Intec Controls PolyGard AT-3300 V3 Manuel utilisateur

Customer Services (858) 578-7887 & (888) GO INTEC

INTEC Controls, 12700 Stowe Dr., Suite 110, Poway, CA 92064

Fax (858) 578-4633 & (888) FX INTEC

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Specication subject to change without notice.

Printed in USA 150313

March 13, 2015 – Revision

Polygard® is a registered trademark of MSR AT-3300_V3_UserManual

PolyGardAT-3300 V3

Transmitter for Combustible Gases

Serial No. ET03-002

User Manual

April 2009

12700 Stowe Drive, Suite 100, Poway, CA 92064 | Ph: (858) 578.7887 & (888) GO.INTEC | relevantsolutions.com/inteccontrols

Polygard® is a registered trademark of MSR | AT-3300_V3_UserManual

January 04, 2016 – Revision

Printed in USA 150313

Page 02

1Intended Use...............................................................................................................................3

2Functional Description .........................................................................................................3

2.1 Control Mode.............................................................................................................................3

2.2 Sensor .......................................................................................................................................3

3 Installation....................................................................................................................................4

3.1 Mounting Instructions ................................................................................................................4

3.2 Installation .................................................................................................................................4

4Electrical Connection ............................................................................................................5

4.1 Wiring Connection .....................................................................................................................5

5Commissioning .........................................................................................................................5

5.1 Calibration .................................................................................................................................6

5.1 Manual Calibration ....................................................................................................................6

5.1.1 Zero-point...............................................................................................................................6

5.1.2 Gain .......................................................................................................................................6

5.1.3 Calculation of Control Voltage ...............................................................................................6

5.2 Calculation calibration gas < >target gas (backup calibration) .................................................7

Cross-sensitivity data AT-34XX V3.....................................................................................................7

5.3 Option Relay Output..................................................................................................................8

6Inspection and Service.........................................................................................................9

6.1 Inspections ................................................................................................................................9

6.2 Calibration .................................................................................................................................9

6.3 Exchange of Sensor Element....................................................................................................9

7Troubleshooting .......................................................................................................................9

7.1 Analog Mode .............................................................................................................................9

8Technical Data .........................................................................................................................10

9 Figures..........................................................................................................................................11

10 Notes and General Information...................................................................................14

10.1 Intended Product Application...............................................................................................14

10.2 Installers’ Responsibilities ...................................................................................................14

10.3 Maintenance ........................................................................................................................14

10.4 Limited Warranty..................................................................................................................14

Speciﬁcations subject to change without notice. | USA 151203 | Page 2of 14

12700 Stowe Drive, Suite 100, Poway, CA 92064 | Ph: (858) 578.7887 & (888) GO.INTEC | relevantsolutions.com/inteccontrols

AT-3300_V3 – UserManual

Polygard® is a registered trademark of MSR | AT-3300_V3_UserManual

Printed in USA 150313

Page 03

Transmitter with cathalytic bead sensor for combustible gases and vapours

1 Intended Use

The PolyGard gas transmitter with digital processing of the measuring values and temperature compensation

is used for the continuous monitoring of the ambient air to detect the presence of combustible gases and

vapours, such as natural gas, methane, propane, butane and ammonia etc. below the lower explosion limit

(LEL). The transmitter is used for monitoring leakages in gas pipes, gas fan heaters, gas heating systems, gas

engines (block heating stations), gas boilers, gas fittings, gas transfer stations, gas valves, natural-gas fuelling

stations, domestic gas boiler installations, gas operated vehicles in underground car parks etc.

The intended sites are all areas being directly connected to the public low voltage supply, e.g. residential,

commercial and industrial ranges as well as small enterprises (according to EN50 082).

The PolyGard® AT-33XX transmitter must not be used in potentially explosive atmospheres.

2 Functional Description

2.1 Control Mode

Analog mode:

The analog output can be selected as current signal with (0)4-20 mA or as voltage signal (0)2-10 V.

2.2 Sensor

The integrated sensor works according to the catalytic bead principle. The ambient air being monitored diffuses

through a sintered metal disk into the sensor. Here the combustible gases and vapours are burned by catalytic

means at a heated detector element (pellistor). The resulting combustion heat also heats up the detector

element. This heating changes the resistance of the detector element which is proportional to the partial

pressure of the combustible gases.

