Detcon FP-700 Manuel utilisateur

INSTRUCTION MANUAL

Detcon Model FP-700

FP-700 Combustible Gas Sensor

0-100% LEL

0-50% LEL

DETCON, Inc.

4055 Technology Forest Blvd.,

The Woodlands, Texas 77381

Ph.281.367.4100 / Fax 281.298.2868

www.detcon.com

June 05, 2018 • Document #3168 • Revision 5.1

Model FP-700

Model FP-700 ii

This page left intentionally blank

Model FP-700

Model FP-700 iii

Table of Contents

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

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

1.2 Sensor Electronics Design .................................................................................................................. 2

1.3 Modular Mechanical Design............................................................................................................... 3

1.4 Plug-in Replaceable Sensor ................................................................................................................ 4

2. Installation....................................................................................................................................................5

2.1 Operational Guidelines for Safe Use – HazLoc Certifications........................................................... 5

2.2 Sensor Placement................................................................................................................................ 6

2.3 Sensor Contaminants and Interference ............................................................................................... 7

2.4 Mounting Installation.......................................................................................................................... 8

2.5 Electrical Installation........................................................................................................................ 10

2.6 Field Wiring...................................................................................................................................... 11

2.7 Initial Start Up................................................................................................................................... 13

3. Operation....................................................................................................................................................15

3.1 Programming Magnet Operating Instructions................................................................................... 15

3.2 Operator Interface............................................................................................................................. 16

3.3 Normal Operation ............................................................................................................................. 17

3.4 Calibration Mode (AutoZero and AutoSpan) ................................................................................... 18

3.4.1 AutoZero....................................................................................................................................... 18

3.4.2 AutoSpan...................................................................................................................................... 18

3.5 Program Mode .................................................................................................................................. 20

3.5.1 Navigating Program Mode ........................................................................................................... 21

3.5.2 View Sensor Status....................................................................................................................... 21

3.5.3 Set AutoSpan Level...................................................................................................................... 22

3.5.4 Set Gas Factor............................................................................................................................... 23

3.5.5 Set Cal Factor ............................................................................................................................... 24

3.5.6 Set Serial ID ................................................................................................................................. 25

3.5.7 Set Bridge Voltage........................................................................................................................ 25

3.5.8 Signal Output Check..................................................................................................................... 26

3.5.9 Restore Factory Defaults .............................................................................................................. 26

3.6 Program Features .............................................................................................................................. 27

3.6.1 Operational Features..................................................................................................................... 27

3.6.2 Fault Diagnostic/Failsafe Features ............................................................................................... 28

4. RS-485 Modbus™ Protocol .......................................................................................................................30

Content Description.............................................................................................................................................30

5. Service and Maintenance............................................................................................................................32

5.1 Calibration Frequency....................................................................................................................... 32

5.2 Visual Inspection .............................................................................................................................. 32

5.3 Condensation Prevention Packet....................................................................................................... 32

5.4 Replacement of Plug-in Combustible Gas Sensor............................................................................ 33

5.5 Replacement of ITM......................................................................................................................... 33

5.6 Replacement of FP-700 Sensor Assembly........................................................................................ 34

6. Troubleshooting Guide...............................................................................................................................35

7. Customer Support and Service Policy........................................................................................................38

8. FP-700 Sensor Warranty ............................................................................................................................39

9. Appendix ....................................................................................................................................................40

9.1 Specifications.................................................................................................................................... 40

9.2 Spare Parts, Sensor Accessories, Calibration Equipment................................................................. 43

10. Revision Log..........................................................................................................................................44

Model FP-700

Model FP-700 iv

Table of Figures

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

Figure 2 Wheatstone Bridge................................................................................................................................. 2

Figure 3 Response Curves.................................................................................................................................... 2

Figure 4 ITM Circuit Functional Block Diagram................................................................................................. 3

Figure 5 Sensor Assembly Front View ................................................................................................................ 3

Figure 6 Sensor Assembly Breakaway................................................................................................................. 4

Figure 7 FP Replaceable Sensor Cell................................................................................................................... 4

