Trolex TX6383 Series Page 2 Installation And Operating Data Download

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FLAMMABLE GAS SENSOR/TRANSMITTER

A T E X

GROUP I & II

INTRINSICALLY

SAFE

INSTALLATION & OPERATING DATA

Stationary gas sensors for the detection of a wide range of
flammable gases.

Suitable for use in SIL 1 and SIL 2 applications, in accordance with
any conditions or restrictions

Poison resistant CATALYTIC COMBUSTION sensors.

Pre-calibrated plug-in gas sensing module with a standardised
output signal for convenient replacement and servicing.

Calibration available for a wide range of flammable gases.

LCD readout of gas concentration with OVERRANGE indication.

Convenient push button calibration of ZERO and SPAN.

Signal fix during calibration to prevent false alarms.

Output signal versions:- 4 to 20 mA 0.4 to 2 V 5 to 15 Hz.

Stainless steel reinforced polycarbonate housing.

Intrinsically safe for use in Group I and Group II hazardous areas.

Special versions with weatherproof plug and socket
connections in place of cable glands.

Optional format with remote mounted gas sensing
module in robust metal housing.

1 PRINCIPAL OPERATING FEATURES

2/28

TT X

X 66 33 88 33

ISSUE S 01/15

Summary of Contents for TX6383 Series

Page 1: ...ENSIONS 4 4 TECHNICAL DETAILS 4 5 INSTALLATION 6 6 CONNECTIONS 11 7 CONTROLS AND INDICATORS 14 8 CALIBRATION 15 9 MAINTENANCE 20 10 APPROVALS AND CERTIFICATION 23 11 FUNCTIONAL SAFETY 25 PETROCHEMICAL PROCESSING MINING TUNNELLING OFFSHOREPLATFORMS MANUFACTURING PROCESS PLANTS STORAGEAREAS WAREHOUSING WATERMANAGEMENT SEWAGE TREATMENT POWER GENERATION GASSTORAGE DISTRIBUTION MARINE SHIPPING APPLICAT...

Page 2: ...ng Calibration available for a wide range of flammable gases LCD readout of gas concentration with OVERRANGE indication Convenient push button calibration of ZERO and SPAN Signal fix during calibration to prevent false alarms Output signal versions 4 to 20 mA 0 4 to 2 V 5 to 15 Hz Stainless steel reinforced polycarbonate housing Intrinsically safe for use in Group I and Group II hazardous areas Sp...

Page 3: ...ribution Marine and shipping applications Telecommunications A choice of output signals for direct interfacing with most standard industrial monitoring systems 2 APPLICATION TRIP AMPLIFIER for use with analogue output sensors CONFIGURABLE SENSOR CONTROLLER for monitoring up to 8 analogue output sensors COMMANDER DISTRIBUTED I O SYSTEM for large scale general plant monitoring systems and the mining...

Page 4: ...s 124 0 15 0 26 0 GAS SENSING MODULE Plug in gas sensing module with signal conditioning Precalibrated and standardised output signal Measuring Range 0 to 5 v v CH4 Calibrated for Methane Alternative sensing ranges available to specification Linearity 1 0 to 60 FULL SCALE 5 from 60 up to 100 FULL SCALE Maximum Drift 25 C 0 25 v v per month Response Time T90 20 secs Sensing Element Life 5 years in ...

Page 5: ...20 mA 4 TX6383 03 GENERAL PURPOSE APPLICATIONS 24 V dc NOT SUITABLE F OR USE IN CLASSIFIED HAZARDOUS AREAS Output 5 to 15 Hz Max Load Opto isolated 2 mA max Supply 6 5 to 16 5 V dc Max Current 80 mA Output 4 to 20 mA Max Load 24 V 240 ohms Supply Minimum 6 5 V at the sensor supply terminals 3 and 4 Max Current 100 mA Output 4 to 20 mA Max Load 24 V 240 ohms Supply 6 5 to 30 V dc Nominal Current 10...

Page 6: ...p II are the correct safety barriers fitted 5 INSTALLATION A 20 mA 4 0 4 V 2 V 5 Hz 15 Hz 12 V dc 24 V dc GROUPI GROUPII 5 1 Conformity Check TX6383 01 FLAMMABLE GAS SENSOR TRANSMITTER GROUP I TX6383 02 FLAMMABLE GAS SENSOR TRANSMITTER GROUP II TX6383 03 FLAMMABLE GAS SENSOR TRANSMITTER GENERAL PURPOSE TX6383 84 01 FLAMMABLE GAS SENSOR TRANSMITTER GROUP I with Remote Gas Sensing Module TX6383 84 0...