In addition to the catalytic detector element, the sensor also has a similarly heated inactive compensator

element. Both elements are part of a Wheatstone measuring bridge. Environmental influences such as

temperature, ambient moisture or thermal conductivity of the monitored ambient air affect both elements to the

same extent so that the influences on the measuring signal are almost completely compensated.

The integrated measuring amplifier converts this sensor current into a linear output signal. The zero point

(Zero) and the amplification (Gain) are calibrated by potentiometers.

Speciﬁcations subject to change without notice. | USA 151203 | Page 3of 14

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Printed in USA 150313

Page 04

Certain substances and gases in the monitored ambient can affect the sensitivity of the sensor, or poison the

sensor completely.

The following are currently known:

- polymerising substances, such as ethylene oxide, acrylonitrile, butadiene, styrene, silicone.

- corrosive substances, such as halogenated hydrocarbons.

- catalytic poisons, such as sulphur and phosphor compounds, silicon compounds, metal vapours.

Caution:

There is a small quantity of corrosive liquid in the sensor element. If in case of damage a person or an area

comes in contact with the liquid, the affected person or area must wash the liquid off with water immediately.

Out of use sensors must be disposed in the same way as batteries.

3 Installation

Note:

Avoid any force (e.g. by thumb) on the sensor element during operation or installation. Electronics can be

destroyed by static electricity. Therefore, do not touch the equipment without a wrist strap connected to ground

or without standing on a conductive floor (acc. to DIN EN100015).

3.1 Mounting Instructions

When choosing the mounting site please pay attention to the following:

• The mounting height depends on the gas type to be monitored.

For gases and vapours with a density >air, the transmitter must be located near the ground.

For gases and vapours with a density < air, the transmitter must be located at the highest point

possible. Gas density and mounting height can be read from the table Cross-sensitivity data.

• Choose mounting location of the sensor according to the local regulations.

• Consider the ventilation conditions! Do not mount the transmitter in the centre of the airflow (air

passages, suction holes).

• Mount the transmitter at a location with minimum vibration and minimum variation in temperature

(avoid direct sunlight).

• Avoid locations where water, oil etc. may influence proper operation and where mechanical damage

might be possible.

• Provide adequate space around the sensor for maintenance and calibration work.

Duct mounting

• Mount only in a straight section of duct with minimum air vortex. Keep a minimum distance of 1 m (3,5

feet) from any curve or obstacle.

• Mount only in a duct system with a maximum air velocity of 10 m/s (2000 ft/min) or less.

• Mounting must be performed so that the probe openings are in line with the airflow.

3.2 Installation

• Open the cover. Unplug basic PCB carefully from the bottom part.

• Fix bottom part by screws vertically to the wall (terminal blocks to the ground).

• Plug in the basic PCB at X4 and X5 with care. Replace the cover.

Speciﬁcations subject to change without notice. | USA 151203 | Page 4of 14

12700 Stowe Drive, Suite 100, Poway, CA 92064 | Ph: (858) 578.7887 & (888) GO.INTEC | relevantsolutions.com/inteccontrols

AT-3300_V3 – UserManual

Polygard® is a registered trademark of MSR | AT-3300_V3_UserManual

Printed in USA 150313

Page 05

4 Electrical Connection

Consider static electricity! See 3. Mounting

• Installation of the electrical wiring should only be performed by a trained specialist according to the

connection diagram, without any power applied to conductors and according to the corresponding

regulations!

• Avoid any influence of external interference by using shielded cables for the signal line, but do not

connect the shield.

• Recommended cable analog mode: (20 AWG), max. res. 73 Ω/km (20.8 Ω/1000 ft).

• It is important to ensure that the wire shields or any bare wires do not short the mounted PCB.

4.1 Wiring Connection

• Open the cover. Unplug basic PCB carefully from terminal blocks at X4 and X5.

• Insert the cable, connect cable leads to terminal blocks. See fig. 1 and 2.

• Replug the PCB in the terminal blocks X4, X5. Replace cover.

5 Commissioning

Consider commissioning instructions at any exchange of sensor elements.

Only trained technicians should perform the following:

• Check mounting location.