Figure 8 HazLoc Certification Approval Label.................................................................................................... 5

Figure 9 Outline and Mounting Dimensions (Sensor Assembly only)................................................................. 8

Figure 10 Outline and Mounting Dimensions (Stainless Steel Junction Box)..................................................... 9

Figure 11 Outline and Mounting Dimensions (Aluminum Junction Box)........................................................... 9

Figure 12 Outline and Mounting Dimensions (Mini Stainless Steel Junction Box) .......................................... 10

Figure 13 Typical Installation ............................................................................................................................ 11

Figure 14 Sensor Wire Connections................................................................................................................... 13

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

Figure 16 Magnetic Programming Switches...................................................................................................... 15

Figure 17 FP-700 Software Flowchart............................................................................................................... 17

Figure 18 Sensor Assembly................................................................................................................................ 32

Figure 19 Plug-in Sensor (Bottom View)........................................................................................................... 35

List of Tables

Table 1 Wire Gauge vs. Distance....................................................................................................................... 12

Table 2 Gas/Cal Factors ..................................................................................................................................... 24

Table 3 Modbus™ Registers.............................................................................................................................. 30

Table 4 Modbus™ Special Registers ................................................................................................................. 31

Shipping Address: 4055 Technology Forest Blvd., 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 • sales@detcon.com

Model FP-700

FP-700 Instruction Manual Rev. 5.1 Page 1 of 46

1. Introduction

1.1 Description

Detcon Model FP-700 combustible gas sensors are non-intrusive “Smart” sensors

designed to detect and monitor combustible gases in air. Range of detection is 0-100%

LEL or 0-50% LEL. The sensor features an LED display of current reading, fault and

calibration status. The unit is equipped with standard analog 4-20mA and Modbus™ RS-

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

guides the user through each step via fully scripted instructions displayed on the LED

display.

The microprocessor-supervised electronics are packaged in an encapsulated module and

housed in an explosion proof casting. The unit includes a 4 character alpha/numeric LED

used to display sensor readings, and the sensor’s menu driven features when the hand-held

programming magnet is used.

Catalytic Bead (Pellistor) Sensor Technology

The sensor technology is a poison-resistant catalytic bead type. Catalytic bead sensors show a strong response

to a long list of combustible gases. The sensor is supplied as a matched-pair of detector elements mounted in a

plug-in replaceable module. One bead is a catalytically active detector and the other is a non-active reference

detector. Each detector consists of a fine platinum wire coil embedded in aluminum oxide. A catalytic mixture

is applied to the active detector while the reference detector is treated so that oxidation of the gas does not occur.

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

catalytic bead sensors are specifically designed to be resistant to poisons such as sulfides, chlorides, and

silicones. The sensors are characteristically stable and capable of providing reliable performance for periods

exceeding 5 years in most industrial environments.

Figure 1 Sensor Cell Construction

Principle of Operation

Method of detection is by diffusion/adsorption. Air and combustible gases pass through a sintered stainless steel

filter and contact the heated surface of both the active and reference detectors. The surface of the active detector

promotes oxidation of the combustible gas molecules while the reference detector has been treated not to support

this oxidation. The reference detector serves as a means to maintain zero stability over a wide range of

temperature and humidity.

When combustible gas molecules oxidize on the surface of the active detector, heat is generated, and the

resistance of the detector changes. Electronically, the detectors form part of a balanced bridge circuit. As the

active detector changes in resistance, the bridge circuit unbalances. This change in output is conditioned by the

amplifier circuitry, which is an integral part of the sensor design. The response and clearing characteristics of

the sensor are rapid and provide for the continuous and accurate monitoring of ambient air conditions.

Main Housing Insert

Printed Circuit Board

Gold Plated Pins

Platinum Wire

Construction

of Detector

Bead

Catalyst

Alumina Bead Catalytic Beads

Model FP-700

FP-700 Instruction Manual Rev. 5.1 Page 2 of 46

Figure 2 Wheatstone Bridge

Performance Characteristics

The detector elements maintain good sensitivity to combustible gas concentrations in the Lower Explosive Limit

(LEL) range, as shown in the response curves in Figure 3. However, for gas concentrations significantly above

the LEL range (100% LEL = 5% by volume Methane), the bridge output begins to decrease. Ambiguous

readings above the LEL range dictate that alarm control logic be of the latching type, wherein alarms are held

in the “ON” position until reset by operations personnel.

