General Monitors 580A Instruction Manual Download Page 4

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Model 580A

3.9.3

Replacing a Sensor .................................................................................................... 24

4.0

MAINTENANCE.................................................................................................................... 25

4.1

General maintenance .............................................................................................................. 25

4.2

Periodic System Verification.................................................................................................... 25

5.0

TROUBLESHOOTING.......................................................................................................... 26

5.1

General .................................................................................................................................... 26

5.2

Troubleshooting Table............................................................................................................. 26

5.3

Fault Codes ............................................................................................................................. 27

6.0

CUSTOMER SUPPORT ....................................................................................................... 28

6.1

General Monitors’ Offices ........................................................................................................ 28

6.2

Other Sources of Help ............................................................................................................. 28

7.0

APPENDIX............................................................................................................................ 29

7.1

Warranty .................................................................................................................................. 29

7.2

General Specifications - Controller.......................................................................................... 30

7.2.1

Mechanical Specifications .......................................................................................... 30

7.2.2

Environmental Specifications ..................................................................................... 30

7.2.3

Electrical Specifications.............................................................................................. 30

7.2.4

System Specifications ................................................................................................ 30

7.3

General Specifications - Sensor .............................................................................................. 30

7.3.1

System Specifications ................................................................................................ 30

7.3.2

Environmental Specifications ..................................................................................... 30

7.4

Cable Requirements................................................................................................................ 31

7.5

Sensors.................................................................................................................................... 31

7.6

Accessories ............................................................................................................................. 32

7.6.1

Calibration Equipment ................................................................................................ 32

7.6.2

Sensor Covers ............................................................................................................ 32

7.7

Recommended Spare Parts .................................................................................................... 33

7.8

Sample Calibration Schedule and Checklist ........................................................................... 34

7.9

Product Configuration Table.................................................................................................... 35

7.10

Engineering Documentation .................................................................................................... 36

7.10.1

Panel Assembly, Panel Mount – 98, Ref: 10199C ..................................................... 36

Summary of Contents for 580A

Page 1: ...ed in this document may be used and disseminated only for the purposes and to the extent specifically authorized in writing by General Monitors Instruction Manual General Monitors reserves the right to change published specifications and designs without prior notice MAN580A Part No MAN580A Revision B 11 22 04 ...

Page 2: ...Model 580A ii This page intentionally left blank ...

Page 3: ...rces of Gas Emission 9 2 5 4 Environmental Factors 9 2 5 5 Catalytic Poisons 9 2 6 Sensor Installation 10 2 7 Alarm Wiring Connections 13 3 0 START UP AND OPERATION 15 3 1 Types of User Interfaces 15 3 2 Initial Application of Power 16 3 3 Resetting Latched Alarms 16 3 4 Calibration Check Mode 17 3 5 Calibration Mode 18 3 6 Aborting Calibration 19 3 7 Setup and Setup Check modes 19 3 7 1 Entering ...

Page 4: ...er 30 7 2 1 Mechanical Specifications 30 7 2 2 Environmental Specifications 30 7 2 3 Electrical Specifications 30 7 2 4 System Specifications 30 7 3 General Specifications Sensor 30 7 3 1 System Specifications 30 7 3 2 Environmental Specifications 30 7 4 Cable Requirements 31 7 5 Sensors 31 7 6 Accessories 32 7 6 1 Calibration Equipment 32 7 6 2 Sensor Covers 32 7 7 Recommended Spare Parts 33 7 8 ...

Page 5: ...attery Backup System 7 Figure 3 Rear Terminal Connections REF 20659 8 Figure 4 Junction Box Assembly Sensor 12 Figure 5 Protection Circuit for Relay Contacts 14 Figure 6 Front Panel Display 15 Figure 7 Portable Purge Calibrator 17 Figure 8 Panel Assembly Panel Mount 98 Ref 1019 36 ...

Page 6: ...ensor Guards 13 Table 5 Alarm Relay Contacts 13 Table 6 Alarm Relay Terminations 13 Table 7 Setup Display Options 23 Table 8 Troubleshooting Table 27 Table 9 Maximum Cable Lengths 31 Table 10 GMI Sensors Available for 580A System 31 Table 11 Recommended Spare Parts 33 Table 12 Calibration Schedule 34 Table 13 Product Configuration Table 35 ...