• Select output signal form: Current or voltage, and starting point 0 or 20%. See fig. 4.

• Check power voltage.

• Check PCB AT-33XX V3 for proper mounting at X4 and X5.

• Check the sensor for proper mounting at the connectors X8 of the PCB AT-33XX V3 (only AT-34XX

V3).

• Calibrate the transmitter (if not already factory-calibrated).

Required instruments for commissioning (calibration) of the transmitter:

• Test gas bottle with synthetic air (20 % O2, 80 % N).

• Test gas bottle with test gas (methane etc.) in the range of 30 – 60 % of the measuring range.

• Gas pressure regulator with flow meter to control the gas flow to 150 ml/min.

• Calibration adapter with tube, (silicon-free, e.g. Viton). Calibration set CALKIT-AT. See fig. 06.

• Digital voltmeter with range 0 – 10VDC, accuracy 1% and a small screwdriver.

Note: Prior to calibration the sensor element must be fully stabilized by applying power voltage for at least 4

hour without interruption.

Please observe proper handling procedures for test gas bottles (regulations TRGS 220)!

Attention: Combustible calibration gases are toxic, never inhale the gas!

Symptoms: Dizziness, headache and nausea.

Procedure if exposed: Take the victim into fresh air at once, call a doctor.

Speciﬁcations subject to change without notice. | USA 151203 | Page 5of 14

12700 Stowe Drive, Suite 100, Poway, CA 92064 | Ph: (858) 578.7887 & (888) GO.INTEC | relevantsolutions.com/inteccontrols

AT-3300_V3 – UserManual

Polygard® is a registered trademark of MSR | AT-3300_V3_UserManual

Printed in USA 150313

Page 06

5.1 Calibration

Depending on the version and the control mode there are three different possibilities to calibrate the

transmitter:

5.1 Manual Calibration

5.1.1 Zero-point

• Connect calibration adapter carefully to the sensor element.

• Apply synthetic air (150 ml/min; 1 Bar (14.5 psi ) ± 10%).

• Wait 2 minutes until the signal is stable, push button “Zero” for 5 seconds.

After successful calibration the measuring signal is corrected automatically. Depending on the

selected signal starting point the measuring signal shows the following values:

Signal start at 2 V or 4 mA 40 mV = 0 ppm

Signal start at 0 V or 0 mA 0 mV = 0 ppm

If the zero-point is out of the admissible range (> 20 mV at starting point 0% / > 60 mV at starting

point (20%) before calibration, there is no correction of the measuring signal. The sensor has to be

replaced.

• Remove calibration adapter carefully by turning lightly. Check the sensor for correct mounting!

5.1.2 Gain

• Connect calibration adapter carefully to the sensor element.

• Apply calibration test gas (150 ml/min; 1 Bar (14.5 psi) ± 10%).

• Wait two minutes until the signal is stable, adjust control voltage with potentiometer ”Gain” until the

signal corresponds to the calculated value ± 3 mV, see calculation section 5.2.3.

• Remove calibration adapter with a careful light turn. Check the sensor for correct mounting!

By limiting the gain factor, calibration will not be possible any more when the sensitivity of the sensor

reaches a residual sensitivity of 30 %. Then the sensor has to be replaced.

5.1.3 Calculation of Control Voltage

Signal start 2 V / 4 mA

Control voltage (mV) = 160 (mV) x test gas concentration (% LEL) + 40 (mV)

measuring range (% LEL)

Signal start 0 V / 0 mA

Control voltage (mV) = 200 (mV) x test gas concentration (% LEL)

measuring range (% LEL)

Speciﬁcations subject to change without notice. | USA 151203 | Page 6of 14

12700 Stowe Drive, Suite 100, Poway, CA 92064 | Ph: (858) 578.7887 & (888) GO.INTEC | relevantsolutions.com/inteccontrols

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Example:

Measuring range 100 % LEL

Test gas concentration 40 % LEL (methane)

Control voltage: Signal start 2 V / 4 mA 104 mV

Control voltage: Signal start 0 V / 0 mA 80 mV

Signal start 2 V / 4 mA Signal start 0 V / 0 mA

160 (mV) x 40 (% LEL) + 40 (mV) = 104 mV 200 (mV) x 40 (% LEL) = 80 mV

100 (% LEL) 100 (% LEL)

5.2 Calculation calibration gas < >target gas (backup calibration)

ÜWGas = KALGas x ( KGas / ÜGas) ÜWGas = Target gas % LEL

KALGas = Calibration gas % LEL

Gas = Factor relative sensitivity % LEL calibration gas

Gas = Factor relative sensitivity % LEL target gas

Example:

Calibration gas 30% LEL/Methane

Target gas Propane

30 % LEL/methane x (100/63) 47.6% LEL/Propane

The factor of the relative sensitivity can be read from the table cross sensitivity data.

