Detcon TP-700 Manuel utilisateur

INSTRUCTION MANUAL

Detcon Model TP-700

TP-700 Hydrogen Sulfide Sensor

This manual covers the following ranges:

0-20ppm, 0-50ppm, 0-100ppm and 0-200ppm

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 #3150 • Revision 4.1

Model TP-700

Model TP-700 ii

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Model TP-700

Model TP-700 iii

Table of Contents

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

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

1.2 Sensor Electronics Design .................................................................................................................. 1

1.3 Modular Mechanical Design............................................................................................................... 2

1.4 Plug-in Replaceable Sensor ................................................................................................................ 3

2. Installation....................................................................................................................................................4

2.1 ATEX Operational Guidelines for Safe Use....................................................................................... 4

2.2 Sensor Placement................................................................................................................................ 5

2.3 Sensor Contaminants and Interference ............................................................................................... 6

2.4 Mounting Installation.......................................................................................................................... 7

2.5 Electrical Installation .......................................................................................................................... 9

2.6 Field Wiring...................................................................................................................................... 10

2.7 Initial Start Up................................................................................................................................... 12

2.7.1 Initial Operational Tests ............................................................................................................... 13

3. Operation....................................................................................................................................................14

3.1 Programming Magnet Operating Instructions................................................................................... 14

3.2 Operator Interface............................................................................................................................. 15

3.3 Normal Operation ............................................................................................................................. 16

3.4 Calibration Mode (AutoSpan)........................................................................................................... 17

3.5 Program Mode .................................................................................................................................. 19

3.5.1 Navigating Program Mode ........................................................................................................... 19

3.5.2 View Sensor Status....................................................................................................................... 20

3.5.3 Set AutoSpan Level...................................................................................................................... 21

3.5.4 Set Range...................................................................................................................................... 21

3.5.5 Set Serial ID ................................................................................................................................. 22

3.5.6 Set Heater Power .......................................................................................................................... 22

3.5.7 Signal Output Check..................................................................................................................... 23

3.5.8 Restore Factory Defaults .............................................................................................................. 23

3.6 Program Features .............................................................................................................................. 24

3.6.1 Operational Features..................................................................................................................... 24

3.6.2 Fault Diagnostic/Failsafe Features ............................................................................................... 24

4. RS-485 Modbus™ Protocol .......................................................................................................................27

Content Description.............................................................................................................................................27

5. Service and Maintenance............................................................................................................................29

5.1 Calibration Frequency....................................................................................................................... 29

5.2 Visual Inspection .............................................................................................................................. 29

5.3 Condensation Prevention Packet....................................................................................................... 29

5.4 Replacement of Plug-in H2S Sensor ................................................................................................. 29

5.5 Replacement of ITM......................................................................................................................... 30

5.6 Replacement of TP-700 Sensor Assembly........................................................................................ 31

5.7 Replacement of the Bottom Housing................................................................................................ 31

6. Troubleshooting Guide...............................................................................................................................32

7. Customer Support and Service Policy........................................................................................................35

7.1 Warranty Notice................................................................................................................................ 35

8. TP-700 Sensor Warranty............................................................................................................................36

8.1 Plug-in H2S Sensor Warranty ........................................................................................................... 36

8.2 ITM Electronics Warranty................................................................................................................ 36

8.3 Terms & Conditions.......................................................................................................................... 36

9. Appendix ....................................................................................................................................................37

9.1 Specifications.................................................................................................................................... 37

Model TP-700

Model TP-700 iv

9.2 Spare Parts, Sensor Accessories, Calibration Equipment................................................................. 39

10. Revision Log......................................................................................................................................... 40

Table of Figures

Figure 1 ITM Circuit Functional Block Diagram................................................................................................. 2

Figure 2 Sensor Assembly Front View ............................................................................................................... 2

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

Figure 4 TP Plug-in Sensor Cell........................................................................................................................... 3

Figure 5 ATEX Approval Label........................................................................................................................... 4

Figure 6 Outline and Mounting Dimensions (Sensor Assembly only)................................................................. 7

Figure 7 Outline and Mounting Dimensions (Stainless Steel Junction Box)....................................................... 8

Figure 8 Outline and Mounting Dimensions (Aluminum Junction Box)............................................................. 8

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

Figure 10 Typical Installation ............................................................................................................................ 10

