Refrigerant Leak Detection System Installation Instructions • With AC Present: 0mA Note: use these...

Part # LKDT-PNL-1; LKDT-BATT-BCKP-KIT

RLDPK_INS 08/10/2011 For the latest technical documentation, visit www.novar.com/manuals 1

Refrigerant Leak Detection System Installation Instructions

Table of Contents Introduction ......................................................................................1 Hardware Specifications ..................................................................3 Functional Overview ......................................................................10 Panel Installation ............................................................................29 Sensor Installation ..........................................................................30 Horn/Strobe installation .................................................................32 Wiring the System..........................................................................33 Checking Installation .....................................................................38 Recommended Gas Alarm Settings ...............................................38 Maintenance ...................................................................................39 Model & Part Numbers ..................................................................41

Introduction

Novar Refrigerant Gas Leak Alarm Panel Kits, see Figure 1, are designed to continuously monitor refrigeration racks and walk-in coolers/freezers for the presence of refrigerant gases. Novar’s Refrigerant Gas Leak Alarm Panel Kits provide easily accessible I/O interfaces that allow connection to controllers from multiple manufacturers.

Figure 1. Refrigerant Gas Leak Alarm Panel Kit

Continuous, remote monitoring can be realized by simply interfacing the



Refrigerant Gas Leak Alarm Panel (RGLAP) to any Executive Controller using any standard I/O module supporting a 4-20mA interface. Continuous, off-site monitoring can be realized by simply interfacing the Novar Refrigerant Gas Leak Alarm Panel to an 8IM Module or Rack Input Module and an Executive Controller.

The Novar Refrigerant Gas Leak Alarm Panel Kit is a stand-alone, one-zone, refrigerant-gas-detection system which consists of the following components:

Novar Refrigerant Gas Leak Alarm Panel

Figure 2. Novar Refrigerant Gas Leak Alarm Panel

Honeywell/Manning AirScanTM IR Refrigerant Sensor

Figure 3. Honeywell/Manning AirScanTM IR Refrigerant Sensor



System Sensor Horn/Strobe Audio/Visual Alarm

Figure 4. System Sensor Horn/Strobe Audio/Visual Alarm

Battery Backup Panel

Figure 5. Battery Back-up Panel

Hardware Specifications Refrigerant Gas Leak Alarm Panel

Enclosed Fuse Holder (600V, 30A) (F1):

Indicating: No Poles: One Amperage: 30A Case: Thermoplastic Torque Rating: 17.7in/lbs Wire Range: #8-#14 AWG CU Fuse Size: 13/13"DIA x 1.5" Fuse: ATDR

120VAC-to-24VDC, 2.5A, Class 2 Power Supply Module (PS-1):



Type: 24V/2,5A Input Rated Voltage Vin: 100VAC to 240VAC Voltage Range: 85VAC to 264VAC Line Frequency Range: 47Hz to 63 Hz Mains Buffering: > 40 ms Rated Current Iin: 1.22A to0.66A Output Rated Voltage Vout: 24VDC Residual Ripple/Spikes: < 200/300mVpp Setting Range: 22.2VDC to 26.4VDC Rated Current Iout: 2.5A Current Limitation: 3.4A typ. Efficiency at Full Load: 87% typ.

Environmental Conditions Transportation and Storage Temperature: -40°C to +70°C Ambient Temperature During Operation:-20°C to +55°C Degree of Protection:IP 20 Pollution Degree Environment:2 Humidity Rating:Climate category 3K3 acc. to EN 60721, relative air humidity 5...95 %, without condensation EMC Interference Emission:EN 50081-1, class B acc. to EN 55022 EMC Interference Immunity:EN 61000-6-2, EN 61000-4-2/-3/-4/-5/-6/-11 Safety Protection Class:Class II (without protective earth PE) Galvanic Isolation Primary/Secondary:SELV output voltage acc. to EN 60950 and EN 50178

AC Fail Relay (RLY-2):

Coil Voltage:120VAC Poles:DPDT Contact Amperes:20A Features:Locking Push Button = M4 Bi-Polar LED

Relay Module (RLY-1):

Coil Voltage:24VDC Poles:3PDT Contact Amperes:15A Features:Locking Push Button = M4 Bi-Polar LED

Terminal Block Style Connectors (TB-1):

Torque Rating:4.2in/lbs Wire Range:22-12 AWG STR (copper wire 60°C)



Honeywell Manning Dual Alarm Relay Module

Power Supply Requirements: +18 to +26 VDC Power Supply Current: 120 mA Max Operating temperature: -10° F to +120° F Humidity Conditions: 0% to 95% RH non-condensing Relay Contacts: Isolated 5A @ 125 VAC / 100 VDC Set point Adjustment: 33%/100% full-scale (20 mA) and 50%/100% full-scale (20 mA) Built-in hysteresis: 2-second time delay for both On/Off transitions Dimensions: 8.5” high x 8.5” wide x 2.5” deep LED Status Indicators (Internal): Power (green), Low Alarm (yellow), High Alarm (red) Connectors: Screw terminal type 22-gauge to 18-gauge stranded copper Maximum distance from controller: 1000 feet Load Resistor: 50Ω to 400Ω



Honeywell Manning AirScanTM iR Refrigerant Sensor

Figure 6. Honeywell Manning AirScan iR Specifications



System Sensor Horn/Strobe Audio/Visual Alarm

Figure 7. System Horn Strobe Specifications



Fire-Lite CHG-75 Battery Charger:

Primary (AC) Power - TB1, Terminals 1 (Hot), 2 (Neutral) & 3 (Earth)

120VAC, 60Hz, 2.05A maximum 220/240VAC, 50Hz, 1.14A maximum (JP1 cut) Fuse F1 - 6.25A (slow blow 3AG) Wire size: Minimum 14 AWG with 600 volt insulation

Secondary Power (Battery) Charging Circuit - TB2, Terminals 1 (+) & 2 (-)

Supports lead-acid batteries only Float Charge Voltage: 27.6VDC Maximum Charge Current: 4.5A (peak) Maximum Battery Capacity: 75AH Supervised and Current-limited: F2 – 15A replaceable fuse

24 VDC Secondary (Battery) Input Power

The CHG-75 current consumption from the battery is as follows: • During AC Loss: 60mA • With AC Present: 0mA Note: use these values in battery calculations for host FACP

Battery Output - TB2, Terminals 3 (+) & 4 (-)

Provides battery backup connection to other loads Current-limited: F3 – 15A replaceable fuse

SLC (Signal Line Circuit) Connector - TB3, Terminals 1(B+), 2(A+), 3(B-) & 4(A-) Voltage 24VDC nominal, 27.6VDC maximum Maximum Loop Current 400mA (short circuit) or 100mA (normal) Maximum Loop Resistance 40ohms Supervised and Power-limited Trouble Contact Rating - TB4, Terminals 1 (C), 2 (NO) & 3 (NC) Fail-safe Form-C Relay Contacts Rated for 2A @ 30VDC (resistive) BAT-12260 26AHR Lead Acid Battery:

Nominal voltage: 12VDC Nominal capacity (20 hr): 26.0AH

Dimensions

Total height 125 mm (4.92") Container height 125 mm (4.92") Length 166 mm (6.54"); width 175 mm (6.89")

Weight

Approximately 8.80 kg (19.40 lbs)



Container material: UL94HB ABS, UL94V-0 ABS.

Internal resistance (25°C, 77°F): ~ 10 m.

Discharge capacity under different temperatures

40°C: ~ 102% 25°C: ~ 100% 0°C: ~ 85%

Capacity 25°C/77°F

20hr @ 1.3A: 26.0AH 5hr @ 4.16A: 20.8AH 1hr @ 15.6A: 15.6AH 1C @ 26.0A: 13.0AH

Charging voltage (25°C, 77°F)

Standby use: 13.65V ± 0.15V

Cycle use: 14.7V ± 0.3V

Maximum discharge current: 300A (5 sec)

Maximum charging current: 7.8A

Self-discharge residual capacity (25°C, 77°F)

After 3 months: ~ 90% After 6 months: ~ 82% After 12 months: ~ 70%

Piezoelectric Trouble Buzzer:

Sound level Category : Medium Sound Level

Mode of Operation: Slow Pulse

Voltage Rating: 6 to 28VDC

Frequency Range: 1900 Hz ±300 Hz

Loudness (Min. Voltage): 60 dB(A) min. @ 2 FT and 6VDC

Loudness (Max Voltage): 75 dB(A) min. @ 2FT and 28VDC

Current Draw

5 mA Max @ 6VDC 23 mA Max @ 28VDC

Min Pulse Rate (PPS): 0.5 @ 6VDC

Max Pulse Rate (PPS): 2.0 @ 28VDC

Duty Cycle (%): 50 (Approx)

Storage Temperature: -40°F to 185°F (-40°C to +85°C)

Operating Temperature: -22°F to 149°F (-30°C to +65°C)



Weight (Typical): 2.1 oz (59 g)

Housing: 6/6 Nylon, Color Black

Functional Overview

The Novar Refrigerant Gas Leak Alarm Panel kit consists of a Novar Refrigerant Gas Leak Alarm Panel, a Honeywell/Manning AirScanTM IR infrared refrigerant gas sensor, and a Spectrometry Advance System Sensor horn/strobe audio/visual alarm. An optional 24VDC Battery Backup Panel is also available if required by the customer or local authority. Figure 8. is a block diagram of the system.

Continuous, off-site monitoring can be accomplished by simply interfacing the Novar Refrigerant Gas Leak Alarm Panel to either a Novar 8IM or Rack Input Module and an Executive Controller. Interfacing to an 8IM Module is implemented by connecting the 4mA-to-20mA current-loop output (CNT-SIG and CNT-GND) to one of the 8IM Module’s current inputs. For Rack Input Module implementation, one of the three normally-open, dry-contact outputs provided (ALARM #1NO / ALARM#1COM, ALARM #2NO / ALARM#2COM, or ALARM #3NO / ALARM#3COM ) should be used.



Figure 8. System Block Diagram

Refrigerant Gas Leak Alarm Panel

The Novar Refrigerant Gas Leak Alarm Panel consists of the following components (See Figure 9):

Enclosed Fuse Holder (F1) 120VAC-to-24VDC, 2.5A, Class-2 Power Supply Module

(PS-1)



AC Fail Relay Module (RLY-2) Honeywell/Manning Dual Alarm Relay Module (RDARM) Relay Module of Three Normally-Open, Dry Contacts

(RLY-1) Terminal Block Style Connector for Outside Connections

(TB-1) Three Status Lamps (located on the center, lower front of

the panel) SpectrAlert® Advance System Sensor Horn/Strobe

Audio/Visual Alarm

Figure 9. RGLAP Inside View

Enclosed fuse holder (F1), class-2 power supply module (PS-1), AC fault relay module (RLY-2), relay module (RLY-1), and terminal connectors (TB-1) of the Novar Refrigerant Gas Leak Alarm Panel are all mounted on 1-3/8 inch (35mm) wide DIN rail.

The Honeywell/Manning Dual Alarm Relay Module (RDARM) is mounted with threaded standoffs and nuts at each corner of the board.

The SpectrAlert® Advance System Sensor Horn/Strobe Audio/Visual Alarm is snap-fitted to a four-screw-mounted base-plate at the top center of the panel door.

For ease of installation, all modules and terminals have wire-cage and screw connections (Figure 10).



Figure 10. Wire-cage screw connections

The enclosed fuse holder F1 (see Figure 11) contains a 600V, 30A fuse which is easily replaceable by use of a fuse lift-handle system. If an over-current fault should occur within the system, the fuse will open removing the system from the 120VAC power line. One replacement fuse is mounted inside the panel at the lower right (see Figure 11).

Figure 11. Fuse placement

The 120VAC-to-24VDC power supply (PS-1 in Figure 12) sources



[email protected] to all components of the system.

120VAC line power is supplied to the module through two wire-cage and screw terminals. One terminal (L1) connects to line voltage through fuse module F1; the other (Neutral) through the TB-1 terminal block connector.

Figure 12. 24VDC power supply

The AC fail relay (RLY-2 in Figure 13) prevents system power failure if a power-line loss should occur by switching from the 120VAC-to-24VDC power supply to the optional +24VDC Battery Backup Panel if installed. Battery Backup Panel connections are made at TB-1 BATT(+) and BATT (-). If a power outage should occur, the Battery Backup option will allow the Refrigerant Gas Leak Alarm Panel to continue normal operation for twenty-four hours and then be capable of operating in alarm mode for five minutes if a refrigerant leak should occur during the power outage. The AC fail relay has both mechanical and LED status indicators and a locking push button.



Figure 13. Power system failure prevention

Output from the Honeywell/Manning AirScanTM IR infrared refrigerant gas sensor is input to a Honeywell/Manning Dual Alarm Relay Module (Figure 14). The Dual Alarm Relay Module is a 4mA-to-20mA, feed-through device designed to provide remote dual stage alarm relay outputs and can be used with any Honeywell/Manning Systems gas sensor. Setpoint adjustment is by a two-position switch, allowing standard trip levels of 33% / 100 % full scale trip levels or 50 % / 100% full scale. The 2A@24VDC SPDT relays are unpowered in normal state. Three LED's located at the center of the module indicate status of power (green), low alarm (yellow), and high alarm (red).

Figure 14. Relay module



Connections are made to the Dual Alarm Relay Module (RDARM) from panel terminal blocks TB-1 (CNT-SIG, CNT-GND, SEN-GND, SEN-24V, and SEN-GND) through two board mounted connector blocks, one providing gas sensor +24V power, ground, and 4mA-to-20mA signal input; the other providing control panel +24V power, ground, and 4mA-to-20mA control signal.

NOTE!

In the event that offsite monitoring will not being utilized (not connected to a Novar 8IM Module), to enable the alarm function of the alarm panel a properly sized (wattage), 50Ω to 400Ω resistor must be connected between terminals CNT-SIG and CNT-GND. If this is not done, the Dual Alarm Relay Module will not alarm in the event of a detected gas leak.

The Relay Module (RLY-1 in Figure 15) provides three normally-open, dry contacts which are used for auxiliary monitoring of alarms or external equipment interfacing. The relay has both mechanical and LED status indicators and a locking push button.

Figure 15. Relay module

Three status lamps are located on the lower front of the panel (Figure 16). After the 120VAC power is applied, the left-side green status lamp will be illuminated. The center blue 24VDC power status lamp is illuminated with the presence of either battery-backup power or the 24VDC power supply. The right-side red alarm status lamp is illuminated only during an alarm.



Figure 16. Alarm Panel

Upon detection of a refrigeration gas leak, the alarm status lamp is illuminated by the Dual Alarm Relay Module’s low-alarm relay, which also activates the SpectrAlert® Horn/Strobe Alarm, causing the strobe to flash at a one-hertz rate and the horn to sound.

NOTE!

Alarms are automatically silenced when the detected refrigerant has dissipated in the area being monitored and the gas sensor sampling chamber has been cleared. Provision is made for the addition of external strobe/horn devices at connector terminals H/S 24V and H/S GND.

Manning AirScanTM IR

The Honeywell Manning AirScanTM IR infrared sensor (Figure 17) is a microprocessor-based sensor that is selective to refrigerants and provides years of service at the highest level of accuracy and reliability. This highly versatile sensor features SensorCheckTM, a unique technology that continuously monitors sensor performance that enables it to provide worry-free performance throughout the life of the sensor. A true “diffusion” design sensor, the Honeywell Manning AirScanTM IR sensor does not require pumps or filters and allows all points of gas detection to be monitored perpetually, unlike sample draw systems.



Figure 17. Air Scan

Gas detection by the infrared method is based on the principle that most gases absorb infrared energy at a characteristic frequency. In this instrument, a broad band infrared source emits energy which is then band-pass filtered to produce a narrow range of frequencies characteristic of the refrigerants’ (CFC/HCFC/HFC) absorption spectra. Any refrigerant in the gas sample cell (Figure 18) selectively absorbs energy reaching the detector. This reduction in energy is detected, amplified and sent to the signal processing portion of the system. The Honeywell Manning AirScanTM IR Sensor line is a three-wire, 4mA-to-20mA sensor for two bands of refrigerants available in a range of 0—3,000ppm, but can be adjusted for lower ranges, if required. The low-band or R-404a infrared sensor reacts to R-123, R-134a, R-404a and R-507. The high-band or R-22 Honeywell/Manning AirScanTM IR sensor reacts to R-22.

Figure 18. Sample cell



Internal compensation for environmental changes allows the sensor to automatically adapt to fluctuating temperature and humidity conditions.

Every two seconds SensorCheckTM technology monitors the AirScanTM

IR source and ensures that the dual channels are functioning properly. A notification signal will be transmitted if any of several performance parameters are not met. Monitoring equipment must be configured to indicate a fault if the signal is less than 1.5mA. All signals over 20mA must be considered a high gas concentration. Honeywell Manning infrared sensors are normally long-lived (5 years plus), unless physically damaged or wetted with water or other liquid. Power and signal connections for the Honeywell Manning AirScanTM IR are made through a wire-cage and screw connector (see Figure 19).

Figure 19. Screw connector

Sensor operation status is indicated by the blink pattern of seven LED’s located in a vertical row on the right side of the sensor circuit board (see Figure 20). LED status is differentiated by color and duration/pattern of blink(s).



Figure 20. Sensor circuit board

After power-up, the green power LED is continuously on, both fault LED’s are off, and the green source LED is blinking once every 2 seconds. The green power LED is continuously ON once power is applied. The yellow system LED indicates the following:

Continuous ON during normal filtered output run mode -

“dead band” from 4mA to 4.6mA Slow blink during normal non-filtered output run mode Fast blink indicating unit lost calibration data Off during 4mA-to-20mA loop check

The yellow calibrate LED indicates the following:

Continuous momentary on for auto-zero mode activation Slow blink for 4mA output calibration mode Medium double blink indicates 4mA-to-20mA loop check

0.5mA (low) Fast blink for span calibration mode and 4mA-to-20mA

loop check 22mA (high)

The red fault LED indicates the following (all scenarios produce a 0.5mA output):



Continuous on indicates a failed source, low signal, or

circuit failure Slow blink indicates the power supply 24VDC input

voltage is too low Medium double blink indicates sensor is outside the

operating temperature range Fast blink indicates the signal drifted below 4mA and needs

to be re-calibrated, only in non-filtered output run mode (no dead-band)

The red mA fault LED attempts to output a 0.5mA. A fast blink indicates 4mA-to-20mA loop failure or load resistance too high. The green source LED blinks once every 2 seconds to indicate when source is energized and also that the source is not short circuited. The green ATMOS LED is continuously on and indicates ATMOS circuitry is active or adjusting the enclosure’s internal environmental conditions for the sensor to function reliably. The above description on LED indicators is very limited; See AirScan IR Manual for full details.

Pushbutton S1 (Figure 21) is used to initiate the auto-zero function, program the 4mA output calibration, and initiate the 4mA-to-20mA loop test.

Figure 21. Pushbutton S1



System Sensor SpectrAlert® Horn/Strobe Audio/Visual Alarm

The SpectrAlert Advance horns, strobes, and horn/strobes can be used indoors or outdoors in wet or dry applications and can provide reliable operation from −40°F to 151°F.

Figure 22. Honeywell Sensor SpectrAlert Horn/Strobe

Like the entire SpectrAlert Advance product line, these devices include a variety of features that increase their application versatility while simplifying installation. All devices feature plug-in designs with minimal intrusion into the back box, which make installations fast and foolproof while virtually eliminating costly and time-consuming ground faults. All horns, strobes, and horn/strobes use a universal mounting plate with an onboard shorting spring that tests wiring continuity before the device is installed, protecting devices from damage. The SpectrAlert Advance is housed in a NEMA 4X rated, 5.6” x 4.7” x 2.5 deep (without weather-proof back box) enclosure.

24VDC Battery Backup Panel

The Battery Backup Panel (Figure 23) allows the Refrigerant Leak Detection Panel to continue with normal operation for twenty-four hours and then be capable of operating in alarm mode for at least five minutes. The Refrigerant Leak Detection Panel transfers to the Battery Backup Panel when 120VAC power is lost.

The Refrigerant Leak Detection Panel automatically returns to primary power when the 120VAC power has been restored.

Simultaneously, when 120VAC power is lost, a 24VDC trouble audible will sound (pulses on/off for one second) until the primary power has



been restored. The audible buzzer cannot be manually silenced.

Battery Backup Panel dimensions are 15.6” x 15.5” x 5.13”; weight is approximately 60lbs with batteries.

The Battery Backup Panel consists of the following components:

Fire-Lite CHG-75 Battery Charger Fire-Lite BB-26 Battery Box Fire-Lite BAT-12260 26AH, Lead-Acid, Sealed Battery (2

required). Piezoelectric Buzzer with Bracket Assembly

Figure 23. Battery Backup Panel

CHG-75 Battery Charger

The CHG-75 battery charger (Figure 24) is designed to charge lead-acid batteries that provide emergency standby power. Two 12V batteries (BAT-12260) are used in series to supply a nominal 24VDC. The battery charger is compatible with any lead-acid batteries with a rating of 25AH to 75AH. The CHG-75 can be configured for 120VAC operation or 220/240VAC operation via jumper selection.



Figure 24. Battery Charger

Two screw terminal blocks, one insulated located at the lower-left-side of the module and one non-insulated located at the right-hand side of the module, provide connection points for line power, battery, and RGLAP +24VDC power out (see Figure 24 and Figure 25).

Figure 25. Wiring Board



Line power connections Line, Neutral, and Ground enter the CHG-75 through the insulated, screw-terminal block located at the lower-left side of the module. BAT-12260 + and - connections are made at the lower two screw terminals located on the right-hand side of the module. RGLAP +24VDC power out connections are made at the upper two screw terminals located on the right-hand side of the module. Status indication LEDs are provided on the CHG-75 circuit board to monitor various charger conditions:

AC LED – green LED indicates AC power is present Trouble LED – yellow LED turns on for charger troubles or

trouble indication from the Master Trouble Input Low Battery LED – yellow LED turns on when the battery

voltage drops too low Charging LED – yellow LED indicates battery is being

charged, turns off when the CHG-75 is trickle charging Ground Fault LED – yellow LED turns on to indicate

ground fault on the charger BB-26 Battery Box

The battery box is designed to contain two BAT-12260 12V, 26AH, lead-acid, sealed batteries; a CHG-75 battery charger; and a piezoelectric alarm buzzer with bracket assembly.