Cross-sensitivity data AT-33XX V3

Type of gas/vapour Chemical mark

Sensitivity1%

% LEL/Methane

LEL/

% v/v

Gas Density

Air = 1

Mounting

high

Acetone

(CH3)2CO

2.60

2.00

Floor

Acetylene

C2H2

2.00

0.90

Ceiling

Benzene

C6H6

1.30

2.70

Floor

Cyclohexane

C6H12

1.30

2.91

Floor

Ethylene

CH2

2.30

0.98

Ceiling

Ethane

C2H6

3.00

1.05

Floor

Ethyl Alcohol

C2H5OH

3.30

1.59

Floor

Ethyl Acetate

CH3COOC2H5

2.20

3.04

Floor

Ethylene Oxide

C2H4O

2.60

1.52

Floor

Hydrogen

107

4.00

0.07

Ceiling

JP8 25 0.7

JET_A 46 0.7

Methane CH4100 4.40 0.55 Ceiling

Methanol CH3OH 84 6.70 1.11 Floor

n-Butane C4H10 51 1.80 2.11 Floor

n-Heptane C7H16 44 1.05 3.46 Floor

n-Hexane C6H14 46 1.02 2.98 Floor

n-Octane C8H18 38 0.95 1.66 Floor

Propane C3H863 1.70 1.55 Floor

n-Pentane C5H12 50 1.40 2.49 Floor

1according to information of the sensor manufacturer.

The table does not claim to be complete. Other gases can have an influence on the sensitivity, too.

7KHindicated sensitivity data are only standard values referring to new sensor elements.

Speciﬁcations subject to change without notice. | USA 151203 | Page 7of 14

12700 Stowe Drive, Suite 100, Poway, CA 92064 | Ph: (858) 578.7887 & (888) GO.INTEC | relevantsolutions.com/inteccontrols

AT-3300_V3 – UserManual

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Printed in USA 150313

Page 08

5.3 Option Relay Output

The two relays are activated in dependence of the gas concentration. If the gas concentration exceeds the

adjusted alarm threshold, the corresponding relay switches on. If the gas concentration falls below the

threshold minus hysteresis, the relay switches off again.

The contact function for relay 2, NC (normally closed) or NO (normally open), can be selected via the jumper

NO/NC. See fig 1 and 3. Relay 1 is equipped with a change-over contact.

Via the MODBus interface the two alarm thresholds and the hysteresis are freely adjustable at the PC within

the measuring range. The procedure can be read from the user manual “MODBus Software”.

The following parameters are factory-set.

Alarm threshold 1 = Relay 1: 10 % LEL

Alarm threshold 2 = Relay 2: 20 % LEL

Switching hysteresis: 5 % LEL

Speciﬁcations subject to change without notice. | USA 151203 | Page 8of 14

12700 Stowe Drive, Suite 100, Poway, CA 92064 | Ph: (858) 578.7887 & (888) GO.INTEC | relevantsolutions.com/inteccontrols

AT-3300_V3 – UserManual

Polygard® is a registered trademark of MSR | AT-3300_V3_UserManual

Printed in USA 150313

Page 09

6 Inspection and Service

6.1 Inspections

Inspection, service and calibration of the transmitters should be done by trained technicians and executed at

regular intervals. We therefore recommend concluding a service contract with MSR or one of their authorized

partners.

6.2 Calibration

(See section 5.1 and 5.2)

•At commissioning and at periodic intervals determined by the person responsible for the gas detection

system (recommendation every 12 months).

•After exchange of the sensor

•If in case of operational or climatic influences the sensitivity of the sensor falls below 70 % in

operation, calibration will not be possible any more. Then the sensor has to be changed.

