Detcon CXT-IR Manuel utilisateur

Model CXT-IR

Operator’s Installation and Instruction Manual

Covers all Model CXT-IR Sensors

DETCON, Inc.

4055 Technology Forest Blvd, Suite 100

The Woodlands, Texas 77381

Ph.281.367.4100 / Fax 281.298.2868

www.detcon.com

June 13, 2018 • Document # 3822 • Revision 2.1

Model CXT-IR

Model CXT-IR ii

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Model CXT-IR

Model CXT-IR iii

Table of Contents

Introduction ................................................................................................................................................. 1

1.1 Description.......................................................................................................................................... 1

1.2 Modular Design .................................................................................................................................. 3

1.2.1 CXT-IR Intelligent Transmitter Module ........................................................................................ 3

1.2.2 Field Replaceable Sensor................................................................................................................ 4

1.3 CXT Wireless Network....................................................................................................................... 5

1.4 Battery Pack Options .......................................................................................................................... 5

1.4.1 Detconꞌs Smart Battery Pack .......................................................................................................... 5

1.4.2 D Cell Lithium Battery Pack .......................................................................................................... 7

1.4.3 Tri-C Lithium Battery Pack............................................................................................................ 8

Installation................................................................................................................................................... 9

2.1 Hazardous Locations Installation Guidelines for Safe Use................................................................. 9

2.2 Sensor Placement.............................................................................................................................. 10

2.3 Sensor Contaminants and Interference ............................................................................................. 12

2.4 Sensor Mounting............................................................................................................................... 12

2.5 Electrical Installation........................................................................................................................ 15

2.5.1 Applying Power to the Unit.......................................................................................................... 15

2.6 Initial Start Up................................................................................................................................... 17

2.6.1 Combustible Gas Sensors............................................................................................................. 17

Operation ................................................................................................................................................... 18

3.1 Operator Interface............................................................................................................................. 19

3.2 Normal Operation ............................................................................................................................. 20

3.3 Calibration Mode.............................................................................................................................. 20

3.3.1 AutoZero....................................................................................................................................... 21

3.3.2 AutoSpan...................................................................................................................................... 21

3.4 Program Mode .................................................................................................................................. 23

3.4.1 Navigating Program Mode ........................................................................................................... 23

3.4.2 View Sensor Status....................................................................................................................... 24

3.4.3 Set Gas Type................................................................................................................................. 26

3.4.4 Set AutoSpan Level...................................................................................................................... 26

3.4.5 Set Gas Factor............................................................................................................................... 26

3.4.6 Bump Test .................................................................................................................................... 28

3.4.7 Restore Defaults ........................................................................................................................... 28

3.4.8 Set RF Channel............................................................................................................................. 28

3.4.9 Alarm Settings.............................................................................................................................. 29

3.4.10 Set Modbus ID ......................................................................................................................... 29

3.5 Fault Diagnostic/Failsafe Feature ..................................................................................................... 29

Modbus™ TM Communications............................................................................................................... 30

4.1 General Modbus™ Description ........................................................................................................ 30

4.1.1 Modbus™ Exceptions .................................................................................................................. 30

4.1.2Modbus™ Broadcast Requests..................................................................................................... 31

4.2 Modbus™ Register Map and Description......................................................................................... 31

4.2.1 CXT Sensor Registers .................................................................................................................. 33

4.2.2 CXT Transceiver Registers .......................................................................................................... 34

Service and Maintenance........................................................................................................................... 36

5.1 Replacement of the Batteries/Battery Pack....................................................................................... 36

5.1.1 Units with 12V Smart Battery Pack.............................................................................................. 36

5.1.2 Units with D-Size Non-Rechargeable Batteries ........................................................................... 36

5.1.3 Units with Tri-‘C’ sized Lithium Battery Holder......................................................................... 38

5.2 Replacement of Plug-in Sensor......................................................................................................... 39

5.3 Replacement of ITM – Aluminum Junction Box.............................................................................. 40

Model CXT-IR

Model CXT-IR iv

5.4 Replacement of ITM – Stainless Steel Mini Condulet...................................................................... 40

Troubleshooting Guide.............................................................................................................................. 41

Customer Support and Service Policy....................................................................................................... 43

CXT-IR Sensor Warranty.......................................................................................................................... 44

Appendix ................................................................................................................................................... 45

9.1 Specifications.................................................................................................................................... 45

9.1.1 System Specifications................................................................................................................... 45

