Detcon TP-524D, Instruction Manual

Page 1: ...roSafe H2S Gas Sensor ALM ALM TM TP 524D Hydrogen Sulfide Sensor This manual covers the following ranges 0 20ppm 0 50ppm and 0 100ppm DETCON Inc 4055 Technology Forest Blvd Suite 100 The Woodlands Texas 77381 Ph 281 367 4100 Fax 281 298 2868 www detcon com June 05 2018 Document 3269 Revision 0 8 ...

Page 2: ...Model TP 524D Model TP 524D ii This page left intentionally blank ...

Page 3: ...3 3 3 Normal Operation 15 3 4 Calibration Mode AutoSpan 15 3 5 Program Mode 17 3 5 1 View Sensor Status 18 3 5 2 Set AutoSpan Level 19 3 5 3 Set Range 20 3 5 4 Set Heater Power 20 3 5 5 Signal Output Check 21 3 5 6 Restore Factory Defaults 21 3 5 7 Alarm 1 and 2 Settings 22 3 5 8 Fault Settings 23 3 6 Program Features 23 3 6 1 Operational Features 23 3 6 2 Fault Diagnostic Failsafe Features 23 4 S...

Page 4: ...igure 8 Typical Installation 8 Figure 9 Sensor Connector PCB 9 Figure 10 Magnetic Programming Tool 12 Figure 11 Magnetic Programming Switches 12 Figure 12 TP 524D Software Flowchart 14 Figure 13 Replaceable H2S Sensor 28 List of Tables Table 1 Cross Interference Gases 6 Table 2 Wire Gauge vs Distance 9 Shipping Address 4055 Technology Forest Blvd Suite 100 The Woodlands Texas 77381 Mailing Address...

Page 5: ...sor s menu driven features when the hand held programming magnet is used PGM 1 PGM 2 MODEL TP 524D HOUSTON TEXAS FLT 1 2 CAL MicroSafe H2S Gas Sensor ALM ALM TM Figure 1 Sensor Assembly Front View 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 ...

Page 6: ... 1 TP 524D Plug in Transmitter 2 Field Replaceable H2S Gas Sensor 3 Connector PCB 4 Splash Guard TP 524D Plug in Transmitter The Plug in Transmitter Module is a microprocessor based package that plugs into the connector board located in the explosion proof junction box Circuit functions include extensive I O circuit protection sensor pre amplifier sensor temperature control on board power supplies...

Page 7: ...s an infinite shelf life and is supported by a 10 year industry leading warranty Figure 4 Field Replaceable H2S Sensor NOTE The Field Replaceable H2S Gas Sensor is constructed from 316 Stainless Steel in order to maximize corrosion resistance in harsh environments Base Connector PCB The base connector board is mounted in the Junction Box The connector board includes Lug less terminal connections f...

Page 8: ...cations to block any unused connections 4 Removal of the Junction box cover or threaded sensor housing 399 800000 000 violates the Ex d protection method and hence power must be removed from the sensor prior its safe removal 5 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 splas...

Page 9: ...th 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...

Page 10: ...ce 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 O2 in the background gas and the reading is affected by changing O2 levels Interfe...

Page 11: ...ting plate and attach the mounting plate to the pole using U Bolts Pole Mounting brackets for Detcon Junction Box s are available separately 8 32 tapped ground point 4 6 3 4 NPT Ports 6 125 5 5 6 45 1 4 mounting holes 5 25 Wall or other mounting surface H2S Sensor Splash Guard 2 2 1 PGM 1 PGM 2 MODEL TP 524D HOUSTON TEXAS FLT 1 2 CAL MicroSafe H2S Gas Sensor ALM ALM TM Figure 7 Typical Outline and...

Page 12: ...the conduit seal shall be placed within 18 of the enclosure Crouse Hinds type EYS2 EYD2 or equivalent are suitable for this purpose NOTE The Detcon Warranty does not cover water damage resulting from water leaking into the enclosure Drain Conduit T EYS Seal Fitting PGM 1 PGM 2 MODEL TP 524D HOUSTON TEXAS FLT 1 2 CAL MicroSafe H2S Gas Sensor ALM ALM TM Figure 8 Typical Installation NOTE Any unused ...

Page 13: ... supply of power should be from an isolated source with over current protection as stipulated in table NOTE 4 A 250 ohm load resistor is needed on the 4 20 mA line when it is not being used Terminal Connections CAUTION Do not apply System power to the sensor until all wiring is properly terminated Refer to Section 2 7 Initial Start Up Customer Wiring White Blue Yellow Black Wiring to H2S Sensor Fi...

Page 14: ...age and shipping This prevents water from contacting the sensor film and as a result helps to retain the stability of the factory span calibration IMPORTANT NOTE Do not remove the desiccant cap and cover until power is applied to the sensor Store the desiccant caps with the desiccant packets in a sealed container i e zip lock Bag for future use It is mandatory to reinstall the desiccant cap and pa...

Page 15: ... the 1 2 minutes the display increases to a level near that of the applied calibration gas value c Remove test gas and observe that the display decreases to 0 Initial operational tests are complete Detcon H2S gas sensors are factory calibrated prior to shipment and should not require significant adjustment on start up However it is recommended that a complete calibration test and adjustment be per...