6.3 Exchange of Sensor Element

Consider static electricity! See point 3.

Sensor should always be installed without power applied:

•Unplug basic PCB AT-33XX V3 carefully from the bottom part.

•Unplug old sensor from the PCB.

•Take the new sensor out of the original packing.

•Plug in the sensor element into the PCB ET03 at XB7/XB8.

•Replug the PCB AT-33XX V3 into terminal blocks X4, X5 carefully.

•Calibrate according to section 5.

7 Troubleshooting

7.1 Analog Mode

Trouble Cause Solution

Jumper 0-20 % not set Check jumper position

Power voltage not applied

Measure tension at X4:

Two-wire: Pin 1 (+) and 4 (-)

Three-wire: Pin 1 (+) and 2 (-)

PCB AT-33XX V3 not plugged in

correctly at X4 and X5

Replug PCB correctly

Output signal < 3 mA / 1,5 V

and/or control voltage < 30 mV

only for starting signal 2V/4 mA

Wire break Check the wiring

Output signal > 22 mA /220 mV Short-circuit Check the wiring

Sensor element not calibrated Calibrate sensor element

Control voltage does not reach

the calculated value Sensor sensitivity < 30 % Replace sensor element

Power voltage not applied Measure tension at X4

No reaction of the output signal

in spite of gas concentration Signal (Pin 4) not wired correctly Check the wiring

Speciﬁcations subject to change without notice. | USA 151203 | Page 9of 14

12700 Stowe Drive, Suite 100, Poway, CA 92064 | Ph: (858) 578.7887 & (888) GO.INTEC | relevantsolutions.com/inteccontrols

AT-3300_V3 – UserManual

Polygard® is a registered trademark of MSR | AT-3300_V3_UserManual

Printed in USA 150313

Page 10

8 Technical Data

General sensor performances

Gas type Combustible gases/ vapours

See Ordering Information

Sensor element Ex sensor, catalytic bead

Pressure range Atmosphere ± 20 %

Storage temperature range 5 °C to 30 °C (41 °F to 86 °F)

Storage time Max. 6 months

Mounting height Depending on gas type

AT-33XX V3

Measuring range 0 - 100 % LEL

Detection limit 0,5 % LEL

Accuracy ± 1 % of signal/methane

Repeatability ± 2 % of signal/methane

Long-term zero drift < 5 % measuring range/year

Long-term sensitivity drift < 2 % measuring range/month

Response time t90 < 10 sec./methane

Life expectancy > 3 years/normal operating environment

Temperature range - 10 °C to + 40 °C (14 °F to 104 °F)

Humidity, continuous 15 – 90 % RH non condensing

Humidity, intermitted 0 – 99 % RH non condensing

Electrical

Power supply 16 - 28 VDC/AC, reverse polarity protected

Power consumption (without options) 35 mA, max. (0,85 VA)

Output signal

Analog output signal

Selectable: Current / tension

Starting point 0 / 20 %

(0) 4 – 20 mA, load ≤ 500 Ω,

(0) 2 - 10 V; load ≥ 50 k Ω

proportional, overload and short-circuit proof

Serial interface

Transceiver RS 485 / 19200 Baud

Protocol, depending on version MSR_DT05 or MOD_Bus

Physical

Enclosure* Stainless steel V2A

Enclosure colour* Natural, brushed

Dimensions* (H x W x D) 113 x 135 x 45 mm /(5.35 x 4.5 x 1.8 in.)

Weight* Approx. 0,5 kg (1.1 Ibs.)

Protection class* IP 55

Mounting* Wall mounting, pillar mounting

Cable entry Standard 1 x M 20

Wire connection Screw-type terminal min. 0,25, to. 2,5 mm2

24 to 14 AWG

Wire distance Current signal ca. 500 m (1500 ft.)

Voltage signal ca. 200 m (500 ft.)

Speciﬁcations subject to change without notice. | USA 151203 | Page 10 of 14

12700 Stowe Drive, Suite 100, Poway, CA 92064 | Ph: (858) 578.7887 & (888) GO.INTEC | relevantsolutions.com/inteccontrols

AT-3300_V3 – UserManual

Polygard® is a registered trademark of MSR | AT-3300_V3_UserManual

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