STATUS SCIENTIFIC CONTROLS FGD10 Series Installation, Commissioning & Routine Gas Testing Manual Download

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STATUS SCIENTIFIC CONTROLS

Issue:

Date:

7/1/20

Firmware:

V2.4.yy

Installation, Commissioning &

Routine Gas Testing Manual

Gas Detector

Type FGD10A

Oxygen - Toxic Gases

(Relay version)

Summary of Contents for FGD10 Series

Page 1: ...STATUS SCIENTIFIC CONTROLS Issue 16 Date 7 1 20 Firmware V2 4 yy Installation Commissioning Routine Gas Testing Manual Gas Detector Type FGD10A Oxygen Toxic Gases Relay version ...

Page 2: ......

Page 3: ...ument housing and GSH4 sensor housing are certified to that standard Notified Body for Hazardous Area Certification CSA Group Netherlands B V Utrechtseweg 310 6812 AR Arnhem Netherlands Notified Body number 2813 Notified Body for ATEX Quality Assurance Notification SGS Fimko Oy Särkiniementie 3 Helsinki 00211 Notified Body Number 0598 Hazardous Area Certificate Number SIRA 08ATEX1031X II 2 G Ex d ...

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Page 5: ...9 7 2 1 Gas connection points 19 7 2 2 Sampling time 20 7 2 3 Suggested calibration gas levels 20 8 SOFTWARE FEATURES 21 8 1 MENU MODE SELECTION 22 8 1 1 E 1 Sensor Zero 23 8 1 2 E 2 Sensor Span 23 8 1 3 E 3 Sensor FSD 23 8 1 4 E 4 Output Zero 4mA 23 8 1 5 E 5 Output Span 20mA 23 8 1 6 E 6 Decimal Places 24 8 1 7 E 7 Firmware Version 24 8 1 8 E 8 Sensor Selection 25 8 1 9 E 9 Engineer diagnostics ...

Page 6: ... 9 2 2 Analogue Output Span 36 10 ERROR CODES 37 10 1 EXAMPLE 1 100 PPM TOXIC SENSOR 37 10 2 EXAMPLE 2 5000 PPM TOXIC SENSOR 37 11 COMMUNICATIONS PROTOCOL 38 11 1 HARDWARE CONNECTIONS 38 11 2 CONTROL BYTE CONSTANTS 38 11 3 FRAME STRUCTURE 39 11 4 VARIABLES 39 11 5 READING A VARIABLE 40 11 5 1 Read example read live data 41 11 6 WRITING A VARIABLE 42 12 ROUTINE GAS TESTING 43 13 SENSOR REPLACEMENT ...

Page 7: ...STATUS SCIENTIFIC CONTROLS Installation Commissioning Routine Gas Testing FGD10A Oxygen Toxic Gas Detector TD18 002 Issue 16 Change Note 1904 Page 6 1 FIRMWARE REVISION ...

Page 8: ... Stock No FGD10A Oxygen Toxic Gas Detector Magnetic pen Installation manual Calibration certificate Optional Weather guard 3 SCOPE OF THE MANUAL This manual relates specifically to the version of the FGD10A gas detector with the following features An Oxygen or Toxic sensor for the detection of various gases Output signals in the form of 4 to 20mA and RS232 communications Three control relays each ...

Page 9: ... CONTROLS Installation Commissioning Routine Gas Testing FGD10A Oxygen Toxic Gas Detector TD18 002 Issue 16 Change Note 1904 Page 8 Description FGD10A GAS DETECTOR FGD10A GAS DETECTOR FITTED WITH PROTECTIVE WEATHERGUARD ...

Page 10: ...g having two cable gland entries and containing the connection terminals electronics and display window The housing containing the gas sensor has an M27 thread and is screwed into the bottom of the unit The sensor housing itself is a certified component and must not be removed in service Behind the display window are A 4 digit LCD display Four magnetically operated switches that are activated thro...

Page 11: ...larm Level 2 Fault Versions without relays fitted are also available The self adhesive label on the outer surface of the enclosure indicates whether or not the relays are fitted as shown below 3 2 Alternative gas types Versions of the FGD10A are available for detection of other gases fitted with any of the following sensor types Infrared for detecting hydrocarbons and carbon dioxide Pellistor for ...

