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MAN0443.P65 Issue 13 Aug 04

5701 Control System

05701-M-5001 A02279

CHAPTER 5 - COMMISSIONING AND

MAINTENANCE INSTRUCTIONS

WARNING

High ac mains voltages may be present at the system power supply
unit and at the relay terminals of the interface cards. Appropriate
safety precautions must be taken when commissioning or servicing
the system.

IMPORTANT

Commissioning and maintenance of the system should be carried out
by trained authorised personnel only.

1.

GENERAL

The following guide to commissioning and maintenance should be
used in conjunction with the relevant instructions issued with the
sensors being used.

The following information applies to the setup of a system with a single
power supply connection to the DC Input Card. For information on
systems where power is applied to each individual channel, please
contact Zellweger Analytics.

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Summary of Contents for 5701

Page 1: ...Sieger System 57 5701 Control System Operating Instructions ...

Page 2: ...s essential IMPORTANT NOTICES 1 Zellweger Analytics Limited can take no responsibility for installation and or use of its equipment if this is not done in accordance with the appropriate issue and or amendment of the manual 2 The user of this manual should ensure that it is appropriate in all details to the exact equipment to be installed and or operated If in doubt the user should contact Zellweg...

Page 3: ...l issue status table these pages will always carry the overall issue status of the manual The remaining chapter issues will reflect the latest issue of those chapters at the time of print of a manual e g Issue A B C etc for chapters of provisional information and 1 2 3 etc for chapters of confirmed information HELP US TO HELP YOU Every effort has been made to ensure the accuracy in the contents of...

Page 4: ...ellweger Analytics Limited Actioned By Date Response Date To Marketing Communications Zellweger Analytics Limited Hatch Pond House 4 Stinsford Road Nuffield Estate POOLE Dorset BH17 0RZ United Kingdom Tel 44 0 1202 676161 Fax 44 0 1202 678011 email tracy dawe zelana com From Address Tel Fax email I suggest the following corrections changes be made to Chapter Section THANK YOU FOR YOUR ASSISTANCE ...

Page 5: ...SYSTEM CONCEPT 2 SYSTEM DESCRIPTION 3 CONTROLS AND FACILITIES 4 INSTALLATION INSTRUCTIONS 5 COMMISSIONING AND MAINTENANCE INSTRUCTIONS 6 OPERATING INSTRUCTIONS 7 ENGINEER S OPERATING INSTRUCTIONS 8 SPECIFICATION 9 ORDERING INFORMATION 10 SPECIAL CONDITIONS FOR SAFE USE ACCORDING TO EC TYPE EXAMINATION CERTIFICATE BVS 04 ATEX G 001 X ...

Page 6: ...6 MAN0443 P65 Issue 13 Aug 04 5701 Control System 05701 M 5001 A02279 5701 CONTROL SYSTEM OPERATING INSTRUCTIONS ...

Page 7: ...1 1 CHAPTER 1 SYSTEM CONCEPT MAN0443 P65 Issue 13 Aug 04 5701 Control System 05701 M 5001 A02279 5701 SERIES CONTROL SYSTEM CHAPTER 1 SYSTEM CONCEPT ...

Page 8: ...CONCEPT MAN0443 P65 Issue 13 Aug 04 5701 Control System 05701 M 5001 A02279 CONTENTS Section Page 1 PRINCIPAL FEATURES 1 3 2 CONSTRUCTION 1 4 FIGURES Figure Page 1 5701 Control System 1 6 2 5701 Control System Over View 1 7 ...

Page 9: ...ng Simple field connections for wire up to 2 5mm2 Single channel mode of operation for high integrity systems Channel Control Cards removable without disturbing other wiring Catalytic bridge or 4 20mA input Optional alarm change over relay outputs Multi alarm mode for master zoned and voted alarms Rising falling STEL and LTEL RATE alarm outputs Update alarm on individual or multi channel alarms Re...

Page 10: ...nnections A single channel of gas detection therefore consists of a Sensor Drive Module In order to achieve compatibility with a range of different inputs and sensor types the circuitry necessary to control the sensor is housed on an independent plug in Sensor Drive Module These modules plug directly into a Channel Control Card and are factory fitted There are two different modules one for catalyt...

Page 11: ...face Relay Cards are mounted one above the other in a 6U rack The backplane printed circuit board still provides the common power and signal routeing between the individual Channel Control Cards while short cables at the rear of the cards connect each Channel Control Card to their respective Interface Relay Card Simple calibration and checking of the system is carried out using push buttons on the...

Page 12: ...Card Engineering Card External DC or 8 16 Way AC to DC PSU Backplane Interface Sensor Sensor Sensor PC or Printer Interface Section Control Card Section RFI Protected Sub Rack Figure 1 5701 Control System RS232 Field Interface or Relay Card Field Interface or Relay Card Single Channel Control Card Single Channel Control Card Optional module Optional Module Outputs ...

Page 13: ...ytic Figure 2 5701 Control System Over View OR OR OR A1 A2 Fault Control Cards Sensor Sensor Sensor Relay Relay Relay Sensor DC Input Card OR Analogue Output Module 2 x A2 2 x A1 Fault Inhibit 2 x A3 A1 A2 A3 Fault Inhibit Interface Cards Rear Access 8 or 16 Way Front Access 8 or 16 Way Optional Modules Master Alarm Update or Event Printing or Modbus Interface ...

Page 14: ...2 1 MAN0443 P65 Issue 13 Aug 04 5701 Control System 05701 M 5001 A02279 CHAPTER 2 SYSTEM DESCRIPTION 5701 SERIES CONTROL SYSTEM CHAPTER 2 SYSTEM DESCRIPTION ...

Page 15: ...1 5 2 Field Interface Card 2 11 5 3 Double SPCO Relay Card 2 14 5 4 Triple SPCO Relay Card 2 16 5 5 Triple DPCO Relay Card 2 18 5 6 High Integrity Relay Card 2 20 6 ENGINEERING CARD 2 23 7 DC INPUT CARD 2 25 7 1 General 2 25 7 2 Rear Access Connections 2 26 7 3 Front Access Connections 2 27 8 AC TO DC POWER SUPPLY UNITS 2 28 8 1 Types of Power Supply Unit 2 28 8 2 Power Supply Unit Upgrades 2 28 8...

Page 16: ...ections Simple alarm handling and operation is provided by each channel control card Complex alarm handling is achieved by communication between a specified number of control cards via the backplane of the rack An engineering card is fitted to each rack and provides control of the rack backplane communications control card interrogation and facilitates maintenance In addition optional modules fitt...

Page 17: ...de by 6U high Part Number 05701 A 0501 for front field wiring connections c Half 19 inch wide by 3U high Part Number 05701 A 0512 for rear field wiring connections d Half 19 inch wide by 6U high Part Number 05701 A 0502 for front field wiring connections All four versions have two separate chambers One is sealed against electromagnetic interference and contains the control cards while the other ch...

Page 18: ...Issue 13 Aug 04 5701 Control System 05701 M 5001 A02279 CHAPTER 2 SYSTEM DESCRIPTION Typical Eight Channel Rear Access Rack Rear View Typical Eight Channel Front Access Rack Relay Interface Chamber Front Cover Removed ...

Page 19: ... front access rack Part Number 05701 A 0451 b or the eight channel half width front access rack Part Number 05701 A 0452 A front door on each cabinet provides security and dust protection while a clear panel in the door allows the channel card displays to be viewed when the door is closed The base of each cabinet contains a selection of preformed knockout cable gland entries Cabinet ...

Page 20: ...t Channel Cards and Engineering Card Interface Relay Cards and DC Input Card Accessory Plate suitable for mounting DIN rails circuit breakers relays etc 16 Channel Cabinet Installation Blanking Panel 16 Way AC to DC Power Supply Unit Channel Cards and Engineering Card Interface Relay Cards and DC input Card Accessory Plate suitable for mounting DIN rails circuit breakers relays etc ...

Page 21: ...lled and is fully definable for a wide range of connected gas detectors and application requirements The software configuration setup is stored in an EEPROM There are two types of control card depending on the type of gas detector being fitted to the system a Single Channel Control Card 4 20mA Part Number 05701 A 0301 b Single Channel Control Card Catalytic Part Number 05701 A 0302 Each of the abo...

Page 22: ...sensor drive modules are provided a Sensor Drive Module 4 20mA Part Number 05701 A 0283 b Sensor Drive Module Catalytic Part Number 05701 A 0284 The Sensor Drive Module conditions the incoming catalytic or 4 20mA sensor signal and provides the necessary sensor power supply It contains all the circuitry necessary to generate the voltages and currents required to drive the sensor the circuitry to ac...

Page 23: ... connectors J1 and J2 while the Analogue Output Module when fitted plugs into J3 and J4 Link LK1 available on MkII cards only is used when individually powering control cards See Chapter 4 Section 16 2 8 Way Analogue Output Module Connectors 14 Way Connectors To Sensor Drive Modules Liquid Crystal Display LEDs Reset Select Push Button Switch 32 Way Socket SK2 To Backplane 15 Way D Type Socket SK1 ...

Page 24: ...eld Interface Card and the four types of relay card provide the interface between a Single Channel Control Card and the field wiring 5 2 Field Interface Card Part Number 05701 A 0326 5 2 1 General For use in systems with master relays Used on all channels except the master Provides connections between the sensor and the control card only No relays fitted ...

Page 25: ...EM DESCRIPTION 5 2 2 Rear Access Connections 26 Ground 28 Sensor 01 Connection 30 Not Connected 32 Analogue O P 34 Remote Reset In 36 0V Out In Ground 25 Sensor S Connection 27 Sensor NS Connection 29 Analogue O P 31 Remote Inhibit In 33 24V Out In 35 User Terminal Reference Slot Location ...

Page 26: ...M DESCRIPTION 5 2 3 Front Access Connections 35 24V Out In 33 Remote Inhibit In 31 Analogue O P 29 Sensor NS Connection 27 Sensor S Connection 25 Ground 0V Out In 36 Remote Reset In 34 Analogue O P 32 Not Connected 30 Sensor 01 Connection 28 Ground 26 Slot Location User Terminal Reference ...