Page 7: ...l 580A Two Channel Combustible Gas Monitor contains components which can be damaged by static electricity Special care must be taken when wiring the system to ensure that only the connection points are touched Only catalytic bead sensors designed by General Monitors will work with the Model 580A Controller Any attempt to use a sensor that has not been approved by General Monitors will void the war...

Page 8: ...eady With proper installation calibration and maintenance the system provides continuous monitoring of hazardous areas The user must assume all liability for misuse of General Monitors gas detection systems The system s full two year warranty will be voided if customer personnel or third parties damage the system during repair attempts Customer Support For additional product information not contai...

Page 9: ...ty of monitoring any gas or vapor other than those specified at the time of purchase The Model 580A Controller consists of a controller plus two sensor assemblies The controller is fully solid state It should be mounted in a weather protected non hazardous area Several GMI mounting accessories are available for panel wall or 19 inch rack installation For hazardous areas an explosion proof housing ...

Page 10: ...el 580A Controller is a two channel system where the controller continuously monitors the inputs of two sensors The sensors are monitored independently i e they are not scanned nor are the signals summed The unit has Channel LED indicators for two channels LED indicators for High Low Fault Calibration and Setup Mode Button that is accessed using a small screw driver Digital Display in LEL High Low...

Page 11: ... 1 and Division 2 Groups B C D hazardous areas On some occasions different sensor housing may be supplied The appropriate sensor is provided if GMI is made aware of the gas or vapor that is to be monitored Most combustible gases may be monitored including most hydrocarbons and hydrogen CAUTION Sensors have a different sensitivity to each gas GMI should be consulted if a sensor is expected to detec...

Page 12: ... is RFI resistant do not mount the controller in close proximity to radio transmitters or similar equipment It is recommended that a wiring service loop be used to facilitate gaining access to the alarm set points Care should be taken to assure adequate ventilation Do not mount the controller in a manner which restricts the natural convection airflow from normal ambient air The controller operatin...

Page 13: ...time power outages may last General Monitors recommends that a Lead Acid type battery be used This type of battery can be expected to last for several years with minimum maintenance The customer furnished battery may be connected as shown below Manual or relay switching is not required There is no provision for battery charging A customer furnished battery charger must be used to keep the battery ...

Page 14: ...Model 580A 8 Figure 3 Rear Terminal Connections REF 20659 ...

Page 15: ... than air sensors are generally placed near the floor or ground when there are no air currents in the area Gases with a density equal to air or slightly greater than air tend to rise particularly when air currents are present 2 5 2 Air Currents If there are winds fans or other sources of air movement combustible gases tend to rise or to accumulate in certain sections of a facility Local air curren...

Page 16: ...sensor 2 6 Sensor Installation Various types of sensors can be provided with the Model 580A Controller However the installation method is identical in all cases Please refer to Section 7 6 for further information The sensor assembly Figure 4 is used most often It consists of P N 10001 1 sensor plus GMI P N 10252 1 Sensor Housing This assembly P N 10001 1 P N 10252 1 is CSA approved for NEC Class I...

Page 17: ...tion is not used 2 Sensor cables are connected at the controller to the terminal blocks located along the top of the rear of the controller The channel numbers 1 2 read from top to bottom on this terminal 3 Connect the cable so that the terminal color at the sensor housing matches the terminal color at the controller as follows Figure 4 TERMINAL NUMBER WIRE COLOR CH1 CH2 Black B1 B1 Red R2 R2 Whit...

Page 18: ...Model 580A 12 Figure 4 Junction Box Assembly Sensor ...

Page 19: ...DPDT double pole double throw and are rated 4 amps at 115 VAC resistive The fault alarm contact is SPDT single pole double throw 4 amps at 115 VAC resistive These contacts are brought out to terminals on the rear of the controller as follows CONTACT CONDITION ALARM RELAY OPEN COM CLOSED Fault 4 C 3 Low Alarm 2 3 C 1 4 High Alarm 2 3 C 1 4 Table 5 Alarm Relay Contacts The above chart shows the high...