Page 7: ...gas release is expected to occur This way the earliest possible warning of a gas release can be given to initiate shutdown functions alarm functions or safe evacuation of the premises 5 3 System Integrity If a gas monitoring system should fail for any reason it is important that the system is capable of immediately alerting operational staff to this fact The sensor will indicate a system failure o...

Page 8: ...of release Conversely gases or vapours heavier than air will tend to fall and accumulate in concentrations for long periods of time This is a particular problem in pits trenches machine rooms etc Normal air movements in and around such gas concentrations will have the inevitable effect of producing zones of highly flammable mixtures This knowledge of the characteristics of the gas assists when pos...

Page 9: ...d or deficient atmospheres 5 9 Discrimination Catalytic combustion sensors can detect a wide range of flammable gases but they cannot discriminate between individual gases They will respond to most or all of the flammable components present in the atmosphere without distinguishing between them 5 10 Contamination The response of catalytic combustion gas sensors can be affected by air borne contamin...

Page 10: ...nology require regular zero and span check and adjustment operations to ensure that they remain accurate The pellistor device ages during its lifetime and its baseline and sensitivity characteristics will change These operations are normally performed three weekly The pellistors baseline tends to move positively throughout its lifetime In the early stages of the lifetime the baseline tends to move...

Page 11: ... power the sensor enabling operating distances up to 1000 m 1 2 3 4 5 TX6383 V Supply 0 V 0 4 to 2 V signal 6 7 8 0 V Supply TX9132 1 2 3 4 5 TX6383 V Supply 0 V 0 4 to 2 V signal 6 7 8 TX9132 FLAMMABLE GAS SENSOR TRANSMITTER A T E X M1 GROUPI II INTRINSICALLY SAFE 6 CONNECTIONS TX6383 FLAMMABLE GAS SENSOR TRANSMITTER 3 WIRE 4 WIRE V 2 V 0 4 OUTPUTSIGNALOPTIONS 1 2 3 4 5 Signal 0 V Supply 6 7 8 0 ...

Page 12: ...eas Mining when used with approved equipment eg TX9131 Trip Amplifier or a TX9042 Programmable Sensor Controller THE COMPLETE SYSTEM BOTH SENSOR AND MONITORING DEVICE CAN BE MOUNTED IN THE HAZARDOUS AREA The interconnecting cable between the sensor and the monitoring device must have steel wire armoured protection or a braided earth screen The cross sectional area of the conductors must be a minim...

Page 13: ...Barrier MTL787S 1 2 3 4 5 Supply 6 7 8 1 2 4 3 MTL 787S MTL 779 24 V 0 V 0 V 0 V V 1 2 4 3 4 to 20 mA Signal HAZARDOUS SAFE TX6383 02 Group II sensor connections using isolation safety barriers Max Cable Length 1 km using 1 5 mm2 cable conductors Power Isolation Barrier Pepperl Fuchs KFD2 SL2 EX 2B Signal Isolation Barrier Pepperl Fuchs KFD2 STC4 EX 1 1 2 3 4 5 Supply 6 7 8 1 2 8 7 3 11 12 KFD2 ST...

Page 14: ...nd waterproof to IP66 Gas inlet port to IP54 Housing Material Brass or Stainless steel Maximum Cable Length Extendible up to 500 m using 1 5 mm2 cable conductors General Purpose only DISCONNECTING THE REMOTE GAS SENSING MODULE The connecting cable between the remote gas sensing module and the Transmitter is normally supplied connected at both ends The cable can be disconnected via a plug and socke...

Page 15: ...r Product Support Department Alternatively the gas sensing module may be re calibrated when required using a Trolex TX6520 Gas Test Kit equipped with both Air and Test Gas canisters 8 1 Prepare to Calibrate The sensor should be powered for a minimum of 30 minutes prior to commencing calibration Connect the application tube of the gas test kit to the inlet aperture of the gas sensing module The ind...

Page 16: ...ted output signal of the sensor to be FIXED at ZERO SCALE This will prevent the possibility of false alarm signals being activated in the monitoring equipment during the calibration process The display will continue to show the measured value of gas concentration during the calibration process The gas sensing module will automatically return to the normal measuring mode if the pushbuttons are oper...

Page 17: ...nsing element The indicator will NOT flash GREEN Press CALIBRATE ZERO until the indicator is flashing GREEN about 3 seconds Release and the indicator will briefly show RED to denote ZERO setup The Gas Sensing Module will immediately return to the NORMAL measuring mode Switch off the purge air supply G G R G The Gas Sensing Module will automatically return to the NORMAL measuring mode if NO pushbut...