Page 27: ... alarm level and fault condition 5 3 2 Rear Access Connections NC Normally Closed NO Normally Open COM Common Relay contact conditions refer to the no power state of the relay Ground 25 Sensor S Connection 27 Sensor NS Connection 29 Analogue O P 31 Remote Inhibit In 33 24V Out In 35 Fault NC 1 Fault COM 3 Not Connected 5 A1 1 NC 7 A1 1 COM 9 A2 1 NC 11 2 Fault NO 4 Not Connected 6 Not Connected 8 ...

Page 28: ... 3 Front Access Connections 0V Out In 36 Remote Reset In 34 Analogue O P 32 Not Connected 30 Sensor 01 Connection 28 Ground 26 35 24V Out In 33 Remote Inhibit In 31 Analogue O P 29 Sensor NS Connection 27 Sensor S Connection 25 Ground A2 1 NO 12 A2 1 COM 10 A1 1 NO 8 Not Connected 6 Not Connected 4 Fault NO 2 11 A2 1 NC 9 A1 1 COM 7 A1 1 NC 5 Not Connected 3 Fault COM 1 Fault NC Slot Location User...

Page 29: ...nhibit COM 6 Inhibit NO 8 A1 1 NO 10 A2 1 COM 12 A2 1 NO 14 A3 1 NO 16 Not Connected 18 Not Connected 20 Not Connected 22 Not Connected 24 Not Connected 26 Ground 28 Sensor 01 Connection 30 Not Connected 32 Analogue O P 34 Remote Reset In 36 0V Out In Fault NC 1 Fault COM 3 Inhibit NC 5 A1 1 NC 7 A1 1 COM 9 A2 1 NC 11 A3 1 NC 13 A3 1 COM 15 Not Connected 17 Not Connected 19 Not Connected 21 Not Co...

Page 30: ... 30 Sensor 01 Connection 28 Ground 26 Not Connected 24 Not Connected 22 Not Connected 20 Not Connected 18 Not Connected 16 A3 1 NO 14 A2 1 NO 12 A2 1 COM 10 A1 1 NO 8 Inhibit NO 6 Inhibit COM 4 Fault NO 2 35 24V Out In 33 Remote Inhibit In 31 Analogue O P 29 Sensor NS Connection 27 Sensor S Connection 25 Ground 23 Not Connected 21 Not Connected 19 Not Connected 17 Not Connected 15 A3 1 COM 13 A3 1...

Page 31: ...ss Connections Fault NC 1 Fault COM 3 Inhibit NC 5 A1 1 NC 7 A1 1 COM 9 A2 1 NC 11 A3 1 NC 13 A3 1 COM 15 A1 2 NC 17 A2 2 NC 19 A2 2 COM 21 A3 2 NC 23 Ground 25 Sensor S Connection 27 Sensor NS Connection 29 Analogue O P 31 Remote Inhibit In 33 24V Out In 35 NC Normally Closed NO Normally Open COM Common Relay contact conditions refer to the no power state of the relay 2 Fault NO 4 Inhibit COM 6 I...

Page 32: ...ogue O P 32 Not Connected 30 Sensor 01 Connection 28 Ground 26 A3 2 NO 24 A3 2 COM 22 A2 2 NO 20 A1 2 NO 18 A1 2 COM 16 A3 1 NO 14 A2 1 NO 12 A2 1 COM 10 A1 1 NO 8 Inhibit NO 6 Inhibit COM 4 Fault NO 2 35 24V Out In 33 Remote Inhibit In 31 Analogue O P 29 Sensor NS Connection 27 Sensor S Connection 25 Ground 23 A3 2 NC 21 A2 2 COM 19 A2 2 NC 17 A1 2 NC 15 A3 1 COM 13 A3 1 NC 11 A2 1 NC 9 A1 1 COM ...

Page 33: ...card is fitted with eight relays seven of which are fully configurable while the eighth is used for fault alarm The relay states are monitored by the control card to ensure correct operation of the relays In the case of a malfunction the fault relay of the high integrity relay card de energises The fault relay shall always be monitored in order to ensure correct operation of the system Additional ...

Page 34: ...NC Normally Closed NO Normally Open COM Common Relay contact conditions refer to the no power state of the relay 2 RL1 NO Fault 4 RL2 COM 6 RL2 NO 8 RL3 NO 10 RL4 COM 12 RL4 NO 14 RL5 NO 16 RL6 COM 18 RL6 NO 20 RL7 NO 22 RL8 COM 24 RL8 NO 26 Ground 28 Sensor 01 Connection 30 Not Connected 32 Analogue O P 34 Remote Reset In 36 0V Out In Slot Location User Terminal Reference 5 6 2 Rear Access Connec...

Page 35: ...O 20 RL6 NO 18 RL6 COM 16 RL5 NO 14 RL4 NO 12 RL4 COM 10 RL3 NO 8 RL2 NO 6 RL2 COM 4 RL1 NO Fault 35 24V Out In 33 Remote Inhibit In 31 Analogue O P 29 Sensor NS Connection 27 Sensor S Connection 25 Ground 23 RL8 NC 21 RL7 COM 19 RL7 NC 17 RL6 NC 15 RL5 COM 13 RL5 NC 11 RL4 NC 9 RL3 COM 7 RL3 NC 5 RL2 NC 3 RL1 COM Fault 1 RL1 NC Fault Slot Location User Terminal Reference 5 6 3 Front Access Connec...

Page 36: ... or an engineering key The Engineering Key is used to unlock functions that can alter the operation of a control card The Engineering Card is always fitted into the right hand slot of the rack and provides a Routeing of the 24V dc input from the DC Input Card to the backplane of the rack b A backplane serial communications controller and monitor c A time and date reference d An RS232 external engi...

Page 37: ...rovides time stamped reporting of alarm and fault events as they occur and system status at predetermined regular intervals c Modbus Interface Module RS422 485 This facility provides for digital communication between the System 57 Control System and an external computer system using the RS422 485 serial data format and the Modbus communication protocol d Modbus Interface Module RS232 This facility...

Page 38: ...e dc supply is routed through the Engineering Card and sub rack back plane to all cards in the rack and is protected by a fuse on the DC Input Card There is a two part terminal block TB1 to aid removal of the card without disconnecting each of the connected wires If required a stand by backup battery supply may also be connected to the auxiliary dc input connections The PSU and AUX connections are...

Page 39: ...V In PSU 1 11 0V In PSU 1 10 24V In PSU 2 or 24V Out PSU 1 9 0V In PSU 2 or 0V Out PSU 1 8 24V In AUX 1 7 0V In AUX 1 6 24V In AUX 2 or 24V Out AUX 1 5 0V In AUX 2 or 0V Out AUX 1 4 24V Out Fused 3 0V Out Fused 2 Ground 1 Ground TB2 6 5 4 3 2 1 PSU 1 and PSU 2 and AUX 1 and AUX 2 must be compatible with parallel connection 7 2 Rear Access Connections Note For high integrity systems it is possible ...

Page 40: ...r 24V Out AUX 1 7 0V In AUX 1 8 24V In AUX 1 9 0V In PSU 2 or 0V Out PSU 1 10 24V In PSU 2 or 24V Out PSU 1 11 0V In PSU 1 12 24V In PSU 1 PSU 1 and PSU 2 and AUX 1 and AUX 2 must be compatible with parallel connection 7 3 Front Access Connections Note For high integrity systems it is possible to connect the dc power direct to individual relay cards Connections to the Engineering Card optional mod...

Page 41: ...its are provided with internal connections to enable a power upgrade to 100W by the addition of a second 50W Switched Mode AC to DC Power Supply Module Part Number 05701 A 0440 A second sub unit Part Number 05701 A 0441 can be fitted to the basic 16 way power supply unit if more than 100W is required to operate the system The additional sub unit will contain a 50W Switched Mode AC to DC Power Supp...

Page 42: ...w Rear View 24V dc Output Voltage 50W per Fitted Module Input ac Supply Voltage 8 4 8 Way AC to DC Power Supply Unit Layout 8 5 16 Way AC to DC Power Supply Unit Layout Input ac Supply Voltage 24V dc Output Voltage 50W per Fitted Module Input ac Supply Voltage 24V dc Output Voltage 50W per Fitted Module Optional Sub Unit ...

Page 43: ...NIT 05700 A 0405 Iss 2 INPUT 85 264V AC OUTPUT 24V DC 47 440Hz POWER 50W OR 110 340V DC 100W Indicates 50W Unit Top View 50W Switched Mode AC to DC Power Supply Module Additional 50W Switched Mode AC to DC Power Supply Module 8 7 100W Sub Unit Layout The 100W Sub unit is a 50W Sub unit with an additional 50W Switched Mode AC to DC Power Supply Module fitted as shown below This type of unit is iden...

Page 44: ... 13 Aug 04 5701 Control System 05701 M 5001 A02279 CHAPTER 2 SYSTEM DESCRIPTION 9 FRONT PANEL BLANKING PANEL Matching blank front panels are available for fitting to the rack in all unused single channel control card spaces ...

Page 45: ...2 32 MAN0443 P65 Issue 13 Aug 04 5701 Control System 05701 M 5001 A02279 CHAPTER 2 SYSTEM DESCRIPTION ...

Page 46: ...3 1 CHAPTER 3 CONTROLS AND FACILITIES MAN0443 P65 Issue 13 Aug 04 5701 Control System 05701 M 5001 A02279 5701 SERIES CONTROL SYSTEM CHAPTER 3 CONTROLS AND FACILITIES ...

Page 47: ...Section Page 1 INTRODUCTION 3 3 2 SINGLE CHANNEL CONTROL CARD 3 8 2 1 General 3 8 2 2 Liquid Crystal Display 3 9 2 3 LEDs 3 11 2 4 Reset Select Push button 3 12 2 5 Extraction Slot 3 13 2 6 Display Label and Cover 3 13 3 ENGINEERING CARD 3 14 3 1 General 3 14 3 2 LED Indicators 3 14 3 3 Engineering Push buttons 3 15 ...

Page 48: ...t is detected in the control card or associated sensor and is not user configurable In addition the FAULT LED will be illuminated b Inhibit Alarm The inhibit alarm activates when the system alarms are inhibited for any reason and is not user configurable In addition the INHIBIT LED will be illuminated c A1 A2 and A3 Level Alarms The A1 A2 and A3 level alarms are activated when the level of gas bei...