Figure 3 Response Curves

1.2 Sensor Electronics Design

Intelligent Sensor 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 extensive I/O circuit protection,

sensor pre-amplifier, bridge voltage (temperature) control, on-board power supplies, microprocessor, LED

display, magnetic programming switches, linear 4-20mA DC output, and Modbus™ RS-485 output. Magnetic

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

tool, thus allowing non-intrusive operator interface with the ITM. Calibration can be accomplished without

declassifying the area. Electrical classifications are Class I, Division 1, Groups B C D, Class I, Zone 1, Group

IIB+H2and II 2G Ex d IIB+H2Gb.

Sensor

Cell

Zero

Adjust

Output

Input

Voltage

Compensator /

Reference Bead

Detector /

Active Bead

Model FP-700

FP-700 Instruction Manual Rev. 5.1 Page 3 of 46

Figure 4 ITM Circuit Functional Block Diagram

Program Switch #1

LED Display

Program Switch #2

Splashguard Adapter

Lockdown Set-Screw

detcon inc.

LEL Sensor

MODEL

FP-700

Figure 5 Sensor Assembly Front View

1.3 Modular Mechanical Design

The Model FP-700 Sensor Assembly is completely modular and made up of four parts (See Figure 6 for

Assembly Break-away):

1) FP-700 Intelligent Transmitter Module (ITM)

2) Field Replaceable Plug-in Combustible Gas Sensor

3) Model 700 Housing Bottom Assembly (contains the Housing Bottom, Flame Arrestor, Retaining Ring,

and rubber O-Rings)

4) Splash Guard.

NOTE: All metal components are constructed from electro-polished 316 Stainless Steel in order to maximize

corrosion resistance in harsh environments.

I/O

Circuit

Protection

RS-485

4-20mA

Display

Micro-

Processor

Temperature

Control

Pre-Amp

Analog 4-20mA Out

Modbus™ RS-485 Output

Power In

Power Supply

Plug-In

Sensor

Element

Model FP-700

FP-700 Instruction Manual Rev. 5.1 Page 4 of 46

Housing Bottom

Locking Set-Screw

Splash Guard

O-Rings

Intelligent Transmitter Module

(ITM) Microprocessor controlled

circuit encapsulated in an

explosion proof housing

Splashguard

Adapter Plug-In replaceable

H2S Sensor

Magnetic

Programming

Switches

Lens and LCD

Display Interconnect

Wiring

detcon inc.

LEL Sensor

MODEL

FP-700

Figure 6 Sensor Assembly Breakaway

1.4 Plug-in Replaceable Sensor

The Detcon combustible gas sensor is a poison-resistant and field proven design. It is packaged as true plug-in

replaceable type sensor with over-sized gold-plated connections that eliminate corrosion problems. It can be

accessed and replaced in the field very easily by releasing the locking screw and unthreading the housing bottom.

The Detcon combustible gassensor has an infinite shelf life, and is supported by a 2-year warranty. The expected

service life is 3-5 years.

Figure 7 FP Replaceable Sensor Cell

Caution: Hazardous areas must be declassified before removing and/or replacing the

plug in sensor

Model FP-700

FP-700 Instruction Manual Rev. 5.1 Page 5 of 46

2. Installation

2.1 Operational Guidelines for Safe Use – HazLoc Certifications

1. It is recommended for end-users to read and reference the procedures described in IEC 60079-29-2 for

guidance on the proper installation, operation, and servicing of this type of combustible gas detectors.

2. Install sensor only in areas with classifications matching with those described on the ATEX approval

label. Follow all warnings listed on the label.