Page 20: ...nected to the High alarm Low alarm and Fault alarm relays must be clamped down as shown in the diagrams below Unclamped inductive loads can generate voltage spikes in excess of 1000 Volts Spikes of this magnitude will cause false alarms and possible damage Figure 5 Protection Circuit for Relay Contacts ...

Page 21: ... its various functions User interfaces consist of a digital display status indicators a channel select button a mode button and a reset button Figure 6 Front Panel Display The digital display provides the user with the gas concentration at the sensor site fault diagnostic codes calibration prompts and setup parameters The highest gas concentration of the two channels is displayed ...

Page 22: ...er to access the desired channel In normal mode if there are no faults pressing the Channel Select button causes the display to show the gas reading of another channel Releasing the button restores the highest gas concentration display The button also allows selecting a channel for Calibration and Calibration Check mode 3 2 Initial Application of Power Before applying power for the first time doub...

Page 23: ...arm 1 Enter the Calibration Check mode by pressing and holding the Mode button until the CAL LED flashes about ten seconds The unit displays the calibration level When the CAL LED flashes release the Mode button The channel is now in the Calibration Check mode 2 When the Mode button is released the display flashes a pair of bars for about ten seconds After that C1 or C2 displays for a short time i...

Page 24: ...ower up the sensor at least an hour before calibration To calibrate the Model 580A 1 Make sure the calibration gas is the same concentration as the user specified calibration level 2 Make sure the sensor is seeing clean air 3 Enter the Calibration mode by following the same procedure for entering the Calibration Check mode Press and hold the Mode button until the CAL LED becomes steady approximate...

Page 25: ... Check mode allows the operator to view the selected options for the module without allowing any changes to be made Once this mode has been entered the module automatically displays each of the selected options for a short period of time and then it returns to normal operation The Setup mode allows the operator to change the operating parameters by making choices for selected options The Setup Che...

Page 26: ...y If the Password option is enabled the right digit of the display is blank and a 0 appears in the left digit on the display Press the Mode button until the first number of your password displays and then wait about five seconds The left digit of the display blanks out and a 0 appears in the right digit on the display Press the Mode button until your correct password number displays then wait abou...

Page 27: ...exceeded the Low alarm outputs activate The display indicates the current Low alarm set point Press the Mode button repeatedly until the desired Low alarm set point appears on the display 5 to the High set point in increments of 5 The Low set point cannot be set higher than the High set point A set point of 30 is the factory default for this selection In case of common alarms this option is availa...

Page 28: ...Model 580A 22 Press the Mode button repeatedly until the desired value displays the unit then executes the Setup Check mode and then returns to normal operation ...

Page 29: ...that option OPTION DESCRIPTION ENTER SELECTION Password Enter the Password if the Password is enabled High Alarm Options Set the Energized En De Energized dE Option Set the Latching LA Non Latching nL Option Set the High alarm set point Low Alarm Options Set the Energized En De Energized dE Option Set the Latching LA Non Latching nL Option Set the Low alarm set point Calibration Level Set the cali...

Page 30: ...play A gradual drop in reading indicates the presence of background or combustible gases Keeping the hand over the sensor wait for the reading to stabilize and start the calibration without the calibration cap 3 When AC displays remove your hand from the sensor place the cap over the sensor and continue the calibration 3 9 3 Replacing a Sensor When a sensor is replaced the new sensor must be calib...

Page 31: ...results vary Section 3 6 The removal of particulate matter from accessory sensor covers may be facilitated by the use of an appropriate halogen free solvent Water and ethanol are examples of suitable solvents Dry the sensor cover thoroughly with compressed air if necessary before refitting to the sensor body A calibration check must be made after the cleaned cover is re installed because the clean...

Page 32: ...ion we recommend that the factory be consulted and if necessary that the system be returned to the factory for repair This section is intended to be a guide in correcting problems that may arise in the field This section is not all inclusive and General Monitors should be contacted for assistance if the corrective actions listed do not eliminate the problem If equipment or qualified personnel requ...

Page 33: ... sensor to clean air for at least five minutes Then attempt another calibration If the second attempt fails replace the sensor If this fault continues to occur after the sensor has been replaced consult the factory or your GMI Representative F3 Software Checksum Error This fault occurs during initial power up of the unit If this fault occurs remove and reapply power to the unit If the fault contin...