Page 12: ...s overloading of the FGD10A gas detector it is important that the installer observes the relay contact rating and ensures that external circuits connected to the relay contacts are suitably protected from exceeding that rating and associated cabling is adequately rated and suitably installed Guidance on the correct installation of systems is provided by EN60079 14 2014 It is the responsibility of ...

Page 13: ... enclosure towards the pcb mounted terminal connections situated near to the front of the enclosure 4 1 Mounting and terminal access The FGD10A should be mounted and secured using the mounting holes on the main unit Figures 2 and 3 shows details of the FGD10A terminal connections these can be accessed as follows 1 Switch OFF the supply to the FGD10A 2 Release the grub screw located near the lip of...

Page 14: ...S SCIENTIFIC CONTROLS Installation Commissioning Routine Gas Testing FGD10A Oxygen Toxic Gas Detector TD18 002 Issue 16 Change Note 1904 Page 13 Figure 1 Unplugging the display board for connection purposes ...

Page 15: ...t to a high integrity earth ATEX certified Ex d armoured cable glands PSU Aout 0V Rx Tx RS232 Armoured cable Armoured cable Mount vertically as shown N O COM N C Relay 1 Alarm 1 N O COM N C Relay 2 Alarm 2 N O COM N C Relay 3 Fault Important Connect enclosure earth point to a high integrity earth ATEX Certified compound filled conduit seals stopping boxes PSU Aout 0V Rx Tx RS232 Conduit Conduit Mo...

Page 16: ...loggers remote displays control cards the gas levels currently being detected by the system The output is in the form of the industry standard 4 to 20mA current source The analogue output is factory set such that 4mA represents zero gas and 20mA represents the full scale gas level of the FGD10A Figure 4 Analogue Output 4 4 RS232 Output This output is designed to be compatible with a PC fitted with...

Page 17: ...o not over tighten 4 5 Applying power Once the installation is complete and the covers are secure then power can be applied The power source should be between 8 and 24 volts dc When power is first applied to the FGD10A an initialisation procedure is performed as follows All segments on the LCD are shown 8 8 8 8 The software version is displayed 1 0 0 The manufacturer code is displayed SSCL The sen...

Page 18: ...ration certificate before attempting to check the zero setting and gas response 4 7 Zero gas With no gas present check that the instrument reads zero on the display a If the instrument reads zero then no adjustment is required and gas response testing may now be carried out as described in Section 0 b If the instrument does not read zero then adjustment of the zero setting is required as described...

Page 19: ...ctor TD18 002 Issue 16 Change Note 1904 Page 18 Figure 6 Arrangement for Application of a Certified Test Gas Certified Test Gas Cylinder Remote Sampling Point 6mm O D Sampling Tube Calibration Adaptor Metal sampling adaptor Stock No SS336 Without weatherguard With weatherguard Flow Regulator 1 Litre min ...

Page 20: ...as described in Section 5 1 2 Sensor Span 4 7 1 Gas connection points Certified test gas can be applied either a directly to the FGD10A via the appropriate sampling calibration adaptor or b remotely by connecting a test gas sampling tube to the appropriate sampling calibration adaptor and installing a test point at the remote end of the tube Method b avoids the need to gain direct access to the un...

Page 21: ...adaptor Stock No SS336 is required in order to present the gas to the FGD10A sensor 4 7 2 Sampling time Apply the test gas and allow a sufficient time for the sample to reach the gas detector The response time will vary according to the length of the sampling tube 4 7 3 Suggested calibration gas levels Oxygen sensor Zero 100 N2 Span 20 9 O2 Toxic sensor Zero gas free air must contain oxygen Span 5...

Page 22: ...ow the associated parameter may be changed via the selected menu option and what effect the change to the parameter has on the operation of the FGD10A The FGD10A incorporates magnetically operated switches to allow non intrusive operation of the menu system To press the switch requires movement of the stylus pen over the appropriate button The key press LED will light to indicate that the button p...

Page 23: ...nstruments simple menu system To select a calibration mode follow this procedure Press the MENU button E 1 appears on the display Press UP or DOWN until the required menu option is displayed Press ENTER to select the calibration mode To exit the menu press MENU While the instrument is in menu mode any data displayed on the screen will alternate between the cal number and the reading The following ...