Page 49: ...el crossing a preconfigured threshold and is not related to any other control channel The relevant LED A1 A2 A3 Fault Inhibit will illuminate on the control card with the alarm condition CAUTION Depending upon the configuration control cards configured for Zoned Master or Voted alarms may not give individual alarm outputs h Zoned Alarm A zoned alarm is caused by the input to any control channel fr...

Page 50: ...s in fault or inhibit do not prevent voted alarm outputs k Update Alarm Version 2Vx Software only The update alarm facility provides a common alarm indication whenever a new alarm occurs even if a previous alarm condition exists The update alarm can be configured to operate on a single channel or on a grouped alarm eg master or zoned The update alarm is especially useful in systems configured with...

Page 51: ...the power is removed from it eg in the event of a system power failure The LEDs will illuminate when an alarm or fault condition occurs irrespective of the relay configured state q Normally De energised A normally de energised relay is activated when the power is applied to it eg in the event of an alarm condition The LEDs will illuminate when an alarm or fault condition occurs irrespective of the...

Page 52: ...1 2V4 2V5 2V6 Fault Alarm Yes Yes Yes Yes Yes Inhibit Alarm Yes Yes Yes Yes Yes A1 A2 A3 Alarm Yes Yes Yes Yes Yes STEL LTEL Alarm No Yes Yes Yes Yes 30 Minute STEL No No Yes Yes Yes Rate Alarm No No Yes Yes Yes Zoned Alarm Yes Yes Yes Yes Yes Master Alarm Yes Yes Yes Yes Yes Voted Alarm Yes Yes Yes Yes Yes Vote Compensation No No No No Yes Update Alarm No No Yes Yes Yes Time Delay Relays No No Ye...

Page 53: ...sensor and conditions the incoming sensor signal The received sensor signal is then processed by the microprocessor and the resultant value and any necessary alarm action depending on the channel configuration is carried out The channel card front panel can be subdivided into five areas Display Label and Cover LCD Display Alarm LEDs Reset Select Push button Extraction Slot RESET SELECT 5701 A3 A2 ...

Page 54: ...ay This consists of 25 segments providing an indication of the sensor gas reading in the form of an analogue bar graph which covers the sensor range between 10 and 110 fsd There are two possible modes of operation a Solid in which the segments fill the area between zero and the actual gas reading b Single Line in which a single segment indicates the actual gas reading Each of these modes can be op...

Page 55: ...our character 14 segment display which provides intelligent reporting of the sensor status or information on a selected engineering function For control cards fitted with the high integrity relay outputs performing master zone or voted alarms the alarm state will also be indicated as follows BEAM Beam Blocked Alarm MSTR Master Alarm ZONE Zoned Alarm VOTE Voted Alarm In the case of an Update alarm ...

Page 56: ...ions such as zero span 1st span and alarm test Depending upon the configuration the control card may enter the inhibit mode for a short period of time immediately after a fault condition is cleared During the inhibit condition the channel card will continue to read the gas sensor reading however no action is taken in the event of an alarm condition being exceeded c A1 Red LED The A1 LED indicates ...

Page 57: ...tched setups the indicated alarms will clear automatically when the alarm condition clears b Channel Select The RESET SELECT push button when pressed for approximately 1 5 seconds selects the control card for operations controlled from the Engineering Card c Extended Reset The RESET SELECT push button when pressed continuously for five seconds i Clears the channel maximum and minimum gas readings ...

Page 58: ...g the card out of the rack 2 6 Display Label and Cover A clear perspex cover clips to the front panel and retains the label which provides identification of the control card type sensor scale LED and push button functions Two different label colours are used a Grey Blue Control cards fitted with Catalytic Sensor Drive Modules b Violet Control cards fitted with 4 20mA Sensor Drive Modules The persp...

Page 59: ...rvals indicates a low dc power input level A flashing LED at approximately 0 5 second intervals indicates a hardware fault 3 2 2 Red LED Provides an indication of the operation of the Engineering Card communications status as follows Off Engineering Card functioning correctly and the engineering functions are locked Operators functions are operational to allow the checking of various control card ...

Page 60: ...the rack When the up and down push buttons are operated simultaneously a print out command is selected of the control card configuration and status 3 3 5 Accept Push button When the accept push button is operated during any of the engineers functions this button confirms adjustments that have been made and then cancels that function 3 3 6 Reject Push button When operated during any of the engineer...

Page 61: ... Catalytic bridge output sensitivity in mV 3 3 10 ZERO Push button The ZERO push button can only be used when the Engineering Key is fitted to the Engineering Card and is used to calibrate the zero point of the selected control card 3 3 11 SPAN Push button The SPAN push button can only be used when the Engineering Key is fitted to the Engineering Card and is used to calibrate the span point of the...

Page 62: ...y configured relay output alarm functions Inhibit can only be used if the Engineering Key is fitted to the Engineering Card however if the Engineering Key is subsequently removed the selected control card remains in the inhibit mode 3 3 15 Engineering Serial Port The Engineering Serial Port is a miniature DIN socket which provides three functions a Connection point for the Engineering Key to unloc...

Page 63: ...3 18 CHAPTER 3 CONTROLS AND FACILITIES MAN0443 P65 Issue 13 Aug 04 5701 Control System 05701 M 5001 A02279 ...

Page 64: ...MAN0443 P65 Issue 13 Aug 04 5701 Control System 05701 M 5001 A02279 CHAPTER 4 INSTALLATION INSTRUCTIONS 4 1 5701 SERIES CONTROL SYSTEM CHAPTER 4 INSTALLATION INSTRUCTIONS ...

Page 65: ...ospheres In addition appropriate local or national regulations shall be used IMPORTANT NOTICES 1 Zellweger Analytics Limited can take no responsibility for installation and or use of its equipment if this is not done in accordance with the appropriate issue and or amendment of the manual 2 The user of this manual should ensure that it is appropriate in all details to the exact equipment to be inst...

Page 66: ...LLATION 4 13 9 PANELINSTALLATION 4 16 10 RACK INSTALLATION 4 18 11 SENSOR INSTALLATION 4 19 11 1 General 4 19 11 2 Sensor Line Resistance 4 19 11 3 Cable Resistance Guide 4 21 11 4 Catalytic Sensors 4 21 11 5 4 20mA Loop Powered Sensors 4 22 11 6 4 20mATransmitters 4 22 12 CONTROL CARD SENSOR DRIVE MODULE CONFIGURATION 4 23 12 1 General 4 23 12 2 Single Channel Control Card Catalytic Input Link Se...

Page 67: ...s 2000 Toxic Transmitter Connections 4 56 14 OUTPUT CONNECTIONS 4 61 14 1 Relay Outputs 4 61 14 2 Analogue Output 4 62 15 REMOTE INPUT CONNECTIONS 4 65 16 DC POWER CONNECTIONS 4 67 16 1 General 4 67 16 2 Individually Powered Control Cards 4 68 17 AC TO DC POWER SUPPLY UNIT CONNECTIONS 4 69 18 UPGRADING THEAC TO DC POWER SUPPLY UNITS 4 71 18 1 General 4 71 18 2 8 Way and 16 Way AC to DC Power Suppl...

Page 68: ...Cutout as required e Fit the System 57 rack into the Cabinet 19 Mounting Frame or Panel Cutout f Install the sensors and wire back to the System 57 g Check and if necessary reconfigure the Single Channel Control Cards h Wire the sensors to the Field Interface Relay Card terminal blocks i Wire the outputs from Field Interface Relay Card terminal blocks j Wire the power supply to the DC Input Card A...

Page 69: ...Carefully unpack the equipment observing any instructions printed on or contained in the packaging b Check the contents for transit damage and against the packing note for deficiencies c Locate the configuration sheet supplied with the unit and confirm that each channel card type and settings are compatible with the proposed sensors ...

Page 70: ...t and 3U rear access racks are compatible with the standard 19 483mm sub rack format and may therefore be fitted into any suitable 19 mounting frame b Cabinet Wall mounting cabinets are available in two sizes to accommodate the 19 and half 19 6U front access rack assemblies c Panel Alternatively all the racks are suitable for fitting directly into a panel cutout aperture Power supply units are ava...

Page 71: ...uld be routed away from sources of interference such as ac power cables motors machinery etc All sensor cabling is subject to a maximum cable length that is dependant upon the cable line resistance and sensor types The current ratings of the power and relay cables should always be higher than the worst case maximum load requirement All sensor field cables must be screened in order to ensure correc...

Page 72: ...r budget calculation sheet allows for a quick and easy calculation of the worst case power requirement for the system In many cases a lower power rating can be used however a more detailed power budget analysis should be performed to confirm the exact requirement The 8 Way AC to DC Power Supply Units can provide a 50W dc supply or a 100W dc supply depending upon whether one or two switch mode modu...

Page 73: ...___ Relay Card High Integrity ____ 1 70 Analogue Output Module excludes loop power ____ 0 50 ____ Allowance for Transmitters and Sensors powered from System 57 PSU Searchline ____ 5 00 ____ Searchline Excel Receiver ____ 8 00 ____ Searchline Excel Transmitter S R ____ 6 50 ____ Searchline Excel Transmitter L R ____ 7 50 ____ Searchline Excel Cross Duct TX RX ____ 13 0 ____ Searchpoint 500 ____ 10 ...

Page 74: ...rack As such careful consideration must be given to thermal planning To achieve most from the convection cooling always ensure that the air can flow freely through the rack and power supply Do not obstruct the air vent holes in the top and bottom of the rack and if possible space the control cards evenly within the rack It is recommended that during commissioning the operating temperature of the r...

Page 75: ...be connected to that control card Ensure that where an AC to DC Power Supply Unit is to be used this is compatible with the local mains ac supply voltage and that the PSU power rating is adequate for its individual system load Note The model 05701 A 0405 and 05701 A 0406 AC to DC Power Supply Units operate without the requirement of input voltage adjustments from an 85V to 264V 47Hz to 440Hz ac su...

Page 76: ...he mounting brackets will accept up to a 10mm diameter screw 5 Secure the cabinet in position using appropriate mounting screws 6 Fit the System 57 Rack and AC to DC Power Supply Unit if required into the cabinet in the positions shown 7 Pass cables through the gland adjacent to field terminal blocks where possible keeping the sensor cable s separate from the other wiring 8 Prepare and connect the...

