered up and operational and will open when a fault or alarm occurs The exact operation of the common alarm relays can be changed to suite the users application Each sample zone has a corresponding output which is normally set to 5 following a zone alarm for that particular zone These outputs can interface with external equipment and alarm panels or to other relays to provide supplementary switching The unit also includes an RS485 interface enabling the measured gas levels status and alarm data to be collected by a central alarm system Details of the communication protocols available over the RS485 connection are available on request The RS485 interface also enables the unit to be connected to the CPC UK Einstein 2 system manager In addition the unit may connected to the CPC UK Viewpoint interface enabling the unit to be connected to a TCP IP based network allowing status and alarm data to be viewed using a standard web browser The unit maintains a data log record of measured gas concentrations for the last 72 hours and an alarm log of the last 50 alarm events This data can be viewed via the units LCD in
30. rface operation The unit presents information live values set points data logs etc on the LCD The user navigates through this information using the keypad buttons UP E Bl V DOWN Fig 3 0 Keypad buttons 3 1 2 Entering alphanumeric variables names and passwords etc The keypad buttons are also used to change variables on the unit these maybe numeric or alphanumeric If a user is prompted to enter an alphanumeric variable such as a zone name the user must select one character at a time using the and M buttons to select the character required When the character required is displayed pressing the button will move the cursor to the next character to be entered When all the characters have been entered pressing the ENTER button complete the process The characters available are I 56 ABCDEDGHIJKLMNOPQURSTUVWXYZ0123456789 SPACE A 3 1 3 Inactivity Timeout If the unit detects no button presses for 30 seconds the display will automatically revert to the status overview screen 18 3 2 System screen layout The user interface system screens are divided into sections allowing the user to quickly navigate through information and configuration variables Figure 3 1 shows a diagram of all the system screens available Note In order to access the screens shown explained in this sec
31. setup Selecting YES returns the user to the Change name password screen Selecting NO returns the user to the Status overview screen 28 Select the number of samples using A Press eve to proceed to the next screen Select the mode using A V Press to proceed to the next screen Select YES or NO V The system will proceed to the next screen following selection 4 Alarms The unit generates alarms whenever leaks spills zone alarms flow faults and system faults are detected There are two types of alarms Fatal alarms and Non Fatal alarms Fatal Alarms A fatal alarm occurs when a major hardware or software problems has stopped the unit functioning correctly When a fatal alarm occurs an alarm description will be displayed on the LCD The user will be prompted to enter a password to reset the fatal alarm Most fatal alarms display a message code when a fatal alarm occurs please record the code and contact CPC UK for further assistance Non Fatal Alarms Non fatal alarms include Zone alarms Leak alarms Spill alarms Flow faults When a non fatal alarm occurs the unit will notify the user of the alarm on the LCD and will continue sampling The alarm message will remain on the LCD until the user has acknowledged it With the exception of Spill alarms no password is required to acknowledge a non fatal alarm
32. setup a minimum PPM reading threshold If a reading from a sample zone is above 1 PPM but below the low reading threshold the reading will be displayed and Change the threshold using V recorded as 0 PMM If the reading rises above the low reading threshold it will be displayed and recorded as the actual PPM reading measured by the unit If you do not wish to change the low reading threshold press ENTER to proceed Press to proceed to the next screen 3 5 11 Run self test The user can switch the unit into a self test mode When in self test the unit shuts all sample zone valves causing the vacuum pump to create a vacuum inside the unit The unit use s an internal air pressure sensor to check adequate Select YES or NO V vacuum can be produced The system will proceed to the next screen T following selection Note The unit will automatically enter a 10 20 second self TUR test cycle once every 24 hours 3 5 12 More changes The last screen in the system setup menu asks the user if they would like to make more changes to the system setup Selecting YES returns the user to the Change Select YES or NO V admin password screen Selecting NO returns the user to the Status overview screen The system will proceed to the next screen following selection 23 3 6 Manual override menu The manual override me