The CHG-75 module is located and mounted on four #4-40 threaded studs. One #4-40 stud, located at the left side of the CHG-75 module, is provided for battery box grounding.

The BB-26 box dimensions are 15.6" (39.62cm) wide, 15.5" (39.37cm) high, and 5.125" (13.02cm) deep.

For installation wiring, the box is designed with one 1.125” diameter (2.857cm) knockout located on the left-side top of the box; four identical knockouts are located in both sides and the rear of the box.

Two mounting holes are provided at the top of the battery box for installation of optional AM-1and VM-1 meters.

For installation mounting, the BB-26 battery box has two mounting holes located in the back of the box (see Figure 26)



Figure 26. Battery Box



Figure 27. Mounting Diagram Optional Ammeter (AM-1) or Voltmeter (VM-1)

Optional ammeter (AM-1) and voltmeter (VM-1) are available for the CHG-75 battery charger. Meter ranges are 0A-to-10A and 0V-to-50V respectfully. The meters indicate charge voltage and charge current. Both meters are wired to the CHG-75 and mounted in mounting holes provided in the BB-26 battery box.

BAT-12260

The BAT 12260 battery is a 12V, 26AH, lead-acid, sealed battery. Two are required and are serially configured for a nominal output voltage of 24VDC.



Piezoelectric Trouble Buzzer with Custom Bracket Assembly

A piezoelectric buzzer (Figure 28) is employed to sound a one-second pulse rate, 70dB(A)@2Ft audible alarm when primary line power to the Battery Backup and RGLP is lost. The alarm will sound until primary power is restored and cannot be manually silenced.

Figure 28. Piezoelectric buzzer

The piezoelectric buzzer is mounted on a custom bracket which is mounted to the CHG-75 module.

The buzzer is powered by the +24VDC battery source and is operated by the CHG-75 module Form-C, trouble-relay contacts.

Panel Installation This section covers the mounting of the Refrigerant Gas leak Alarm Panel (RGLAP). It assumes that the work is being completed by an engineer, technician, or service person that is performing control systems installation.

Mounting and Orientation

The Panel is to be mounted per the requirements of the Customer or Authority having jurisdiction. The panel is to be mounted at a height which allows appropriate access to the interior of the panel. When mounting the panel to paneling or drywall, use hollow-wall anchors or appropriate fasteners to insure that the assembly remains secure. The panel should be on the outside of the space being monitored near the entrance of that space.

Screw Locations

The RGLAP should be installed plumb and level and securely fastened to



a rigid mounting surface. The enclosure utilizes four mounting holes on the back of the box (see Figure 29 below).

Figure 29. Mounting hole locations

Sensor Installation This section covers the mounting of the Manning AirScanTM IR.


Because each sensor can only “report” what it is seeing at the moment, it is very important that the sensor be located where leaks are most likely to occur. CFC/ HCFC/HFC vapor is heavier than ambient air, so in a room with no air movement it will tend to settle. For quickest detection, mount the sensor about one to two feet from the floor, close to the potential leak source.



If the primary application is the fastest possible leak detection, mount the sensor near the potential leak sources. In doing this, be aware that the indicated concentration may not be representative of personnel exposure and easy access for the required calibration and maintenance could be compromised.

General Considerations:

Must be easily accessible for calibration and maintenance. Always mount the sensor vertically. Mount the sensor close to the potential leak source for

fastest possible leak detection. Protect sensor from water, excessive humidity, and wash-

down. Take air movement and ventilation patterns into account. To prevent electrical interference, keep sensor and wire

runs away from mercury vapor lights, variable speed drives, and radio repeaters.

Protect sensor from physical damage (fork lifts, etc.). Do not mount the sensor over a door in a refrigerated area.

Very Important:

Sensor must be mounted vertically. Never mount sensor flat on a ceiling. Enter enclosure only through existing hole in bottom of

enclosure. Always make a drip loop in the conduit. Never mount sensor on a vibrating surface.

NOTE!

Mount sensor enclosures through the flange holes as shown in Figure 30 and always mount vertically.



Figure 30. Sensor Dimensions

Horn/Strobe installation

This section covers the mounting of the Remote Horn and Strobe. The Horn/Strobe is to be mounted per the requirements of the Customer or Authority having jurisdiction. An installed weatherproof back box should not be left without an installed unit for extended periods of time to avoid water accumulation.


The wall-mount back box shipped with these products must be mounted with the internal post (Figure 31A) in the lower left corner.*Attach the device mounting plate (Figure 31B) to the weatherproof back box (Figure 31C) using the four non-painted screws (Figure 31D) included with the product. Hook the tabs on the product housing into the grooves on the mounting plate. Then, swing the product into position to engage the pins on the device with the terminals on the mounting plate. Verify that the tabs on the back of the device are fully engaged with the mounting plate. Finally, secure the device to the mounting plate by tightening the single screw attached to the front of the housing (Figure 31E). For tamper resistance, the captured screw may be replaced with the Torx screw supplied with the device. For conduit installation refer to the Proper Installation of SpectrAlert® Advance Outdoor Audible Visible Appliances guide.

Screw Locations

The Horn and Strobe should be installed plumb and level and securely fastened to a rigid mounting surface. The enclosure utilizes two flange holes on the either side of the box (see Figure 31 below).



Figure 31. Horn Strobe details

Wiring the System

CAUTION!

All wiring must comply with local and national electrical codes.

CAUTION!

Disconnect power before beginning installation. Failure to do so can cause electrical shock or equipment damage.

NOTE!

This product should be installed by a trained and experienced technician. Failure to follow these instructions carefully could damage the product or cause unexpected system operation.


The 120VAC-to-24VDC power supply (PS-1) sources [email protected]



to all components of the Novar Refrigerant Leak Detection System through Terminal Block 1 (TB1). 120VAC line power is supplied to the module through two wire cage and screw terminals using 18 AWG. One terminal (L1) connects to terminal 1 (on TB1) line voltage through the fuse module; the other (Neutral) through the terminal block connector terminal 2 (TB1). Connect the Earth Ground to terminal 3.

NOTE!

Refer to the wire diagram in the panel door pocket for further detail.

NOTE!

In the event that offsite monitoring will not being utilized (not connected to an Input/Output Module), to enable the alarm function of the alarm panel a properly sized (wattage), 50Ω to 400Ω resistor must be connected between terminals CNT-SIG and CNT-GND. If this is not done, the Dual Alarm Relay Module will not alarm in the event of a detected gas leak.

Connecting to a Novar system

The RGLAP is typically connected to a Novar 8IM Module, or other input/output module. Connect TB1 terminals 6 (Signal), and 7 (Ground) in the RGLAP (see Figure 32) to the 8IM module sensor input field termination block. There are 8 screw terminals; the signal wire is to be connected to the positive terminal and ground to the negative terminal on the 8IM module.

Connecting to a third party system

The RGLAP may be connected to an input/output device from other third party suppliers designed to accept a 4mA-20mA signal. Connect TB1 terminals 6 (Signal) and 7 (Ground) in the RGLAP connect to the Third party input/output module as specified by the manufacture. The Novar Refrigerant Leak Detection System can be monitored by any other manufacturer’s control equipment using the normally open dry relay contacts provided in the RGLAP.



NOTE!

In the event that offsite monitoring will not being utilized (not connected to an Input/Output Module), to enable the alarm function of the alarm panel a properly sized (wattage), 50Ω to 400Ω resistor must be connected between terminals CNT-SIG and CNT-GND. If this is not done, the Dual Alarm Relay Module will not alarm in the event of a detected gas leak.

Figure 32. Contactor Panel Manning AirScan™IR

NOTE!

Nearly all start-up problems are due to improper wiring or monitor configuration. Please follow these guide-lines carefully.

Always use three conductors, insulated, stranded, shielded copper cable. Use only three conductor cable, not two cables of two conductor wire.



Do not pull sensor wiring with AC power cables. This will cause electrical interference. Be sure there are no breaks or splices in sensor wiring runs. If cable runs cannot be made without a splice, all connections must be soldered. Soldering should be done using a rosin flux to tie the connecting ends of sensor wires to ensure a positive and long-lasting contact. Ground the shield at the main control panel. Connect the shield wire in the sensor terminal block labeled shield. Tape all exposed shield wire at the sensor to insulate it from the enclosure.

All penetrations into a refrigerated room should be sealed to prevent condensate from forming in the conduit and dripping into the sensor enclosure. Make drip loops for cables going into sensor housings. Follow the special mounting instructions on the enclosure (…This End Up).

NOTE!

Circuit board mounted sensor provides a linear 4/20 mA output. Monitoring equipment may have a maximum input impedance of 500 ohms.

Cable Recommendation: Use #18/3 (Belden #8770) for cable runs up to 200 feet. Use #16/3 (Belden #8618) for cable runs up to 1,000 feet. Use only the existing punched holes for connections to the sensor. Connection to RGLAP: The sensor wires are connected to terminal block 1 (TB-1 Figure 33) on terminals 8 (signal), 9 (24V) and 10 (Ground)

NOTE!

Allow the sensor to operate for 12 hours with the enclosure sealed prior to testing the sensors. This will give the sensor time to reach thermal equilibrium to the external and internal temperatures while in operation. Because sensors are normally located at a distance from the main unit, the test time required and accuracy of the response checks will be improved if two people perform the start-up procedures and use radio contact. To avoid possible activation of the H/S both internal and remote do not connect the signal wire during this period.



Figure 33. Wiring

Remote Horn/Strobe

The Horn/strobe can be wired (Figure 34) using #12 to #18 AWG. The remote horn/strobe is connected to the RGLAP on terminal block 1 (TB1) on terminals 11 (24V), 12 (Ground).

Figure 34. Terminals



Checking Installation Manning AirScan™ IR

NOTE!

Before applying power, make a final check of all wiring for continuity, shorts, grounds, etc. It is usually best to disconnect external alarms and other equipment from the sensor until the initial start-up procedures are completed.

For detail in verifying proper operation of the Manning AirScan™ IR sensor please reference section 3 of the Honeywell Installation and Instruction manual Manning AirScan™IR Refrigerant Sensor 19546

AirScan™-IR-com RGLAP - HORN/STROBE

1. Apply 120 VAC 2. Verify the 120 VAC lamp is lit. 3. Verify the 24 VDC lamp is lit 4. Exposes the sensor to the recommended about of gas that is being

monitored per the Calibration manual (Refer to the AirScan Calibration manual)

5. Verify that the RGLAP responses causing appropriate alarm function (Horn/Strobe active and front panel alarm lamp is lit).

6. Allow alarm to clear before leaving

Recommended Gas Alarm Settings User Configuration Settings

Only the Dual Relay Module is capable of configuration. The user can select one of two set point adjustments (left position: 33%/100% full scale, right position: 50%/100% full scale).

Factory Defaults

The Dual Relay Module is factory pre-set for 33%/100% set point trip levels. The gas sensor has been calibrated at an altitude of 1,000 ft. above sea level. For installations where the altitude is greater than 3,500 ft. above



sea level, it is necessary to recalibrate the sensor “span” during the initial setup for more accuracy and reliability. Calibration is accomplished by using a Manning “CK” Calibration Kit for the specific gas to be detected. For information on Calibration kits please refer to the Manning Calibration Kit Instruction and Calibration Manual.

Maintenance Manning AirScan™ IR

Expose each sensor to test gases monthly to verify that the sensor has a normal response. This will also check the alarm lights and relay action of the monitoring equipment.

NOTE!

It is essential that signal voltages be taken and logged on a consistent basis at least monthly. Periodically, sensors should be exposed to refrigerant sample and the results logged.

For proper operation it is essential that the test and calibration schedule be adhered to. Honeywell Analytics recommends the following maintenance schedule:

Calibration should be performed with certified calibration

gas every six months. Calibration kits are available from Honeywell Analytics.

All tests and calibrations must be logged. It is highly

recommended that certified calibration gas be used every six months.

NOTE:

For information on Calibration kits please refer to the Manning Calibration Kit Instruction and Calibration Manual.

Interchangeability

The 404a and 407a gas sensors are interchangeable with any RGLAP, provided it is used for monitoring the appropriate refrigerant gas.




Only the AC fuse is serviceable. A Replacement fuse will be included with each panel. The Dual Relay Module and Indoor Horn/Strobe is also field replaceable. All other hardware failures will require panel replacement.

Outdoor Horn/Strobe

No user serviceable parts. Failures will require Horn/Strobe replacement.



Model & Part Numbers

The part numbers below should be used to order Novar parts.

OS/ Part No. Product

LKDT-404A-KIT-1 404a Refrigeration Leak Detector Panel Kit LKDT-407A-KIT-1 407a Refrigeration Leak Detector Panel Kit LKDT-PNL-1 Refrigeration Leak Alarm Panel (no sensor-spare part) 815003000 404A Refrigerant Sensor M-700071 407A Refrigerant Sensor P2WHK-P Horn/Strobe, 24 VDC, Outdoor w/Back Box, White

LKDT-BATT-BCKP-KIT Battery Back-up Unit w/Power Supply, Battery Cabinet, Trouble Buzzer Assembly and (2) BAT-12260 Sealed Lead-Acid Batteries

P2WH-P Horn/Strobe, 24 VDC, Indoor w/o Back Box, White (spare part) BAT-12260-M Battery, 12 VDC, 26 AHR, Sealed Lead Acid (spare part) M-700124 Dual Relay Module (spare part)



Regulatory Compliance

Refrigerant Gas Leak Alarm Panel:

UL/ULC: UL-508A CE

24VDC Supply

CE CE marking acc. to 2004/108/EG and 2006/95/EG UL UL 508 (Listed, File E197259), UL 60950

(Recognized, File E151273), NEC Class 2 for 6EP1332-1SH42

FM Class I, Division 2, Groups A,B,C,D, T4 GL Approval for shipbuilding to Germanischer Lloyd ABS Approval for shipbuilding to American Bureau of

Shipping for 6EP1322-1SH02 und 6EP1332-1SH42 ATEX ATEX94/9/EC Kat.3;Ex, nA IIC T3

Horn/Strobe Alarm:

UL 1638 (strobe) and UL 464 (horn) UL Listed: 1638 (strobe) 464 (horn) S4011 (chimes, horn strobes, horns) S3593 (outdoor and alert strobes) FM Approved: 3023572 MEA Approved: MEA452-05-E State of California State Fire Marshall: 7300-1653:187 (outdoor strobes) 7125-1653:188 (horn strobes, chime strobes) 7135-1653:189 (horns, chimes)

Manning AirScanTM IR Refrigerant Sensor

N/A

System Sensor Outdoor Horn/Strobe

UL 1638 (strobe) and UL 464 (horn) UL Listed: 1638 (strobe) 464 (horn)



S4011 (chimes, horn strobes, horns) S3593 (outdoor and alert strobes) FM Approved: 3023572 MEA Approved: MEA452-05-E State of California State Fire Marshall: 7300-1653:187 (outdoor strobes) 7125-1653:188 (horn strobes, chime strobes) 7135-1653:189 (horns, chimes)

Battery Backup Panel:

BAT-12260

UL Recognized Components: files MH19884 (B & B Battery), MH20567 (UPG, previously Jolt), MH20845 (Power-Sonic).

Note:

The listings and approvals below apply to BAT Series Batteries. In some cases, certain modules may not be listed by certain approval agencies, or listing may be in process. Consult factory for latest listing status.

CHG-75 Battery Charger

UL Listed S1287 MEA 297-01-E California State Fire Marshal 7315-0075:201 (power units)

Piezoelectric Buzzer UL Listed



The material in this document is for information purposes only. The content and the product it describes are subject to change without notice. Novar makes no representations or warranties with respect to this document.

In no event shall Novar be liable for technical or editorial omissions or mistakes in this document, nor shall it be liable for any damages, direct or incidental, arising out of or related to the use of this document. No part of this document

may be reproduced in any form or by any means without prior written permission from Novar.

Copyright © 2011 by Honeywell International, Inc.. All Rights Reserved.

Novar 6060 Rockside Woods Blvd.,

Cleveland, OH 44131 Phone: 1.800.348.1235

www.novar.com

Manning Calibration Kit 19546 CK 07/09 REVH Copyright © 2009 Honeywell Analytics. All Rights Reserved. 1

Manning Calibration Kit Instruction and Calibration Manual

07/09

Release H Draft

Honeywell Confidential & Proprietary This work contains valuable, confidential, and proprietary information. Disclosure, use

or reproduction outside of Honeywell Inc. is prohibited except as authorized in writing. This unpublished work is protected by the laws of the United States and other countries.


Notices and Trademarks Copyright 2009 by Honeywell International Inc.

Release H July 2009

While this information is presented in good faith and believed to be accurate, Honeywell disclaims the implied warranties of merchantability and fitness for a particular purpose and makes no express warranties except as may be stated in its written agreement with and for its customers.

In no event is Honeywell liable to anyone for any indirect, special or consequential damages. The information and specifications in this document are subject to change without notice.

Manning is a registered trademark of Honeywell International Inc.

Other brand or product names are trademarks of their respective owners.

Honeywell Analytics 405 Barclay Blvd. Lincolnshire, IL 60069 USA

1-800-538-0363


About This Document World Wide Web The following Honeywell web sites may be of interest.

Honeywell Organization WWW Address (URL)

Corporate www.honeywell.com

Honeywell Analytics www.honeywellanalytics.com

Manning Gas Detection www.manningsystems.com

Telephone Contact us by telephone at the numbers listed below.

Organization Phone Number

United States Honeywell Analytics Inc. 1-800-538-0363 1-913-712-5576 1-913-712-5580 Fax

Canada Honeywell Analytics Inc. 1-888-749-8878

Europe Honeywell PACE +44 (0)1202 676161

Asia Pacific Honeywell Asia Pacific Inc. +82 (0)2 2025 0307

Middle East Honeywell Analytics Inc. +971 4 3458 338

Sales Information Contact us at [email protected]

http://www.honeywell.com/

http://www.honeywellanalytics.com/

http://content.honeywell.com/global/

mailto:[email protected]


Contents Serial number:

Section Title Page

01 Introduction 5

02 Electrochemical F2 Sensor (EC-F2) 6

03 Electrochemical F2 Replacement Cell 7


05 Electrochemical F3 O2 Sensor (EC-F3) 9


07 Electrochemical F9 LCD Sensor (EC-F9) 12

08 Solid State Sensors (SS) 14

09 Linear Solid State Sensors (LSS) 16

10 Infrared NH3 Sensor (IR-NH3) 17

11 Infrared CO2 Sensor (IR-CO2) 18

12 Infrared Refrigerant Sensor (IR-R) 19

13 Infrared Refrigerant Sensor (IR-F9) 20

14 Bulk Semiconductor Sensor (SB) 22

15 Combustible Gas Transmitter (CGT) 23

16 Electrochemical P1 Portable Sensor (EC-P1) 24

17 Electrochemical P2 Portable Sensor (EC-P2) 25

18 Gas Tracker (GT) 26

19 Field Testing of Vent Line Sensors (VL) 27

20 Replacement Parts Ordering Guide 28


1 Introduction

This manual has been prepared to help in the calibration of Manning equipment. Please refer to the manual shipped with each piece of equip-ment for further information.

The calibration kit may contain either one or two disposable bottles filled with the dry gas appropriate for the sensor. Included in the kit is a calibration adapter, hose, valve, and flow meter.

Figure 1 shows the parts included in the Manning Calibration Kit, and Figure 2 shows how to hook up the span or zero gas to a typical sensor (in this case, the Manning EC-F2 sensor).

Be sure the calibration procedure matches the Manning equipment that is installed before proceeding with zero and span calibrations. Because calibration gas has a shelf life, each bottle has an expiration date printed on it. Do not use the calibration gas after the expiration date.

This manual must be carefully followed by all individuals who have or will have the responsibility for Manning equipment. Warranties made by Honeywell Analytics with respect to this equipment will be voided if the equipment is not used and serviced in accordance with the instructions in this manual. If in doubt about a procedure, please contact Honeywell Analytics before proceeding.

Please refer to the equipment instruction manuals for additional information

INSTRUCTIONS IN LID

1200

900600

300

0psi

USE NO OIL

Calibration adapterwith hose

Flow regulator(1.0 LPM)

Instructionsin lid

Zero gas

Span gas

E/C-F2

SHLD GND +24 SIG

SH

LD

GN

D

+2

4

SIG

NH3 PPMMODEL: EC-F2-NH3S/N: 0000

SPAN

ZERO

SENSOR

TEST(-)

TEST(+)

40 to

200 MVDC

®

1200

900600

300

0psi

USE NO OIL

Figure 1: Parts included in the Manning Calibration Kit

Figure 2: Typical calibration arrangement


2 EC-F2 Calibration Procedure

General Information The Manning EC-F2 sensor should be calibrated a minimum of once every six months, or after exposure to a large concentration of gas. The Manning EC-F2 sensor generally becomes less sensitive with age, therefore regular calibration is critical to maintain the accuracy of the sensor.

Zero Calibration After the unit is installed and has been powered up for a minimum of 24 hours, the unit should be zero calibrated by the following two procedures.

NOTE: If the sensor output is erratic immediately after the installation of a new cell, it may be a high gain (span) setting left over from a previous cell that was adjusted for aging.

• Be sure the unit is in clean air, or apply zero air at 1.0 L/min.†

• Adjust the zero pot (see Figure 3, Note 2) until the sensor outputs 4.0 mA (40 mV from Test [—] to Test [+]) (see Figure 3, Note 3).

Span Calibration • Perform zero adjustment before spanning.

• The table below shows what span gas to use and what the signal should be for various sensor ranges:

Sensor Range Span Gas Calibrated Signal (ppm) (ppm) Voltage (mV)

0—100 100 200

0—250 100 104

0—250 250 200

0—500 250 120

0—1,000 1,000 200

• Place calibration adapter firmly over the sensor.

• Apply span gas at 1.0 L/min† (span gas must be in air, not nitrogen or other carrier).

• After span gas has been on sensor for two minutes, adjust the span pot until the correct output is achieved (see Figure 3, Note 1).

For combinations not shown in the previous table, use the following formula to determine the output:

SGC Signal (mA) = x 16 + 4 SFSV

Where:

SGC = Span Gas Concentration, SFSV = Sensor Full Scale Value.