Page 24: ...FSD The sensor measuring range is set by this menu From the menu system select menu option E 3 and press ENTER Using the INCrease and DECrease buttons select the required value Press ENTER Note Pressing MENU instead of ENTER will exit the menu without changing the value Press MENU to close the menu system Note changing the FSD must be used with caution The setting must be within the capability of ...

Page 25: ...ead of ENTER will exit the menu without changing the number of decimal places to which the gas level will be displayed Press MENU to close the menu system Note that when the sensor type is first selected the optimum number of decimal places for a given sensor type and range is automatically selected Increasing the number of decimal places to which detected gas levels are displayed does not increas...

Page 26: ...mical 0 200ppm Toxic ELT6 Electro chemical 0 500ppm Toxic ELT7 Electro chemical 0 1000ppm Toxic ELT8 Electro chemical 0 9999ppm Toxic The sensor type is selected as follows From the menu system select menu option E 8 and press ENTER Using the NEXT and PREVIOUS buttons select the required sensor Press ENTER Note Pressing ENTER whilst in menu option E 8 will reset the factory defaults for the displa...

Page 27: ...lose the menu system 4 8 10 E 13 Relay 1 The unit is fitted with a relay that is operated in conjunction with the alarm level The user can select if the relay is normally Energized E or normally de energised d when the unit is not in an alarm condition From the menu system select menu option E 13 and press ENTER The display will show the following E r Normally energized rising alarm d r Normally d...

Page 28: ...ally energized falling alarm d F Normally de energized falling alarm The mode of operation can be changed by pressing the UP button Press ENTER to accept the new relay mode of operation Note Pressing MENU instead of ENTER leaves the unit without change Press MENU to return the instrument to its standard mode of operation 4 8 12 E 15 Alarm Level 1 The gas level that will cause Relay 1 to change sta...

Page 29: ...essing MENU instead of ENTER aborts the feature Press MENU to return the instrument to its standard mode of operation 4 8 14 E 19 Positive Zero Suppression This option is used to allow the user to suppress small amounts of positive sensor zero drift The setting can be set between 0 and 10 of the sensor range as set by the FSD value Press MENU to open the menu system Using the NEXT and PREVIOUS but...

Page 30: ...t by the FSD value Press MENU to open the menu system Using the NEXT and PREVIOUS buttons select menu option E 20 Press ENTER Using the INCREASE and DECREASE buttons set the required zero suppression value Press ENTER to store the new value Note Pressing the MENU button rather than the ENTER button exits without any change Press MENU to close the menu system 4 8 16 E 21 Toxic Sensor Bias This opti...

Page 31: ...ware manual to carry out the actual programming of the FGD10A module 4 8 18 E 29 Relay 3 The unit is fitted with a relay that is operated in conjunction with a fault condition The user can select if the relay is normally Energized E or normally de energised d when the unit is not in a fault condition From the menu system select menu option E 29 and press ENTER The display will show the following E...

Page 32: ...strument to its standard mode of operation Note if the password is in operation then the user will be prompted with PASS when ever the menu key is pressed Pressing the MENU key again will result in the restricted user access i e only the zero and span options will be available Entering the correct password will give access to the full menu facility 4 8 20 E 31 Warm up timer The sensor goes through...

Page 33: ...e full scale gas level to be selected that relates to the 4 to 20 mA output From the menu system select menu option E 47 and press ENTER Using the INCREASE and DECREASE buttons adjust the FSD to the required level Press ENTER will be displayed to indicate that the new setting has been accepted Note Pressing MENU instead of ENTER will exit the menu without changing the FSD Press MENU to close the m...

Page 34: ...esult in the restricted user access i e only the zero and span options will be available Entering the correct password will give access to the full menu facility 5 1 1 Sensor Zero From the menu system select menu option E 1 and press ENTER Ensure the sensor is in a zero gas environment Note Where a purging gas has to be applied use a flow rate of between 500 and 1000cc min Allow sufficient time fo...

Page 35: ...e of between 500 and 1000cc min Allow time for the sensor to respond Using the UP and DOWN buttons set the reading to that of the calibration gas level Press ENTER to span the sensor will be displayed to confirm the sensor span has been performed Note pressing MENU rather than ENTER exits the span feature without performing the calibration Wait until the reading is stable if necessary press ENTER ...