Page 77: ...1 A02279 CHAPTER 4 INSTALLATION INSTRUCTIONS All dimension shown in mm Cabinet Dimensions 630 8 way 337 16 way 540 268 Wall Mounting Bracket Hole Locations Cabinet Mounting Brackets 9 10 2 36 9 27 15 10 100 15 100 430 8 way 367 16 way 57 15 All dimension shown in mm ...

Page 78: ...e Relay Cards 16 Way AC to DC Power Supply Unit Engineering Card DC Input Card Accessory Plate suitable for mounting DIN rails circuit breakers relays etc Eight Channel Cabinet Installation Blanking Panel Channel Cards Interface Relay Cards 8 Way AC to DC Power Supply Unit Engineering Card DC Input Card Accessory Plate suitable for mounting DIN rails circuit breakers relays etc ...

Page 79: ...commodate the System 57 rack and power supply unit where required using the dimensions shown Rack Table of Sizes mm RackAssembly A B C D E Depth 8 Way Rear Access 279 4 261 9 57 0 37 8 132 5 287 6 8 Way Front Access 279 4 261 9 190 5 37 8 266 0 217 6 16 Way Rear Access 482 6 465 1 57 0 37 8 132 5 287 6 16 Way Front Access 482 6 465 1 190 5 37 8 266 0 217 6 Panel Cutout Clearance 8 Way Width 247 He...

Page 80: ...sure adequate support at the rear of rear access racks 4 Prepare and connect the cable ends to Field Interface and Relay Cards terminals For terminal identification see Chapter 2 Where possible keep sensor cables separate from the other wiring 5 Ensure that the rack is properly earthed by connecting a suitable earth cable to the earth stud located at the rear of the rack CAUTION Do not apply power...

Page 81: ...lts through the four mounting holes located on the front flange plates 2 Ensure adequate support at the rear of rear access racks 3 Prepare and connect the cable ends to Field Interface and Relay Card terminals For terminal identification see Chapter 2 Where possible keep sensor cables separate from the other wiring 4 Ensure that the rack is properly earthed by connecting a suitable earth cable to...

Page 82: ... that they are accessible for maintenance work 11 2 Sensor Line Resistance Sensors should be located such that the line resistance of cable does not exceed the maximum permitted The table gives a quick guide to the maximum cable lengths permitted for specific sensors when connected by stranded copper conductor cables of various sizes to a System 57 running at the minimum dc input voltage The figur...

Page 83: ... 540 900 Life Line 3200 4800 6400 9600 16000 Opus LLII Toxic 300 450 600 900 1500 Opus LLII Combustible 250 375 500 750 1250 Searchline minimum dc supply 21V 60 90 120 180 300 Searchpoint 500 32 48 64 96 160 Searchpoint OPTIMA minimum dc supply 19V 180 270 360 540 900 Series 2000 Combustible 450 670 900 1300 2200 Series 2000 Toxic 1600 2400 3200 4800 8000 Searchline Excel Receiver minimum dc suppl...

Page 84: ...ded Copper Conductor Cross Sectional Area mm Maximum resistance at 20 C ohm km 0 50 36 8 0 75 24 5 1 00 18 4 1 50 12 3 2 50 7 4 11 4 Catalytic Sensors The maximum line resistance of cabling for a catalytic sensor varies with the current and voltage requirements of the type of sensor installed It is also subject to a maximum of 10V permitted across terminals S and NS at the Field Interface Relay Ca...

Page 85: ...oltage V 11 6 4 20mA Transmitters The maximum line resistance of cabling for a 4 20mA transmitter powered from the System 57 varies with the voltage and current requirements of the transmitter It is also subject to the minimum supply voltage available from the System 57 Maximum line loop resistance is calculated as follows Vr Vs RL Is Where RL Total Line Resistance ohms Vr Minimum DC Supply to Sys...

Page 86: ...1 to LK3 which allow setting of the bridge current range The following ranges are available Range Current LK1 LK2 LK3 1 219mA to 283mA S C S C S C 2 66mA to 230mA S C S C O C 3 118mA to 182mA O C S C O C 4 70mA to 134mA O C O C O C S C Short Circuit O C Open Circuit The above information is only provided to allow the configuration of the Sensor Drive Module Catalytic to be checked The current rang...

Page 87: ...o pins of the link are connected Unused links should have their jumper removed from the Sensor Drive Module altogether or carefully fitted over a single pin of an unused link as follows Sensor Drive Module Open Closed and Spare Link Arrangements The closed link positions required for the most common sensor configurations are given in Section 13 3 LK13 LK1 05701 A 0283 Open Spare Shorted ...

Page 88: ... the Sensor Operating Instructions and run the field cables back to the System 57 unit The sensor cables should be routed away from sources of interference such as ac power cables motors machinery etc Use the information on the configuration sheet provided with the unit to decide which sensor to connect to each channel The following sections describe the sensor connections for the Catalytic and 4 ...

Page 89: ...al of the Field Interface Relay Card or to a suitable instrument earth point Combustible Sensor Junction Box and Terminal Block Connections Note Where a sensor is earthed locally either to the Earth Stud or through the sensor casing or mounting to avoid earth loops the screen sheath of the cable should only be connected at one end i e at the sensor or at the Interface Relay Card Single Channel Con...

Page 90: ...nal Block Connections Single Channel Control Card Catalytic 05701 A 0302 Fitted with Catalytic Sensor Drive 05701 A 0284 Note Where a sensor is earthed locally either to the Earth Stud or through the sensor casing or mounting to avoid earth loops the screen sheath of the cable should only be connected at one end i e at the sensor or at the Interface Relay Card ...

Page 91: ...ected to one of either the S 01 or NS terminals on the Field Interface or Relay Card that is attached to the required Single Channel Display Card The two terminals used will vary depending upon whether the location of the measuring resistance is in the loop supply or return paths Link options must also be set correctly on the 4 20mA Sensor Drive Module see Section 12 3 The sensor cable screen shou...

Page 92: ...or Measuring Resistance in Supply Return LK4 Junction Box Red Red Green Yellow Sensor Screen SensePoint Toxic Sensor SignalPoint Toxic Sensor Blue Blue S 01 Screen Junction Box Terminal Block 01 S Single Channel Control Card 4 20mA 05701 A 0301 Fitted with 4 20mA Sensor Drive 05701 A 0283 Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328 05701 A 0329 05701 A 0330 S 01 Arrows Indica...

Page 93: ...mounting to avoid earth loops the screen sheath of the cable should only be connected at one end i e at the sensor or at the Interface Relay Card 811 911 ECC S2000 Toxic Sensor Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328 05701 A 0329 05701 A 0330 01 NS Arrows Indicate Direction of Loop Current Flow Screened Cable Earth Terminal 29 Brown Blue Junction Box Terminal Block Juncti...

Page 94: ...nnel Control Card require either three or four wire connections and the sensor documentation will indicate the 0V and 24V power connections and the positive and negative loop connections At the System 57 end of the field cable the sensor wires should be connected to the S 01 NS 0V or 24V terminals on the Field Interface or Relay Card that is attached to the required Single Channel Display Card The...

Page 95: ...the sensor casing or mounting to avoid earth loops the screen sheath of the cable should only be connected at one end i e the sensor or at the relay interface card Link Positions Single Channel Control Card 4 20mA 05701 A 0301 Fitted with 4 20mA Sensor Drive 05701 A 0283 Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328 05701 A 0329 05701 A 0330 Screened Cable Arrows Indicate Direc...

Page 96: ...mA Sensor Drive 05701 A 0283 Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328 05701 A 0329 05701 A 0330 Screened Cable Arrows Indicate Direction of Loop Current Flow S 01 NS Screen to cable gland Cabinet Protective Earth 28 27 29 Note Where the sensor is earthed locally either to the stud or through the sensor casing or mounting to avoid earth loops the screen sheath of the cable ...

Page 97: ... cable should only be connected at one end i e the sensor or at the relay interface card 28 29 Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328 05701 A 0329 05701 A 0330 Single Channel Control Card 4 20mA 05701 A 0301 Fitted with 4 20mA Sensor Drive 05701 A 0283 The 24V supply for the transmitter may be obtained from either the Relay Field Interface Card terminals 35 24V and 36 0V...

Page 98: ...should be earthed locally The transmitter is earthed through the Earth Stud to avoid earth loops the screen sheath of the cable should only be connected at the transmitter Link Positions Single Channel Control Card 4 20mA 05701 A 0301 Fitted with 4 20mA Sensor Drive 05701 A 0283 Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328 05701 A 0329 05701 A 0330 Screened Cable Arrows Indica...

Page 99: ... Sensor Drive 05701 A 0283 Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328 05701 A 0329 05701 A 0330 Screened Cable Arrows Indicate Direction of Loop Current Flow S 01 NS 24V 4 20mA 0V Cabinet Protective Earth 28 27 29 Note The Apex transmitter should be earthed locally The transmitter is earthed through the Earth Stud to avoid earth loops the screen sheath of the cable should on...

Page 100: ...r is earthed through the Earth Stud to avoid earth loops the screen sheath of the cable should only be connected at the transmitter 28 29 Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328 05701 A 0329 05701 A 0330 Single Channel Control Card 4 20mA 05701 A 0301 Fitted with 4 20mA Sensor Drive 05701 A 0283 Link Positions LK1 LK12 LK9 LK6 36 NS 35 SK4 Comms and Power Apex 1 2 3 4 5 6...

Page 101: ...or casing or mounting to avoid earth loops the screen sheath of the cable should only be connected at one end ie At the sensor or at the Interface relay Card Link Positions Single Channel Control Card 4 20mA 05701 A 0301 Fitted with 4 20mA Sensor Drive 05701 A 0283 Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328 05701 A 0329 05701 A 0330 Screened Cable Arrows Indicate Direction o...

Page 102: ...05701 A 0283 Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328 05701 A 0329 05701 A 0330 Screened Cable Arrows Indicate Direction of Loop Current Flow S 01 NS Earth Stud 24V 4 20mA 0V GND Series 2000 Flammable 11 4 9 2 3 Link fitted for Transmitter Source Cabinet Protective Earth 28 27 29 Note Where a sensor is earthed locally either to the Earth Stud or through the sensor casing o...

Page 103: ... module 04200 A 0145 Screened Cable S 01 NS Cabinet Protective Earth Note 1 Where a sensor is earthed locally either to the Earth Stud or through the sensor casing or mounting to avoid earth loops the screen sheath of the cable should only be connected at one end ie At the sensor or at the Interface relay Card 2 The Optima analogue output is non isolated and is factory configured as current sink o...