For example if 100 ppm SGC gas is used to calibrate a 250 ppm SFSV sensor, the signal would be as follows:

100ppm Signal = x 16 + 4 = 10.4 mA 250ppm

10.4 mA = 104 mV from TEST (—) to TEST (+)

If the correct output cannot be achieved, a replace-ment cell is required.

Figure 3: Zero and span adjustments on the Manning EC-F2 Sensor

E/C-F2

SHLD GND +24 SIG

SH

LD

GN

D

+2

4

SIG

NH3 PPMMODEL: EC-F2-NH3S/N: 0000

SPAN

ZERO

SENSOR

TEST(-)

TEST(+)

40 to

200 MVDC

®

(SENSOR)*40-200 mV

Black-

Red+

mVDC

Note 1: Span adjustment

Note 2: Zero adjustment

Note 3: Sensor output

Calibration adapter slips over sensor

*Sensor may be located externally † Check with Technical Support for use with another type of regulator or the discontinued flow meter.


3 EC-F2 Replacement Cell Procedure

Instructions for Installation • Slide ribbon cable out from under the retaining

clip (see Figure 4).

• Unplug ribbon cable and remove cell from its holder. Discard old cell.

• Install the new cell, plugging in the ribbon cable. Take care to center the plug properly on the header. Notice that the ribbon cable exits the bottom of the plug and curls back over it.

• Slide ribbon cable under the retaining clip and pull it snug to insure plug cannot slide off (see Figure 5).

• Allow the new cell to run for a minimum of one hour, then calibrate the sensor with certified calibration gas.

TROUBLESHOOTING NOTE: If the sensor output is erratic immediately after the installation of a new cell, it may be a high gain (span) setting left over from a previous cell that was adjusted for aging.

Figure 4: Manning EC-F2 Replacement Cell Closeup

E/C-F2

SHLD GND +24 SIG

SH

LD

GN

D

+2

4

SIG

NH3 PPM MODEL: EC-F2-NH3 S/N: 0000

SPAN

ZERO

SENSOR

TEST(-)

TEST(+)

40 to

200 MVDC

®

PlugCell Ribbon cable

Ribbon cableretaining clip

NOTE: Be sure ribbon cable is tucked under retaining clip and pulled snug.

NOTE: Be sure plug is centeredon circuit board pins.

Figure 5: Ribbon Cable Orientation


4 EC-F1 Calibration Procedure

General Information The Manning EC-F1 sensor should be calibrated a minimum of once every six months, or after exposure to a large concentration of gas. The Manning EC-F1 sensor generally becomes less sensitive with age, therefore regular calibration is critical to maintain the accuracy of the sensor.

Zero Calibration After the unit is installed and has been powered up for a minimum of 24 hours, the unit should be zero calibrated by the following two procedures.

NOTE: If the sensor output is erratic immediately after the installation of a new cell, it may be a high gain (span) setting left over from a previous cell that was adjusted for aging.

• Be sure the unit is in clean air, or apply zero air at 1.0 L/min.†

• Adjust the zero pot (see Figure 6, Note 1) until the sensor outputs 4.0 mA (40 mV from Test [—] to Test [+]) (see Figure 6, Note 3).




0—100 100 200

0—250 100 104

0—250 250 200

0—500 250 120

0—1,000 1,000 200






Where:



100ppm Signal = x 16 + 4 = 10.4 mA 250ppm



Figure 6: Checking signal voltage at the Manning EC-F1 Sensor

GND PWR

SEN SEN

SIG

TEST– TEST+

MET MET

40-200 mV

Black-

Red+

mVDC

MANNING SYSTEMSMODEL EC

ZE

RO

SP

AN

Sensor (may be internally mounted)



Note 3: Checking signal voltage

Calibration adapter slipsover sensor with stainlesssteel cap removed

† Check with Technical Support for use with another type of regulator or the discontinued flow meter.


5 EC-F3 O2 Calibration Procedure

General Information The Manning EC-F3 oxygen sensor comes factory calibrated but may require a span adjustment upon installation to compensate for local altitude and barometric pressure conditions.

Effects of Barometric Pressure on Oxygen: The output of the Manning EC-F3-O2 sensor is affected by changes in barometric pressure. If a unit is calibrated at a barometric pressure of 29.00 inches Hg in clean air to output 20.9 % O2, and the barometric pressure changes to 28.00 inches Hg, the output will indicate 20.2 % O2. Because of this, the installer should always perform a nominal calibration as described below when the unit is started up. After the nominal calibration is performed, the output will be expected to vary slightly with barometric pressure.

Nominal Calibration: After the unit is installed and has been powered up for a minimum of 8 hours, a nominal calibration will be achieved by the following method.

• Be sure the unit is in clean air with the area well ventilated.

• The sensor should indicate a concentration of approximately 20.9 %, which is the normal concentration of oxygen in clean air. This will vary depending on elevation and barometric pressure.

• Adjust the span pot until the sensor output indicates a concentration of 20.9 % (see Figure 7, Note 1). For the following ranges, the test signals should be:

Range 0-25%

20.0% = 4 mA or 40 mV (TP1-TP2)

20.9% = 17.37 mA or 173.7 mV

(TP1-TP2)

Range 15-25%

15% = 4 mA or 40 mV (TP1-TP2)

20.9% = 13.44 mA or 134.4 mV

(TP1-TP2)

Zero Calibration DO NOT adjust the zero pot without certified calibra-tion gas. If zero adjustment is required, the following procedure will zero the unit.

• Apply zero gas at 1.0 L/min† (zero gas must be in nitrogen).

• After zero gas has been on sensor for two minutes, adjust the zero pot until the correct output is achieved, (see Figure 7, Note 2).

Span Calibration Span calibration can be achieved by performing the nominal calibration described at the beginning of this section or by using calibration gas as follows:

• Perform zero adjustment before spanning.

• Apply span gas at 1.0 L/min† (span gas must be in nitrogen).


Calibration kits are available from Honeywell Analytics.

Figure 7: Zero and span adjustments to the Manning EC-F3 O2 Sensor

JP1

SHLD GND +24 SIG

TP1 TP2

SPAN

TS1

ZERO

SIG +

TB2

G – +

+

JP202 PREAMP

MANNING SYSTEMS, INC

40-200

Black-

Red+

mVDC

Calibration adapter slipsover sensor

Note 2: Zero pot

Note 1: Nominal calibration—span pot

Reading signal



6 EC-F9-NH3 Calibration Procedure

General Information The Manning EC-F9 sensor should be calibrated a minimum of once every six months, or after exposure to a large concentration of gas. The Manning EC-F9 generally becomes less sensitive with age, therefore regular calibration is critical to maintain the accuracy of the sensor.

Refer to the Manning EC-F9 sensor manual for more in-depth calibration procedure details.

Zero Calibration There is no zero pot as the pre-amp is factory zeroed and should not require any further adjustment.

Span Calibration NOTE: If the sensor output is erratic immediately after the installation of a new cell, it may be a high gain (span) setting left over from a previous cell that was adjusted for aging.

• Confirm that the sensor is in clean air or there is no ammonia present. Output should not be more than 4.6 mA (46 mV from Test[—] to Test[+]) (see Figure 8, Note 2).



0—100 100 200

0—250 250 200

0—250 100 104

0—500 250 120

0—1,000 1,000 200



• After span gas has been on sensor for two

minutes, adjust the span pot until the correct output is achieved (see Figure 8, Note 1).

• For combinations not shown in the previous table, use the following formula to determine the output:


Where:


For example, if 100 ppm SGC gas is used to calibrate a 250 ppm SFSV sensor, the signal would be as follows:

100 ppm Signal = x 16 + 4 = 10.4 mA 250 ppm





6 EC-F9-NH3 Calibration Procedure continued

Figure 8: Span adjustments on the Manning EC-F9 Sensor

SPAN

EC-F9-NH3

SENSORNH3

SN:

PPM

SHLD GND +24 SIG

TEST(-)

TEST(+)

LED

G R Y

JP1

SW1

40 to

200 MVDC

EC-F9A B

JP3

E.O.L.

40-200 mV

Black-

Red+

mVDC


LCD module connector

Note 2: LEDs

Note 4: Sensor cable plugsin here. Verify that sensor is plugged in properly and cable is secured.

Note 5: Pushbutton



7 EC-F9-LCD-NH3 Calibration Procedure

General Information The Manning EC-F9-LCD-NH3 sensor should be calibrated a minimum of once every six months, or after exposure to a large concentration of gas. The Manning EC-F9-LCD-NH3 generally becomes less sensitive with age, therefore regular calibration is critical to maintain the accuracy of the sensor.

Refer to the Manning EC-F9-LCD-NH3 sensor manual for more in-depth calibration procedure details.

Calibration Mode NOTE: If using the Modbus RTU output with the Manning AirAlert-96d controller, while in calibration mode, alarms A, B, and C will not be activated during calibration of the sensor.

NOTE: When replacing an aged or non-responsive cell, the new cell may cause an erratic or jumpy signal, sometimes causing false alarms. This is usually caused by excessive gain leftover from adjusting the span pot (increasing the sensitivity) for the old cell. Once the span calibration is performed on the new cell, the gain will be decreased to match the sensitivity of the new cell, reducing the jumpiness of the new cell.

Figure 9. Perform Span Calibration

NOTE: It is not recommended that any span gas with a concentration lower than ½ of the full-scale range is used for span calibration. For example, for a 0/500 ppm ranged sensor, do not use span gas lower than 250 ppm.

The Manning EC-F9-LCD-NH3 comes factory calibrated and should require minimal adjustments after installation. There is one pot on the preamp that is used for Span calibration. There is no zero pot as the pre-amp is factory zeroed and should not require any further adjustment.

Calibration Kits are available from Honeywell Analytics. Each calibration kit contains certified calibration gas and complete detailed instructions for calibration of all Manning sensors.

Accept Scroll Delay Scroll

Scroll

2 minute delay(timer expires)

Accept

Scroll/Delay

Process time-out(10 minutes)

* Menu *

Range:0-

ApplyGas

ApplyGas

SpanSnsr

ApplyGas

* Menu *

SpanSnsr


7 EC-F9-LCD-NH3 Calibration Procedure continued

Span Calibration The unit is factory calibrated and normally does not need to be spanned upon initial installation. Do not adjust the span pot without certified calibration gas!

If span calibration is required, follow the procedure below:

1 In the MAIN MENU, scroll until the Calib? screen is displayed.

2 Press Accept to enter CALIBRATION MENU. The range of the sensor is displayed.

3 Press Scroll. (2-minute timer starts) Verify LCD shows 0 ppm.

4 Apply span gas at 1.0 L/min† (span gas must be in air, not nitrogen or other carrier).

5 After span gas was applied to sensor for approximately two minutes, the LCD will display SpanSnsr, prompting you to span the sensor. At this time, adjust the span pot until the correct output is achieved (value equal to concentra-tion of span gas).

6 Press Scroll to end the span calibration.

7 Press Accept to exit the CALIBRATION MENU.


NOTE: If sensor output does not rise above 5% of full-scale during the calibration (in the case of a non-responsive cell), the 2-minute timer does not activate and the LCD will not prompt you to span the sensor (SpanSnsr). The LCD will continue to display ApplyGas, but will time-out after 10 minutes if 5% of full-scale is not achieved. The span calibration can be aborted at any time by pressing the Scroll button. Press the Accept button to return to the MAIN MENU.

NOTE: Calibration mode times out after 10 minutes, and normal (idle) operation is resumed.

Refer to Figure 10 to adjust the span of the sensor.

Figure 10. Perform Span Calibration

Accept Scroll Delay Scroll

Scroll

2 minute delay(timer expires)

Accept

Scroll/Delay

Process time-out(10 minutes)

* Menu *

Range:0-

ApplyGas

ApplyGas

SpanSnsr

ApplyGas

* Menu *

SpanSnsr



8 SS Calibration Procedure

General Information Manning SS solid state sensors have no adjustments at the sensor. All adjustments must be made by adjusting the alarm set point of the associated readout alarm unit. Calibration is accomplished by applying the concentration of gas that is wanted to trip the alarm unit. The peak signal voltage at the readout unit should be recorded during application of the calibration gas and the alarm setpoint at the readout unit should then be adjusted to this voltage.

Take care to dampen the supplied sponge with water when calibrating Manning SS sensors because the gas samples must be humidified.

NOTE: This sponge is only used for solid state sensors — never use the sponge for other sensor types.

See the appropriate sensor manual for typical responses to calibration gas.

NOTE: For calibrations at the Model 20 panel, see Figure 12. For the Model 21 panel, see Figure 13.

Zero Calibration There are no adjustments at the sensor, so zero is simply the voltage when the sensor is in clean air (air free from interference gases).

Span Calibration • Document the zero signal in clean air before

spanning.

• Moisten the provided sponge with water, wring it out, and insert it into the calibration adapter. This humidifies the calibration gas sample which is critical for proper sensor response in solid state sensors.

• Apply 250 ppm ammonia/balance air at 1.0 L/min† for two minutes.

• The peak signal voltage at the readout unit should be recorded during application of the calibration gas.

• The alarm setpoint at the readout unit should then be adjusted to the peak signal voltage.

Figure 11: Checking the signal at the Manning SS Sensor (Master)

S2

GR

OU

ND

MA

NN

ING

SY

ST

EM

S,

INC

MA

ST

ER

BO

AR

D R

EV

7.0

S1

TP

2

– +

SIG

O O R R

SH

LD

GN

D

+2

4

SIG

TP

1

VO

UT

S

RE

MO

VE

JUM

PE

R

WH

EN

US

ING

SLA

VE

TB

1

TB

2

TB

3

TB

4

TB

5

TB

6

TB

7

TO

SL

AV

EB

OA

RD

MASTERSENSOR

TO

MA

INU

NIT

MASTERSENSOR

40-200

Black-

Red+

mVDC

Calibration adapter slips over sensor

Checking signalat the sensor



8 SS Calibration Procedure continued

Figure 12: Checking the signal at the Model 20 panel

Figure 13: Checking the signal at the Model 21 panel

POWERSUPPLY

NC C NO

CH 1

NC C NO

HIGH ALARM

L N G

POWER IN 120 VAC

60 Hz

NC C NO

CH 2

NC C NO

CH 3

NC C NO

CH 4

NC C NO

CH 5

NC C NO

CH 6

NC C NO

CH 7

NC C NO

CH 8

NC C NO

CH 9

NC C NO

CH 10

RELAY1

LOALARM

RELAY2

LOALARM

RELAY3

LOALARM

RELAY4

LOALARM

RELAY5

LOALARM

RELAY6

LOALARM

RELAY7

LOALARM

RELAY8

LOALARM

RELAY9

LOALARM

RELAY10LO

ALARM

PPM

20

40

60

80

100

FAULT

HIGH

LOW

20

40

60

80

100

FAULT

PPM

HIGH

LOW

20

40

60

80

100

FAULT

PPM

HIGH

LOW

20

40

60

80

100

FAULT

PPM

HIGH

LOW

20

40

60

80

100

FAULT

PPM

HIGH

LOW

20

40

60

80

100

FAULT

PPM

HIGH

LOW

FAULT

HIGH

LOW

PILOT

FAULT

HIGH

LOW

PILOT

1

2

3

4

5

6

7

8

9

10

R

+

–

R

+

–

R

+

–

R

+

–

R

+

–

R

+

–

R

+

–

R

+

–

R

+

–

TP2

TP1

TPGND HI

HI

LO

SIG

LO

TESTPOINTS

0.4 - 2.0

Black-

Red+

VDC

Checking signalfrom sensor

MOUNT ENCLOSURE THIS END UP.DO NOT BLOCK PERFORATED VENT HOLES.

SENSOR

®

®

Wiring cable

Base unit fuse(power torelay coils)

Remote sensor enclosure

Model 20 Gas Monitoring Alarm System

NOTE: Individual HI alarm relay contacts rated 1/2 amp @ 24 VDC or 120 VAC

MOUNT ENCLOSURE THIS END UP.DO NOT BLOCK PERFORATED VENT HOLES.

SENSOR

®

®

NC

L N

W A

G

C NO

NC C NO

WARNING

RELAY CONTACTS 3A MAX @ 120 VAC

30 O

hm1

Wat

t

ALARM

ALM

TP1

TPGND

TESTPOINT

TESTPOINT

CONTROL

CONTROL

TP12V

TP2

WRN

1-5

Black-

Red+

VDC

Fuse MDL-1/4A

NOTE: Resistor inserted only if Sensor 2 is not connected

Checking SensorVoltage (VDC)

Remote SensorEnclosure

Power Cable

Sensor 1

NOTE: Sensors may be remotely located

Alarm Calibration

Warning Calibration


9 LSS Calibration Procedure

General Information The Manning LSS sensor comes factory calibrated and should require minimal adjustments after installa-tion. There are two pots on the preamp that are used for calibrations.

Zero Calibration After the unit is installed and has been powered up for a minimum of 24 hours, the unit should be zero calibrated by the following:

• Be sure the unit is in clean air.

• Adjust the zero pot until the sensor outputs 4.0 mA (40 mV from Test [—] to Test [+]) (see Figure 14, Note 2 and 3).

Span Calibration The unit is factory calibrated and normally does not need to be spanned upon initial installation. DO NOT ADJUST THE SPAN POT WITHOUT CERTIFIED CALIBRATION GAS! If span adjustment is required, the following procedure will span the unit:

• Perform zero adjustment before spanning (see Figure 14, Note 2).


• Apply span gas at about 1.0 L/min† (span gas must be in air, not nitrogen or other carrier).

• After span gas has been on sensor for two minutes, adjust the span pot until the correct output is achieved (see Figure 14, Notes 1 and 3). After span adjustments, allow the sensor to clear out for two hours and perform zero calibration if necessary.


Sensor Range Span Gas Calibrated Signal (ppm) (ppm) Reading (mV)

0—200 200 200

0—2,000 1,000 120

0—2,000 2,000 200

0—3,000 3,000 200



Where:



1,000 ppm Signal = x 16 + 4 = 12 mA 2,000 ppm

12 mA = 120 mV from TEST (—) to TEST (+)

If the correct output cannot be achieved, a replace-ment sensor may be required. For technical assistance, please call Honeywell Analytics.

Figure 14: Zero and span adjustments on the Manning LSS Sensor

+

– –

+

MANNING SYSTEMS, INC.MSI LSS 400

REV 0

GND

CAL

CAL

FLT

TEST +

TEST –

ZE

RO

40

TO

20

0M

VD

C

SP

AN

S

SHLD GND +24 SIG

40-200

Black-

Red+

mVDC

17-24

Black-

Red+

VDC



Linear SS sensor


Note 4: Power supply voltage † Check with Technical Support for use with another type of regulator or the discontinued flow meter.


10 IR-F4-NH3 Calibration Procedure

General Information There are only two pots on the pre-amp that are used for calibrations. All other pots are factory set and must never be adjusted. They can only be properly adjusted at the factory.

Zero Calibration After the Manning IR-F4-NH3 is installed and has been powered up for a minimum of 24 hours, the unit may be zero calibrated by the following:

• Confirm that no ammonia is present at the sensor location.

• Connect calibration gas hose to calibration port (see Figure 15, Note 5).

• Press the CAL button on the right side of the back board (see Figure 15, Note 3). The CAL LED should begin to flash.

• Adjust the zero pot (see Figure 15, Note 2) until the sensor outputs 4.0 mA, or 40 mV between TP1 and TP2 (see Figure 15, Note 1). Make small adjustments and wait for output to respond as adjustment response is highly dampened.

• Press the CAL button. The CAL LED should stop flashing. If the CAL button is not pushed, the unit will automatically leave the calibration mode after 10 minutes.


Leave the unit in “calibration mode” (CAL LED flashing).


Sensor Span Calibrated Range Gas Signal Reading (%) (%) (mV)

0—2 1 120

0—2 2 200

• Connect calibration gas hose to calibration port.

• Apply span gas at 1.0 L/min.†


• Push the “CAL” button again to take the unit out of calibration mode.

Figure 15: Zero and span adjustments on the Manning IR-NH3 Sensor

SIG

TB1

TP1

TP2

TS1

TS2

JP2

JP1

+24

GND

SHLD

TO S

OU

RC

E1

2

CAL

FILT CAL

40 - 200

Black-

Red+

mVDC

Note 1:Reading Signal

Note 2:Zero adjust

Note 4:Span adjust

Note 5: Connect Calibration Gas Hose here

Note 3:CAL button

Factory setDO NOT ADJUST



11 IR-F4-CO2 Calibration Procedure


Note that normal, well-ventilated, indoor CO2 levels due to human respiration are typically 0.05% to 0.07% (500-700 ppm). Normal outdoor CO2 levels are typically 0.04% (400 ppm). Zero gas (nitrogen) is required for a proper zero adjustment.

Zero Calibration After the Manning IR-F4-CO2 is installed and has been powered up for a minimum of 24 hours, the unit may be zero calibrated by the following:

• Apply zero gas (pure nitrogen) at the calibra-tion port at 1.0 L/min† (see Figure 16, Note 3).

• Adjust the zero pot (see Figure 16, Note 3) until the sensor outputs 4.0 mA, or 40 mV between TP1 and TP2 (see Figure 16, Note 1). Make small adjustments and wait for output to respond as adjustment response is highly dampened.



Sensor Span Calibrated Range Gas Signal Voltage (%) (%) (mV)

0—1 1 200 0—5 5 200

• Connect calibration gas hose to calibration port.

• Apply span gas at 1.0 L/min† (span gas must be in nitrogen) at the calibration port.

• After span gas has been on sensor for two minutes, adjust the span pot (see Figure 16, Note 2) until the correct output is achieved.



Where:


For example if 0.98% SGC gas is used to calibrate a 1.0% SFSV sensor, the signal would be as follows:

0.98 % Signal = x 16 + 4 = 19.68 mA 1.0 %

19.68 mA = 196.8 mV from TP1 to TP2

For technical assistance or Calibration Kits, please call Honeywell Analytics.

Figure 16: Zero and span adjustments on the Manning IR-F4-CO2 Sensor

SIG

TB1

TP1

TP2

TS1

TS2

JP2

JP1

+24

GND

SHLD

40-200

Black-

Red+

mVDC

GA

S IN


Note 2:Span Adjust

Note 3:Zero Adjust

Factory setDO NOT ADJUST!