Page 34: ...98 Email info generalmonitors co uk IRELAND Ballybrit Business Park Galway Republic of Ireland Phone 353 91 751175 Fax 353 91 751317 Email service gmil ie SINGAPORE No 2 Kallang Pudding Rd 09 16 Mactech Building Singapore 349307 Phone 65 6 748 3488 Fax 65 6 748 1911 Email genmon singnet com sg MIDDLE EAST LOB12 G20 P O Box 61209 Jebel Ali Dubai United Arab Emirates Phone 971 4 8815751 Fax 971 4 88...

Page 35: ...s or other personnel All warranties are contingent upon proper use in the application for which the product was intended They do not cover products which have been modified or repaired without General Monitors approval or which have been subjected to neglect accident improper installation or application or on which the original identification marks have been removed or altered Except for the expre...

Page 36: ...stem Specifications Digital Readout Range 0 99 Lower Explosive Limit LEL Accuracy 3 LEL for 50 LEL gas and 5 for 50 LEL gas Electrical Classification General purpose non hazardous indoors Warranty Two years Approvals CSA 7 3 General Specifications Sensor 7 3 1 System Specifications Type Diffusion low temperature catalytic bead Standard Industrial Types Combustible Gas High Temperature Combustible ...

Page 37: ...h Temperature Standard Industrial Combustible Gas Sensor Same as Part Number 10001 1 except sensor body is stainless steel 10058 1 Same as Part Number 10001 1 except sensor body is stainless steel 10058 1R Same as Part Number 10058 1 except greatly improved resistance to poisons such as HMDS Hexamethyldisiloxane and H2S Hydrogen Sulfide 10022 1 Similar to Part Number 10001 1 except PTB approved 10...

Page 38: ...dirt water etc may do so 7 6 2 1 Dust Guard Assembly P N 10110 1 The Dust Guard assembly is a simple threaded stainless steel type 303 cylinder with a disposable wire screen at one end It is easily unscrewed for cleaning and or replacement of the screen The screen material is stainless steel type 316 with a nominal 40 micron mesh This accessory is specially designed to prevent dust and particulate...

Page 39: ...quent equipment hose downs occur 7 6 2 4 Sensor Flow Chamber P N 10066 The General Monitors Sensor Flow Chamber is constructed of aluminum optional stainless steel construction available The chamber has an internal thread into which a sensor may be screwed and two threaded ports which accept inch tube fittings The chamber is designed for insertion into a sampling system 7 7 Recommended Spare Parts...

Page 40: ... date and reading of calibration check Date Reading Date Reading Date Reading ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ 5 30 day calibration check Record date and reading of calibration check Date Reading Date Reading Date Reading ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ _...

Page 41: ...rial Hydrocarbon 05 Lbs 03 10014 1 Sensor Al Hi Temp Industrial Hydrocarbon 05 Lbs 04 10014 1R Sensor Al Hi Temp Poison Resistant Hydrocarbon 05 Lbs 05 10022 1 Sensor Al Ptb Industrial Hydrocarbon 05 Lbs 06 10058 1 Sensor SS Standard Industrial Hydrocarbon 05 Lbs 07 10058 1R Sensor SS Poison Resistant Industrial Hydrocarbon 05 Lbs 08 10164 1 Sensor AL Hydrogen Specific 05 Lbs 09 10387 4 Sensor AL ...

Page 42: ...Model 580A 36 7 10 Engineering Documentation 7 10 1 Panel Assembly Panel Mount 98 Ref 10199C Figure 8 Panel Assembly Panel Mount 98 Ref 1019 ...

Page 43: ...E regulations For further General Monitors product WEEE disposal information please visit www generalmonitors com customer_support faq_general html All other countries or states please dispose of in accordance with existing federal state and local environmental control regulations ADDENDUM Product Disposal Considerations ...

Page 44: ... list of available sensors 33 mounting 6 non latching alarm 16 periodic calibration check 3 periodic calibration checks 25 portable calibration chamber 34 portable purge calibrator 17 portable purge calibrators 34 power connections 6 recommended spare parts 35 remote reset connection 9 sensor assemblies 5 sensor cover 34 sensor covers 5 25 sensor flow chamber 35 sensor guards 13 sensor installatio...

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