9.1.2 Environmental Specifications....................................................................................................... 45

9.1.3 Electrical Specifications ............................................................................................................... 45

9.1.4 Mechanical Specifications (ITM Only)........................................................................................ 46

9.2 Spare Parts, Sensor Accessories, Calibration Equipment................................................................. 46

9.3 Revision Log..................................................................................................................................... 47

Table of Figures

Figure 1 Sensor Cell Construction ....................................................................................................................... 2

Figure 2 Principle of Operation............................................................................................................................ 2

Figure 3 Sensor Assembly Breakaway................................................................................................................. 3

Figure 4 ITM Circuit Functional Block Diagram................................................................................................. 4

Figure 5 Sensor Assembly Front View ................................................................................................................ 4

Figure 6 Plug-in Sensor........................................................................................................................................ 4

Figure 7 Smart Battery Pack ................................................................................................................................ 6

Figure 8 Quad Battery Charger ............................................................................................................................ 6

Figure 9 D-Cell Lithium Battery Pack ................................................................................................................. 7

Figure 10 Tri C Lithium Battery Holder .............................................................................................................. 8

Figure 11 Approval Labels................................................................................................................................... 9

Figure 12 CXT-IR Sensor with D or Smart Battery Pack Mounting Dimensions ............................................. 13

Figure 13 CXT-IR Sensor with C-Cell Batteries ............................................................................................... 14

Figure 14 Terminal Interconnect for Smart Battery Pack .................................................................................. 16

Figure 15 Magnetic Programming Tool............................................................................................................. 18

Figure 16 Magnetic Programming Switches...................................................................................................... 18

Figure 17 Menu Flow Chart............................................................................................................................... 20

Figure 18 Modbus™ Frame Format................................................................................................................... 30

Figure 19 Battery Orientation Diagram.............................................................................................................. 37

Figure 20 Battery Orientation Diagram.............................................................................................................. 38

Figure 21 Sensor Cell and ITM Mating ............................................................................................................. 39

List of Tables

Table 1 Gas Factors............................................................................................................................................ 27

Table 2 Exception Codes.................................................................................................................................... 31

Table 3 CXT-IR Register Map........................................................................................................................... 32

Table 4 Spare Parts, Sensor Accessories, and Calibration Equipment............................................................... 46

Table 5 Revision Log......................................................................................................................................... 47

Shipping Address: 4055 Technology Forest, Suite 100, The Woodlands, Texas 77381

Mailing Address: P.O. Box 8067, The Woodlands Texas 77387-8067

Phone: 888.367.4286, 281.367.4100 • Fax: 281.292.2860 •www.detcon.com •

Model CXT-IR

CXT-IR Instruction Manual Rev. 2.1 Page 1 of 48

Introduction

1.1 Description

Detcon Model CXT-IR combustible gas sensors are non-intrusive “Smart” sensors designed to

detect and monitor combustible hydrocarbon gases in the air with a detection range of 0-100%

LEL (Lower Explosive Limit). The sensor features an LED display of current reading, fault and

calibration status. A primary feature of the sensor is its method of automatic calibration, which

guides the user through each step via fully scripted instructions illustrated on the LED display.

The microprocessor-supervised electronics are enclosed in an encapsulated module and housed

in an explosion proof casting.

The unit includes:

•a built in 2.4GHz radio to transmit status wirelessly to a controller,

•a four character alpha/numeric LED to display sensor readings, and

•a menu-driven interface when the hand-held programming magnet is in use.

•an optional strobe

Non-Dispersive Infrared (NDIR) Optical Sensor Technology

The sensor technology is designed as a miniature plug-in replaceable component, which can easily be changed

out in the field.

The NDIR sensor consists of (Figure 1):

•one infrared lamp source,

•two pyroelectric detectors (active and reference),

•and one optical gas sample chamber.

The lamp source produces infrared radiation, which interacts with the target gas as it is reflected through the

optical gas sample chamber. The infrared radiation contacts each of the two pyroelectric detectors at the

completion of the optical path. The active pyroelectric detector is covered by a filter specific to the part of the

IR spectrum where the target gas absorbs light. The reference pyroelectric detector is covered by a filter specific

to the non-absorbing part of the IR spectrum. When the target gas is present, it absorbs IR radiation and the

signal output from the active detective decreases accordingly. The reference detector output remains unchanged.

The ratio of the active and reference detector outputs are then used to compute the target gas concentration.