ConnectCalibrationGas Hosehere

Note 4:CalibrationPort



12 IR-F4-R Calibration Procedure


There are two versions of the Manning IR-F4-R. The later version has a calibration button which does not exist on the earlier version. During calibration of the earlier version, ignore the steps relating to the calibration button.

Full scale range of the IR-F4-R22 is 0-3,000 ppm. For convenience, all versions of the Manning IR sensor will be calibrated with 1,000 ppm R-22. Refer to the table under “Span Calibration” to determine the output voltage required for the desired target gas.

Zero Calibration After the unit is installed and has been powered up for a minimum of 24 hours, the unit may be zero calibrated by the following:

• Press the calibration button to put the unit in “CAL” mode (see Figure 17, Note 3). The CAL LED will flash.

• Apply zero gas (pure nitrogen) at 1.0 L/min† (see Figure 17, Note 5).

• Adjust the zero pot (see Figure 17, Note 2) until the sensor outputs 4.0 mA, or 40 mV between TP1 and TP2 (see Figure 17, Note 1). Make small adjustments and wait for the output to respond because adjustment response is highly dampened.

Span Calibration • The unit should be in calibration mode to

perform the span adjustment.

• Perform zero adjustment before spanning.

• Apply span gas at 1.0 L/min.†

• The following table allows the calibration of the Manning IR-R sensor using 1,000 ppm R22 for any target gas listed:

mVDC Signal using 1,000 ppm R22 Target Gas Calibrated Signal Voltage (mV)

R-22 200 (using 3,000 ppm R-22) R-22 93 (using 1,000 ppm R-22) R-12 85 R-11 148 R-404a 84 R-507 84 R-125 91 R-21 146 R-134a 95 R-113 87 R-114 76 MP-39 69

• After span gas has been on sensor for two minutes, adjust the span (see Figure 17, Note 4) pot until the correct output voltage is achieved (see table above). For example, if the target gas in the table above is R404a, apply 1,000 ppm R-22 and adjust the signal voltage to 84 mV. Make small adjust-ments and wait for the output to respond because adjustment response is highly dampened.

• Press the “CAL” Button again to take the unit out of calibration mode.

Figure 17: Zero and span adjustments on the Manning IR-F4-R Sensor

SIG

TB1

TP1

TP2

TS1

TS2

JP2

JP1

+24

GND

SHLD

TO S

OU

RC

E1

2

40 - 200

Black-

Red+

mVDC


Note 2:Zero adjust

Note 4:Span adjust

Note 3:CAL button

Factory setDO NOT ADJUST

Note 5: Connect Calibration Gas Hose here



13 IR-F9-RXX Calibration Procedure


Refer to the Manning AirScanTMiR instruction manual for more in-depth calibration procedure details.

Zero Calibration STEP 1

Start: Press and hold both the “zero” (S1) and “span (S2) buttons simultaneously for one second or until the “system” LED begins to blink slowly. See example to the right. Refer to figure below for switch location.

Figure 18: Zero and span adjustments on the Manning IR-F4-R Sensor

STEP 2

Start: Apply pure nitrogen (N2) into the calibration port at a rate of 1.0 L/min† for at least 45 seconds (OR until output signal is within ± .02 mA of signal deviation/change).

• Press and hold the “zero” button (S1) for approximately 1 second or until the yellow “calibrate” LED is continuous ON.

• When yellow calibration LED is continuous ON, release the “zero” button. The “calibrate” LED will turn off and the unit will be zeroed.

“Zero” programming calibration mode

TEST +

S2

S1

JP3

JP1

JP2

ZERO

SPAN

TEST -

SIG

+24

GND

SHLD

DrawChamber

SYSTEM

CALIBRATE

FAULT

mA FAULT

IR SOURCE

ATMOSACTIVE

POWER

24

Black-

Red+

VDC

40-200

Black-

Red+

mVDC

Note 1: Checkingvoltage to sensorat +24 and GND

Note 2: Readingsignal at TEST+ and TEST-

Rx LEDPushbutton S1Pushbutton S2

Zero AdjustSpan Adjust

Tx LED

Serial PortICSP Programming Port

Tubing tocalibration point

POWER

SYSTEM

CALIBRATE

FAULT

mA FAULT

SOURCE

ATMOS

G

G

G

R

R

Y

Y

SEQUENCELED

OFF

OFF

OFF

N/A

POWER

SYSTEM

CALIBRATE

FAULT

mA FAULT

SOURCE

ATMOS

G

G

G

R

R

Y

Y

SEQUENCELED

N/A

OFF

OFF

N/A

N/A


13 IR-F9-RXX Calibration Procedure continued

Exit: System will automatically resume previous mode. This indicates the parameters are now programmed into memory.

Place multi-meter leads on Test(+) and Test(—) and ensure the output is steadily resting between 3.9 to 4.1 mA. If this isn’t the case, initiate the auto “zero” procedure once again.

Finish: Press and hold both the “zero” (S1) and “span” (S2) buttons simultaneously for one second or until the yellow “system” LED will be ON solid. See the following example. End of zero procedure.

Span Calibration This procedure sets the “span” or concentration level that would depict a 20 mA reading for full-scale target gas on the 4/20 mA output.

NOTE: This procedure should only be performed if the zero procedures are successfully completed.

Start: Set meter to mV DC, place meter leads on Test(+) and Test(—) respectively.

• Press and hold the “span” button (S2) for 1 second or more until the yellow “calibrate” LED blinks fast and the yellow “system” LED is blinking slowly (see the following example). See figure on previous page for switch and potentiometer location.

• Ensure the output rests between 3.9 and 4.1 mA

(39.0 to 41.0 mV). If this is not the case, perform the “zero” procedure again.

• Once the output is within the required range with nitrogen flowing, apply full-scale target gas into the calibration port at a rate of 1.0 L/min† for 1 minute immediately following the nitrogen flow.

• If the signal is 20 mA or greater, adjust the “span” potentiometer counter-clockwise until the signal is near 20 mA. If the output signal is less than 20mA, adjust the “span” potentio-meter clock wise until the signal is near 20mA. Because there is a slight delay in potentio-meter movement, make small adjustments and wait for the output to change because adjustment response is delayed between source pulses.

• Wait until the output signal has stabilized to within ± .02 mA of signal deviation/change. Adjust the “span” potentiometer again until the output reads around 20 mA.

Exit: Press and hold the “span” button (S2) for one second or more until the yellow “calibrate” LED turns off.

POWER

SYSTEM

CALIBRATE

FAULT

mA FAULT

SOURCE

ATMOS

G

G

G

R

R

Y

Y

SEQUENCELED

OFF

OFF

OFF

N/A

POWER

SYSTEM

CALIBRATE

FAULT

mA FAULT

SOURCE

ATMOS

G

G

G

R

R

Y

Y

SEQUENCELED

OFF

OFF

N/A

N/A



14 SB Calibration Procedure


Zero Calibration After the Manning SB sensor is installed and has been powered up for a minimum of 48 hours, the unit should be zero calibrated by the following:

• Be sure the unit is in clean air.

• Adjust the zero pot until the zero indicator green LED lights (see Figure 19, Note 4).

• Depending on the environment, background gases, etc., the zero may slowly drift upward with age. Periodically logging the sensor signals will determine whether an upward trend exists which would indicate that periodic zeroing is necessary.



Sensor Span Calibrated Range Gas Signal Reading

0—1% 1% 200mV

0—2% 1% 120mV

0—2% 2% 200mV

• Apply span gas at 1.0 L/min† (see Figure 19, Note 3). Span gas must be in air, not nitrogen or other carrier.

• After span gas has been on sensor for three minutes, adjust the span pot until the correct output is achieved (see Figure 19, Note 2).


Figure 19: Zero and span adjustments to the Manning SB Sensor

+

+

+

+

++

+

REDLED

+

REDLED

SHLD GND +24 SIG

+

GREENLED

SENSOR

HTL FLT

MANNING SYSTEMS, INC.

ZERO IND

SEN FLT

TPG

SPAN POT

ZEROPOT

ZE

RO

OU

TP

UT

+24V

DC

DC

GN

D

SH

IELD

SE

NS

VO

UT

TP

1

TP

240 - 200

Black-

Red+

mVDC

Reading signal

Note 1: Green LED

Note 3: Cover sensor with Calibration Adapter

Note 2: Span pot

Note 4: Zero pot



15 CGT Calibration Procedure

General Information The Combustible Gas Transmitter can be spanned with 1.00% Methane / balance air. The following table allows the calibration of the Manning CGT using 1.00% Methane / balance air for any target gas.

Table (Signal using 1.00% Methane/bal air)

Gas mV mA % LEL

Methane 72 7.2 20 Propane 96 9.6 35 n-Butane 96 9.6 35 n-Pentane 104 10.4 40 n-Hexane 120 12.0 50 Hydrogen 88 8.8 30 Methanol 88 8.8 30 Ethanol 104 10.4 40 Isopropyl Alcohol 128 12.8 55 Acetone 120 12.0 50 Methyl Ethyl Ketone 120 12.0 50 Benzene 128 12.8 55 Toluene 136 13.6 60 Di-ethyl Ether 56 5.6 10 Ammonia 64 6.4 15

Zero Calibration After the unit is installed and has been powered up for a minimum of 24 hours, the unit may be zero calibrated by the following:

• Apply zero air at 1.0 L/min† (see Figure 20, Note 4).

• Adjust the zero pot (see Figure 20, Note 3) until the sensor outputs 4.0 mA, or 40 mV between Loop “—” and “+” test points (see Figure 20, Note 1).


• Apply 1% Methane / balance air at 1.0 L/min† (see Figure 20, Note 4).

• After span gas has been on sensor for two minutes, adjust the span pot (see Figure 20, Note 2) until the correct output is achieved (see table at left).

For example, if Hydrogen is the target gas, apply the 1.00% methane to the Manning CGT sensor. From the table:

Gas mV mA % LEL

Hydrogen 88 8.8 30

Adjust the span pot until the meter reads 88 mV (8.8 mA). This is equivalent to 30% of the LEL for Hydrogen.

If the correct output cannot be achieved, a replace-ment element is required. For technical assistance, please contact Honeywell Analytics.

Figure 20: Zero and span adjustments to the Manning CGT Sensor

TB1

TB2

P

COMA

S

Z

+VSIG

LOOP

+

–

40-200

Black-

Red+

mVDC

Note 2:Span adjust

Note 1:Reading signal

Note 3:Zero adjust

Note 4: Cover Sensor with Calibration Adapter



0.01 CAL

Warning S.P. Potentiometer

Note 1: Span Potentiometer

Alarm S. P. Potentiometer

Note 2: Zero Potentiometer

16 EC-P1 Calibration Procedure

General Information Calibration is recommended every six months in normal use, or after exposure to a large concentration of gas. Span gas should be specific to the sensor.

The ZERO and SPAN potentiometers used during calibration are located inside the detector behind the front panel (see Figure 21). Remove the four screws in the corners of the front panel and remove the panel.

The calibration procedure requires the use of a bypass tee to allow a span gas to be drawn into the flow cell, and to allow span gas to flow past the sample inlet without creating variable pressure or dilution problems. Calibration gas cannot be fed into the flow cell under pressure from any outside source.

Zero Calibration Be sure the unit is in clean air. With the unit off, press and hold the instrument switch until the display reads CAL/MODE. Then release the switch. The display will change to XXX PPM/WARN SP. Press and release the switch twice more. The display should now read ±XXX/CAL.

After two minutes use a small screw driver to adjust the ZERO potentiometer until the display reads 0 (see Figure 22, Note 2).

If you do not intend to span the unit, press and hold the switch until the display reads DONE. Release the switch and the unit will revert to the normal operating mode.

Span Calibration • Perform a Zero Adjustment prior to making any

span adjustments.

• Using the bypass tee as shown in Figure 19, apply span gas and check to make sure there is a positive flow reading in the vent rotometer. This guarantees that the pump is not drawing in air and diluting the calibration gas sample.

• Press and hold the instrument switch until the display reads DONE. Then release and the unit will switch to the normal operating mode.

Honeywell Analytics provides a rapid turnaround factory calibration service that includes a Certificate of Calibration. Contact Honeywell Analytics for details.

Figure 21: Potentiometers

Figure 22: Zero and calibration flow configuration

• After two minutes adjust the SPAN potentiometer (see Figure 22, Note 1) until the display reads the value of the span gas.

1200

900600

300

0psi

USE NO OIL

Vent through flowmeter

Bypass tee

Calibration Gas


17 EC-P2 Calibration Procedure

General Information Calibration is recommended every six months in normal use. Each SMART-CELL stores its calibration and alarm setpoint information on its own internal memory chip. When the SMART-CELL is plugged into the Manning EC-P2, this information is used by the EC-P2. The SMART-CELL can be field calibrated by the user or returned to Honeywell Analytics for factory calibration.

The calibration procedure requires the use of a bypass tee to allow the gas to be drawn into the flow cell without creating variable pressure or dilution problems. Calibration gas cannot be fed into the flow cell under pressure.

When applying calibration gas, use the bypass tee as shown in Figure 20. The flowrate of calibration gas should be high enough that at least 0.5 SCFH is flowing out of the calibration tee. This can be measured with the supplied flowmeter and insures that air is not being drawn into the unit and diluting the calibration gas.

The unit may be zeroed without spanning it; however, never span the unit without first zeroing it.

Entering Zero/Span Mode • Push power button to turn unit on. Wait for

power up sequence to finish (30 seconds).

• Push and hold the unnamed button (second from left) first, then push and hold the MENU button. Hold both buttons until the screen goes blank (2 seconds). Release both buttons and the unit is now in Programming Mode.

• Push the SENS button and the unit is now in the zero/span mode.

Zero Calibration • Be sure the unit is in clean air or apply zero air

for two minutes.

• Push ZERO button.

• Push SAVE button to save the new zero calibration.

Span Calibration • Push SPAN button.

• Apply span gas for two minutes.

• Push INC button (increase) or DEC button (decrease) until the display matches the span gas concentration.

• Push SAVE button to store new span calibration.

Exiting Zero/Span Mode • Push DONE button twice slowly to get back into

normal operation mode.

Figure 23: Calibration of the Manning EC-P2 Sensor using a bypass tee


Bypass tee

1200

900600

300

0psi

USE NO OIL

CAUTIONDO NOT BLOCK INLETOR OUTLIET PORTS

INLET

OUTLET

TEST UNIT PRIOR TO USE


18 GT Gas Tracker Calibration Procedure

General Information Calibration is recommended every six months in normal use. Span gas must be 10,000 ppm NH3 (1%) and must be balanced in air, not nitrogen.

The SPAN potentiometer (see Figure 24, Note 2) is used during calibration and is located on the small board next to the battery pack.

The calibration procedure requires the use of a bypass tee to allow a span gas to flow past the sample inlet without creating variable pressure or dilution problems. Calibration gas cannot be fed into the flow cell under pressure from any outside source.

Zero Calibration Each unit is factory zeroed. Zero adjustment should not be made in the field.

Span Calibration Do not attempt to span the instrument without certified calibration gas.

• Run the unit for at least 10 minutes prior to calibration.

• Push the CALIBRATION PUSHBUTTON to put the unit in CAL MODE (see Figure 24, Note 1).

• Using the bypass tee as shown in the figure, apply 10,000 ppm span gas for 2 minutes. The flow rate of span gas should be high enough that at least 0.5 L/min is flowing out of the calibration tee. This can be measured with the supplied flowmeter and insures that air is not being drawn into the unit and diluting the calibration gas.

• After 2 minutes adjust the SPAN potentiometer (see Figure 24, Note 2) until the display reads 10,000 ppm.

• Push the CALIBRATION PUSHBUTTON to return the unit to normal operating mode.

Honeywell Analytics provides a rapid turnaround factory calibration service that includes a Certificate of Calibration. Contact Honeywell Analytics for details. For technical assistance, please call Honeywell Analytics.


Figure 24: Zero and span adjustments to the Manning GT

F

I

L

T

E

R

Alarm Setpoint Button

Span Pot

Alarm Pot

Warning Pot

WarningSetpoint Button

CalibrationPushbutton


Bypass tee

1200

900600

300

0psi

USE NO OIL


19 Field Testing of Vent Line Sensors

General Information The Manning VL vent line sensor is factory cali-brated and normally does not need to be spanned. Testing of the VL sensor is normally done in the field by removing the small 3/4" plug and injecting a small amount of propane/butane from an unlit plumber’s torch. Using this simple method, the sensor is challenged with a gas sample and the proper outputs and alarms are observed. (The challenge gas must cause a proper alarm trip.) Refer to the vent line sensor manual for more information.

In a vent line, the recommended trip point level is no lower than 12 mA. Lower setpoints can result in false trips.

Contact Honeywell Analytics to discuss techniques in calibration and testing depending on how the Manning VL sensor is mounted.


20 Replacement Parts Ordering Guide

Manning Replacement Parts and Calibration Gas Quick Reference

Part Number Order Number Description

29 Liter Gas Bottles

10566 RB-NH3/50 Cylinder of 50 ppm Ammonia, Balance Air



10559 RB-NH3/1000 Cylinder of 1,000 ppm Ammonia, Balance Air

10528 RB-NH3/1% Cylinder of 1% Ammonia, Balance Air

10520 RB-NH3/2% Cylinder of 2% Ammonia, Balance Air

17 Liter Gas Bottles

10556 RB-CH4/1% Cylinder of 1% Methane, Balance Air

10748 RB-CH4/4%-Bal N2, 17L Cylinder of 4% Methane, Balance N2

10560 RB-CO2/1% Cylinder of 1% Carbon Dioxide, Balance N2

10561 RB-CO2/5% Cylinder of 5% Carbon Dioxide, Balance N2

10661 RB-CO-200 Cylinder of 200 ppm Carbon Monoxide, Balance Air

10574 RB-N2 Cylinder of N2

10558 RB-O2/15% Cylinder of 15% Oxygen, Balance N2

10562 RB-O2/20.9% Cylinder of 20.9% Oxygen, Balance N2

10564 RB-R22/3000 Cylinder of 3,000 ppm R22, Balance Air

10977 RB-R404a/3000 Cylinder of 3,000 ppm R404a, Balance Air

10557 RB-ZA Cylinder of Zero Air

Replacement Parts

10049 EC-F2-NH3-RC Replacement Ammonia Cell for EC-F2 & EC-F9

10050 EC-F2-NH3-HR-RC Replacement Ammonia Cell for High Range EC-F2 & EC-F9

10091 EC-F3-O2-RS Replacement Oxygen for EC-F3 Sensor

10813 EC-F1-NH3-RC Replacement Ammonia Cell for EC-F1

10111 SS-NH3-RS Replacement Solid State Ammonia Sensor

10117 VL-F7-NH3-RA Replacement Vent Line Ammonia Sensor

10135 EC-P1-NH3-RC Replacement Ammonia Cell for EC-P1

10168 EC-P2-NH3-0/500-SC Replacement Smart Cell for EC-P2 for Ammonia 0/500 ppm

10169 EC-P2-NH3-0/2000-SC Replacement Smart Cell for EC-P2 for Ammonia 0/2,000 ppm

10244 CK-A Calibration Adaptor with 3 feet of tubing

10248 CK-T Portable Calibration Tee

10597 CK-R-1LPM-518 *Regulator 1.0 LMP #518 (for 58/103L cylinders)

10687 CK-R-1LPM-418 *Regulator 1.0 LPM #418 (for 17/34L steel cylinders)

*Note: Honeywell Analytics has discontinued the sale of the Flowmeter Assembly and replaced it with the #418 & #518 1-liter-per-minute fixed flow regulators.

Refrigerant Sensor for Commercial Applications

Manning AirScan iR

Instruction and Installation Manual

07/09

TM

Release A Draft

Honeywell Confidential & Proprietary This work contains valuable, confidential, and proprietary information. Disclosure, use or reproduction outside of Honeywell Inc. is prohibited except as authorized in writing. This unpublished work is protected by the laws of the United States and other countries.

Manning AirScan-iR Refrigerant Sensor 19546 AirScan-iR-comm 07/09 REVA Copyright © 2009 Honeywell Analytics. All Rights Reserved. 1

Notices and Trademarks

Copyright 2009 by Honeywell International Inc. Release A July 2009






1-800-538-0363


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Honeywell PACE

Honeywell Asia Pacific Inc.

Honeywell Analytics Inc.


Symbol Definitions

The following table lists those symbols used in this document to denote certain conditions.

Symbol Definition

ATTENTION: Identifies information that requires special consideration.

TIP: Identifies advise or hints for the user, often in terms of performing a task.

REFERENCE-EXTERNAL: Identifies an additional source of information outside of this bookset.

REFERENCE-INTERNAL: Identifies an additional source of information withinthis bookset.

EARTH GROUND - Functional Earth Connection: This connection shall be bonded to Protective Earth at the source of supply in accordance with national and local electrical code requirements.


Contents

Section 1 Sensor Description 2 Installation

Serial number:

Title System Specifications and Sensor Specifications

A

B

Locating the Sensor TMFigure 1: Mounting Dimensions for the Manning AirScan iRWiring TMFigure 2: Wiring Diagram for Manning AirScan iR Start-up Procedure Figure 3: Required LED Status at Start-up

Pushbutton Operation, LED Indicators, Adjustment Pots and Test Points Figure 4: Board Component Layout Figure 5: LED Layout LED Indicators and Blink Sequence Figure 6: LED Blink Sequence Figure 7: LED Indicator Summary Normal Run Modes 4/20 mA Loop Test Mode Calibration Mode Fault Indicator Error Sequences

Modes of OperationNormal Run Modes 4/20 mA Loop Modes Calibration / Programming Modes

Calibration Figure 8: Board Component Layout 4/20 mA Output Calibration Zero Calibration Figure 9: Board Component Layout Span Calibration

Diagnostic ProceduresSimple Zero Test 4/20 mA Output Loop Integrity Check

TroubleshootingElectrical Interference TMFigure 10: Troubleshooting the Manning AirScan iR Sensor On-Board Diagnostic System Error on 4/20 mA Output Sensor Output at 0 mA Sensor Output at .5 mA Gas Concentration Indicated with No Refrigerant Present IR Source Failure

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1010 10 11 11 12 12 12 10 13

1414 15 16

1717 19 19 20 20

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2323 23 23 24 24 24 24 24

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3 Operation A

B

C

D

E

F

4 Maintenance 5 Replacement Parts 6 Limited Warranty


Introduction

This manual has been prepared to help in the use and installation of the Manning AirScan iR (Infrared Refrigerants) Sensor. This manual will convey the operating principles of the sensor, ensure proper installation, and demonstrate start-up and routine maintenance procedures.