Page 104: ... 04200 A 0146 Screened Cable S 01 NS Cabinet Protective Earth Link Positions LK12 LK10 LK7 LK3 Note 1 Where a sensor is earthed locally either to the Earth Stud or through the sensor casing or mounting to avoid earth loops the screen sheath of the cable should only be connected at one end ie At the sensor or at the Interface relay Card 2 The Optima analogue output is non isolated and is factory co...

Page 105: ...Control Card 4 20mA 05701 A 0301 Fitted with 4 20mA Sensor Drive 05701 A 0283 4 4 1 1 GND ORANGE A 24V DC Supply BLACK 0V WHITE 4 20mA BLUE B 0V DC Supply 4 20mA Output GRN YEL GND RED 24V 35 36 33 34 31 32 29 30 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328 05701 A 0329 05701 A 0330 Arrows Indicate Dire...

Page 106: ...Zellweger Analytics for other option LK3 LK12 LK10 LK7 Three Wire Control Card Current Sink Transmitter Current Source Connection for Searchline Excel Cross Duct Signal Returned to 0V Link Positions 35 36 33 34 31 32 29 30 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328 05701 A 0329 05701 A 0330 Cabinet 28...

Page 107: ...ce model only contact Zellweger Analytics for other option Single Channel Control Card 4 20mA 05701 A 0301 Fitted with 4 20mA Sensor Drive 05701 A 0283 LK3 LK12 LK10 LK7 Link Positions 35 36 33 34 31 32 29 30 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328 05701 A 0329 05701 A 0330 Cabinet 29 27 28 Protect...

Page 108: ...th Stud or through the sensor casing or mounting to avoid earth loops the screen sheath of the cable should only be connected at one end ie At the sensor or at the Interface relay Card 2 The Optima Plus analogue output is non isolated and is factory configured as current sink or current source The actual configuration is identified by a label on the Optima white 4 20mA output lead Single Channel C...

Page 109: ...he sensor casing or mounting to avoid earth loops the screen sheath of the cable should only be connected at one end ie At the sensor or at the Interface relay Card 2 The Optima Plus analogue output is non isolated and is factory configured as current sink or current source Connector and link settings are shown for current source model only contact Zellweger Analytics for other option Single Chann...

Page 110: ... Note Where a sensor is earthed locally either to the Earth Stud or through the sensor casing or mounting to avoid earth loops the screen sheath of the cable should only be connected at one end ie At the sensor or at the Interface relay Card Single Channel Control Card 4 20mA 05701 A 0301 Fitted with 4 20mA Sensor Drive 05701 A 0283 Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328...

Page 111: ...here a sensor is earthed locally either to the Earth Stud or through the sensor casing or mounting to avoid earth loops the screen sheath of the cable should only be connected at one end ie At the sensor or at the Interface relay Card Single Channel Control Card 4 20mA 05701 A 0301 Fitted with 4 20mA Sensor Drive 05701 A 0283 Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328 05701 ...

Page 112: ...th Note Where a sensor is earthed locally either to the Earth Stud or through the sensor casing or mounting to avoid earth loops the screen sheath of the cable should only be connected at one end ie At the sensor or at the Interface relay Card Single Channel Control Card 4 20mA 05701 A 0301 Fitted with 4 20mA Sensor Drive 05701 A 0283 Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 03...

Page 113: ... Note Where a sensor is earthed locally either to the Earth Stud or through the sensor casing or mounting to avoid earth loops the screen sheath of the cable should only be connected at one end ie At the sensor or at the Interface relay Card Single Channel Control Card 4 20mA 05701 A 0301 Fitted with 4 20mA Sensor Drive 05701 A 0283 Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328...

Page 114: ...tted with 4 20mA Sensor Drive 05701 A 0283 28 29 Note Where a sensor is earthed locally either to the Earth Stud or through the sensor casing or mounting to avoid earth loops the screen sheath of the cable should only be connected at one end ie At the sensor or at the Interface relay Card LK3 Link Positions LK1 LK12 LK9 LK6 27 S Arrows Indicate Direction of Loop Current Flow 24V 4 20mA 0V 0V 24 4 ...

Page 115: ...5701 A 0301 Fitted with 4 20mA Sensor Drive 05701 A 0283 LK12 LK10 LK7 LK3 Note Where a sensor is earthed locally either to the Earth Stud or through the sensor casing or mounting to avoid earth loops the screen sheath of the cable should only be connected at one end ie At the sensor or at the Interface relay Card 27 S Arrows Indicate Direction of Loop Current Flow 4 20mA LK2 Fitted For Current So...

Page 116: ...e sensor casing or mounting to avoid earth loops the screen sheath of the cable should only be connected at one end ie At the sensor or at the Interface relay Card Single Channel Control Card 4 20mA 05701 A 0301 Fitted with 4 20mA Sensor Drive 05701 A 0283 Link Positions LK1 LK12 LK9 LK6 0V 28 29 36 35 NS Screened Cable Arrows Indicate Direction of Loop Current Flow 24V 4 20mA 4 20mA 0V GND 4 20mA...

Page 117: ...ows Indicate Direction of Loop Current Flow No Links 24V 4 20mA 4 20mA Barrier Safety Ground 0V Link Positions LK12 LK9 LK6 LK1 Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328 05701 A 0329 05701 A 0330 Single Channel Control Card 4 20mA 05701 A 0301 Fitted with 4 20mA Sensor Drive 05701 A 0283 28 29 The 24V supply for the transmitter may be obtained from either the Relay Field In...

Page 118: ...e Direction of Loop Current Flow Link Positions LK12 LK10 LK7 Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328 05701 A 0329 05701 A 0330 Single Channel Control Card 4 20mA 05701 A 0301 Fitted with 4 20mA Sensor Drive 05701 A 0283 28 29 24V 4 20mA 4 20mA 0V GND Earth Stud 36 35 01 The 24V supply for the transmitter may be obtained from either the Relay Field Interface Card terminal...

Page 119: ...arrier can be used IS Series 2000 Toxic Sensor With Single Safety Barrier Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328 05701 A 0329 05701 A 0330 Single Channel Control Card 4 20mA 05701 A 0301 Fitted With 4 20mA Sensor Drive 05701 A 0283 1 2 Single IS Safety Barrier x 3 NS 01 Arrows Indicate Direction of Loop Current Flow Two Core Screened Cable GND IS Series 2000 Toxic Sensor...

Page 120: ...0301 Fitted With 4 20mA Sensor Drive 05701 A 0283 1 2 Double IS Safety Barrier x 3 S 01 Arrows Indicate Direction of Loop Current Flow Two Core Screened Cable GND IS Series 2000 Toxic Sensor Terminal Block Earth Stud If the measuring resistance is in the negative supply line a double safety barrier must be used Cabinet Protective Earth x 3 28 25 27 29 NS GND Link Positions LK1 LK4 LK10 LK13 WARNIN...

Page 121: ...ned Cable Link Positions LK1 LK6 LK9 Note Where a sensor is earthed locally either to the Earth Stud or through the sensor casing or mounting to avoid earth loops the screen sheath of the cable should only be connected at one end ie At the sensor or at the Interface relay Card Single Channel Control Card 4 20mA 05701 A 0301 Fitted With 4 20mA Sensor Drive 05701 A 0283 Relay Field Interface Card 05...

Page 122: ...an be used 35 36 33 34 31 32 29 30 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328 05701 A 0329 05701 A 0330 Arrows Indicate Direction of Loop Current Flow Single IS Safety Barrier x3 Cabinet Two Core Screened Cable Single Channel Control Card 4 20mA 05701 A 0301 Fitted With 4 20mA Sensor Drive 05701 A 028...

Page 123: ...e Screened Cable Single Channel Control Card 4 20mA 05701 A 0301 Fitted With 4 20mA Sensor Drive 05701 A 0283 28 29 NS 27 25 GND 01 S Protective Earth Loop to Relay Card S Loop to Relay Card 01 Screen to Ground Link Positions LK10 LK13 LK4 LK1 Lifeline IS Lifeline Sensor With Double Safety Barrier Single Channel Control Card 4 20mA 05701 A 0301 Fitted With 4 20mA Sensor Drive 05701 A 0283 If the m...

Page 124: ...n printout or use the relays screen of the Engineering Interface Software to determine the configuration CAUTION When mains ac is connected to the relay contacts a The ac supply should be fused at 5A maximum b A safety earth connection should be made to the ground terminal of the relay card There are four relay card types providing different levels of alarm relay capability See Chapter 2 Section 5...

Page 125: ...ting the analogue output to a loop voltage in excess of 40V may cause permanent damage to the analogue output module The Analogue Output Module provides an isolated current loop output that follows the sensor signal level The output circuit is a passive current control element that can be operated with loop voltages up to 40V The recommended connections are shown below Analogue Output 0V 24V 10V t...

Page 126: ...ore information The analogue output can be connected to voltage input device eg chart recorders by including an external sense resistor in series with the loop and connecting the device input in parallel with the resistor ie Use a 100 ohm resistor and select an input range of 2V on the chart recorder Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328 05701 A 0329 05701 A 0330 Non is...

Page 127: ... O P 24V Chart Recorder Input R 100 Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328 05701 A 0329 05701 A 0330 Analogue Output Connection with 100 Ohm Sense Resistor and Parallel Chart Recorder Single Channel Control Card 05701 A 0301 4 20mA 05701 A 0302 Catalytic Fitted with Analogue Output Module 05701 A 0285 36 35 0V ...

Page 128: ... can be reconfigured easily using a computer attached to the Engineering Port Contact Zellweger Analytics or your local agent for more information The switching level of the remote input pins when enabled is approximately 2V with respect to the dc system 0V The inputs require less than 5mA drive current and irrespective of configuration are internally pulled down to system 0V Active high remote in...

Page 129: ...A 0301 4 20mA 05701 A 0302 Catalytic Remote Inhibit 24V Remote Reset Configured for active high remote inputs Normally Open Contact INHIBIT RESET 33 34 35 Relay Field Interface Card 05701 A 0326 05701 A 0327 05701 A 0328 05701 A 0329 05701 A 0330 Single Channel Control Card 05701 A 0301 4 20mA 05701 A 0302 Catalytic Normally Closed Contact Configured for active low remote inputs 33 Active Low Remo...