Figure 11 Sensor Wire Connections................................................................................................................... 11

Figure 12 Magnetic Programming Tool............................................................................................................. 14

Figure 13 Magnetic Programming Switches...................................................................................................... 14

Figure 14 TP-700 Software Flowchart............................................................................................................... 16

Figure 15 Sensor Assembly................................................................................................................................ 29

Figure 16 Sensor PCB........................................................................................................................................ 32

List of Tables

Table 1 Cross Interference Gases......................................................................................................................... 6

Table 2 Wire Gauge vs. Distance....................................................................................................................... 11

Table 3 Modbus™ Registers.............................................................................................................................. 27

Table 4 Modbus™ Special Registers ................................................................................................................. 28

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 • [email protected]m

Model TP-700

TP-700 Instruction Manual Rev. 4.1 Page 1 of 42

1. Introduction

1.1 Description

Detcon Model TP-700 hydrogen sulfide sensors are non-intrusive “Smart” sensors

designed to detect and monitor H2S in air. Ranges of detection are 0-20ppm, 0-50ppm,

0-100ppm, and 0-200ppm. The sensor features an LED display of current reading, fault

and calibration status. The Sensor 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, called the ITM (Intelligent Transmitter Module).

The ITM includes a four character alpha/numeric LED used to display sensor readings,

and the sensor’s menu driven features when the hand-held programming magnet is used.

Solid State H2S Sensor Technology

The sensor technology is a patented solid-state mixed metal oxide semiconductor.

The sensor consists of two thin films, a temperature sensitive heater film, and a

hydrogen sulfide sensitive sensor film. Both films are deposited on a silicon

microchip by vacuum deposition. The heater film elevates the operating temperature

of the sensorfilm to a level where a good sensitivity and response to hydrogen sulfide

is achieved. The sensor film is a proprietary mixed metal oxide that shows an

extremely stable and dynamic response to hydrogen sulfide gas.

Range of sensitivity is from parts per billion to percent by volume. The rugged

sensor is capable of maintaining its operating characteristics for periods of up to 7-

10 years in most industrial environments and as such, is supported by a 10-year

conditional warranty.

Principle of Operation

Method of detection is by diffusion/adsorption. Air and H2S diffuse through a sintered stainless steel filter

(flame arrestor) and contact the heated surface of the metal oxide sensor film. As hydrogen sulfide gas molecules

react with oxygen ions on the film, there is a decrease in electrical resistance proportional to the gas

concentration. The heater film elevates the temperature of the sensor film creating convection and promoting a

quick response to changing gas concentrations. Electronically, the heater film is used to maintain a constant

temperature of the sensor film enhancing stability and repeatability. The sensor response is reversible and results

in continuous monitoring of ambient air conditions.

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 H2S sensor. Circuit functions include extensive I/O circuit protection, sensor pre-

amplifier, sensor temperature control, on-board power supplies, microprocessor, LED display, magnetic

programming switches, a linear 4-20mA DC output, and a 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

Model TP-700

TP-700 Instruction Manual Rev. 4.1 Page 2 of 42

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.

Figure 1 ITM Circuit Functional Block Diagram

Program Switch #1

LED Display

Program Switch #2

Splash Guard Adapter

Locking Set-Screw

MODEL

TP-700

detcon inc.

S Sensor

Figure 2Sensor Assembly Front View

1.3 Modular Mechanical Design

The Model TP-700 Sensor Assembly is completely modular and is made up of four parts (See Figure 3 for

Assembly Break-away):

1) TP-700 Intelligent Sensor Module (ITM)

2) Field Replaceable Plug-in H2S Gas Sensor

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

and rubber O-Ring’s)

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 TP-700

TP-700 Instruction Manual Rev. 4.1 Page 3 of 42

O-Rings

Splash Guard

Adapter Plug-in Replaceable

H2S Sensor Lens and LED

Display Interconnect

Wires

Housing Bottom

Locking Set-Screw Intelligent Transmitter Module (ITM)

Micro-processor controlled circuit

encapsulated in an Explosion proof

housing.

Magnetic

Programming

Switches

SplashGuard

MODEL

TP-700

detcon inc.

S Sensor

Figure 3 Sensor Assembly Breakaway

1.4 Plug-in Replaceable Sensor

The Detcon solid-state H2S gas sensor is a field proven, 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 solid state H2S sensor has an

infinite shelf life and is supported by a 10 year, industry-leading warranty.