ATTENTION: This manual must be carefully followed by all individuals who have or will have the responsibility for using or servicing the Manning AirScanTMiR Sensor. Warranties made by Honeywell Analytics with respect to this equipment will be voided if the equipment is not used and serviced in accordance with the instructions in this manual. If in doubt about a procedure, please contact Honeywell Analytics before proceeding.

TM


1 Sensor Description

Cable Recommendation: Three conductor, stranded,shielded cable with drain wire, all enclosed in a vinyl jacket. For cable runs up to 200 feet use, #18 AWG (Belden #8770 or equivalent). For cable runs up to 1,000 feet, use #16 AWG (Belden #8618 or equivalent).

Unit Enclosure: NEMA 4, gasketed, molded fiberglassreinforced polyester. Non-painted, non-rusting construction appropriate for food areas. UL 508 listed, CSA certified for use with industrial control equipment.

ATTENTION: The standard Manning AirScan iRis for use in non-classified areas only.

TM

Gas detection by the infrared method is based on theprinciple that most gases absorb infrared energy at a characteristic frequency. In this instrument, a broad band infrared source emits energy which is then band- pass filtered to produce a narrow range of frequencies characteristic of the refrigerants’ (CFC/HCFC/HFC) absorption spectra. Any refrigerant in the gas sample cell selectively absorbs energy reaching the detector. This reduction in energy is detected, amplified and sent to the signal processing portion of the system.

The Manning AirScan iR Sensor line is a three-wire,4/20 mA sensor for two bands of refrigerants available in a range of 0—3,000 ppm, but can be adjusted for lower ranges, if required. The low-band or R-404a infrared sensor reacts to R-123, R-134a, R-404a and TMR-507. The high-band or R-22 Manning AirScan iR sensor reacts to R-22.

Its solid, high-mass metal bench provides structuraland thermal stability, greater immunity to vibration, as well as superior EMI/RFI shielding of the detector and source. Internal compensation for environmental changes allows the sensor to automatically adapt to fluctuating temperature and humidity conditions. The unit exhibits extremely high reliability with no moving parts.

Every two seconds SensorCheck technology monitors TMthe Manning AirScan iR source and ensures that the dual channels are functioning properly. A notification signal will be transmitted if any of several performance parameters is not met.

Monitoring equipment must be configured to indicate a fault if the signal is less than 1.5 mA. All signals over 20 mA must be considered a high gas concentration.

Manning infrared sensors are normally long-lived (5years plus), unless physically damaged or wetted with water or other liquid.

TM

TM

Sensor Specifications

Type: CFC/HCFC/HFC selective infrared gas sensor/ TMtransmitter Manning AirScan iR

Method of Detection: Dual channel infrared energyabsorption (N.D.I.R. Non-dispersive Infrared)

Gases Monitored: Low-Band (R-404a, R-507, R-134a,and R-123), High-Band (R-22)

Range Available: 0—3,000 ppm (can be rescaled to0—1,000 ppm, or 0—500 ppm if required)

SensorCheckTM Features: Dual channel functionality test,source strength evaluation, incoming voltage monitor, IR source integrity check, operating temperature monitor, “zero” down drift monitor, and internal circuitry check.

Accuracy: ± 3% of full scale

Repeatability: ± 1% of full scale

Cross Sensitivity: Not affected by moisture, food odors, floor cleaners, temperature changes, etc.

Operating Humidity: 0—100% RH (condensing) Operating Temperatures: —20° F to +140° F (—29° C to +60° C)

Storage Temperature: —20° F to +140° F (—29° C to +60° C)

Gas Sampling: Diffusion method with no moving parts

Sampling Frequency: Real time continuous monitoringof all points

Response Time: T90 in 10 seconds with full-scale targetcalibration gas @ .75 L/min flow rate

Weight: 4.4 lbs.

Dimensions: 9.59" high x 7.71" wide x 4.52" deep

System Specifications Electrical Power: 24 Volts DC regulated, 1.0 amp.

Output: Linear 4/20 mA output into a load resistor of 500ohms maximum

Cable Length to Sensor: 1,000 feet maximum


2

A

Installation

Locating the Sensor • To prevent electrical interference, keep sensorand wire runs away from mercury vapor lights, variable speed drives, and radio repeaters.

Protect sensor from physical damage (fork lifts,etc.).

Do not mount the sensor over a door in arefrigerated area.

For highly critical locations more than onesensor should be installed in each room.

Because each sensor can only “report” what it is seeing at the moment, it is very important that the sensor be located where leaks are most likely to occur. CFC/ HCFC/HFC vapor is heavier than ambient air, so in a room with no air movement it will tend to settle. For quickest detection, mount the sensor about one to two feet from the floor, close to the potential leak source.

If the primary application is the fastest possible leakdetection, mount the sensor near the potential leak sources. In doing this, be aware that the indicated concentration may not be representative of personnel exposure and easy access for the required calibration and maintenance could be compromised.

General Mounting Considerations: •

• •

•

•

•

Must be easily accessible for calibration andmaintenance.

Always mount the sensor vertically. Mount the sensor close to the potential leak source for fastest possible leak detection.

If personnel protection is the primary application, mount in the “breathing zone.”

Protect sensor from water, excessive humidity,and wash-down.

Take air movement and ventilation patterns intoaccount.

•

•

•

Very Important:

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••

•

•

Sensor must be mounted vertically. Never mount sensor flat on a ceiling. Enter enclosure only through existing hole in bottom of enclosure. Always make a drip loop in the conduit.

Never mount sensor on a vibrating surface.

Mount sensor enclosures through the flange holes asshown in Figure 1, and always mount vertically.

Penthouses: Multi-Coil (defrost one coil at a time) —In this case the best location is usually in the center of the penthouse four or five feet above the grate.

Single Coil (or when all coils defrost at the same time) —In this case high moisture conditions can occur and the sensor should be mounted one foot above the grate.

Engine Rooms: The Manning AirScan iR sensorshould be mounted in a cool part of the room, if possible. Keep the sensor away from hot air exhausting from electric motors or other machinery.

TM

Figure 1: Mounting Dimensions


2 Installation continued

Ground the shield at the main control panel. Connectthe shield wire in the sensor terminal block labeled shield. Tape all exposed shield wire at the sensor to insulate it from the enclosure.

All penetrations into a refrigerated room should besealed to prevent condensate from forming in the conduit and dripping into the sensor enclosure.

Make drip loops for cables going into sensor housings (see Figure 1). Follow the special mounting instructions on the enclosure (…This End Up).

Electrical Power: 24 VDC regulated, 1.0 amp.

Output: Circuit board mounted sensor provides alinear 4/20 mA output. Monitoring equipment may have a maximum input impedance of 500 ohms.

Contact Honeywell Analytics for specific wiring TMinstructions when using Manning AirScan iR sensors TMwith a Manning AirAlert 96d readout unit.

Cable Recommendation: Use #18/3 (Belden #8770) for cable runs up to 200 feet. Use #16/3 (Belden #8618) for cable runs up to 1,000 feet. Use only the existing punched holes for connections to the sensor. Use only the existing punched holes for connections to the sensor.

Monitoring: The Manning AirScan iR RefrigerantSensor may be monitored by any Manning Readout/Alarm unit or other appropriately configured system. Monitoring equipment must be configured to indicate a fault if the signal is below 1.5 mA. All signals above 20 mA must be considered a high gas concentration. A failed sensor will output a 0.5 mA signal.

TM

Ceiling Hung Evaporators: When mounting Manning TMAirScan iR sensors near evaporators, mount the sensor no higher than two feet below the top of the evaporator coil. Do not mount in high air flow (1,200 feet/minute maximum). Never mount the sensor on evaporators as vibration can damage the sensor.

Other Locations: When mounting Manning TMAirScan iR sensors in locations such as roof top air units, ductwork, attic spaces, makeup air intakes, etc., contact Honeywell Analytics for application assistance and recommendations.

B Wiring

Electrical wiring must comply with all applicable codes.Plant equipment that may be involved and operating conditions should be discussed with local operating personnel to determine if any special needs should be considered.

Nearly all start-up problems are due to improper wiringor monitor configuration. Please follow these guidelines carefully.

Always use three conductor, insulated, stranded, shielded copper cable. Use only three conductor cable, not two cables of two conductor wire (see Figure 2).

Do not pull sensor wiring with AC power cables. This will cause electrical interference. Be sure there are no breaks or splices in sensor wiring runs. If cable runs cannot be made without a splice, all connections must be soldered. Soldering should be done using a rosin flux to tie the connecting ends of sensor wires to ensure a positive and long-lasting contact.

If the AirScan iR is to be used with the AirAlert 96d, pleasecall Honeywell Analytics for specific wiring instructions.

Figure 2: Wiring Diagram

TM TM


3 Operation

TM The Manning AirScan iR has several modes of operation, including two normal run modes, two 4/20 mA loop check modes and five calibration modes. These will be explained in Operation, Section C, Modes of Operation. Modes are entered by properly activating pushbuttons located on the circuit board, shown in Figure 4.

Sensor operation status is indicated by the blink pattern of seven LED’s located in a vertical row on the right side of the sensor circuit board (see Figure 4). LED status is differentiated by color and duration/ pattern of blink(s). LED Indicators and Blink Sequences are shown in Figure 6, followed by an explanation of blink patterns.

IMPORTANT: The Manning AirScan iR sensor is factory calibrated and should require minimal adjustments after installation. This sensor was calibrated at an altitude of 1,000 ft. above sea level. For installations where the altitude is greater than 3,500 ft. above sea level, it is necessary to recalibrate the sensor “span” during the initial setup for more accuracy and reliability.

Allow the sensor to operate for 12 hours with theenclosure sealed prior to testing the sensors. This will give the sensor time to reach thermal equilibrium to the external and internal temperatures while in operation. Because sensors are normally located at a distance from the main unit, the test time required and accuracy of the response checks will be improved if two people perform the start-up procedures and use radio contact.

Start-Up Test:

1)

2)

One person exposes each sensor to a small amount of the gas that is being monitored.

The second person stays at the control unit to determine that each sensor, when exposed to the gas fumes, is connected to the proper input and responds, causing appropriate alarm functions.

TM

A Start-Up Procedure Before applying power, make a final check of all wiringfor continuity, shorts, grounds, etc. It is usually best to disconnect external alarms and other equipment from the sensor until the initial start-up procedures are completed.

Check the power supply voltage to the sensor with adigital volt meter set to VDC. Place the black lead on sensor terminal GND and the red lead on +24 (see Figure 4, Note 1). Voltage should be between 21 and 28 VDC. If voltage is outside this range, check power supply and wiring.

After power-up, ensure the LED’s below are operationalas follows (see Figure 3):

• • •

Green “Power” LED continuous ON Both Fault LED’s are OFF Green “source” LED is blinking once every 2 seconds

Figure 3: Required LED Status at Start-up

NOTE: For cold/humid adverse environmental conditions the “ATMOS” LED may be turning on and off periodically. In addition, the “system” LED may be blinking or continuous ON, also described in later sections.


3

B

Operation continued

Pushbutton Operation, LED Indicators, Adjustment Pots and Test Points

TM

•

•

•

“Zero” adjustment pot — adjusts output calibration of the 4 mA nominal resting point

“Span” adjustment pot — adjusts the 20 mAconcentration level or unit span/sensitivity.

Pushbutton S1 — used to initiate the auto-zerofunction, program the 4 mA output calibration, and initiate the 4/20 mA loop test.

Pushbutton S2 — used to program the span setting.

Test(+) and Test(—) for connection to a DC Voltmeter (see Figure 4, Note 2).

The Manning AirScan iR has two internal pushbuttons, and two adjustment pots that are utilized for navigation of test functions, calibrations, and operating modes. In addition, a pair of test points is also provided that assist in the connection to standard meter leads for use in the upcoming calibration and diagnostic procedures (see Figure 4).

Figure 4: Board Component Layout

•

•

IMPORTANT: The pushbutton(s) must be pressedthe correct number of times and at the correct rate.

• When a multi-press sequence must be performed,the button must be pressed rapidly and evenly, lifting one’s finger completely from the actuator for each consecutive press.

For press and hold activations, one’s finger mustalways be applying a down pressure without disruption for the specified time in order to activate the desired mode.

See complete details of each operation in otherparts of the manual.

TM

•

•

The Manning AirScan iR also has a group of LED’s(see Figure 5) that blink in specific sequences (see Figure 6 on next page) to indicate sensor operation and programming modes. A summary of sensor operation and programming modes with corresponding LED blink sequences is shown in Figure 7 on page 12.

Figure 5: LED Layout


3 Operation continued

Red Fault LED (all scenarios produce a .5 mA output)

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•

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Continuous ON indicates a failed source, lowsignal, or circuit failure.

Slow blink indicates the power supply DC 24Vinput voltage is too low.

Medium double blink indicates sensor is outsidethe operating temperature range.

Fast blink indicates the signal drifted below 4 mAand needs to be re-calibrated, only in non-filtered output run mode (no dead-band).

LED Indicators and Blink Sequence Figure 6: LED Blink Sequence

Red mA Fault LED attempts to output .5 mA faultsignal

•

Green Power LED • Continuous ON when power is applied

•

Fast blink indicates 4/20 mA loop failure or loadresistance too high.

Green Source LED

One blink every 2 seconds indicates when sourceis energized and also that the source is not short circuited.

Yellow System LED •

•

• •

Continuous ON during normal filtered output runmode — “dead band” from 4 to 4.6 mA

Slow blink during normal non-filtered output runmode

Fast blink indicating unit lost calibration data

OFF during 4/20 mA loop check

Green ATMOS LED

• Continuous ON indicates ATMOS circuitry is activeor adjusting the enclosure’s internal environmental conditions for the sensor to function reliably.

If the Source LED isn’t blinking, do not proceeduntil the condition is corrected.

If a Fault LED is lighted, immediately refer to FaultIndicator Error Sequences (page 13) to determine potential problem. Do not attempt calibration if a Fault is indicated.

All status LED’s are subordinate to Fault indicators.

If an LED is indicated as OFF, it must actually beOFF for proper sensor operation.

If an LED status is N/A (not applicable), that LEDindication may vary depending on other operational factors.

Yellow Calibrate LED •

• •

•

Continuous momentary ON for auto-zero modeactivation

Slow blink for 4 mA output calibration mode Medium double blink indicates 4/20 mA loopcheck .5 mA (low)

Fast blink for “span” calibration mode and 4/20 mA loop check 22 mA (high)

NOTES:

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•

•

•

•



Figure 7: LED Indicator Summary

See LED indicators and blink sequence descriptions on page 11.

Normal Run Mode 4/20 mA Loop Test Mode

Calibration Mode



Figure 7: LED Indicator Summary, continued See LED indicators and blink sequence descriptions on page 11.

Fault Indicator Error Sequences


3

C

• • • •

•

•

Operation continued

Modes of Operation TM

The Manning AirScan iR has various modes of operation and calibration:

Normal run mode with output filtering Normal run mode without output filtering 4/20 mA loop check 4/20 mA calibration to an external PLC or read-out panel

Neutral gas resting point or “zero” calibrationmode

Span calibration modes

Normal run mode without output filtering This mode outputs a signal that nominally rests at 4 mA and can range continuously from 0 to 27 mA. Any subtle changes in sensor response will be sent to the mA loop output. This mode is entered automatically when the calibration modes are activated. Some users may wish to see the subtle anomalies in the signal near the nominal 4 mA rest area.

Start: If the “system” LED is continuous ON, pressand hold both S1 and S2 simultaneously for 1 second or more until the “system” LED is blinking slowly then release both buttons to enter this mode. If the “system” LED is blinking fast this mode is always engaged and can only be exited by fully calibrating the unit. See the following example.

Normal Run Modes Normal run mode with output filtering This mode outputs a signal from 4 to 27 mA with a “dead band” from 4 to 4.6 mA. This “dead band” masks small environmental anomalies that could facilitate output signal fluctuations or transients around the 4 mA resting point when the unit is not sensing target gas.

Start: If the “system” LED is blinking slowly, pressand hold both S1 and S2 simultaneously for 1 second or more until the “system” LED is continuous ON, then release both buttons. If the “system” LED is blinking fast, this mode cannot be engaged and the factory needs to be contacted. See the following example.



To proceed to the next step in the mA test, press andhold S1 for 1 second or more until the yellow “calibrate” LED is a medium double blink. See the following example. The output should be between .4 and .6 mA.

.5 mA Fault Output Test

4/20 mA Loop Test (22 mA full-scale and .5 mA fault check) Start: Press S1 5 times within a two to three secondperiod of time. The yellow “system” LED will turn off and the yellow “calibrate” LED will blink fast. See the following example. Output should be 21 to 22.5 mA.

22 mA Full Scale Output Test

Exit: Press and hold S1 for 1 second or more until theyellow “system” LED resumes the state before the mA test was initiated and the yellow “calibrate” LED turns off.



Exit: To program the “span” setting and exit this mode, press and hold S2 for 1 second or until the yellow “system” LED resumes the state before the calibration mode was initiated and the yellow “calibrate” LED turns off.

4 mA Output Calibration/Programming Mode

Start: Press and hold S1 for 7 seconds or until theyellow “system” LED turns continuous ON and the yellow “calibrate LED blinks slowly. See the following example.

Once in this mode the “zero” pot can be adjusted tocalibrate the 4 mA output to a PLC, SCADA system, panel, etc.

Calibration/Programming Modes:

Refer to Calibration, Section D before proceeding.

Auto “ZERO” Program Function Start: Press and hold S1 for 1 second or until the yellow“calibrate” LED turns continuous ON. Release S1 and the yellow “calibrate” LED will turn off. This indicates the unit “zero” is now programmed to a neutral or 4 mA resting state for 0 ppm of target gas.

“Span” Calibration/Programming Mode Start: Press and hold S2 for 1 second or until the yellow “system” LED blinks slowly and the yellow “calibrate” LED blinks fast. Once in this mode the “span” pot can be adjusted to determine the 20 mA full-scale concentration.

Exit: To program the 4 mA calibration point and exitthis mode, press and hold S1 for 1 second or until the yellow “system” LED resumes the state before the calibration mode was initiated and the yellow “calibrate” LED turns off.


3

D

Operation continued

Calibration In addition, the LED indicators and blink patternmeanings are also summarized in this section. The calibration procedure will require use and knowledge of the following tools within the sensor:

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•

•

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“Zero” adjustment pot — adjusts output calibrationof the 4 mA nominal resting point

“Span” adjustment pot — adjusts the 20 mAconcentration level or unit span/sensitivity

Pushbutton S1 — used to initiate the auto-zerofunction and program the 4 mA output calibration

Pushbutton S2 — used to program the span setting

Before calibrating the unit, ensure the startup procedure was followed and unit was powered on for a minimum of 12 hours (with the enclosure door closed) in the operating environment.

IMPORTANT NOTE: For environments where the ambient temperature is less than 10° F, during the calibration procedure, the door must be closed as far as possible. This will ensure the sensor temperature will not drop below the minimum operating temperature which could adversely affect the programmed calibration parameters.

There are only two adjustment pots and two push-buttons on the main board that are used for programming the calibration parameters. See Section B, Pushbutton Operation, LED Indicators, Adjustment Pots and Test Points. Use Section B to familiarize yourself with the pushbuttons S1, S2, adjustment pots “zero”, “span”, Test(+), Test(—) and their locations on the main board (see Figure 8).


In addition, there are four LED’s used in the calibrationprocedure. Yellow “system” and “calibrate”, and red “fault” and “mA fault” LED’s located on the main board are utilized as status indicators during the calibration procedure and as diagnostic and trouble indicators.

Non-calibrated Sensor or Loss of Factory Calibration

IMPORTANT: Upon power up, if the yellow “system” LED is showing a fast blink pattern, the unit hasn’t been calibrated yet or has lost the factory calibration and requires a full calibration before it can reliably read the target gas. See the following example. Should this occur, please contact Honeywell Analytics for assistance!



Non-Filtered Output Mode (no signal deadband)

Start: Press and hold both the “zero” (S1) and “span”(S2) buttons simultaneously for one second or until the “system” LED begins to blink slowly. See example below.

This mode will allow any anomalies to be transmittedfrom 0 to 27 mA on the output. This mode is also used in the upcoming Simple Zero Test procedure.

Before continuing with the calibration procedure, determine which of the two Normal output modes is best for the control scheme. Filtered output holds a stable 4 mA signal within a dead-band range while the non-filtered output allows the signal to be seen without any output limitations.

After this output mode choice is made, continue through Steps 1—3 of the Calibration Procedure. As a first step, the 4 mA output is matched to the signal input device being used as a control panel. After this is accomplished, Step 2 (Zero Calibration) and Step 3 (Span Calibration) can be completed in that order.

Filtered Output Mode Each unit is equipped with a filtered output or “dead band” output mode which locks the output at 4 mA for signal readings of 4 to 4.6 mA. This masks surrounding abrupt adverse environmental transients that would cause a small short-term anomaly on the 4 mA resting point for a near 0 ppm reading of the target gas. In this mode, the yellow “system” LED will be ON. See the following example.

Exit: To revert back to “dead band” mode, repeat thesame button press procedure above. This button press sequence will toggle between modes (filtered to non-filtered).



STEP 2

Zero CalibrationThis procedure sets the internal reference that is indicative of 0 ppm of target gas. It MUST be performed before proceeding or every other setting will be offset and inaccurate. The “zero” can be initiated at any time as long as a neutral gas is flowing through the calibration port or the surrounding air is known to be FREE of any target gas down to 1 ppm.

Start: Apply pure nitrogen (N2) into the calibration portat a rate of 1.0 L/min* for at least 3 minutes (OR until output signal is within ± .02 mA of signal deviation/ change).

• Press and hold the “zero” button (S1) for approxi-mately 1 second or until the yellow “calibrate” LED is continuous ON.

When yellow calibration LED is continuous ON,release the “zero” button. The “calibrate” LED will turn off and the unit will be zeroed. See example below.