Page 130: ...d dc power supply and battery backup dc supply Note that current will be drawn from the supply input with the highest voltage and in some circumstances current will be shared between the two inputs Each of the two inputs have twin 24V and 0V terminals for easy through power connection or paralleling of input sources A fused 24V output which is the combination of both dc inputs is provided for powe...

Page 131: ...on Individual powering of a single channel control card is easily achieved as follows 1 On the Single Channel Control Card remove the link LK1 from position 1 2 and refit in position 2 3 as shown below IMPORTANT The individual power supply to the control card must be fused externally by a 1A fuse Note On older versions of the single channel control card the Link LK1 was not fitted In this case the...

Page 132: ...e mains rated for a minimum of 6A Two cables emerge from the rear of the AC to DC Power Supply Unit a AC Input The ac supply cable connections are colour coded BROWN LIVE BLUE NEUTRAL and YELLOW GREEN EARTH If necessary these wires should be connected to the ac supply via a suitable intermediate mains rated terminal block b DC Output The dc output cable connections are colour coded RED 24V and BLA...

Page 133: ...Supply Connections to AC Supply Earth and DC Input Card Together with Auxiliary Battery Backup Supply System Earth DC Input Card TB1 Auxiliary 24V DC Supply eg Battery Backup 24V Output to Ancillary Equipment System Earth AC Input Supply Brown Blue Green Yellow Intermediate Terminal Block L N E L N E Early Models Later Models Colour Sheath Colour Sheath Brown Black Red White Blue Black 12 11 10 9 ...

Page 134: ...ing out any maintenance or upgrade operation 18 1 General There are two types of AC to DC Power Supply Unit an 8 Way 50W and 16 Way 50W The 8 way unit may be upgraded to 100W with the addition of a second 50W Switched Mode Module The 16 way unit may be upgraded to 100W 150W or 200W with the addition of 50W Switched Mode Module s and if necessary a 50W Sub Unit Front View Top View Rear View 8 Way A...

Page 135: ...W Front View Top View Rear View 50W Switched Mode AC to DC Power Supply Module 16 Way AC to DC Power Supply Unit 50W Earth Stud 24V 50W DC Output Input AC Supply Voltage Front View Top View Rear View 50W Switched Mode AC to DC Power Supply Module 50W Switched Mode AC to DC Power Supply Module Earth Stud 24V 100W DC Output Input AC Supply Voltage ...

Page 136: ...dule 50W Switched Mode AC to DC Power Supply Module Input AC Supply Voltage 24V 100W DC Output Earth Stud 16 Way AC to DC Power Supply Unit 150W Front View Top View Rear View 50W Switched Mode AC to DC Power Supply Module 50W Switched Mode AC to DC Power Supply Module 50W Switched Mode AC to DC Power Supply Module Earth Stud 24V 50W DC Output Input AC Supply Voltage Earth Stud 24V 100W DC Output I...

Page 137: ...g cables to the sub unit chassis 3 On the 50W Switched Mode Module to be added to the 50W Sub Unit remove and discard the four packing screws from the underside of the module however retain the long nuts and washers 4 On the 50W Switched Mode Module to be added to the 50W Sub Unit ensure that the spacers under the printed circuit board are correctly located 50W Switched Mode AC to DC Power Supply ...

Page 138: ...cable connectors to the ac input terminal CN1 and dc output terminal CN2 respectively on the added 50W Switched Mode Module as shown below 7 Refit the top cover 18 3 16 Way AC to DC Power Supply Unit Upgrade to 150W or 200W To upgrade the 16 Way AC to DC Power Supply Unit to 150W or 200W proceed as follows 1 Fit a second 50W Sub unit containing a 50W Switched Mode Module to the 16 way AC to DC Pow...

Page 139: ...4 76 MAN0443 P65 Issue 13 Aug 04 5701 Control System 05701 M 5001 A02279 CHAPTER 4 INSTALLATION INSTRUCTIONS ...

Page 140: ... 1 MAN0443 P65 Issue 13 Aug 04 5701 Control System 05701 M 5001 A02279 CHAPTER 5 COMMISSIONING AND MAINTENANCE INSTRUCTIONS 5701 SERIES CONTROL SYSTEM CHAPTER 5 COMMISSIONING AND MAINTENANCE INSTRUCTIONS ...

Page 141: ...NTENANCE INSTRUCTIONS CONTENTS Section Page 1 GENERAL 5 3 2 START UP PROCEDURE 5 4 3 CALIBRATION 5 6 4 MAINTENANCE 5 7 5 ERROR CODES 5 8 5 1 General 5 8 5 2 Self Test Faults 5 9 5 3 Run Time Errors 5 11 5 4 Calibration Errors 5 14 5 5 System Errors 5 17 5 6 Miscellaneous Errors 5 18 6 FAULT FINDING 5 19 ...

Page 142: ...servicing the system IMPORTANT Commissioning and maintenance of the system should be carried out by trained authorised personnel only 1 GENERAL The following guide to commissioning and maintenance should be used in conjunction with the relevant instructions issued with the sensors being used The following information applies to the setup of a system with a single power supply connection to the DC ...

Page 143: ...between the control cards and the backplane 4 Switch on the system power supply 5 Check that a voltage of between 18V and 32V dc exists at the terminal block TB1 6 Switch off the power supply 7 Reconnect the terminal block TB1 to the DC Input Card 8 Switch on the system power supply 9 Check that a voltage of between 18V and 32V dc still exists at the terminal block TB1 10 Check that the Engineerin...

Page 144: ...peat Steps 11 to 14 for the remaining control cards in the rack 16 Reconnect the terminal block TB2 to the DC Input Card and test the optional Engineering Card module in accordance with the relevant operating manual instructions 17 Verify the alarm configuration for each channel using the relay test procedure outlined in Chapter 7 Section 6 18 Verify that the System 57 Control Cards and power supp...

Page 145: ...se for a suitable period as specified in the sensor manual Adjust the sensor head current of catalytic sensors as described in Chapter 7 Section 7 to the required value as indicated in the sensor operating instructions Using the procedures for the type of sensors being used follow the zero and 1st span operational guide in Chapter 7 Sections 8 and 10 and calibrate each channel ...

Page 146: ...n turn and check that channels sensor signal reading and if a catalytic sensor is connected the sensor bridge current 5 With the Engineering Key fitted to the Engineering Card select each channel card in turn and enter the alarms test function 6 Check the alarm levels alarm LED operation alarm relay operation and display operation for each channel 7 Check the operation of all fault and inhibit rel...

Page 147: ...detecting gas will still activate any configured alarm outputs Non active means that it is not possible for the control card to generate any alarms in response to the sensor detecting gas Fault Signal This refers to the indication of the fault condition in response to the error condition Yes means that the appropriate channel front panel fault LED and any configured fault relay will be operated No...

Page 148: ...failure and as such the card needs to be replaced 97 EEPROM Failure The EEPROM holds the application configuration data The EEPROM failure message is displayed if there is a checksum difference or it has been impossible to carry out a checksum test during start up or periodic self test This is a serious card failure and as such the card needs to be replaced 96 No Vps Vps is a voltage which is used...

Page 149: ...current during the startup routine Check the sensor connection and cable line lengths to ensure that maximum line impedance has not been exceeded 93 Configuration Fault The configuration fault message is displayed during start up if the channel card has no configuration information or the configuration is not valid This is a serious card failure and as such the card needs to be replaced 92 Wrong P...

Page 150: ...the sensor connections Remove the channel card and insert it into a compatible working channel and check its operation ER86 may appear during this operation this is normal If the card still indicates a fault it must be replaced If the card is working the sensor should be replaced 88 Under Range Fault The under range fault message is displayed when the sensor signal reading is less than the predete...

Page 151: ...ation and connected sensor Depending on the alarm configuration moving channel cards to alternative slots may compromise the generation of alarms The alarm operation should be checked after the card has been moved and calibrated 85 Power Fail Error The power fail error message is displayed if the system supply voltage falls below approximately 16V dc The error latches if power failure delay is not...

Page 152: ... lifetime is calculated on the difference between the sensitivity measured during 1st SPAN and that measured during subsequent normal SPANs and is only updated during the SPAN function This is a warning that the sensor output is becoming unacceptably low and may be due to age or due to the sensor being poisoned by the presence of silicones sulphur and lead compounds The sensor should be replaced 8...

Page 153: ...ng range of the channel The reset of a latched signal overrange warning condition should only be carried out after checking that the sensor is in clean non target gas air 5 4 Calibration Errors 79 Uncalibrated The uncalibrated message is displayed for new channel cards that have never been calibrated The channel card should be calibrated and its operation checked 78 Calibration Overdue The calibra...

Page 154: ...Zero Signal Too High The zero signal too high message is displayed during calibration when the sensor zero signal is above the pre configured levels and a zero calibration can not be achieved This is typical of the sensor detecting its target gas and zero gas should be applied to the sensor Alternatively for catalytic sensors this would typically signify there is a large imbalance between the two ...

Page 155: ... is displayed during calibration when the sensor span signal is above the pre configured levels and a span calibration can not be achieved This indicates that the output from the sensor is too high due to either a a faulty sensor bad cabling or wrong sensor defaults in configuration b the calibration gas is incorrect Check the calibration gas bottle certificate and age 73 Calibration Gas Too Low T...

Page 156: ...quest has been received for an invalid sub channel address 68 Printer Not Ready Indicates that the serial device attached to the engineering port is not able to accept data 67 Invalid Request Indicates that an invalid request number has been received 66 Serial Communications Timeout Serial communications has timed out Reset card by removing power to the card If problem persists replace the card 65...

Page 157: ...command sent to empty slot Reset card by removing power to the card If problem persists replace the card 62 Not applicable Communications Error A participant in a complex alarm function hosted by this card has stopped communicating Check all cards within the participant group are fully inserted into the rack and are functioning correctly 5 6 Miscellaneous Errors 07 Divide By Zero Internal calculat...

Page 158: ...se FS1 If the voltage is not correct check the system power supply unit The dc input voltage is too low Check dc voltage at the DC Input Card terminals There is a hardware fault Switch power of and then on again If problem persists check the diagnostic printout for error codes Check that the ac mains voltage is between 85V and 264V at the power supply ac connection wires If yes replace the 50W Pow...