3. Detector is performance tested to ANSI/UL 12.13.01:2013 Performance Requirements of Detectors for

Flammable Gases. Performance Testing was completed by CSA Group on March 28, 2018. This Model

FP-700 detector is performance tested only for methane gas measurement in the 0-100 % LEL (0-5%

by volume) range and with use of Accessory PN 613-120000-700 Sensor Splashguard with integral Cal

Port. There are no special conditions for use other than what is specified here in Section 2.1 of

Instruction Manual.

Figure 8 HazLoc Certification Approval Label

4. Ensure that the sensor is properly threaded into a suitable flameproof rated junction box with a

downward pointing female ¾” NPT threaded connection. The sensor should be threaded up at least 5

full turns until tight, with the LED display facing forward (+/-15°). Minimize use of Teflon Tape, or

any type of non-conductive pipe thread coating on the NPT threaded connection.

5. A good ground connection should be verified between the sensor’s metal enclosure and the junction

box. If a good ground connection is not made, the sensor can be grounded to the junction box using the

sensor’s external ground lug. Also verify a good ground connection between the junction box and earth

ground. Installer shall use ring terminal to make connection to earth ground to be secured by screw and

lock washer on sensor housing.

6. Ensure that the Housing Bottom and plug-in sensor are installed during operation. The Housing Bottom

should be threaded tightly to the Intelligent Transmitter Module. The locking setscrew (M3 x 0.6 6g6h

Stainless Steel Allen set screw cup point with yield strength of greater than 40,000 PSI, typical 80,000

PSI) should then be tightened down to keep the Housing Bottom from being inadvertently removed or

from becoming loose under vibration. The locking setscrew ensures that Housing Bottom is only

removable by authorized personnel with the use of special tools. A M1.5 Allen Wrench is required. If

screw requires replacement, only an identical screw may be used.

7. Removal of the Housing Bottom violates the Ex d protection method and hence power must be removed

from the sensor prior to its safe removal.

Model FP-700

FP-700 Instruction Manual Rev. 5.1 Page 6 of 46

8. The screws holding down the retaining plate label are special fasteners of type Stainless Steel Phillips

Pan-head Machine screw, M3 x 0.5, 6g6h having yield strength of greater than 40,000 PSI, typical

80,000 PSI. If screw requires replacement, only an identical screw may be used.

9. Proper precautions should be taken during installation and maintenance to avoid the build-up of static

charge on the plastic components of the sensor. These include the splashguard and splashguard adapter.

10. Do not operate the sensor outside of the stated operating temperature limits.

11. Do not operate the sensor outside the stated operating limits for voltage supply.

12. These sensors meet EN60079-0:2012:A1:2013, EN60079-1:2007.

2.2 Sensor Placement

Selection of sensor location is critical to the overall safe performance of the product. Seven factors play an

important role in selection of sensor locations:

(1) Density of the gas to be detected

(2) Most probable leak sources within the industrial process

(3) Ventilation or prevailing wind conditions

(4) Personnel exposure.

(5) Maintenance access.

(6) Personal Exposure.

(7) Oxygen is required in the background gas

Density

Placement of sensors relative to the density of the target gas is such that sensors for the detection of heavier than

air gases should be located within 4 feet of grade as these heavy gases will tend to settle in low lying areas. For

gases lighter than air, sensor placement should be 4-8 feet above grade in open areas or in pitched areas of

enclosed spaces.

NOTE: Methane and Hydrogen are lighter than air. Most other combustible gases are heavier

than air. Compare the molecular weight, density, or specific gravity of the target gas(es) with

that of air to determine appropriate placement.

Leak Sources

The most probable leak sources within an industrial process include flanges, valves, and tubing connections of

the sealed type where seals may either fail or wear. Other leak sources are best determined by facility engineers

with experience in similar processes.

Ventilation

Normal ventilation or prevailing wind conditions can dictate efficient location of gas sensors in a manner where

the migration of gas clouds is quickly detected.

Personnel Exposure

The undetected migration of gas clouds should not be allowed to approach concentrated personnel areas such as

control rooms, maintenance or warehouse buildings. A more general and applicable thought toward selecting

sensor location is combining leak source and perimeter protection in the best possible configuration.

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