STEP 1

4/20 mA Output Calibration This procedure calibrates the 4/20 mA output to match a PLC input converter or various devices that interpret the 4/20 mA signal output to ensure the 4 mA output rests at a true 4 mA even with minor mismatches in load resistance, long feed wiring, or adverse environmental conditions.

Start: Set meter to mV DC and place meter leads onTest(+) and Test(—) respectively (see Figure 9).

• Press and hold the “zero” button (S1) for 5 seconds or until the “calibrate” LED is blinking slowly and the “system” LED is continuous ON. Make sure the “mA Fault” LED is OFF.

Adjust the zero potentiometer until the output reads 3.99 to 4.01 mA (39.9 to 40.1 mV). This sets the 4 mA resting point. Make small adjustments and wait for the output to change because adjustment response is delayed between source pulses.

• •

4 mA output programming calibration mode “Zero” programming calibration mode

Exit: Press and hold the “zero” button (S1) for onesecond or more until the “calibrate” LED turns off.

The “system” LED will resume the previous state, either“filtered” or “non-filtered” output mode. This indicates the parameters are now programmed into memory.

Exit: System will automatically resume previous mode,either “normal” or “no dead band” mode. This indicates the parameters are now programmed into memory.

Place multi-meter leads on Test(+) and Test(—) andensure the output is steadily resting between 3.9 to 4.1 mA (see Figure 9 on next page). If this isn’t the case, initiate the auto “zero” procedure once again.

*Check with Technical Support for use with another type of regulator or the discontinued flow meter.



Press and hold the “span” button (S2) for 1 secondor more until the yellow “calibrate” LED blinks fast and the yellow “system” LED is blinking slowly. See the following example.


Ensure the output rests between 3.9 and 4.1 mA(39.0 to 41.0 mV). If this is not the case, perform the “zero” procedure again.

Once the output is within the required range withnitrogen flowing, apply full-scale target gas into the calibration port at a rate of 1.0 L/min* for 3 minutes immediately following the nitrogen flow.

If the signal is 26 mA or greater, adjust the “span” potentiometer counter-clockwise until the signal is near 20 mA. Because there is a slight delay in potentiometer movement, make small adjustments and wait for the output to change because adjustment response is delayed between source pulses.

Wait until the output signal has stabilized to within± .02 mA of signal deviation/change. Adjust the “span” potentiometer again until the output reads around 20 mA.

Exit: Press and hold the “span” button (S2) for onesecond or more until the yellow “calibrate” LED turns off. The yellow “system” LED will resume the previous state, either “filtered” or “non-filtered” output mode. This indicates the parameters are now programmed into memory.

STEP 3 Span Calibration This procedure sets the “span” or concentration level that would depict a 20 mA reading for full-scale target gas on the 4/20 mA output. The lower the target gas concentration is for a span of 20 mA, the more sensitive or responsive the unit would be to lower ppm readings.

NOTE: This procedure should only be performed ifthe zero and 4/20 mA procedures are successfully completed.

Start: Set meter to mV DC, place meter leads on Test(+) and Test(—) respectively (see Figure 9).

Apply pure nitrogen (N2) into the calibration port ata rate of 1.0 L/min* for at least 3 minutes (OR until output signal has stabilized to within ± .02 mA of signal deviation/change). If N2 is currently flowing from previous “zero” calibration, disregard the additional flow time.



3

E

Operation continued

Diagnostic Procedures Exit: Press and hold both the “zero” (S1) and “span”(S2) buttons simultaneously for 1 second or more until “system” LED is continuous ON. Unit should be ready for long-term operation.Simple Zero Test

This test will ensure the unit is calibrated for a true“zero” and duly represents an absence of target gas in this condition.


• Apply pure nitrogen (N2) into the calibration portat a rate of 1.0 L/min* for at least 3 minutes. Check the status of the yellow “system” LED. If this LED is continuous ON, place the unit in non- filtered output run mode by pressing both the “zero” (S1) and “span” (S2) buttons simultaneously for 1 second or until the “system” LED begins to blink slowly. See example below.

Wait until output signal has stabilized to within± .02 mA of signal deviation/change.

Output should read between 3.9 and 4.1 mA(39.0 to 41.0 mV).

4/20 mA Output Loop Integrity Check

22 mA High Signal Test

STEP 1

Start: Set meter to mV DC, place meter leads onTest(+) and Test(—) respectively (see Figure 9).

• Press the “zero” (S1) button 5 times. The yellow“calibrate” LED will blink fast and the yellow “system” LED will turn off. The output should be 21 to 22.5 mA (210 to 225 mV).

•

•

If this is not the case, proceed to the next step. •

•

Follow the “zero” procedure above to re-zero theunit

Follow the “simple zero test” procedure to ensurethe unit is resting at the optimum 4 mA point.

If a problem exists on the output signal line, or theoutput load is not within the specified range, the “mA fault” LED will blink either before or upon activation of this test. In some cases the 22 mA high signal output will cause incorrect output load resistance values to surface because of the demand on high resistances to produce high currents.

Low power supply voltages can also be something toinvestigate if this error surfaces only when the 22 mA high test is initiated.

During 4/20 mA loop test (22 mA high) Simple “Zero” test — NO “Dead-band” mode 0 to 26 mA




During 4/20 mA loop test (.5 mA low) During 4/20 mA loop test (22 mA high) w/ Error on output

.5 mA Low Signal Output Test for Fault Conditions

NOTE: The unit must be in the 4/20 mA loop (22 mAhigh) test to proceed with this test.

During 4/20 mA loop test (.5 mA low) with Error

STEP 2 Start: Press and hold the “zero” (S1) button for atleast one second or until the yellow “calibrate” LED shows medium double blink. The yellow “system” LED will remain off and the output should change to .4 to .6 mA (4 to 6 mV).

If a problem exists on the output signal line, or theoutput load is not within the specified range, the “mA fault” LED will blink either before or upon activation of this test.

If an error surfaces during this test only, the possibility of cross-talk can exist on the signal line. This is caused by resistive shorts to power or other voltage sources that can raise the .5 mA target current on the line. Moisture in the connector can cause stray voltage to migrate from the 24V DC pin over to the 4/20 mA signal line. Check connectors or refer to the troubleshooting section or error code analysis section for assistance.

STEP 3

Exit: Press and hold the “zero” (S1) button for at leastone second or until the yellow “calibrate LED turns off. The yellow “system” LED will resume the previous state, either “filtered” or “non-filtered” output mode.

NOTE: In addition to test procedures initiated TMmanually, every 2 seconds SensorCheck technology monitors several performance parameters of the TMAirScan iR. A notification of .5 mA on the output signal is transmitted if any of these parameters is not met.


3

F

Operation continued

Troubleshooting Sensor On-board Diagnostic System It is possible to have the mA output fail during normal run mode. In some instances a mA output circuit that is incorrectly setup can supply 4 mA to the load reasonably well; however, an incorrect circuit arrangement could not be capable of driving 20 mA to the load when required. Therefore, the system will place a fault condition out on the mA loop output and flash the “mA fault” LED indicating the output wiring is not correct or load resistance is too high.

To properly ensure the load is correct, during the 20mA or (high) 4/20 mA integrity test, the output circuit dynamic range is tested to its fullest extent. If the mA fault LED blinks during this test, the load resistance is too high or power supply voltage is too low.

In the case of a mA Failure during Run mode, the “mAfault” LED will blink Fast.

In the case of a mA failure during the mA output test,the “mA fault” LED will also blink Fast. See figure at the top of the next page.

Electrical Interference This sensor has been designed to be highly resistant to EMI/RFI using multiple stages of filtering and protection. However, in extreme environments, some noise pickup can occur directly through the sensor. Insure that the bare shield wire of the instrument cable is properly connected at the readout unit. See Figure TM10, Note 2 for Manning AirScan iR meter test points.

Figure 10: Troubleshooting



IR Source FailureIf the IR source signal strength drops to the point that the unit can no longer function satisfactorily, the “fault” LED will remain continuous ON and the 4/20 mA output will be set to 0.5 mA. See example below. This condition can also occur in environments where there is a significant amount of particulate contamination. Usually is takes an appreciable amount of time for the particles to pose signal degradation, however, under long-term exposure the filter surface could be dirty causing low thermal readings, hence marginal operation for signal analysis.

Error on 4/20 mA output or during 4/20 mA test 20 mA high

To resolve this issue, Place a resistor having at least100 to 250 ohms across the signal output (SIG) and ground (GND). The “mA fault” LED will stop blinking indicating the load or wiring has a problem.

Sensor Output at 0 mA Verify +24 VDC at the sensor terminal block (see Figure 10, Note 1 on previous page).

Check signal voltage between Test(+) and Test(—)(see Figure 10, Note 2). Voltage should be in the range of 40 to 200 mV corresponding to an actual current flow of 4 to 20 mA. If this voltage is 0 mV, the signal has no path to ground. Check monitoring equipment connections and configuration. Input impedance must be 500 ohms or less.

Sensor Output at .5 mA Please see Section D on page 17 for possible fault conditions related to .5 mA output.

Gas Concentration Indicated With No RefrigerantPresent TMThe Manning AirScan iR is designed to be quite specific to CFC/HCFC/HFC’s that are colorless, odor- less gases which can’t be sensed by humans at low levels. Always double-check with another instrument before assuming refrigerants are not present.

Performing a zero and a span calibration using certified calibration gas will confirm or correct the sensor’s reading.

NOTE: 4/20 mA will be set to 0.5 mA.


4 Maintenance

For proper operation it is essential that the test andcalibration schedule be adhered to. Honeywell Analytics recommends the following maintenance schedule:

• Calibration should be performed with certifiedcalibration gas every six months. Calibration kits are available from Honeywell Analytics.

All tests and calibrations must be logged. It ishighly recommended that certified calibration gas be used every six months.

Expose each sensor to test gases monthly to verifythat the sensor has a normal response. This will also check the alarm lights and relay action of the monitoring equipment.


•

5 Replacement Parts

For replacement parts, contact Honeywell Analytics.Be sure to give serial number of unit and model number.


6

1.

Limited Warranty

Limited Warranty Honeywell Analytics, Inc. warrants to the original purchaser and/or ultimate customer (“Purchaser”) of Manning products (“Product”) that if any part thereof proves to be defective in material or workmanship within eighteen (18) months of the date of shipment by Honeywell Analytics or twelve (12) months from the date of first use by the purchaser, whichever comes first, such defective part will be repaired or replaced, free of charge, at Honeywell Analytics’ discretion if shipped prepaid to Honeywell Analytics at 405 Barclay Blvd., Lincolnshire, IL 60069, in a package equal to or in the original container. The Product will be returned freight prepaid and repaired or replaced if it is determined by Honeywell Analytics that the part failed due to defective materials or workmanship. The repair or replacement of any such defective part shall be Honeywell Analytics’ sole and exclusive responsibility and liability under this limited warranty.

Exclusions A. If gas sensors are part of the Product, the gas sensor is covered by a twelve (12) month limited warranty of the manufacturer.

B. If gas sensors are covered by this limited warranty, the gas sensor is subject to inspection by Honeywell Analytics for extended exposure to excessive gas con- centrations if a claim by the Purchaser is made under this limited warranty. Should such inspection indicate that the gas sensor has been expended rather than failed prematurely, this limited warranty shall not apply to the Product.

C. This limited warranty does not cover consum- able items, such as batteries, or items subject to wear or periodic replacement, including lamps, fuses, valves, vanes, sensor elements, cartridges, or filter elements.

3. Warranty Limitation and Exclusion Honeywell Analytics will have no further obligation under this limited warranty. All warranty obligations of Honeywell Analytics are extinguishable if the Product has been subject to abuse, misuse, negligence, or accident or if the Purchaser fails to perform any of the duties set forth in this limited warranty or if the Product has not been operated in accordance with instructions, or if the Product serial number has been removed or altered.

Disclaimer of Unstated Warranties THE WARRANTY PRINTED ABOVE IS THE ONLY WARRANTY APPLICABLE TO THIS PURCHASE. ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED.

Limitation of LiabilityIT IS UNDERSTOOD AND AGREED THAT HONEYWELL ANALYTIC’S LIABILITY, WHETHER IN CONTRACT, IN TORT, UNDER ANY WARRANTY, IN NEGLIGENCE OR OTHERWISE SHALL NOT EXCEED THE AMOUNT OF THE PURCHASE PRICE PAID BY THE PURCHASER FOR THE PRODUCT AND UNDER NO CIRCUMSTANCES SHALL HONEYWELL ANALYTICS BE LIABLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES. THE PRICE STATED FOR THE PRODUCT IS A CONSIDERATION LIMITING HONEYWELL ANALYTICS’ LIABILITY. NO ACTION, REGARDLESS OF FORM, ARISING OUT OF THE TRANSACTIONS UNDER THIS WARRANTY MAY BE BROUGHT BY THE PURCHASER MORE THAN ONE YEAR AFTER THE CAUSE OF ACTIONS HAS OCCURRED.

4.

5.

2.



This work contains valuable, confidential, and proprietary information. Disclosure, use or reproduction outside of Honeywell Inc. is prohibited except as authorized in writing.

This unpublished work is protected by the laws of the United States and other countries.

Honeywell Confidential & Proprietary

Release A Draft

07/09

Instruction and Installation Manual Manning AirScanTMiR

Refrigerant Sensor for Commercial Applications

Notices and Trademarks Copyright 2009 by Honeywell International Inc.

Release A July 2009






1-800-538-0363


About This Document World Wide Web The following Honeywell web sites may be of interest.

Honeywell Organization WWW Address (URL)

Corporate www.honeywell.com

Honeywell Analytics www.honeywellanalytics.com

Manning Gas Detection www.manningsystems.com


Organization Phone Number

United States Honeywell Analytics Inc. 1-800-538-0363 1-913-712-5576 1-913-712-5580 Fax

Canada Honeywell Analytics Inc. 1-888-749-8878

Europe Honeywell PACE +44 (0)1202 676161

Asia Pacific Honeywell Asia Pacific Inc. +82 (0)2 2025 0307

Middle East Honeywell Analytics Inc. +971 4 3458 338


Symbol Definitions The following table lists those symbols used in this document to denote certain conditions.

Symbol Definition

ATTENTION: Identifies information that requires special consideration.

TIP: Identifies advise or hints for the user, often in terms of performing a task.

REFERENCE-EXTERNAL: Identifies an additional source of information outside of this bookset.

REFERENCE-INTERNAL: Identifies an additional source of information within this bookset.

EARTH GROUND - Functional Earth Connection: This connection shall be bonded to Protective Earth at the source of supply in accordance with national and local electrical code requirements.


http://www.honeywell.com/

http://www.honeywellanalytics.com/

http://content.honeywell.com/global/

mailto:[email protected]

Contents Serial number:

Section Title Page 1 Sensor Description System Specifications and Sensor Specifications 6

2 Installation A Locating the Sensor 7 Figure 1: Mounting Dimensions for the Manning AirScanTMiR 7

B Wiring 8 Figure 2: Wiring Diagram for Manning AirScanTMiR 8

3 Operation A Start-up Procedure 9 Figure 3: Required LED Status at Start-up 9

B Pushbutton Operation, LED Indicators, Adjustment Pots and Test Points 10 Figure 4: Board Component Layout 10 Figure 5: LED Layout 10 LED Indicators and Blink Sequence 11 Figure 6: LED Blink Sequence 11 Figure 7: LED Indicator Summary 12 Normal Run Modes 12 4/20 mA Loop Test Mode 12 Calibration Mode 10 Fault Indicator Error Sequences 13

C Modes of Operation 14 Normal Run Modes 14 4/20 mA Loop Modes 15 Calibration / Programming Modes 16

D Calibration 17 Figure 8: Board Component Layout 17 4/20 mA Output Calibration 19 Zero Calibration 19 Figure 9: Board Component Layout 20 Span Calibration 20

E Diagnostic Procedures 21 Simple Zero Test 21 4/20 mA Output Loop Integrity Check 21

F Troubleshooting 23 Electrical Interference 23 Figure 10: Troubleshooting the Manning AirScanTMiR 23 Sensor On-Board Diagnostic System 23 Error on 4/20 mA Output 24 Sensor Output at 0 mA 24 Sensor Output at .5 mA 24 Gas Concentration Indicated with No Refrigerant Present 24 IR Source Failure 24

4 Maintenance 25

5 Replacement Parts 25

6 Limited Warranty 26


Introduction This manual has been prepared to help in the use and installation of the Manning AirScan

TMiR (Infrared Refrigerants)

Sensor. This manual will convey the operating principles of the sensor, ensure proper installation, and demonstrate start-up and routine maintenance procedures.

ATTENTION: This manual must be carefully followed by all individuals who have or will have the responsibility for using or servicing the Manning AirScanTMiR Sensor. Warranties made by Honeywell

Analytics with respect to this equipment will be voided if the equipment is not used and serviced in accordance with the instructions in this manual. If in doubt about a procedure, please contact Honeywell Analytics before proceeding.


1 Sensor Description

Gas detection by the infrared method is based on the principle that most gases absorb infrared energy at a characteristic frequency. In this instrument, a broad band infrared source emits energy which is then band-pass filtered to produce a narrow range of frequencies characteristic of the refrigerants’ (CFC/HCFC/HFC) absorption spectra. Any refrigerant in the gas sample cell selectively absorbs energy reaching the detector. This reduction in energy is detected, amplified and sent to the signal processing portion of the system.

Cable Recommendation: Three conductor, stranded, shielded cable with drain wire, all enclosed in a vinyl jacket. For cable runs up to 200 feet use, #18 AWG (Belden #8770 or equivalent). For cable runs up to 1,000 feet, use #16 AWG (Belden #8618 or equivalent).

Unit Enclosure: NEMA 4, gasketed, molded fiberglass reinforced polyester. Non-painted, non-rusting construction appropriate for food areas. UL 508 listed, CSA certified for use with industrial control equipment.

ATTENTION: The standard Manning AirScanTM

iR is for use in non-classified areas only. The Manning AirScanTMiR Sensor line is a three-wire,

4/20 mA sensor for two bands of refrigerants available in a range of 0—3,000 ppm, but can be adjusted for lower ranges, if required. The low-band or R-404a infrared sensor reacts to R-123, R-134a, R-404a and R-507. The high-band or R-22 Manning AirScanTMiR sensor reacts to R-22.

Sensor Specifications

Type: CFC/HCFC/HFC selective infrared gas sensor/ transmitter Manning AirScanTMiR

Method of Detection: Dual channel infrared energy absorption (N.D.I.R. Non-dispersive Infrared)

Its solid, high-mass metal bench provides structural and thermal stability, greater immunity to vibration, as well as superior EMI/RFI shielding of the detector and source. Internal compensation for environmental changes allows the sensor to automatically adapt to fluctuating temperature and humidity conditions. The unit exhibits extremely high reliability with no moving parts.

Gases Monitored: Low-Band (R-404a, R-507, R-134a, and R-123), High-Band (R-22)

Range Available: 0—3,000 ppm (can be rescaled to 0—1,000 ppm, or 0—500 ppm if required)

SensorCheckTM Features: Dual channel functionality test, source strength evaluation, incoming voltage monitor, IR source integrity check, operating temperature monitor, “zero” down drift monitor, and internal circuitry check.

Every two seconds SensorCheckTM technology monitors the Manning AirScanTMiR source and ensures that the dual channels are functioning properly. A notification signal will be transmitted if any of several performance parameters is not met.

Accuracy: ± 3% of full scale

Repeatability: ± 1% of full scale

Cross Sensitivity: Not affected by moisture, food odors, floor cleaners, temperature changes, etc.

Monitoring equipment must be configured to indicate a fault if the signal is less than 1.5 mA.

All signals over 20 mA must be considered a high gas concentration.

Operating Humidity: 0—100% RH (condensing)

Operating Temperatures: —20° F to +140° F (—29° C to +60° C)

Storage Temperature: —20° F to +140° F (—29° C to +60° C)

Manning infrared sensors are normally long-lived (5 years plus), unless physically damaged or wetted with water or other liquid. Gas Sampling: Diffusion method with no moving parts

Sampling Frequency: Real time continuous monitoring of all points System Specifications

Electrical Power: 24 Volts DC regulated, 1.0 amp. Response Time: T90 in 10 seconds with full-scale target calibration gas @ .75 L/min flow rate Output: Linear 4/20 mA output into a load resistor of 500

ohms maximum Weight: 4.4 lbs.

Cable Length to Sensor: 1,000 feet maximum Dimensions: 9.59" high x 7.71" wide x 4.52" deep


2 Installation

A Locating the Sensor Because each sensor can only “report” what it is seeing at the moment, it is very

important that the sensor be located where leaks are most likely to occur. CFC/ HCFC/HFC vapor is heavier than ambient air, so in a room with no air movement it will tend to settle. For quickest detection, mount the sensor about one to two feet from the floor, close to the potential leak source.

If the primary application is the fastest possible leak detection, mount the sensor near the potential leak sources. In doing this, be aware that the indicated concentration may not be representative of personnel exposure and easy access for the required calibration and maintenance could be compromised.

General Mounting Considerations:

• Must be easily accessible for calibration and maintenance.

• Always mount the sensor vertically.

• Mount the sensor close to the potential leak source for fastest possible leak detection.

• If personnel protection is the primary application, mount in the “breathing zone.”

• Protect sensor from water, excessive humidity, and wash-down.

• Take air movement and ventilation patterns into account.

Figure 1: Mounting Dimensions

• To prevent electrical interference, keep sensor

and wire runs away from mercury vapor lights, variable speed drives, and radio repeaters.

• Protect sensor from physical damage (fork lifts, etc.).

• Do not mount the sensor over a door in a refrigerated area.

• For highly critical locations more than one sensor should be installed in each room.

Very Important:

• Sensor must be mounted vertically.

• Never mount sensor flat on a ceiling. • Enter enclosure only through existing hole in

bottom of enclosure. • Always make a drip loop in the conduit.

• Never mount sensor on a vibrating surface.

Mount sensor enclosures through the flange holes as shown in Figure 1, and always mount vertically.

Penthouses: Multi-Coil (defrost one coil at a time) — In this case the best location is usually in the center of the penthouse four or five feet above the grate.

Single Coil (or when all coils defrost at the same time) — In this case high moisture conditions can occur and the sensor should be mounted one foot above the grate.

Engine Rooms: The Manning AirScanTMiR sensor should be mounted in a cool part of the room, if possible. Keep the sensor away from hot air exhausting from electric motors or other machinery.