Page 36: ...nalogue output Advantage Direct measurement of output Disadvantage The analogue output has to be disconnected to allow the connection of the meter Voltage measurement Permanently connect a 10R resistor in series with the analogue output When calibration is required connect a voltmeter or multimeter set to measure voltage in the mV range across the 10R resistor Advantage No need to disturb wiring b...

Page 37: ... the ENTER button exits the zero feature without performing the calibration Press the MENU button to close the menu system Note The ZERO factor will be displayed momentarily on exit 5 2 2 Analogue Output Span Always zero the analogue output prior to performing a span operation From the menu system select menu option E 5 and press ENTER Using the INCREASE and DECREASE buttons adjust the output to t...

Page 38: ... 37 6 ERROR CODES The FGD10 Oxygen Toxic Gas Detector has only 1 error code ERROR_SENSOR_NEG_DRIFT 2 the gas level is below 10 of the FSD 6 1 Example 1 100 ppm toxic sensor The error flag will be raised when the gas level is less than 10 ppm 6 2 Example 2 5000 ppm toxic sensor The error flag will be raised when the gas level is less than 500 ppm ...

Page 39: ...o point P2P protocol is a frame based protocol 7 1 Hardware connections PC 9 way D connector FGD10A connection 2 Tx 3 Rx 5 0V PC 25 way D connector FGD10A connection 3 Tx 2 Rx 7 0V 7 2 Control Byte Constants The following control byte constants are used in the P2P protocol1 Read RD 0x13 00010011 Data Link Escape DLE 0x10 00010000 Write WR 0x15 00010101 Acknowledge ACK 0x16 00010110 Negative Acknow...

Page 40: ... frame s start and end are prefixed with another DLE byte stuffing Following the EOF is a 16 bit checksum of the entire frame each byte is added to produce the checksum 7 4 Variables Each piece of accessible data on a device is referred to as a Variable Each variable is referenced by a Variable ID A variable ID may be any number of bytes long The available Variables and their corresponding Variabl...

Page 41: ...with the Variable ID to be read DLE RD var id DLE EOF Csum hi Csum lo Byte stuffing Device response on success where requested variable data 255 bytes DLE DAT data len data DLE EOF Csum hi Csum lo Byte stuffing Device response on failure DLE NAK reason Where reason is a single byte failure code the meaning of which depends on the device type i e Reason 1 NotReadable Reason 2 ReadOutOfRange ...

Page 42: ...sum High byte Checksum low byte i e 0x10 0x13 0x01 0x10 0x1F 0x00 0x53 Device response on success DLE DAT Data length Data DLE EOF Checksum High byte Checksum low byte i e 0x10 DLE 0x1A DAT 0x0D Data length 0x03 Version 0x01 Display mode 0x07 Sensor Type 0x00 0x00 Gas reading signed integer x 100 0 0xAE 0x0B Current sensor temperature signed integer x 100 29 9 0x92 0x08 Active sensor signal unsign...

Page 43: ...OF Csum hi Csum lo Byte stuffing Device response on success DLE ACK Where data to write is 255 bytes send a DAT frame DLE DAT data len data DLE EOF Csum hi Csum lo Byte stuffing Device response on write success DLE ACK Device response on write failure DLE NAK reason Where reason is a single byte failure code the meaning of which depends on the device type i e Reason 1 NotWritable Reason 2 WriteOut...

Page 44: ...ing a 20 9 O2 test gas after exposure to nitrogen This reading should be retained for future reference as it can provide an indication of the health of the sinter flame arrestor This is situated in the base of sensor housing and it is through this device that the gas passes in order to reach the sensor itself If necessary carry out adjustment of the span setting as described in section 5 1 2 Carry...

Page 45: ... Routine Gas Testing FGD10A Oxygen Toxic Gas Detector TD18 002 Issue 16 Change Note 1904 Page 44 sensor replacement 8 1 Oxygen Toxic sensor Step1 Turn cover securing stud anti clockwise to allow cover to open Step 2 Remove cover by rotating anti clockwise ...

Page 46: ...Oxygen Toxic Gas Detector TD18 002 Issue 16 Change Note 1904 Page 45 Step 3 Remove display board which can be left to dangle on its retaining wire Remove PCBs from the support pillars and the datamate cable from the board left in the enclosure Step 4 Remove wires from terminal block ...