Figure 4 TP Plug-in Sensor Cell

Model TP-700

TP-700 Instruction Manual Rev. 4.1 Page 4 of 42

2. Installation

2.1 ATEX Operational Guidelines for Safe Use

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

label. Follow all warnings listed on the label.

Figure 5 ATEX Approval Label

2. 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.

3. 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

lockwasher on sensor housing.

4. 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(M3.5 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.

5. 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.

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

Pan-head Machine screw, M3 x 0.56g6h having yield strength ofgreater than 40,000 PSI, typical 80,000

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

7. 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.

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

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

10. These sensors meet EN60079-0:2012, EN60079-1:2007.

M/Y:

S/N:

RATED11

-30VDC, 85mA MAX

T amb = -40° C to +75°C, IP66

0035

KEMA 06ATEX2152X

WARNING: KEEPCOVER TIGHT WHILECIRCUITS

ARE ALIVE. WARNING: UNDERSTANDMANUAL

ORIGIN USA

Model TP-700

TP-700 Instruction Manual Rev. 4.1 Page 5 of 42

2.2 Sensor Placement

Selection of sensor location is critical to the overall safe performance of the product. Five 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) Additional Placement Considerations

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: H2S is heavier than air.

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.

Maintenance Access

Consideration should be given to providing easy access for maintenance personnel. Consideration should also

be given to the consequences of close proximity to contaminants that may foul the sensor prematurely.

NOTE: In all installations the gas sensor should point straight down (refer to Figure 10).

Improper sensor orientation may result in false readings and permanent sensor damage.

Additional Placement Considerations

The sensor should not be positioned where it may be sprayed or coated with surface contaminating substances.

Painting sensor assemblies is prohibited.

Although the sensor is designed to be RFI resistant, it should not be mounted in close proximity to high-powered

radio transmitters or similar RFI generating equipment.

Model TP-700

TP-700 Instruction Manual Rev. 4.1 Page 6 of 42

When possible mount in an area void of high wind, accumulating dust, rain or splashing from hose spray, direct

steam releases, and continuous vibration. If the sensor cannot be mounted away from these conditions then

make sure the Detcon Harsh Environment Splashguard accessory is used.

Do not mount in locations where temperatures will exceed the operating temperature limits of the sensor. Where

direct sunlight leads to exceeding the high temperature-operating limit, use a sunshade to help reduce

temperature.

2.3 Sensor Contaminants and Interference

Solid State H2S sensors may be adversely affected by exposure to certain airborne substances. Loss of sensitivity

or corrosion may be gradual if such materials are present in sufficient concentrations.

The more common materials that potentially cause problems with the sensors are as follows:

•Silicone vapors such as those found in greases and lubricants

•Halide Compounds containing Chlorine, Chlorine Dioxide, Fluorine, HF, HCl, and Bromine

•Caustic and Acid liquids and concentrated vapors

•Heavy metals such as tetraethyl lead

The presence of such contaminants in an area does not preclude the use of this H2S sensor technology, although

it is likely that the sensor lifetime will be shorter as a result. Use of this sensor in these environments may

require more frequent calibration checks to ensure safe system performance.

Solid State H2S sensors require O2in the background gas and the reading is affected by changing O2 levels.

Interference Data

There are some gases typically found in industrial environments that can cause a cross-interference response on

the sensor. See the Table below for some examples.

Table 1 Cross Interference Gases

GAS PPM GAS PPM

Methane

25,000 = 0

Ammonia

500 = 1

Ethane

5,000 = 0

Diesel Fuel

1000 = 0

Hexane

5,000 = 0

Dimethyl Sulfide

4.4 = 0

Propane

5,000 = 0

Ethylene

200 = 0

Butane

5,000 = 0

Freon 12

1,000 = 0

Carbon Monoxide

800 = 0

Hydrogen

1,000 = 8

Carbon Dioxide

5,000 = 0

Methyl Mercaptan

10 = 5

Carbon Disulfide

14 = 0

Sulfur Dioxide

300 = 0

Methanol

500 = 5

Toluene

32 = 0

Isopropanol

500 = 3

Ethanol

500 = 5

NOTE: The Detcon MOS Sensor Cell can be damaged to the point of non-functioning if the

unit is left off power and in the presence normal air levels of moisture for periods exceeding 8

hours.

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