2 Installation continued

Ceiling Hung Evaporators: When mounting Manning AirScanTMiR sensors near evaporators, mount the sensor no higher than two feet below the top of the evaporator coil. Do not mount in high air flow (1,200 feet/minute maximum). Never mount the sensor on evaporators as vibration can damage the sensor.

Other Locations: When mounting Manning AirScanTMiR sensors in locations such as roof top air units, ductwork, attic spaces, makeup air intakes, etc., contact Honeywell Analytics for application assistance and recommendations.

B Wiring Electrical wiring must comply with all applicable codes. Plant equipment that may be involved and operating conditions should be discussed with local operating personnel to determine if any special needs should be considered.

Nearly all start-up problems are due to improper wiring or monitor configuration. Please follow these guide-lines carefully.

Always use three conductor, insulated, stranded, shielded copper cable. Use only three conductor cable, not two cables of two conductor wire (see Figure 2).

Do not pull sensor wiring with AC power cables. This will cause electrical interference. Be sure there are no breaks or splices in sensor wiring runs. If cable runs cannot be made without a splice, all connections must be soldered. Soldering should be done using a rosin flux to tie the connecting ends of sensor wires to ensure a positive and long-lasting contact.

If the AirScanTMiR is to be used with the AirAlertTM96d, please call Honeywell Analytics for specific wiring instructions.

Ground the shield at the main control panel. Connect the shield wire in the sensor terminal block labeled shield. Tape all exposed shield wire at the sensor to insulate it from the enclosure.

All penetrations into a refrigerated room should be sealed to prevent condensate from forming in the conduit and dripping into the sensor enclosure.

Make drip loops for cables going into sensor housings (see Figure 1). Follow the special mounting instructions on the enclosure (…This End Up).

Electrical Power: 24 VDC regulated, 1.0 amp.

Output: Circuit board mounted sensor provides a linear 4/20 mA output. Monitoring equipment may have a maximum input impedance of 500 ohms.

Contact Honeywell Analytics for specific wiring instructions when using Manning AirScanTMiR sensors with a Manning AirAlertTM96d readout unit.

Cable Recommendation: Use #18/3 (Belden #8770) for cable runs up to 200 feet. Use #16/3 (Belden #8618) for cable runs up to 1,000 feet. Use only the existing punched holes for connections to the sensor. Use only the existing punched holes for connections to the sensor.

Monitoring: The Manning AirScanTMiR Refrigerant Sensor may be monitored by any Manning Readout/Alarm unit or other appropriately configured system. Monitoring equipment must be configured to indicate a fault if the signal is below 1.5 mA. All signals above 20 mA must be considered a high gas concentration. A failed sensor will output a 0.5 mA signal.

Figure 2: Wiring Diagram


3 Operation

The Manning AirScanTMiR has several modes of operation, including two normal run modes, two 4/20 mA loop check modes and five calibration modes. These will be explained in Operation, Section C, Modes of Operation. Modes are entered by properly activating pushbuttons located on the circuit board, shown in Figure 4.

Sensor operation status is indicated by the blink pattern of seven LED’s located in a vertical row on the right side of the sensor circuit board (see Figure 4). LED status is differentiated by color and duration/ pattern of blink(s). LED Indicators and Blink Sequences are shown in Figure 6, followed by an explanation of blink patterns.

A Start-Up Procedure Before applying power, make a final check of all wiring for continuity, shorts, grounds, etc. It is usually best to disconnect external alarms and other equipment from the sensor until the initial start-up procedures are completed.

Check the power supply voltage to the sensor with a digital volt meter set to VDC. Place the black lead on sensor terminal GND and the red lead on +24 (see Figure 4, Note 1). Voltage should be between 21 and 28 VDC. If voltage is outside this range, check power supply and wiring.

After power-up, ensure the LED’s below are operational as follows (see Figure 3):

• Green “Power” LED continuous ON

• Both Fault LED’s are OFF

• Green “source” LED is blinking once every 2 seconds

NOTE: For cold/humid adverse environmental conditions the “ATMOS” LED may be turning on and off periodically. In addition, the “system” LED may be blinking or continuous ON, also described in later sections.

IMPORTANT: The Manning AirScanTMiR sensor is factory calibrated and should require

minimal adjustments after installation. This sensor was calibrated at an altitude of 1,000 ft. above sea level. For installations where the altitude is greater than 3,500 ft. above sea level, it is necessary to recalibrate the sensor “span” during the initial setup for more accuracy and reliability.

Allow the sensor to operate for 12 hours with the enclosure sealed prior to testing the sensors. This will give the sensor time to reach thermal equilibrium to the external and internal temperatures while in operation. Because sensors are normally located at a distance from the main unit, the test time required and accuracy of the response checks will be improved if two people perform the start-up procedures and use radio contact.

Start-Up Test:

1) One person exposes each sensor to a small amount of the gas that is being monitored.

2) The second person stays at the control unit to determine that each sensor, when exposed to the gas fumes, is connected to the proper input and responds, causing appropriate alarm functions.

Figure 3: Required LED Status at Start-up



B Pushbutton Operation, LED Indicators, Adjustment Pots and Test Points

The Manning AirScanTMiR has two internal push-buttons, and two adjustment pots that are utilized for navigation of test functions, calibrations, and operating modes. In addition, a pair of test points is also provided that assist in the connection to standard meter leads for use in the upcoming calibration and diagnostic procedures (see Figure 4).


• “Zero” adjustment pot — adjusts output

calibration of the 4 mA nominal resting point

• “Span” adjustment pot — adjusts the 20 mA concentration level or unit span/sensitivity.

• Pushbutton S1 — used to initiate the auto-zero function, program the 4 mA output calibration, and initiate the 4/20 mA loop test.

• Pushbutton S2 — used to program the span setting.

• Test(+) and Test(—) for connection to a DC Volt meter (see Figure 4, Note 2).

IMPORTANT: The pushbutton(s) must be pressed the correct number of times and at the correct rate.

• When a multi-press sequence must be performed, the button must be pressed rapidly and evenly, lifting one’s finger completely from the actuator for each consecutive press.

• For press and hold activations, one’s finger must always be applying a down pressure without disruption for the specified time in order to activate the desired mode.

• See complete details of each operation in other parts of the manual.

The Manning AirScanTMiR also has a group of LED’s (see Figure 5) that blink in specific sequences (see Figure 6 on next page) to indicate sensor operation and programming modes. A summary of sensor operation and programming modes with corresponding LED blink sequences is shown in Figure 7 on page 12.

Figure 5: LED Layout



LED Indicators and Blink Sequence Figure 6: LED Blink Sequence

Green Power LED

• Continuous ON when power is applied

Yellow System LED

• Continuous ON during normal filtered output run mode — “dead band” from 4 to 4.6 mA

• Slow blink during normal non-filtered output run mode

• Fast blink indicating unit lost calibration data

• OFF during 4/20 mA loop check

Yellow Calibrate LED

• Continuous momentary ON for auto-zero mode activation

• Slow blink for 4 mA output calibration mode

• Medium double blink indicates 4/20 mA loop check .5 mA (low)

• Fast blink for “span” calibration mode and 4/20 mA loop check 22 mA (high)

Red Fault LED (all scenarios produce a .5 mA output)

• Continuous ON indicates a failed source, low signal, or circuit failure.

• Slow blink indicates the power supply DC 24V input voltage is too low.

• Medium double blink indicates sensor is outside the operating temperature range.

• Fast blink indicates the signal drifted below 4 mA and needs to be re-calibrated, only in non-filtered output run mode (no dead-band).

Red mA Fault LED attempts to output .5 mA fault signal

• Fast blink indicates 4/20 mA loop failure or load resistance too high.

Green Source LED

• One blink every 2 seconds indicates when source is energized and also that the source is not short circuited.

Green ATMOS LED

• Continuous ON indicates ATMOS circuitry is active or adjusting the enclosure’s internal environmental conditions for the sensor to function reliably.

NOTES:

• If the Source LED isn’t blinking, do not proceed until the condition is corrected.

• If a Fault LED is lighted, immediately refer to Fault Indicator Error Sequences (page 13) to determine potential problem. Do not attempt calibration if a Fault is indicated.

• All status LED’s are subordinate to Fault indicators.

• If an LED is indicated as OFF, it must actually be OFF for proper sensor operation.

• If an LED status is N/A (not applicable), that LED indication may vary depending on other operational factors.



Figure 7: LED Indicator Summary


Normal Run Mode

4/20 mA Loop Test Mode

Calibration Mode



Figure 7: LED Indicator Summary, continued


Fault Indicator Error Sequences



C Modes of Operation The Manning AirScanTMiR has various modes of operation and calibration:

• Normal run mode with output filtering

• Normal run mode without output filtering

• 4/20 mA loop check

• 4/20 mA calibration to an external PLC or read-out panel

• Neutral gas resting point or “zero” calibration mode

• Span calibration modes

Normal Run Modes

Normal run mode with output filtering This mode outputs a signal from 4 to 27 mA with a “dead band” from 4 to 4.6 mA. This “dead band” masks small environmental anomalies that could facilitate output signal fluctuations or transients around the 4 mA resting point when the unit is not sensing target gas. Start: If the “system” LED is blinking slowly, press and hold both S1 and S2 simultaneously for 1 second or more until the “system” LED is continuous ON, then release both buttons. If the “system” LED is blinking fast, this mode cannot be engaged and the factory needs to be contacted. See the following example.

Normal run mode without output filtering This mode outputs a signal that nominally rests at 4 mA and can range continuously from 0 to 27 mA. Any subtle changes in sensor response will be sent to the mA loop output. This mode is entered automatically when the calibration modes are activated. Some users may wish to see the subtle anomalies in the signal near the nominal 4 mA rest area.

Start: If the “system” LED is continuous ON, press and hold both S1 and S2 simultaneously for 1 second or more until the “system” LED is blinking slowly then release both buttons to enter this mode. If the “system” LED is blinking fast this mode is always engaged and can only be exited by fully calibrating the unit. See the following example.



4/20 mA Loop Test (22 mA full-scale and .5 mA fault check)

Start: Press S1 5 times within a two to three second period of time. The yellow “system” LED will turn off and the yellow “calibrate” LED will blink fast. See the following example. Output should be 21 to 22.5 mA.

22 mA Full Scale Output Test

To proceed to the next step in the mA test, press and hold S1 for 1 second or more until the yellow “calibrate” LED is a medium double blink. See the following example. The output should be between .4 and .6 mA.

.5 mA Fault Output Test

Exit: Press and hold S1 for 1 second or more until the yellow “system” LED resumes the state before the mA test was initiated and the yellow “calibrate” LED turns off.



Calibration/Programming Modes:

Refer to Calibration, Section D before proceeding.

Auto “ZERO” Program Function

Start: Press and hold S1 for 1 second or until the yellow “calibrate” LED turns continuous ON. Release S1 and the yellow “calibrate” LED will turn off. This indicates the unit “zero” is now programmed to a neutral or 4 mA resting state for 0 ppm of target gas.

“Span” Calibration/Programming Mode

Start: Press and hold S2 for 1 second or until the yellow “system” LED blinks slowly and the yellow “calibrate” LED blinks fast. Once in this mode the “span” pot can be adjusted to determine the 20 mA full-scale concentration.

Exit: To program the “span” setting and exit this mode, press and hold S2 for 1 second or until the yellow “system” LED resumes the state before the calibration mode was initiated and the yellow “calibrate” LED turns off.

4 mA Output Calibration/Programming Mode

Start: Press and hold S1 for 7 seconds or until the yellow “system” LED turns continuous ON and the yellow “calibrate LED blinks slowly. See the following example.

Once in this mode the “zero” pot can be adjusted to calibrate the 4 mA output to a PLC, SCADA system, panel, etc.

Exit: To program the 4 mA calibration point and exit this mode, press and hold S1 for 1 second or until the yellow “system” LED resumes the state before the calibration mode was initiated and the yellow “calibrate” LED turns off.



D Calibration Before calibrating the unit, ensure the startup procedure was followed and unit was powered on for a minimum of 12 hours (with the enclosure door closed) in the operating environment.

IMPORTANT NOTE: For environments where the ambient temperature is less than 10° F,

during the calibration procedure, the door must be closed as far as possible. This will ensure the sensor temperature will not drop below the minimum operating temperature which could adversely affect the pro-grammed calibration parameters.

There are only two adjustment pots and two push-buttons on the main board that are used for program-

ming the calibration parameters. See Section B, Pushbutton Operation, LED Indicators,

Adjustment Pots and Test Points. Use Section B to familiarize yourself with the pushbuttons S1, S2, adjustment pots “zero”, “span”, Test(+), Test(—) and their locations on the main board (see Figure 8).


In addition, the LED indicators and blink pattern meanings are also summarized in this section. The calibration procedure will require use and knowledge of the following tools within the sensor:

• “Zero” adjustment pot — adjusts output calibration of the 4 mA nominal resting point

• “Span” adjustment pot — adjusts the 20 mA concentration level or unit span/sensitivity

• Pushbutton S1 — used to initiate the auto-zero function and program the 4 mA output calibration

• Pushbutton S2 — used to program the span setting

In addition, there are four LED’s used in the calibration procedure. Yellow “system” and “calibrate”, and red “fault” and “mA fault” LED’s located on the main board are utilized as status indicators during the calibration procedure and as diagnostic and trouble indicators.

Non-calibrated Sensor or Loss of Factory Calibration

IMPORTANT: Upon power up, if the yellow “system” LED is showing a fast blink pattern,

the unit hasn’t been calibrated yet or has lost the factory calibration and requires a full calibration before it can reliably read the target gas. See the following example. Should this occur, please contact Honeywell Analytics for assistance!



Before continuing with the calibration procedure, determine which of the two Normal output modes is best for the control scheme. Filtered output holds a stable 4 mA signal within a dead-band range while the non-filtered output allows the signal to be seen without any output limitations.

After this output mode choice is made, continue through Steps 1—3 of the Calibration Procedure. As a first step, the 4 mA output is matched to the signal input device being used as a control panel. After this is accomplished, Step 2 (Zero Calibration) and Step 3 (Span Calibration) can be completed in that order.

Filtered Output Mode Each unit is equipped with a filtered output or “dead band” output mode which locks the output at 4 mA for signal readings of 4 to 4.6 mA. This masks surrounding abrupt adverse environmental transients that would cause a small short-term anomaly on the 4 mA resting point for a near 0 ppm reading of the target gas. In this mode, the yellow “system” LED will be ON. See the following example.

Non-Filtered Output Mode (no signal deadband)

Start: Press and hold both the “zero” (S1) and “span” (S2) buttons simultaneously for one second or until the “system” LED begins to blink slowly. See example below.

This mode will allow any anomalies to be transmitted from 0 to 27 mA on the output. This mode is also used in the upcoming Simple Zero Test procedure.

Exit: To revert back to “dead band” mode, repeat the same button press procedure above. This button press sequence will toggle between modes (filtered to non-filtered).



STEP 1

4/20 mA Output Calibration This procedure calibrates the 4/20 mA output to match a PLC input converter or various devices that interpret the 4/20 mA signal output to ensure the 4 mA output rests at a true 4 mA even with minor mismatches in load resistance, long feed wiring, or adverse environmental conditions.

Start: Set meter to mV DC and place meter leads on Test(+) and Test(—) respectively (see Figure 9).

• Press and hold the “zero” button (S1) for 5 seconds or until the “calibrate” LED is blinking slowly and the “system” LED is continuous ON. Make sure the “mA Fault” LED is OFF.

• Adjust the zero potentiometer until the output reads 3.99 to 4.01 mA (39.9 to 40.1 mV). This sets the 4 mA resting point. Make small adjustments and wait for the output to change because adjustment response is delayed between source pulses.

4 mA output programming calibration mode

Exit: Press and hold the “zero” button (S1) for one second or more until the “calibrate” LED turns off.

The “system” LED will resume the previous state, either “filtered” or “non-filtered” output mode. This indicates the parameters are now programmed into memory.

STEP 2

Zero Calibration This procedure sets the internal reference that is indicative of 0 ppm of target gas. It MUST be performed before proceeding or every other setting will be offset and inaccurate. The “zero” can be initiated at any time as long as a neutral gas is flowing through the calibration port or the surrounding air is known to be FREE of any target gas down to 1 ppm.

Start: Apply pure nitrogen (N2) into the calibration port at a rate of 1.0 L/min* for at least 3 minutes (OR until out-put signal is within ± .02 mA of signal deviation/ change).

• Press and hold the “zero” button (S1) for approxi-mately 1 second or until the yellow “calibrate” LED is continuous ON.

• When yellow calibration LED is continuous ON, release the “zero” button. The “calibrate” LED will turn off and the unit will be zeroed. See example below.

“Zero” programming calibration mode

Exit: System will automatically resume previous mode, either “normal” or “no dead band” mode. This indicates the parameters are now programmed into memory.

Place multi-meter leads on Test(+) and Test(—) and ensure the output is steadily resting between 3.9 to 4.1 mA (see Figure 9 on next page). If this isn’t the case, initiate the auto “zero” procedure once again.





STEP 3

Span Calibration This procedure sets the “span” or concentration level that would depict a 20 mA reading for full-scale target gas on the 4/20 mA output. The lower the target gas concentration is for a span of 20 mA, the more sensitive or responsive the unit would be to lower ppm readings.

NOTE: This procedure should only be performed if the zero and 4/20 mA procedures are successfully completed.


Press and hold the “span” button (S2) for 1 second or more until the yellow “calibrate” LED blinks fast and the yellow “system” LED is blinking slowly. See the following example.

Ensure the output rests between 3.9 and 4.1 mA (39.0 to 41.0 mV). If this is not the case, perform the “zero” procedure again.

Once the output is within the required range with nitrogen flowing, apply full-scale target gas into the calibration port at a rate of 1.0 L/min* for 3 minutes immediately following the nitrogen flow.

If the signal is 26 mA or greater, adjust the “span” potentiometer counter-clockwise until

the signal is near 20 mA. Because there is a slight delay in potentiometer movement, make small adjustments and wait for the output to change because adjustment response is delayed between source pulses.

Wait until the output signal has stabilized to within ± .02 mA of signal deviation/change. Adjust the “span” potentiometer again until the output reads around 20 mA.

Exit: Press and hold the “span” button (S2) for one second or more until the yellow “calibrate” LED turns off. The yellow “system” LED will resume the previous state, either “filtered” or “non-filtered” output mode. This indicates the parameters are now programmed into memory.

Apply pure nitrogen (N2) into the calibration port at a rate of 1.0 L/min* for at least 3 minutes (OR until output signal has stabilized to within ± .02 mA of signal deviation/change). If N2 is currently flowing from previous “zero” calibration, disregard the additional flow time.




E Diagnostic Procedures

Simple Zero Test This test will ensure the unit is calibrated for a true “zero” and duly represents an absence of target gas in this condition.


• Apply pure nitrogen (N2) into the calibration port at a rate of 1.0 L/min* for at least 3 minutes. Check the status of the yellow “system” LED. If this LED is continuous ON, place the unit in non-filtered output run mode by pressing both the “zero” (S1) and “span” (S2) buttons simultan-eously for 1 second or until the “system” LED begins to blink slowly. See example below.

• Wait until output signal has stabilized to within ± .02 mA of signal deviation/change.

• Output should read between 3.9 and 4.1 mA (39.0 to 41.0 mV).

If this is not the case, proceed to the next step.

• Follow the “zero” procedure above to re-zero the unit

• Follow the “simple zero test” procedure to ensure the unit is resting at the optimum 4 mA point.

Simple “Zero” test — NO “Dead-band” mode 0 to 26 mA

Exit: Press and hold both the “zero” (S1) and “span” (S2) buttons simultaneously for 1 second or more until “system” LED is continuous ON. Unit should be ready for long-term operation.

4/20 mA Output Loop Integrity Check

22 mA High Signal Test

STEP 1


• Press the “zero” (S1) button 5 times. The yellow “calibrate” LED will blink fast and the yellow “system” LED will turn off. The output should be 21 to 22.5 mA (210 to 225 mV).

If a problem exists on the output signal line, or the output load is not within the specified range, the “mA fault” LED will blink either before or upon activation of this test. In some cases the 22 mA high signal output will cause incorrect output load resistance values to surface because of the demand on high resistances to produce high currents.

Low power supply voltages can also be something to investigate if this error surfaces only when the 22 mA high test is initiated.

During 4/20 mA loop test (22 mA high)




During 4/20 mA loop test (22 mA high) w/ Error on output

.5 mA Low Signal Output Test for Fault Conditions

NOTE: The unit must be in the 4/20 mA loop (22 mA high) test to proceed with this test.

STEP 2

Start: Press and hold the “zero” (S1) button for at least one second or until the yellow “calibrate” LED shows medium double blink. The yellow “system” LED will remain off and the output should change to .4 to .6 mA (4 to 6 mV).

If a problem exists on the output signal line, or the output load is not within the specified range, the “mA fault” LED will blink either before or upon activation of this test.

If an error surfaces during this test only, the possibility of cross-talk can exist on the signal line. This is caused by resistive shorts to power or other voltage sources that can raise the .5 mA target current on the line. Moisture in the connector can cause stray voltage to migrate from the 24V DC pin over to the 4/20 mA signal line. Check connectors or refer to the troubleshooting section or error code analysis section for assistance.

During 4/20 mA loop test (.5 mA low)

During 4/20 mA loop test (.5 mA low) with Error

STEP 3

Exit: Press and hold the “zero” (S1) button for at least one second or until the yellow “calibrate LED turns off. The yellow “system” LED will resume the previous state, either “filtered” or “non-filtered” output mode.

NOTE: In addition to test procedures initiated manually, every 2 seconds SensorCheckTM technology monitors several performance parameters of the AirScanTMiR. A notification of .5 mA on the output signal is transmitted if any of these parameters is not met.



F Troubleshooting Electrical Interference This sensor has been designed to be highly resistant to EMI/RFI using multiple stages of filtering and protection. However, in extreme environments, some noise pickup can occur directly through the sensor. Insure that the bare shield wire of the instrument cable is properly connected at the readout unit. See Figure 10, Note 2 for Manning AirScanTMiR meter test points.