The technique is referred to as non-selective and may be used to monitor most any combustible hydrocarbon

gas. Unlike catalytic bead type sensors, Detcon IR sensors are completely resistant to poisoning from corrosive

gases and can operate in the absence of an oxygen background. The sensors are characteristically stable and

capable of providing reliable performance for periods exceeding 5 years in most industrial environments.

Model CXT-IR

CXT-IR Instruction Manual Rev. 2.1 Page 2 of 48

Figure 1 Sensor Cell Construction

Principle of Operation

The target gas diffuses through a sintered stainless steel flame arrestor and into the volume of the sample gas

optical chamber. An alternating miniature lamp provides a cyclical IR radiation source, which reflects through

the optical gas sample chamber and terminates at the two pyroelectric detectors. The active and reference

pyroelectric detectors each give an output which measures the intensity of the radiation contacting their surface.

The active detector is covered by an optical filter specific to the part of the IR spectrum where the target gas

absorbs light. The reference detector is covered by a filter specific to the non-absorbing part of the IR spectrum.

When present, the target gas absorbs a fraction of the IR radiation and the signal output from the active detector

decreases accordingly. The signal output of the reference detector remains unchanged in the presence of the

target gas. The ratio of the active/reference signal outputs is then used to compute the target gas concentration.

By using the ratio of the active/reference signal outputs, measurement drift caused by the changes in the intensity

of the IR lamp source or changes in the optical path’s reflectivity is prevented (Figure 2).

Figure 2 Principle of Operation

Performance Characteristics

The IR sensor maintains strong sensitivity to most all combustible hydrocarbon gases within the LEL range.

When compared with the typical catalytic bead LEL sensor, the IR sensor exhibits improved long-term zero and

span stability. Typical zero calibration intervals are quarterly to semi-annual and typical span intervals are semi-

annual to annual.

NOTE

Actual field experience is always the best determination of appropriate calibration intervals.

NOTE

The CXT-IR sensor will not respond to combustible gases that are not hydrocarbons, such as

H2, NH3, CO, H2S….etc. It can only be used to measure hydrocarbon type gases.

The IR sensor generates different signal sensitivity levels for different combustible hydrocarbon target gases.

Unless otherwise specified the CXT-IR sensor will be factory calibrated for methane service. If the target

hydrocarbon gas is other than methane, then theunit will have to be span calibrated and configured in accordance

with this CXT-IR sensor instruction manual.

Model CXT-IR

CXT-IR Instruction Manual Rev. 2.1 Page 3 of 48

1.2 Modular Design

The Model CXT-IR Sensor Assembly is completely modular and is made up of four parts (Figure 3)

1) CXT-IR Intelligent Transmitter Module (ITM)

2) Plug-in infrared Sensor

3) CXT Series Bottom Housing

4) Splash Guard

100 Series Bottom

Housing Assembly

Plug-in

Replaceable

Sensor Cell Intelligent Transmitter Module (ITM)

Micro-processor controlled circuit

encapsulated in an Explosion proof

housing.

Magnetic

Programming

Switches

Rain Shield

34" NPT Locking

Nut

Ferrite Bead

Figure 3 Sensor Assembly Breakaway

NOTE

All metal components are constructed from electro polished 316 Stainless Steel in order to

maximize corrosion resistance in harsh environments.

1.2.1 CXT-IR Intelligent Transmitter Module

The Intelligent Transmitter Module (ITM) is a fully encapsulated microprocessor-based package that accepts a

plug-in field replaceable combustible gas sensor.

Circuit functions include (Figure 4):

•extensive I/O circuit protection,

•sensor pre-amplifier,

•on-board power supplies,

•microprocessor,

•LED display,

•magnetic programming switches,

•built-in 2.4GHz radio

Magnetic program switches located on either side of the LED Display are activated by a hand-held magnetic

programming tool, allowing a non-intrusive operator interface with the ITM. The program switches allows

calibration without declassifying the area.

Model CXT-IR

CXT-IR Instruction Manual Rev. 2.1 Page 4 of 48

Figure 4 ITM Circuit Functional Block Diagram

Program Switch #1

LED Display

Program Switch #2

Housing Bottom

Locking Set-Screw

detcon inc.

LEL Sensor

detcon inc.

MODEL

CXT- IR

Figure 5 Sensor Assembly Front View

1.2.2 Field Replaceable Sensor

Detconꞌs infrared gas sensors are field proven, plug-in sensors with over-sized gold-plated connections that

eliminate corrosion problems. The sensor can be accessed and replaced in the field easily by releasing the locking

screw and unthreading the splashguard adapter assembly.