Page 159: ...if the LED extinguishes Insert the Engineers Key into the Engineering Card and then operate the INHIBIT push button This should toggle the inhibit LED on and off otherwise check the remote inhibit level Remove the Engineering Key from the Engineering Card Check that all the control cards are fitted to the rack and are working If a card has been removed deliberately fit the Engineering Key into the...

Page 160: ...f necessary remove the inhibit Check to see that the type of relay interface card fitted can support the expected alarm Check the channel card configuration to see that the relay is configured for the expected operation Swop the relay interface card with another of the same type and test relay action by using the Engineering Card alarm test function See previous guide for ALARM LED See previous gu...

Page 161: ...5 22 MAN0443 P65 Issue 13 Aug 04 5701 Control System 05701 M 5001 A02279 CHAPTER 5 COMMISSIONING AND MAINTENANCE INSTRUCTIONS ...

Page 162: ...6 1 MAN0443 P65 Issue 13 Aug 04 5701 Control System 05701 M 5001 A02279 CHAPTER 6 OPERATING INSTRUCTIONS 5701 SERIES CONTROL SYSTEM CHAPTER 6 OPERATING INSTRUCTIONS ...

Page 163: ...ROUTINES 6 4 3 CONTROL CARD 6 5 3 1 Reset 6 5 3 2 Reset TWA Calculations 6 5 3 3 Select 6 5 3 4 Deselect 6 5 4 ENGINEERING CARD 6 6 4 1 General 6 6 4 2 Timeout 6 6 4 3 Bar Graph Display 6 6 4 4 Catalytic Sensor Bridge Current 6 6 4 5 View Alarm Level Settings 6 7 4 6 Sensor Signal Monitoring 6 8 4 7 View Clock Calendar 6 8 4 8 Maintenance Record Printout 6 9 ...

Page 164: ...ing instructions refer to the facilities available for general operation and interrogation of the system without the Engineering Key fitted Facilities that may effect the way the system operates are covered in the Engineer s Operating Instructions Chapter 7 which refers to facilities available when the Engineering Key is fitted ...

Page 165: ...ent check Sensor signal monitoring Accept an update alarm View clock calendar Initiate a maintenance record printout Channel reset and select are performed by the channel card RESET SELECT push button while the remaining functions are performed when a channel control card is selected using the Engineering Card push button controls Only one channel card can be selected at any one time and while sel...

Page 166: ... required channel card RESET SELECT push button for approximately five seconds During this period the selected icon will start to flash on and off and when the flashing stops the reset is complete 3 3 Select To select a channel card for operations controlled from the Engineering Card push and hold the required channel card RESET SELECT push button for approximately 1 5 seconds until the icon displ...

Page 167: ...sh buttons are pressed within the timeout period the selected channel card will automatically be deselected 4 3 Bar Graph Display When operating the Engineering Card without an Engineering Key fitted the selected channel s bar graph display will continue to indicate the actual gas reading during the operation of the available Engineering Card functions 4 4 Catalytic Sensor Bridge Current The opera...

Page 168: ...cted channel card display will indicate the A1 level alarm as indicated opposite Note The up arrow A indicates a rising alarm while the down A arrow indicates a falling alarm 3 Push the ALARMS push button a second time and the selected channel card display will indicate the A2 level alarm 4 Push the ALARMS push button a third time and the selected channel card display will indicate the A3 level al...

Page 169: ... drive module fitted to the channel card as follows a Catalytic Sensor Drive Module The display will show the live bridge voltage measured between 01 and 02 in mV 02 is the centre point of the second half of the Wheatstone bridge which is on the channel card b 4 20mA Sensor Drive Module The display will show the live sensor loop current in mA 3 Push the or push buttons or wait 30 seconds to exit t...

Page 170: ...een time and date 4 Push the or push buttons or wait 30 seconds to exit the CLOCK mode 4 8 Maintenance Record Print Out A detailed printout of the status for each channel or a summary of the whole rack can be initiated using the Engineering Card The data is fed in ASCII text format to the engineering serial port on the Engineering Card front panel To output the maintenance record for each channel ...

Page 171: ... interval 10 min LTEL Threshold 010 0 fsd Value 0 000 fsd RATE Threshold 05 0 fsd Value 0 074 fsd Max signal 026 2 fsd Min signal 000 0 fsd Present signal 8 0 fsd Relay Interface High Integrity RL 1 Norm energised RL 2 Norm de energised RL 3 Norm de energised RL 4 Norm de energised RL 5 Norm de energised RL 6 Norm de energised RL 7 Norm de energised RL 8 Norm de energised Notes 1 The information p...

Page 172: ...Rack info Card type Engineering card S W v02 10 Eng key override in active Customer name DMT Customer site Essen Serial No 22411A17 Slot 01 Card type 5701 S W v02 40 Serial number 22411C01 Tag Vent 23C Gas Methane Range 0 100 Active alarms FT Slot 02 Type 5701 S W v00 75 Serial No 22411C02 Tag 23C 03 Gas Methane Range 0 100 Active alarms A1 Slot 12 Type 5701 S W v00 75 Serial No 22411C02 Tag Unkno...

Page 173: ...6 12 MAN0443 P65 Issue 13 Aug 04 5701 Control System 05701 M 5001 A02279 CHAPTER 6 OPERATING INSTRUCTIONS ...

Page 174: ...7 1 MAN0443 P65 Issue 13 Aug 04 5701 Control System 05701 M 5001 A02279 CHAPTER 7 ENGINEER S OPERATING INSTRUCTIONS 5701 SERIES CONTROL SYSTEM CHAPTER 7 ENGINEER S OPERATING INSTRUCTIONS ...

Page 175: ...3 UNLOCKING THE ENGINEERING CARD 7 5 4 SELECTED CARD OPERATIONS 7 6 5 CHANNEL INHIBIT 7 7 6 ALARM CONFIGURATION AND RELAY TEST 7 8 7 CATALYTIC SENSOR BRIDGE CURRENTADJUSTMENT 7 11 8 ZERO SIGNAL CALIBRATION 7 12 9 SPAN SIGNAL CALIBRATION 7 14 10 FIRST TIME SPAN SIGNAL CALIBRATION 7 16 11 SENSOR SIGNAL MONITORING 7 17 12 SETTING THE CLOCK CALENDAR 7 18 13 MAINTENANCE OPERATING ROUTINES 7 20 ...

Page 176: ...NSTRUCTIONS 1 GENERAL The engineer s operating instructions refer to the additional facilities available to setup and maintain the system Because the operation of the system can be altered or impeded by these functions they can only be performed when the Engineering Card is unlocked by the Engineering Key ...

Page 177: ...l Reset Channel Select Channel Inhibit Alarm Configuration and Relay Test Catalytic Bridge Current Adjustment Zero Signal Calibration Span Signal Calibration 1st Span Signal Calibration Sensor Signal Monitoring Clock Calendar Adjustment Channel select and reset are carried out by the channel card RESET SELECT push button See Chapter 6 Section 3 The remaining engineering functions are carried out a...

Page 178: ...D To unlock the Engineering Card plug the Engineering Key into the Engineering Card front panel socket The Engineering Card Unlocked LED will illuminate to indicate that it is unlocked External Engineering Engineering Key Port Note Inserting and then removing the Engineering Key resets the Engineering Card communications failure warning indication ...

Page 179: ...elected control card indicted value If held in the operated position the display will be increased by one unit every 0 5 seconds b The down push button which may be used to lower the selected control card indicated value If held in the operated position the display will be decreased by one unit every 0 5 seconds c Theacceptpush button whichmaybeusedtoaccepttheselected control card displayed value ...

Page 180: ...e state d A1 A2 and A3 alarm LEDs continue to operate as normal and reflect the current status of the channel e If the channel is a participant in a master zoned or voted alarm function the control card alarm will also be excluded from the master zone or voted alarm function To select the inhibit function proceed as follows 1 Plug the Engineering Key into the Engineering Card front panel socket an...

Page 181: ...splaying the select icon 3 Push the Engineering Card ALARMS push button and check that the selected control card message display shows A1 for a rising alarm threshold or A1 for a falling alarm threshold 4 Check that the selected control card digital display indicates the A1 alarm threshold point Notes 1 The analogue display continues to show the sensor live measurement 2 If an alarm is disabled wi...

Page 182: ...t the relays and the FAULT LED the INHIBIT push button must be used to set the control card into the uninhibited state 12 Use the and push buttons to raise or lower the simulated gas level over a range of levels that includes the A1 A2 A3 and underrange fault values Check that the selected control card indicates the simulated gas level on the analogue and digital display and that the appropriate a...

Page 183: ...ol card front panel RESET SELECT push button The simulated gas level and relay states will remain set allowing several control cards to be tested simultaneously When the control card is reselected the card will return to the TEST mode 2 If the inhibit is removed the external relays will operate IMPORTANT When the TEST mode is used always ensure that the channel control card is returned to the unin...

Page 184: ...ard RESET SELECT push button for approximately 1 5 seconds and check that the selected control card indicates it has been selected by displaying the select icon 3 Push the Engineering Card BEAD mA push button and check that the selected control card message display shows mA and the digital display shows the actual bridge current 4 If the displayed bridge current is not set to the required value us...

Page 185: ... card to prevent false alarms being generated One of the following displays will be shown on the selected control message display a Indicates a stable gas reading b A A A A Indicates a rising gas reading c V V V V Indicates a falling gas reading 4 Check that the selected control card digital display and bar graph continue to display the current sensor signal level Note Pushing the push button at t...

Page 186: ...oviding this is within the configured upper and lower zero signal limit values The control card will then automatically return to the normal selected state b If the signal is outside the stored signal limits an error message will be displayed on the selected control card display c Automatically return to the normal selected state however the inhibit on the control card will remain active 8 If the ...

Page 187: ...omatically be inhibited and one of the following displays will be shown on the control card message display a Indicates a stable gas reading b A A A A Indicates a rising gas reading c V V V V Indicates a falling gas reading CAUTION On Control Cards fitted with version 2 4 software when zero suppression is enabled the span gas concentration may be displayed as zero 0 until the span gas is applied N...

Page 188: ... its span calibration parameter to the new displayed value providing this is within the configured upper and lower span signal limit values b Set the last calibration date to the current date and reset the calibration reminder if this is enabled c Automatically return to the normal selected state however the inhibit on the control card will remain active d If the displayed value is outside the sto...