Page 16: ...old the programming magnet is held in place over the switch location for three seconds For 10 second hold the programming magnet is held in place over the switch location for 10 seconds The 3 and 10 second holds are generally used to enter calibration program menus and save new data The momentary contact is generally used to move between menu items and to modify set point values Arrows and are use...

Page 17: ...ormal Operation Current Reading and Fault Status Calibration Mode AutoSpan Program Mode View Sensor Status Sensor Model Type Current Software Version Range of Detection AutoSpan Level Days Since Last AutoSpan Remaining Sensor Life Sensor Heater Power Sensor Heater Voltage Raw Sensor Resistance mA Output Input Voltage Supply Sensor Temperature Alarm 1 Level Alarm 1 Ascending Alarm 1 Latching Alarm ...

Page 18: ...0 PGM1 2 3 Simulation PGM1 2 10 Restore Defaults Auto Time Out Auto Time Out Auto Time Out Signal Output Check inc PGM1 2 3 PGM1 S PGM2 S PGM1 2 3 PGM1 2 M Set Range dec Auto Time Out inc PGM1 2 3 PGM1 2 M Auto Time Out Alarm 1 Ascending PGM1 2 3 PGM1 2 M Alarm 1 Level Alarm 1 Level Alarm 1 Latching Alarm 1 Ascending Alarm 2 Level Alarm 2 Latching Alarm 2 Ascending Fault Latching inc dec Y N inc P...

Page 19: ...an gas source containing H2S gas in air balance A fixed flow rate of 200 500cc min is recommended NOTE 1 Before performing AutoSpan Calibration verify that the AutoSpan level matches the span calibration gas concentration as described in Section 3 5 2 Set AutoSpan Level NOTE 2 The span gas source must have a normal background concentration of 20 9 O2 H2S balanced with Air Pure Nitrogen background ...

Page 20: ...sented If it fails to meet the minimum in range signal change criteria within 2 minutes the display will report Range Fault twice and the sensor will return to normal operation aborting the AutoSpan sequence The sensor will continue to report a Range Fault and will not clear the fault until a successful AutoSpan is completed Assuming acceptable sensor signal change after 3 minutes the reading will...

Page 21: ...ent where the conditions of IP66 ingress have been presented to the detector An example would be after an extreme wash down event or after sustained and concentrated dust exposure event In these cases the unit must be confirmed to be reading accurately before safe operation is restored NOTE It is mandatory to bump test or span calibrate the detector following field situations where exposures to IP...

Page 22: ...lly revert to Normal Operation 3 5 1 View Sensor Status View Sensor Status displays all current configuration and operational parameters including sensor type software version number detection range AutoSpan level and Days since last AutoSpan estimated remaining sensor life heater power heater voltage raw resistance mA output input voltage and sensor ambient temperature From the View Sensor Status...

Page 23: ...ng The menu item appears as Alarm 2 Latching or Non Latching Fault Latching The menu item appears as Fault Latching or Non Latching When the status list sequence is complete the display will revert to the View Sensor Status text scroll The user can either 1 review list again by executing another 3 4 second hold 2 move to another menu item by executing a momentary hold over PGM1 or PGM2 or 3 return...

Page 24: ...ver PGM1 or PGM2 for 3 seconds to accept the new value The display will scroll Range Saved and revert to Set Range text scroll Move to another menu item by executing a momentary hold or return to Normal Operation via automatic timeout of about 15 seconds the display will scroll Set Range 7 times and then return to Normal Operation NOTE When switching between ranges it may be necessary to readjust ...

Page 25: ...ive until the function is stopped During simulation mode the 4 20mA value will be increased from 4 0mA to 20 0mA in 1 of range increments at about a 1 second update rate and then decreased from 20 0mA to 4 0mA NOTE Signal Output Check stays active indefinitely until the user stops the function There is no automatic timeout for this feature To end simulation mode hold magnet over PGM1 or PGM2 for 3...

Page 26: ...e alarm threshold This is the most common mode of operation for the TP 524D The alarm LEDs can also be activated in descending mode In this mode the alarm LEDs will activate when the concentration is below the alarm threshold The menu item appears as Alarm X Settings From the Alarm X Settings text scroll hold the programming magnet over PGM1 or PGM2 until the prompt appears and continue to hold th...

Page 27: ...tion via automatic timeout of about 15 seconds the display will scroll Fault Settings 4 times and then return to Normal Operation 3 6 Program Features Detcon TP 524D H2S gas sensors incorporate a comprehensive set of diagnostic features to achieve Fail Safe Operation These Operational features and Failsafe Diagnostic features are detailed below 3 6 1 Operational Features Over Range When gas greate...

Page 28: ...g AutoSpan sequence Section 3 4 the Stability Fault will be declared A Stability Fault will cause a Fault Detected message to scroll once a minute on the sensor display and drop the mA output to 0mA The sensor should be considered as Out of Service until a successful AutoSpan calibration is performed Clearing Fault AutoSpan If the sensor fails the signal stability criteria during AutoSpan sequence...