NOTE

Detconꞌs combustible sensors have a long shelf life and are supported by an industry-leading

warranty.

Figure 6 Plug-in Sensor

I/O

Circuit

Protection

Accessory

connections

Antenna

Power In

Wireless

Power

supplies

Micro-

Processor

Intrinsically

Safe Barrier

Plug-In

Sensor

Model CXT-IR

CXT-IR Instruction Manual Rev. 2.1 Page 5 of 48

1.3 CXT Wireless Network

The CXT-IR sensor utilizes a transceiver radio, based on the IEEE 802.15.4 standard. The transceiver operates

at 2.4 GHz using DSSS encoding for robustness. DSSS was initially used by the military to resist jamming but

later was widely adopted for wireless implementations since it was robust in noisy environments. DSSS

transmits data across a wider frequency range than the actual frequency range required for the information. This

operation minimizes cross talk and interference from other transceivers and is less susceptible to noise from

other sources.

The IEEE 802.15.4 defines 16 separate RF Channels that can be used in the 2.4 GHz range. The default channel

is 1 but can be changed if there is RF interference or if there is an existing network using that channel.

Transceivers will only respond to other transceivers with the same RF Channel.

NOTE

If there are multiple CXT-IR networks in the same vicinity, each system must reside on a

different RF Channel to keep data from one appearing on the other system.

The 802.15.4 standard also implements a mesh network allowing any CXT-IR transceiver to relay or repeat data

between adjacent neighbors. This makes the network very robust and provides the following immediate benefits.

•Allows re-routing of data in case of loss of a transceiver

•Allows re-routing around wireless obstacles

•Longer distances between transceivers because data can “hop” from one transceiver to the next

•Included in sensor, controller and alarm station transceivers

•CXT-IR transceivers can be deployed with less concern about physical location.

1.4 Battery Pack Options

The CXT-IR can be powered by a battery pack that enables the IR to be remotely mounted without the need for

external cabling. Detcon offers several battery pack options that are factory installed. Contact Detcon for more

information on these options.

1.4.1 Detconꞌs Smart Battery Pack

The Detcon’s plug-in Smart Battery Packs provides an output of 12VDC (See Figure 7). There are two versions

of the Smart Battery Pack. The first one is the 12V 2200mAh battery Pack (Detcon’s part number 976-0BP303-

120) and the second is the 12V 2900mAh Battery Pack. The CXT-DM monitors the battery pack for remaining

battery life. The battery packs consists of rechargeable Lithium-Ion batteries and are equipped with integrated

safety electronics that include a fuel gauge, voltage monitor, and current and temperature monitoring circuits.

This “smart” circuitry continuously monitors the battery’s condition and reports critical status information to the

wireless transceiver via the Modbus™ registers. The battery packs are designed to plug into an 8-pin Beau

connector on the Terminal Board that the sensor is connected to. The battery Pack and Terminal Board are

housed in Detcon’s Aluminum Condulet to protect them from exposure to outside elements and still provide

Class I Div 1, C, and D approvals. Operating periods before recharge will vary based on sensor attached, but

can be as long as 3.5 months for the 12V 2200mAh battery pack, and 5 months for the 12V 2900mAh battery

pack before battery recharging is required. Improper use of the battery pack may be hazardous to personnel or

the environment and will void the warranty.

Model CXT-IR

CXT-IR Instruction Manual Rev. 2.1 Page 6 of 48

Figure 7 Smart Battery Pack

Quad Battery Charger (Optional)

Detcon’s Smart Battery Pack can be charged as needed using Detcon’s optional Quad Battery Charger which

can charge up to four battery packs at one time. The Quad Battery Charger comes with a plug-in AC/DC adapter

that plugs into a standard 100-240VAC outlet for power. The DC end of the adapter plugs into the DC power

jack of the charger providing 24VDC. The Quad Battery Charger has four charging ports, each with 8-pin Beau

connectors for battery pack connection. The ports and connectors are keyed to prevent incorrect positioning and

connection. Each port has its own “FAULT” LED indicator and “CHARGE” LED indicator and will display

either a red light or green light depending on the status of each battery being charged. Charging times will vary

depending on the charge state of each battery pack, but a full charge of a depleted battery pack can take up to 24

hours.

Figure 8 Quad Battery Charger

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