Figure 10: Troubleshooting

Sensor On-board Diagnostic System It is possible to have the mA output fail during normal run mode. In some instances a mA output circuit that is incorrectly setup can supply 4 mA to the load reasonably well; however, an incorrect circuit arrangement could not be capable of driving 20 mA to the load when required. Therefore, the system will place a fault condition out on the mA loop output and flash the “mA fault” LED indicating the output wiring is not correct or load resistance is too high.

To properly ensure the load is correct, during the 20 mA or (high) 4/20 mA integrity test, the output circuit dynamic range is tested to its fullest extent. If the mA fault LED blinks during this test, the load resistance is too high or power supply voltage is too low.

In the case of a mA Failure during Run mode, the “mA fault” LED will blink Fast.

In the case of a mA failure during the mA output test, the “mA fault” LED will also blink Fast. See figure at the top of the next page.



Error on 4/20 mA output or during 4/20 mA test 20 mA high

To resolve this issue, Place a resistor having at least 100 to 250 ohms across the signal output (SIG) and ground (GND). The “mA fault” LED will stop blinking indicating the load or wiring has a problem.

Sensor Output at 0 mA Verify +24 VDC at the sensor terminal block (see Figure 10, Note 1 on previous page).

Check signal voltage between Test(+) and Test(—) (see Figure 10, Note 2). Voltage should be in the range of 40 to 200 mV corresponding to an actual current flow of 4 to 20 mA. If this voltage is 0 mV, the signal has no path to ground. Check monitoring equipment connections and configuration. Input impedance must be 500 ohms or less.

Sensor Output at .5 mA Please see Section D on page 17 for possible fault conditions related to .5 mA output.

Gas Concentration Indicated With No Refrigerant Present The Manning AirScanTMiR is designed to be quite specific to CFC/HCFC/HFC’s that are colorless, odor-less gases which can’t be sensed by humans at low levels. Always double-check with another instrument before assuming refrigerants are not present.

Performing a zero and a span calibration using certified calibration gas will confirm or correct the sensor’s reading.

IR Source Failure If the IR source signal strength drops to the point that the unit can no longer function satisfactorily, the “fault” LED will remain continuous ON and the 4/20 mA output will be set to 0.5 mA. See example below. This condition can also occur in environments where there is a significant amount of particulate contamination. Usually is takes an appreciable amount of time for the particles to pose signal degradation, however, under long-term exposure the filter surface could be dirty causing low thermal readings, hence marginal operation for signal analysis.

NOTE: 4/20 mA will be set to 0.5 mA.


4 Maintenance Expose each sensor to test gases monthly to verify that the sensor has a normal response. This will also check the alarm lights and relay action of the monitoring equipment.


For proper operation it is essential that the test and calibration schedule be adhered to. Honeywell Analytics recommends the following maintenance schedule:

• Calibration should be performed with certified calibration gas every six months. Calibration kits are available from Honeywell Analytics.

• All tests and calibrations must be logged. It is highly recommended that certified calibration gas be used every six months.

5 Replacement Parts For replacement parts, contact Honeywell Analytics. Be sure to give serial number of unit and model number.


6 Limited Warranty

1. Limited Warranty Honeywell Analytics, Inc. warrants to the original purchaser and/or ultimate customer (“Purchaser”) of Manning products (“Product”) that if any part thereof proves to be defective in material or workmanship within eighteen (18) months of the date of shipment by Honeywell Analytics or twelve (12) months from the date of first use by the purchaser, whichever comes first, such defective part will be repaired or replaced, free of charge, at Honeywell Analytics’ discretion if shipped prepaid to Honeywell Analytics at 405 Barclay Blvd., Lincolnshire, IL 60069, in a package equal to or in the original container. The Product will be returned freight prepaid and repaired or replaced if it is determined by Honeywell Analytics that the part failed due to defective materials or workmanship. The repair or replacement of any such defective part shall be Honeywell Analytics’ sole and exclusive responsibility and liability under this limited warranty.

2. Exclusions

A. If gas sensors are part of the Product, the gas sensor is covered by a twelve (12) month limited warranty of the manufacturer.

B. If gas sensors are covered by this limited warranty, the gas sensor is subject to inspection by Honeywell Analytics for extended exposure to excessive gas con-centrations if a claim by the Purchaser is made under this limited warranty. Should such inspection indicate that the gas sensor has been expended rather than failed prematurely, this limited warranty shall not apply to the Product.

C. This limited warranty does not cover consum-able items, such as batteries, or items subject to wear or periodic replacement, including lamps, fuses, valves, vanes, sensor elements, cartridges, or filter elements.

3. Warranty Limitation and Exclusion Honeywell Analytics will have no further obligation under this limited warranty. All warranty obligations of Honeywell Analytics are extinguishable if the Product has been subject to abuse, misuse, negligence, or accident or if the Purchaser fails to perform any of the duties set forth in this limited warranty or if the Product has not been operated in accordance with instructions, or if the Product serial number has been removed or altered.

4. Disclaimer of Unstated Warranties THE WARRANTY PRINTED ABOVE IS THE ONLY WARRANTY APPLICABLE TO THIS PURCHASE. ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED.

5. Limitation of Liability

IT IS UNDERSTOOD AND AGREED THAT HONEYWELL ANALYTIC’S LIABILITY, WHETHER IN CONTRACT, IN TORT, UNDER ANY WARRANTY, IN NEGLIGENCE OR OTHERWISE SHALL NOT EXCEED THE AMOUNT OF THE PURCHASE PRICE PAID BY THE PURCHASER FOR THE PRODUCT AND UNDER NO CIRCUMSTANCES SHALL HONEYWELL ANALYTICS BE LIABLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES. THE PRICE STATED FOR THE PRODUCT IS A CONSIDERATION LIMITING HONEYWELL ANALYTICS’ LIABILITY. NO ACTION, REGARDLESS OF FORM, ARISING OUT OF THE TRANSACTIONS UNDER THIS WARRANTY MAY BE BROUGHT BY THE PURCHASER MORE THAN ONE YEAR AFTER THE CAUSE OF ACTIONS HAS OCCURRED.


April 2010

Guidelines:Proper Installation of SpectrAlert® Advance Outdoor Audible Visible Appliances

Report

Guidelines: Proper Installation of SpectrAlert Advance Outdoor Audible Visible Appliances

2 System Sensor. Advanced Ideas. Advanced Solutions.

Designed to be watertight and to operate in a wide temperature range, SpectrAlert Advance outdoor audible visible (AV) appliances are an ideal solution for fire, general signaling, mass notification, or emergency communication system (ECS) projects that require exterior notification or notification in areas where ambient conditions may exceed the environmental tolerances of typical indoor AV devices. While SpectrAlert Advance outdoor devices are easy to install, several installation procedures and guidelines unique to outdoor models must be followed in order for the devices to perform as intended in outdoor environments.

As a supplement to the installation manuals System Sensor includes with every product, this white paper provides an overview of the proper installation procedures to follow when installing outdoor devices. Please refer to the installation manual included with your product or accessible at www.systemsensor.com/av for more complete installation instructions. If these instructions are not followed, your notification appliance may not perform as intended.

SpectrAlert Advance Outdoor Product Line

The SpectrAlert Advance outdoor product line includes two groups of devices: standard and replacement (-R) models. All standard devices (Table 1) ship with the required outdoor back box.

Replacement (-R) models (Table 2) do not ship with the outdoor back box. These models are designed specifically for use in flush-mount applications and are to be used with the SpectrAlert Advance WTP series of weatherproof plates (Table 3).

Horns Strobes Horn Strobes Speakers Speaker Strobes

HRK SRK P2RK SPWK SPSWK

SRHK P2RHK SPRK SPSRK

SWK P2WK SPCWK SPSRHK

SWHK P2WHK SPSCWK

SCRK P2RHK-120 SPSCWHK

SCRHK P2RK-P SPSWK-P

SCWK P2RHK-P SPSRK-P

SCWHK P2WK-P

SRK-P P2WHK-P

SRHK-P P4RK

SWK-P P4WK

SWHK-P PC2RK

PC2RHK

PC2WK

PC2WHK

PC4WK

PC4WHK

Table 1 – Standard Outdoor Models


System Sensor. Advanced Ideas. Advanced Solutions. 3

Metal Outdoor Back Boxes for Horns, Strobes, and Horn Strobes

SA-WBB Wall Mount Metal Outdoor Back Box, Red

SA-WBBC Ceiling Mount Metal Outdoor Back Box, Red

SA-WBBW Wall Mount Metal Outdoor Back Box, White

SA-WBBCW Ceiling Mount Metal Outdoor Back Box, White

Weatherproof Outdoor Mounting Plates for Horns, Strobes, and Horn Strobes

WTP Flush Mount Weatherproof Plate, Red

WTPW Flush Mount Weatherproof Plate, White

Metal Outdoor Back Boxes for Speakers and Speaker Strobes

MWBB Wall Mount Metal Outdoor Back Box, Red

MWBBW Wall Mount Metal Outdoor Back Box, White

MWBBCW Ceiling Mount Metal Outdoor Back Box, White

Weatherproof Outdoor Mounting Plates for Speakers and Speaker Strobes

WTP-SP Flush Mount Weatherproof Plate, Red

WTP-SPW Flush Mount Weatherproof Plate, White

Table 3 – Outdoor Back Boxes and Weatherproof Mounting Plates

Proper Installation of Outdoor Devices

SpectrAlert Advance outdoor products (model numbers end in “K” or “K-R” for replacement models) come in red and white, are available in wall- or ceiling-mount versions, and may be used indoors or outdoors. Standard products must be installed using the proper SpectrAlert Advance weatherproof back box.* Metal weatherproof back boxes ship with horns, strobes, and horn strobes. Plastic weatherproof back boxes ship with standard speakers and speaker strobes. Metal weatherproof back boxes are also available as an accessory for use with speaker and speaker strobe outdoor products (see Table 3). Plastic outdoor back boxes will begin shipping with horn, strobe, and horn strobe models in late 2010. Do not attempt to use boxes other than those specified for use with your product.

*An installed weatherproof back box should not be left without an installed unit for extended periods of time to avoid water accumulation and potential damage.

SpectrAlert Advance also provides a full range of accessory back boxes and weatherproof mounting plates for outdoor AV appliances (Table 3). Note that specific back box and mounting plate models are designed to work with specific device types.

Horns Strobes Horn Strobes Speakers Speaker Strobes

HRK-R SRK-R P2RK-R SPWK-R SPSWK-R

SRHK-R P2RHK-R SPRK-R SPSRK-R

SWK-R P2WK-R

SWHK-R P2WHK-R

P4RK-R

Table 2 – Replacement (-R) Outdoor Models (for use with WTP weatheproof plates)



Installing the SpectrAlert Advance Weatherproof Back Box

The weatherproof back box includes small knockout plugs to mount directly to the wall, ceiling, or to a 1900 weatherproof electrical box. If small knockouts are removed, they must be sealed with silicone.

The back box also includes threaded holes on the top and bottom of the back box for ¾-inch NPT conduit adapters. In addition, conduit knockouts in the back of the back box are provided for ¾-inch NPT conduit entry. When using the rear conduit entry holes, the unused holes on the top and bottom of the outdoor back box must be properly sealed. Plugs and O-rings are provided with the product for this purpose. Teflon tape or silicone should be used on the conduit plug threads to ensure a proper seal.

Water may compromise the back box due to condensation or direct exposure to rain or snow, so it is the responsibility of the installer to make sure that all openings and connections are properly sealed. Note that even outdoor installations that are protected from direct exposure to rain are still subject to condensation or leakage through hidden areas, such as a soffit. Watertight fittings should be used for all wiring connections (see Liquid-Tight Connectors and How to Use Them), including the knockout plugs on the back of the box.

Installing Outdoor Speakers and Speaker Strobes

The plastic weatherproof back box shipped with speakers and speaker strobes is equipped with removable side flanges for mounting. System Sensor recommends securing the back box directly to the wall or ceiling using the flanges. If this approach is not possible or is undesirable for aesthetic reasons, installers can use the small knockout plugs on the back of the back box.

Attach the device mounting plate (Figure 1:B) to the weatherproof back box (Figure 1:A) using the four non-painted screws included with the product (Figure 1:C). Hook the tabs on the product housing into the grooves on the mounting plate. Then, swing the product into position to engage the pins on the device with the terminals on the mounting plate. Verify that the tabs on the back of the device are fully engaged with the mounting plate. Finally, secure the device to the mounting plate using the four #8-32×3/8-inch flat head screws (Figure 1:D).

Figure 1 – Mounting Outdoor Speakers and Speaker Strobes to a Weatherproof Back Box



Flush Mounting Outdoor Speakers and Speaker Strobes

The WTP-SP weatherproof plate is for installation with SpectrAlert Advance outdoor replacement (-R) speakers and speaker strobes. This accessory plate enables installers to flush mount an outdoor unit on a number of different surfaces, including brick, ceramic tile, concrete, and masonry brick. Sold separately from the device, the WTP-SP is offered in red and white (WTP-SPW) and is designed for use in both indoor and outdoor applications. The plate is designed specifically to work with the proper SpectrAlert Advance K-series outdoor replacement products (see Speakers and Speaker Strobes in Table 2). The WTP-SP is compatible with 4×4×21/8-inch back boxes. Do not attempt to use this weatherproof plate with devices or back boxes other than those specified for use with this product.

When installing, attach the device mounting plate to the WTP-SP. Check the orientation of the back box to the WTP-SP plate and observe which holes will be used for mounting the back box. Place the Well Nuts (Figure 2:A) into the two holes that will NOT be used in mounting the WTP-SP to the back box. Place the device mounting plate onto the WTP-SP and secure by tightening the two #8-32×½-inch pan head screws (Figure 2:B) into the well nuts. Secure the WTP-SP and device mounting plate assembly to the back box using the two #8-32×½-inch pan head screws (Figure 2:C). Tighten the screws until the WTP-SP gasket is evenly compressed around the perimeter at least 50 percent.

Figure 2 – WTP-SP and Device Mounting Plate Assembly and Attachment to Back Box

An outdoor-rated silicone caulk (not supplied) may be applied around the WTP-SP to fill in around grout lines or uneven surfaces. It is recommended that the silicone should be added after the plate is attached but before the plate is completely screwed down to the surface. This will provide the best indication as to where to apply the silicone.

Connect the field wiring to the proper terminals. For how to connect the field wiring, please follow the instructions listed in the installation manual supplied with the device.

Next, attach the device to the mounting plate by hooking the tabs on the device housing into the grooves on the mounting plate.



Figure 3: Mounting Outdoor Horns, Strobes, and Horn Strobes to a Weatherproof Back Box

Installing Outdoor Horns, Strobes, and Horn Strobes

The wall-mount back box shipped with these products must be mounted with the internal post (Figure 3:A) in the lower left corner.*

Attach the device mounting plate (Figure 3:B) to the weatherproof back box (Figure 3:C) using the four non-painted screws (Figure 3:D) included with the product. Hook the tabs on the product housing into the grooves on the mounting plate. Then, swing the product into position to engage the pins on the device with the terminals on the mounting plate. Verify that the tabs on the back of the device are fully engaged with the mounting plate. Finally, secure the device to the mounting plate by tightening the single screw attached to the front of the housing (Figure 3:E). For tamper resistance, the captured screw may be replaced with the Torx screw supplied with the device.

Flush Mounting Outdoor Horns, Strobes, and Horn Strobes

The WTP weatherproof plate is for installation with SpectrAlert Advance outdoor replacement (-R) horns, strobes, and horn strobes. This plate enables installers to flush mount an outdoor unit on a number of different surfaces, including brick, ceramic tile, concrete, and masonry brick. Sold separately from the device, the WTP is offered in red and white (WTPW) and may be used indoors or outdoors. These plates are designed specifically to work with the proper SpectrAlert Advance K-series outdoor replacement products (see Horns, Strobes, and Horn Strobes in Table 2). The WTP is compatible with 4×4×1¼- or 2×4×1½-inch back boxes. Do not attempt to use this weatherproof plate with devices or back boxes other than those specified for use with this product.

*An installed weatherproof back box should not be left without an installed unit for extended periods of time to avoid water accumulation and potential damage.



Figure 5: Assembly Attachment to 4×4-inch Back Box

Figure 7: Installed Device and WTPFigure 6: Assembly Attachment to 2×4-inch-Back Box

To install, place the device mounting plate on the WTP and secure it using four #6-32×3/8-inch pan head screws (Figure 4:A). Secure the WTP and device mounting plate assembly to the back box using two #8-32×2-inch pan head screws when using a 4×4-inch back box (Figure 5:B). When using the 2×4-inch back box, secure the WTP assembly using the two #6-32×2-inch pan head screws (Figure 6:C). Tighten the screws until the WTP gasket is evenly compressed around the perimeter at least 50 percent.

An outdoor-rated silicone caulk (not supplied) may be applied around the WTP to fill in around grout lines or uneven surfaces. It is recommended that the silicone be added after the plate is attached but before the plate is completely screwed down to the surface. This will provide the best indication as to where to apply the silicone.

Connect the field wiring to the terminals. Please follow the instruction manual supplied with the device.

Attach the device to the mounting plate by hooking the tabs on the device housing into the grooves on the mounting plate. Then, swing the product into position to engage the pins on the device with the terminals on the mounting plate. Make sure that the tabs on the back are fully engaged with the mounting plate.

Secure the device to the WTP by tightening the single mounting screw (Figure 7:D) attached to the front of the device housing. For tamper resistance, the captured screw may be replaced with the Torx screw supplied with the device.

Figure 4: WTP and Device Mounting Plate Assembly



How to Install Conduit Plugs

In order to maintain watertight performance, any unused conduit openings in SpectrAlert Advance weatherproof back boxes must be sealed using the conduit plugs provided with the product. First, slide the O-ring onto the conduit plug that is shipped with the unit. Install the conduit plug and O-ring in any unused threaded opening on the top and bottom of the back box using Teflon tape or silicone sealant on the plug’s threads. Tighten the plug so it compresses the O-ring slightly without pushing it out of place. Do not over tighten. Repeat for any unused threaded openings in the back box.

Liquid-Tight Connectors and How to Use Them

This section provides an overview of the different types of liquid-tight connectors available. It also shows how to use these connectors to provide a watertight seal when connecting conduit to outdoor device weatherproof back boxes — either through the rear knockout holes or through the threaded openings on the top and bottom of the back box.

Types of Liquid-Tight Conduit Connectors

The conduit openings used to bring wire into any SpectrAlert Advance outdoor product should always be protected with a watertight conduit connector. There are several connector options available, including:

• Flexible liquid-tight conduit connector available in metal or plastic• Rigid PVC conduit connector• Cord grip connector• Rigid conduit hub

While the proper SpectrAlert Advance weatherproof back box or mounting plate must be used with the correct product in order for the installation to remain watertight, each of the connectors above can be used in the threaded conduit openings or the rear knockouts as appropriate to the installation.

For example, when a System Sensor outdoor notification product is installed properly in conjunction with the appropriate plastic or metal outdoor back box, it will provide a NEMA 4X rating. However, when a rear knockout is removed from the back box, the product no longer maintains this rating unless a NEMA 4X-rated liquid-tight conduit connector is used.

The use of silicone sealant in the rear knockouts or threaded conduit openings is not recommended in lieu of using a liquid-tight connector or the provided conduit plugs. This approach will result in an unapproved installation that may not have the required watertight properties.

In applications where local codes do not require product wiring to be installed in conduit, it is recommended that a watertight cord grip connecter or a watertight connector with a small length of conduit be used when using the rear knockouts to maintain a watertight seal.

How to Install Liquid-Tight Conduit Connectors in Rear Knockouts

To install a liquid-tight conduit connector, first remove a rear knockout from the metal weatherproof back box by placing the blade of a flat blade screwdriver along the edge of the slot and striking the screwdriver as you slowly work the blade around the slot.



Plug

O-RingConduit Nut

O-Ring or Sealing Washer

Rigid or Flexible Outdoor-Rated Conduit

Liquid-Tight Conduit Connector

Figure 8: Liquid-Tight Connectors

Figure 9: Install in Top Threaded Openings

Liquid-Tight Conduit Connector

Rigid or Flexible Outdoor-Rated Conduit

Plug

O-Ring

Insert the liquid-tight conduit connector into the knockout opening. Make sure that the connector’s gasket is in between the connector and the back box. If a gasket is not provided with the connector, follow the manufacturer’s instructions on how to use the connector in a knockout (an O-ring may need to be purchased separately). Attach the conduit connector to the conduit per the manufacturer’s instructions. Next, tighten the conduit connector nut on the inside of the back box and then secure the weatherproof back box to the mounting surface.

Remember to plug any unused conduit openings with the conduit plugs provided (see How to Install Conduit Plugs).

How to Install Liquid-Tight Conduit Connectors in Threaded Openings

To install a liquid-tight conduit connector, first secure the weatherproof back box to the mounting surface. Thread the liquid-tight conduit connector into a threaded opening following the connector manufacturer’s instructions for liquid-tight applications (this may require the use of Teflon tape or another thread sealant). Finally, connect the conduit to the connector per the manufacturer’s instructions.

Remember to plug any unused conduit openings with the conduit plugs provided (see How to Install Conduit Plugs).



Installation Gallery

This section includes a gallery of outdoor AV appliance installations to provide visual highlights of proper and improper installations methods. See the explanatory caption below each image for more information.

Proper Installations

A watertight fitting has been properly used to run conduit into the bottom opening of the weatherproof back box.

Silicone caulk may be used to seal the space between the mounting surface and the back box. However, silicone does not replace the need to use liquid-tight connectors when wiring the device through the rear conduit openings (not shown).

A liquid-tight connector has been properly used to run conduit into a weatherproof back box.

This conduit plug has been properly installed with the provided gasket compressed between the plug and the back box. Teflon tape has also been wrapped around the plug’s threads (not shown).



Improper Installations

This gasket has been installed incorrectly, resting on top of the conduit plug rather than being compressed between the plug and the back box.

Silicone caulk has been used improperly in place of a conduit plug. Silicone caulk has not been appropriately applied to seal the space between the rough wall surface and the back box.

Silicone caulk has been used improperly between the product and the gasket. A weep hole has been drilled into the bottom conduit plug. Drilling holes into the bottom conduit plug is not recommended.

A conduit connector has not been used to run wiring into the back opening. This provides a path for water to enter the device.


©2010 System Sensor. Product specifications subject to change without notice. AVWP00100 • 4/10 • #2296

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