Page 29: ...com or contact Detcon customer service Input Voltage Fault If the detector is currently receiving an input voltage that is outside of the 11 5 28VDC range an Input Voltage Fault is declared An Input Voltage Fault will cause the Fault Detected message to scroll once a minute on the sensor display If an Input Voltage Fault occurs the 4 20mA signal will be set at 0mA until the fault condition is reso...

Page 30: ...spect for signs of corrosion pitting and water damage During visual inspection the Splash Guard should be inspected to insure that it is not blocked Examine the porous 316SS flame arrestor within the sensor s bottom housing for signs of physical blockage or severe corrosion Also inspect inside the Junction Box for signs of water accumulation or Terminal Block corrosion Condensation Prevention Pack...

Page 31: ...aintain area classification b Plug the new Transmitter Module into the connector PCB and reinstall the junction box cover c Perform Set Range Set Heater Power and Set AutoSpan Level then perform a successful AutoSpan before placing sensor assembly into operation Replacement of the Connector PCB NOTE It is necessary to remove power to the Junction Box while changing the Transmitter Module in order ...

Page 32: ...PCB and verify resistance between the blue and yellow wires using an ohmmeter At room temperature the sensor s normal reading range should be 100 K ohms to 25 meg ohms Failure would be open circuit Replace the H2S sensor if an open circuit is found AutoSpan Calibration Faults Range Stability and Clearing To clear any AutoSpan Calibration fault the AutoSpan process must be completed successfully Se...

Page 33: ...or Calibration Repeatability Probable Causes Failed Sensor use of wrong Cal Gas or problems w cal gas and delivery or Interference Gases Check for adequate Sensor Life Check Heater Voltage Setting should be 240 5mW at 25ºC ambient temperature Verify use of span gas Humidifying Tube Check validity of cal gas using H2S pull tube or other means check MFG date on cal cylinder Check for obstructions th...

Page 34: ...to correct terminals Swap with a known good Transmitter Module to determine if Transmitter Module is faulty Faulty 4 20mA Output If Sensor has a normal reading with no Faults displayed and the 4 20 mA signal output is 0mA Check that wiring is properly connected at terminal blocks and through to controller inputs The 4 20mA output loop must be closed resistance of 1000 ohms to avoid the Loop Fault ...

Page 35: ... in Section 7 TP 524D Sensor Warranty Detcon Inc will repair or replace without charge any such equipment found to be defective during the warranty period Full determination of the nature of and responsibility for defective or damaged equipment will be made by Detcon Inc personnel Defective or damaged equipment must be shipped to the Detcon Inc factory or representative from which the original shi...

Page 36: ... shows that the sensor cell was damaged by moisture exposure due to improper handling and protection during periods of removed power or storage The sensor cell must be protected during periods of removed power or storage by use of a Dust Cap P N 600 003307 000 and a Desiccant Packet P N 960 240010 000 Terms Conditions The original serial number must be legible on each sensor element base Shipping ...

Page 37: ...Class I Division 1 Groups B C D Tamb 40 C to 40 C Class I Zone 1 Group IIB H2 CSAus Class I Division 1 Groups B C D Tamb 25 C to 40 C Class I Zone 1 Group IIB H2 FM Approvals Class I Division 1 Groups B C D Tamb 40ºC Ta 60ºC ATEX EExd IIB H2 T4 Tamb 40ºC Ta 60ºC Performance Approvals ISA 92 00 01 Part I 2010 H2S Performance Requirements Safety Approvals CCSAUS CSA NRTL US OSHA Certified FM ATEX CW...

Page 38: ... box Electrical Specifications Input Voltage 12 28 VDC Power Consumption Normal operation 68mA 1 7 watt Maximum 85mA 2 watts RFI EMI Protection Complies with ISO 92 0 01 Analog Output Linear 4 20mA DC current 1000 ohms maximum loop load 24VDC 0mA All Fault Diagnostics 2mA In Calibration 4 20mA 0 100 full scale 22mA Over range condition Status Indicators 4 digit LED Display with gas concentration f...

Page 39: ...ation Accessories 985 241100 321 In Line Humidifying Tube 943 000006 038 Threaded Calibration Adapter 943 020000 000 Span Gas Kit Includes calibration adapter In Line Humidifying Tube 200cc min fixed flow regulator and carrying case Does Not include gas 942 010112 010 Span Gas cylinder 10ppm H2S in air for 20ppm range Contains 58 liters of gas and is good for 80 calibrations 942 010112 025 Span Ga...

Page 40: ... 04 23 12 Updated Section 6 2 and 8 2 Field Wiring load resistor LU 0 4 10 31 13 Added setting LED Alarm Levels LU 0 5 03 07 14 Add notation on use of desiccant pack with sensor cell BM 0 6 07 21 17 Add CAUTION NOTE to bump calibrate after IP66 events and ISA 92 00 01 2010 Performance Test Update BM 0 7 12 06 17 Updated Electrical Classification Approval Temperatures BM 0 8 06 05 18 Updated Condui...

Page 41: ... 37 Shipping Address 4055 Technology Forest Blvd 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 sales detcon com This page left intentionally blank ...