Page 18: ...nister Switch off the test gas supply 5 seconds after SCROLLING has ceased the gas sensing module will automatically return to the NORMAL measuring mode TEST GAS Y Y R G R Re apply the test gas for a few seconds to verify the response of the sensor DO NOT PRESS CALIBRATE SPAN UNTIL THE DISPLAYED VALUE HAS FULLY STABILISED The CALIBRATE SPAN will NOT function if the level of gas concentration detec...

Page 19: ... a PROTECT state to prevent oxidisation damage Pellistor Signal Gas 0 P v v Refer to Section 8 6 Clamp 0 R G RESET Briefly interrupt the power supply to the sensor to RESET the OVER RANGE condition This will only be effective when the gas concentration has receded and the pellistor in the gas sensing module has reset itself from the PROTECT state Refer to Section 8 6 8 6 Pellistor Protection Catal...

Page 20: ...ng Modules The gas sensing modules should be changed at regular intervals to ensure accuracy of response The response of the Pellistor sensor will gradually shift due to normal device decay The average life is about 5 years influenced mostly by the operating environment and the mean level of exposure to flammable gas during its lifetime The shifting response of the cell should be checked at regula...

Page 21: ...arily be self evident in the Sensor and consequently it must be regularly checked and maintained 9 7 Remove Gas Sensing Modules TX6383 84 Insert a bar into one of the radial holes in the gas inlet bush take care not to damage the internal filter and unscrew the gas inlet bush Remove the filter from the gas inlet bush Clean or replace the filter as necessary Fit a new or cleaned filter to the gas i...

Page 22: ...ntenance and Calibration Log ORDER REF TX6383 DATE SUPPLIED SERIAL No USER GAS TYPE LOCATION 9 MAINTENANCE continued DATE SCHEDULED FAILURE RE CALIBRATE CHANGE GAS RETURN TO COMMENTS SENSING MANUFACTURER MODULE 22 28 INSTALLATION OPERATING DATA T T X X 6 6 3 3 8 8 3 3 ISSUE S 01 15 ...

Page 23: ...irective 2004 108 EC 10 2 ANZEx Certification TX6383 Flammable Gas Sensor Transmitter Ex Certificate Number ANZEx 12 3021X Ex Certification Code Ex ia I Ex ia d IIB T4 Conditions for Safe Use Prior to installation it is essential that the user refers to the above certificate to ensure that the termination and cable parameters are fully complied with and are compatible with the application Copies o...

Page 24: ...S 11 293 Ex certification codes Ex ia I 20 C Ta 40 C Ex ia d IIB T4 20 C Ta 40 C General Conditions for Safe Use Prior to installation it is essential that user refers to the above certificates to ensure that the termination and cable parameters are fully complied with and are compatible with the application Copies of certificates are available from Trolex T T X X 6 6 3 3 8 8 3 3 ISSUE S 01 15 ...

Page 25: ...ons that are outside the scope of the TX6383 Flammable Gas Sensor Transmitter and will rely on personnel who are competent in the functional safety aspects of the various lifecycle activities mentioned above SIL Suitability The versions and configurations of the TX6383 Flammable Gas Sensor Transmitter identified in Table 1 in Section 11 3 below and are suitable for use in gas detection safety func...

Page 26: ...ection 4 of this manual 4 to 20 mA output Sensor type CH4 Element safety function Safety Manual 2 3 wire loop or 4 wire powered connection power supply and load as specification noting Group I certified equipment requirements To produce a 4 to 20 mA output that correlates with 0 to 5 v v concentration range of methane See Section 11 of this manual Table 1 Basic Element Information Parameter Value ...

Page 27: ...in a non redundant configuration 6 The unit must be calibrated at commissioning and at 3 month intervals during operation and the sensor head replaced as indicated by the calibration check Proof Testing Periodic proof tests of the element safety function must be performed to identify any dormant dangerous failures particularly when used in low demand safety functions refer to Section 9 2 of this m...

Page 28: ...om 28 28 11 FUNCTIONAL SAFETY continued INSTALLATION OPERATING DATA 11 6 System Configuration Drawing The illustration below shows how the TX6383 is to be used with other system elements If a controller other than the TX9042 is used then the out of range fault indication signal from the TX6383 must be detected and acted upon to assert a system fault T T X X 6 6 3 3 8 8 3 3 ISSUE S 01 15 ...

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