Page 189: ...bration proceed as indicated in Section 9 Steps 1 to 6 but push the 1st SPAN push button Note 1 In Step 6 when the span calibration is updated the new sensor calibration date and the last sensor calibration date will both be set to the current date 2 On control cards configured for catalytic sensor inputs the sensor span signal value is recorded as the new sensor value This value will be used to p...

Page 190: ... 1 5 seconds until the selected icon appears on the channel display 2 Push the SIGNAL push button and the selected channel card display will indicate the sensor signal The displayed value will depend on the type of sensor drive module fitted to the channel card as follows a Catalytic Sensor Drive Module The display will show the live bridge voltage measured between 01 and 02 in mV 02 is the centre...

Page 191: ...g the select icon 3 Push the Engineering Card CLOCK push button and the selected control card digital display will show the time of day eg 23 59 with the HOURS value flashing 4 Push the Engineering Card CLOCK push button a second time and the selected control card digital display will display the time of day eg 23 59 with the MINUTES value flashing 5 Push the Engineering Card CLOCK push button a t...

Page 192: ...quired to set any new date and time Note Pressing the push button at any time during the above sequence will return the Engineering Card to the selected mode without changing the clock time and calendar date 9 Press the push button to set the Engineering Card real time clock to the new date and time and return the control card to the selected mode ...

Page 193: ...3 P65 Issue 13 Aug 04 5701 Control System 05701 M 5001 A02279 CHAPTER 7 ENGINEER S OPERATING INSTRUCTIONS 13 MAINTENANCE RECORD PRINTOUTS For details of maintenance record printouts refer to Chapter 6 Section 4 8 ...

Page 194: ...8 1 MAN0443 P65 Issue 13 Aug 04 5701 Control System 05701 M 5001 A02279 CHAPTER 8 SPECIFICATION 5701 SERIES CONTROL SYSTEM CHAPTER 8 SPECIFICATION ...

Page 195: ...L 8 3 3 RFI EMC CONFORMITY 8 3 4 POWER SUPPLIES 8 3 5 INDIVIDUAL MODULE PARAMETERS 8 4 5 1 Interface Relay Cards 8 4 5 2 Single Channel Control Card 8 4 5 3 Catalytic Bridge Module 8 5 5 4 4 20mA Input Module 8 6 5 5 Analogue Output Module 8 6 5 6 Engineering Card 8 7 5 7 DC Input Card 8 8 6 CABINET ASSEMBLIES 8 8 7 RACK ASSEMBLIES 8 10 8 POWER SUPPLY UNITS 8 11 ...

Page 196: ...hapter 10 Special Conditions for Safe Use Ensure that all conditions therein are met 2 ENVIRONMENTAL Operating Temperature 5O C to 55O C 0 for EXAM approved systems Storage Temperature 25O C to 55O C Humidity 0 to 90 RH Non condensing 3 RFI EMC CONFORMITY EMC Directive 89 336 EEC Conforms to EN 50270 1999 Special conditions The optional recorder output may be in error by 5 fsd during some test con...

Page 197: ...Card External AC Power Supply 85V to 264V at 47Hz to 440Hz Using optional AC to DC PSU 5 INDIVIDUAL MODULE PARAMETERS 5 1 Interface Relay Cards Dimensions Height 112mm Width 25mm Depth 102mm Weight Field Interface 95g Double SPCO 155g Triple SPCO 205g Triple DPCO 245g High Integrity 255g Power Field Interface 0 0W Double SPCO 0 8W Triple SPCO 1 0W Triple DPCO 1 6W High Integrity 1 7W Relay Operati...

Page 198: ... and Inhibit Push Button Alarm Reset Card Select Alarm Setting Point Resolution In 1 fsd steps Display Alarm Point Linearity 1 fsd Repeatability 1 fsd Remote Facilities Inhibit Alarm Reset Remote Inhibit Reset Inputs Active For Inputs More than 2V Maximum Input Voltage 32V Maximum Input Current 5mA Power Consumption Catalytic 3 75W typical Includes Catalytic Sensor 4 20mA 3 25W typical DC Supply 1...

Page 199: ...A Full Scale Signal Range 15mV to 600mV Bridge Imbalance Default Limits 100mV from centre at 2V bridge voltage Adjustment Electronic adjustment of bridge balance and signal gain Fault Detection Open circuit Short circuit single bead failure Over Range Default 10 above fsd Under Range Default 10 below zero 5 4 4 20mA Input Module Loop Powered Output Voltage Isolated 20V 5 regulated 25mA maximum for...

Page 200: ...rrent source with external supply Signal Range 0 25mA Measurement Signal Range 0 20mA or 4 20mA selected by the software Linearity From Input Better than 2 fsd Repeatability From Input Better than 1 fsd Depending upon the installation a loss of performance of less than 5 fsd may be observed under extreme conditions of EMC susceptibility Note The repeatability performance derating is a consequence ...

Page 201: ...sumption 1 5W typical DC Supply 18V to 32V dc Dimensions Height 112mm Width 25mm Depth 170mm Weight 152g 5 7 DC Input Card DC Supply 18V to 32V dc Dimensions Height 112mm Width 25mm Depth 102mm Weight 129g Fuse Rating 10A Anti surge 1 x inches Field Terminals 2 5mm 14 AWG 6 CABINET ASSEMBLIES Material Mild steel Weight 8 way 10 0kg 16 way 13 5kg Gland Entries Knockout 8 way 2 x M256 x PG11 8 x M20...

Page 202: ...t hand side Colour RAL 7015 slate grey Mounting Bracket Holes 10mm diameter Rack Mounting Universal 19 inch profile 19 inch width and half 19 inch width Earthing Points Main cabinet M6 Door M5 Mounting Plate Galvanised steel Dimensions Cabinet Mounting Brackets 100 100 430 15 15 8 way 367mm 16 way 570mm All dimension shown in mm 630 268 8 way 337 16 way 540 ...

Page 203: ...ccess rack only Material Galvanised steel Earthing Point M5 stud Mounting Universal 19 inch and half width 19 inch mounting Power Consumption 1 5W Supply Voltage 18 to 32V dc Weight including Engineering Card and DC Input Card 16 Way Front Access 5 8kg 16 Way Rear Access 4 1kg 8 Way Front Access 3 9kg 8 Way Rear Access 2 8kg Cabinet Mounting Brackets All dimension shown in mm 9 10 2 36 9 27 15 10 ...

Page 204: ...Access 482 6 465 1 57 0 37 8 132 5 287 6 16 Way Front Access 482 6 465 1 190 5 37 8 266 0 217 6 Panel Cutout Clearance 8 Way Width 247 Height as column E 16 Way 450 as column E C E D A B C E D A B Mounting Holes 7mm 8 POWER SUPPLY UNITS Mounting Universal 19 and half 19 mounting Supply Voltage 85V to 264V ac 47Hz to 440Hz 110V to 340V dc For information on dc input contact Zellweger Analytics Inru...

Page 205: ... full load and recovers automatically Safety Approvals 50W Module approved to UL1950 IEC950 CSA 22 2 No 234 Output Voltage 24V 10 dc Output Configurations Half 19 Rack 50W or 100W Full 19 Rack 50W 100W 150W or 200W Earthing Point M5 stud Weight Half 19 Rack 50W 900g Full 19 Rack 50W 960g 50W Module 230g Sub Unit 815g Dimensions PSU Assembly A B Clearance Width Height 8 Way 279 4 261 9 222 41 16 Wa...

Page 206: ...9 1 MAN0443 P65 Issue 13 Aug 04 5701 Control System 05701 M 5001 A02279 CHAPTER 9 ORDERING INFORMATION 5701 SERIES CONTROL SYSTEM CHAPTER 9 ORDERING INFORMATION ...

Page 207: ...le Channel Control Card 05701 A 0302 Control Card 05701 A 0351 Catalytic Sensor Drive 05701 A 0284 Interconnecting Cable 05701 C 0390 Blanking Panel 05701 A 0365 Analogue Output Module 05701 A 0285 A1 A2 A3 Fault Inhibit A1 A2 Fault 2 x A1 2 x A2 2 x A3 Fault Inhibit High Integrity Relay Card 05701 A 0303 7 x SPCO Configurable 1 x SPCO Fault Engineering Card 05701 A 0361 Optional Modules Modbus In...

Page 208: ... 8 Way Sub rack 05701 A 0506 Engineering Card 05701 A 0361 DC Input Card 05701 A 0325 Interconnecting Cable 05701 C 0390 Key Kit 05701 A 0550 16 Way Sub rack 05701 A 0505 Engineering Card 05701 A 0361 DC Input Card 05701 A 0325 Interconnecting Cable 05701 C 0390 Key Kit 05701 A 0550 8 Way Sub rack 05701 A 0516 Engineering Card 05701 A 0361 DC Input Card 05701 A 0325 Key Kit 05701 A 0550 16 Way Sub...

Page 209: ...9 4 MAN0443 P65 Issue 13 Aug 04 5701 Control System 05701 M 5001 A02279 CHAPTER 9 ORDERING INFORMATION ...

Page 210: ...1 M 5001 A02279 CHAPTER 10 SPECIAL CONDITIONS FOR SAFE USE ACCORDING TO EC TYPE EXAMINATION CERTIFICATE BVS 04 ATEX G 001 X 5701 SERIES CONTROL SYSTEM CHAPTER 10 SPECIAL CONDITIONS FOR SAFE USE ACCORDING TO EC TYPE EXAMINATION CERTIFICATE BVS 04 ATEX G 001 X ...

Page 211: ...d for the error codes ER80 ER81 ER87 and ER88 parameters signal over range signal under range fault over range and fault under range The error codes ER87 ER88 and ER81 parameters fault over range fault under range and signal under range shall be set latching When operated with remote sensors e g Sensepoint which may deliver signals within the measuring range at concentrations above the measuring r...

Page 212: ...te access via Modbus shall be avoided This certificate is concerned solely with information which can be obtained from Modbus functions 02 and 04 When a control card 5701 is configured for master or voted alarms as well as master or voted fault or inhibit messages high integrity relay cards should be used If no high integrity relay cards are used triple relay cards shall be used In such cases both...

Page 213: ...ng the details below UK Office Keison Products P O Box 2124 Chelmsford Essex CM1 3UP England Tel 44 0 330 088 0560 Fax 44 0 1245 808399 Email sales keison co uk Please note Product designs and specifications are subject to change without notice The user is responsible for determining the suitability of this product ...

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