Page 47: ...ENTIFIC CONTROLS Installation Commissioning Routine Gas Testing FGD10A Oxygen Toxic Gas Detector TD18 002 Issue 16 Change Note 1904 Page 46 Step 5 Remove sensor insert from FGD10A enclosure using extraction tool ...

Page 48: ...sioning Routine Gas Testing FGD10A Oxygen Toxic Gas Detector TD18 002 Issue 16 Change Note 1904 Page 47 Step 6 Separate the two sensor insert components Once separated remove old sensor and replace with a new sensor and mate the two component parts ...

Page 49: ...ng Routine Gas Testing FGD10A Oxygen Toxic Gas Detector TD18 002 Issue 16 Change Note 1904 Page 48 Step 7 Apply Loctite 243 or a compound equal strength to the threads Insert the sensor housing into the FGD10A enclosure using the insertion tool loctite ...

Page 50: ...TIFIC CONTROLS Installation Commissioning Routine Gas Testing FGD10A Oxygen Toxic Gas Detector TD18 002 Issue 16 Change Note 1904 Page 49 Step 8 Terminate the wires dependIing on which type of gas sensor is fitted ...

Page 51: ...lation Commissioning Routine Gas Testing FGD10A Oxygen Toxic Gas Detector TD18 002 Issue 16 Change Note 1904 Page 50 Step 9 Fix datamate cable the boards removed from the support pillars and finally the display board back into position ...

Page 52: ...LS Installation Commissioning Routine Gas Testing FGD10A Oxygen Toxic Gas Detector TD18 002 Issue 16 Change Note 1904 Page 51 Step 10 Replace cover and fully tighten Step 11 Turn the cover securing stud clockwise until secure ...

Page 53: ...tch OFF the supply to the FGD10A 2 Release the grub screw located near the lip of the enclosure cover Note It is not necessary to remove the grub screw to release the enclosure front cover 3 Remove the enclosure front cover by rotating it several times in an anti clockwise direction 4 Unplug the display board from within the enclosure 5 Remove the 3 screws located around the edge of the next board...

Page 54: ...t power 5 Watts maximum Internal fuse 1 Amp antisurge Nanofuse Analogue output 4 to 20mA 10 bit resolution Relays Relay 1 Alarm 1 Relay 2 Alarm 2 Relay 3 Fault Contact Rating 300Vac 3 Amps Non inductive load RS232 output Communications with PC at 19200 baud Sensor type Oxygen or electrochemical toxic Measurement range Various depends upon sensor Response time depends upon sensor Measurement resolu...

Page 55: ... Installation Commissioning Routine Gas Testing FGD10A Oxygen Toxic Gas Detector TD18 002 Issue 16 Change Note 1904 Page 54 Dimensions Optional Weatherguard 115 126 Centres 190 136 2 x 7mm dia mounting holes Maximum Depth 127mm ...

Page 56: ... in the gas detector is 0 11mm maximum and should not be enlarged during maintenance etc 2 Only Loctite 243 or a compound equal strength shall be re applied to the threads of the type SI M sensor after replacing the sensing element 3 The SI IR sensors shall not be installed or removed when an explosive gas atmosphere is present Note Conditions 1 and 3 are not applicable to this product WARNING DO ...

Page 57: ...supply 8Vdc to 24Vdc 5W Relay contact rating 300Vac 3 Amps Installation instructions The cable entry devices and blanking elements of unused apertures shall be of a certified flameproof type suitable for the conditions of use and correctly installed With the use of conduit a suitable certified sealing device such as a stopping box with compound shall be provided immediately at the entrance to the ...

Page 58: ...STATUS SCIENTIFIC CONTROLS Installation Commissioning Routine Gas Testing FGD10A Oxygen Toxic Gas Detector TD18 002 Issue 16 Change Note 1904 Page 57 CUSTOMER NOTES ...

Page 59: ...STATUS SCIENTIFIC CONTROLS Installation Commissioning Routine Gas Testing FGD10A Oxygen Toxic Gas Detector TD18 002 Issue 16 Change Note 1904 Page 58 CUSTOMER NOTES ...

Page 60: ...STATUS SCIENTIFIC CONTROLS Installation Commissioning Routine Gas Testing FGD10A Oxygen Toxic Gas Detector TD18 002 Issue 16 Change Note 1904 Page 59 CUSTOMER NOTES ...

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