33. te It is advised that when naming channels the sample zone number is always included within the name 3 8 2 Change refrigerant type The refrigerant type that should be detected maybe setup by the user Each unit is able to detect three different types of refrigerant each sample zone maybe setup to detect one of these three refrigerants A sample zone may also be set to GENERIC at this setting all three refrigerants maybe detected by a sample zone however the accuracy will be less If you do not wish to change the refrigerant type press ENTER to proceed 3 8 3 Change leak threshold The sample reading from each zone is compared against a leak threshold if the sample reading is above the leak threshold but below the spill threshold and has been so for number of sample cycles specified in the Leak Alarm Delay variable then a leak alarm will be generated The user is able to setup different leak thresholds for each sample zone If you do not wish to change the leak threshold press ENTER to proceed Note The leak threshold cannot be set higher than the spill threshold Note Pressing the l button will increment the threshold in steps of 25 PPM Pressing the V button will decrement the threshold in steps of 5 PPM 26 Press to proceed to the next screen Input password Press exer to proceed to the next screen Select the zone using
34. terface 1 2 Principle of operation The IR em gas monitoring system uses the principle of Non Dispersive Infrared NDIR absorption to measure refrigerant or ammonia gas concentrations in the atmosphere Most gases absorb Infrared IR light to some extent with different gases absorbing a certain wavelength s of IR light Higher gas concentrations in a certain volume of air mean that more molecules of that gas will be present The greater the number of gas molecules present in the path of an IR light beam the more IR radiation of a certain wavelength will be absorbed Therefore measuring how much IR light of a certain wavelength passes through a sample of air we can determine how much gas of certain type is present in that sample The essential components of the unit are IR Source A source of IR radiation The IR source will actually produce IR radiation at a range of different wavelengths covering the entire Infrared band which extends to visible light IR Filter An optical filter used to select a specific band of IR light centred on a certain wavelength the wavelength for the gas to be measured The unit uses one filter for the gas to be measured and another filter for reference Sample Cell The sample to be measured is transported into a sample cell The windows at each end of the sample cell allow the IR radiation from the IR Source to pass through the sample IR Detector A detector sensitive to IR light wave
35. ting power to the unit cece 11 2 4 oet e tere ath cp o NR ERE Paru RE cs 12 2 5 Exhaust tube Shaye eaaa 13 2 6 Connection Terminals esse 13 2 61 Zone OULPUUS iecsceicetteccteedeceeusn ceived eevicwehsteveesDcacsdecscataaitevsettiercfeerstaveccueninels 14 2 6 2 RS485 Interface 15 26 3 Alarm REA YS te xe aate d erar Ra 15 2 7 Jumper links and DIP 5 16 2 7 1 Woodley Network Mode Settings cccccceeeeeeceeeeeeeeeeeeeeeeaaeeeeeaaaeeeeesaaaeeeeeaas 16 2 7 2 Camero Network Mode Settings cccccseeeeeeeceeeeeeeeeeeeeeeaaeeeeeeaaaeeeeeaaaaeeeeeaas 17 3 User Interface iic 18 3 1 Basic user interface enne enne nnne 18 3 1 2 Entering alphanumeric variables names and passwords etc 18 3 1 3 Inactivity eden aa aaa nn ha ot ERR ERE Pee 18 3 2 System screen layout eio it peer cg b ea cused e guae ias 19 3 3 Warm m E 20 3 4 SATUS M CERT 20 3 5 5ystemisetup REP RR
36. tion the user may first be prompted to enter a password other keys may also need to be pressed a number of times in order to reach the screen in question ONLY DISPLAYED AFTER WARM UP SCREEN POWER UP UNTIL UNIT IS FULLY OPERATIONAL STATUS OVERVIEW e ENTER V ZONE HISTORICAL DATA FORMAT CHANGE DATE SYSTEM SETUP MANUAL OVERRIDE MENU PASSWORD REQ CHANGE PASSWORD CHANGE SAMPLE PASSWORD REQ MODE CHANGE ADMIN PASSWORD SELECT ZONE CHANGE USER MORE CHANGES PASSWORD YES NO Y N CHANGE ZONE OUTPUT TYPE CHANGE DATE BACK TO STATUS OVERVIEW CHANGE TIME CLEAR LOGS CHANGE ALARM RELAY LED SETUP N Ed RELAY LED DURING LEAK ALARM LOW READING RELAY LED DURING THRESHOLD SPILL ALARM RUN SELF TEST RELAY LED DURING FAULT ALARM MORE CHANGES RELAY STATE YES NO DURING ALARM Y N STATUS OVERVIEW Figure 3 1 System screens OTHER ZONE 1 DATALOG ZONE 2DATA LOG L J3 ZONES ZONE 1 DATALOG ZONE 2DATA LOG ZONE 1 DATALOG ZONE 2DATA LOG ENTER Y Y OTHER READINGS OTHER READINGS ALARM LOG ALARM LOG OTHER ALARMS 19 ZONE SETUP MENU SELECT ZONE PASSW
37. ualified electricians prior to installation Colour coded sample tubes are taken from the unit to the sample point locations such as compressors condensers pressure relief valves cold rooms chilled display cases air conditioning units valve assembly s etc Each sample point must be terminated with an air filter preventing dust and dirt travelling back to the unit A secondary in line filter must be fitted near the unit just before connection to the units manifold protecting the unit from dirt and dust in the event of a damaged or missing end of line air filter Connections are then made to optional secondary equipment such as alarm beacons auto diallers etc via its outputs and also to a central alarm system via the units RS485 interface if required Figure 2 0 Illustrates a typical application schematic RS485 Connection to central alarm system Outputs to alarm beacons buzzers p auto dialiers Mains Supply other monitoring systems etc In line filter Sampling of air at Plant equipment Refrigerators Cold store Sample tubing evaporators Air Conditioning Waters Chillers etc Figure 2 0 Schematic of typical application 2 1 Mounting the unit The unit should be mounted in a location where ambient conditions are within the specified operating range for the unit Temperature range 5 C to 40 C Humidity RH lt 95 non condensing The unit must be secured in an upr
Download Pdf Manuals
Related Search