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2-1

Multi-Channel Combustible Monitor

Operational Theory 2

Teledyne Analytical Instruments

Operational Theory

2.1

Introduction

The Model 1220 combustible gas analyzer is composed of four com-

ponents:

1.

System Chassis

2.

Control Unit

3.

Channel Modules

4.

Combustible Sensors

The System Chassis provides structural support and electrical inter-

connection for a Control Unit and up to eight Channel Modules. Each
Channel Module can monitor one or two sensors (dual-sensor option).

2.2

System Chassis

All electrical connections are located on the rear of the system chassis.

The nine terminal strips constitute one each for the Channel Modules and
one for the Control Module.

2.3

Control Unit

The Control Unit provides control of electrical power to the channel

module, audio alarms and external alarms through the common alarm
relays.

Alarm signals from any Channel Module trigger the corresponding

relays in the Control Unit. For example, “high” alarm signals from any
channel trigger the “high” alarm relay in the system control module. There
are three such relays in the Control Unit, one each for high, caution and
failure alarms. The failure alarm relay in the Control Unit is operated
“fail-safe”; however, the gas level alarm relays can be optionally connected

Control Unit - Front Panel

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Содержание 1220

Страница 1: ...ED WHEN SERVICING THIS SYSTEM HAZARDOUS VOLTAGES EXIST ON CERTAIN COMPONENTS INTERNALLY WHICH MAY PERSIST FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND OR SERVICING BEFORE CONDUCTING ANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISOR MANAGER DANGER Instruction Manual Model 1220 Multi Channel Combustible Monitor ...

Страница 2: ...y parts in so far as such alterations do not adversely affect our warranty ImportantNotice This instrument provides measurement readings to its user and serves as a tool by which valuable data can be gathered The information provided by the instrument may assist the user in eliminating potential hazards caused by his process however it is essential that all personnel involved in the use of the ins...

Страница 3: ... available options are listed below with check boxes Any that are incorpo rated in the instrument for which this manual is supplied are indicated by a check mark in the box Instrument Serial Number _______________________ Options Included in the Instrument with the Above Serial Number Dual Sensor A second sensor PCB is installed to allow the Channel Module s to monitor two sensors simultaneously ...

Страница 4: ...al that the operator understand and test the operation of the total system Safety Checklist q Verify that the instrument is powered correctly q Verify that the instrument works all functions q Verify that alarm indications give the intended results q Verify that unauthorized personnel cannot tamper with the instrument or its auxiliary equipment q Institute routine test calibration procedures q Ide...

Страница 5: ...Combustible Sensors 2 3 2 5 1 Response of Combustibles to Various Gases 2 7 Installation 3 1 Unpacking the Analyzer 3 1 3 2 System Chassis 3 2 3 2 1 Location 3 2 3 2 2 Power 3 2 3 2 3 Electrical Connections 3 2 3 3 Control Unit 3 5 3 3 1 ControlUnit Fuses 3 5 3 3 2 Control Unit Jumper Settings 3 6 3 4 Channel Modules 3 8 3 4 1 Removing the Channel Module Cover 3 8 3 4 2 Changing the Fuse 3 8 3 4 3...

Страница 6: ...r Ch M 4 10 4 4 5 2 Zero Span Calibrating a Dual Sensor Ch M 4 10 4 5 Alarm Configuration Procedures 4 11 4 5 1 Defining the Setpoint for the High or Caution Alarm 4 11 4 5 2 Configuring Alarm Relay Settings 4 11 4 5 2 1 Setting the Fail safe or Non Faile safe Mode 4 11 4 5 2 2 Setting the Latching or Non Latching Mode 4 12 4 6 Setting the ID Code 4 12 4 7 Enabling Disabling the Pass Code 4 12 4 8...

Страница 7: ...laced to monitor the atmosphere surrounding their location The system is designed to provide indications of the state of each detector and to actuate individual external alarm indicators as well as alarms common to all channels The alarms are user configurable 1 2 Description The 1220 system is comprised of a System Chassis Control Unit Channel Modules and Remote Sensors Each System Chassis contai...

Страница 8: ...nel Modules Each channel module is a complete self contained instrument including integral power supply and requires only external AC power A channel is operational simply when plugged into the System Chassis Because a channel module plugs into the control module channels can easily be added after installation to monitor additional locations on any control module originally supplied with less than...

Страница 9: ...1 3 Multi Channel Combustible Monitor Introduction 1 Teledyne Analytical Instruments Model 1220 Combustible Monitor Front Panel ...

Страница 10: ...cal inert bead Each bead is integrated onto a platinum heating coil and is mounted on a stainless steel support bar With this rugged mounting system the detector is extremely vibration and shock resistant The detectors are installed near the potential source of leaks in the region expected to be first exposed to the gas Combustible Gas Detector 1 2 5 Terminal Strip Housing The terminal strip housi...

Страница 11: ... the rear of the system chassis The nine terminal strips constitute one each for the Channel Modules and one for the Control Module 2 3 Control Unit The Control Unit provides control of electrical power to the channel module audio alarms and external alarms through the common alarm relays Alarm signals from any Channel Module trigger the corresponding relays in the Control Unit For example high al...

Страница 12: ...tains universal power supplies that operate on 100 240 VAC 50 60Hz The power switch on the Control Unit switches power for the entire system The line is protected by two 3 Amp fuses accessible from the front panel A 1 8 A fuse is furnished for the electronic circuitry of the Control Unit The green power LED indicates that the Unit is ON Alarm switch S2 has two positions Normally the switch is set ...

Страница 13: ...for the detector is provided with a stable current of 300mA Each detector is connected in a bridge circuit with the output signal feeding an operational amplifier A block diagram of the functional relationships of the Channel Module is shown in Figure 2 3 2 5 Combustible Sensors The basic elements of the combustible gas detector are shown in Figure 2 1 The two beads each consist of a small coil of...

Страница 14: ...by the same current but lacking the catalytic material will be similarly affected by these extraneous factors but not significantly affected by oxidation of the combustible gas These two beads are placed in close proximity to one another so that they are affected by the same environmental factors Thus the differences between the changes in resistance of the two coils are directly related to the co...

Страница 15: ...w the source Table 1 Detector Response to Gases COMPOUND LEL RESPONSE FACTOR Methane 5 0 1 00 Hydrogen 4 0 0 86 Carbon Monoxide 12 5 0 32 Ethane 3 0 1 20 Ethylene 2 7 1 26 Acetylene 2 5 1 39 Propane 2 2 1 42 Propylene 2 0 1 33 Butane 1 9 1 54 Hexane 1 1 1 50 Cyclohexane 1 3 1 44 Heptane 1 05 1 59 Benzene 1 3 1 50 Toluene 1 2 1 48 Ethylene Oxide 3 6 0 76 Methyl Ethyl Ketone 1 8 0 96 Methyl Acrylate...

Страница 16: ...ing Electronics S2 Keyboard A to D Converter Digital to Analog Converter DAC 0 10 V dc Concentration 4 20 mA dc Concentration RS 485 Power Supply 1 AC DC Power Supply 2 AC DC M U X To CPU Central Processing Unit CPU S1 12 V Test 5 15 V Test Analog Output Test R e l a y s High Failure Caution Display LED Indicators ...

Страница 17: ...lene at 2 would be 2 0 X 1 26 2 52 methane equiva lent NOTE The LEL and the response factors cannot be used directly for calibration See Table II on page 4 16 for calibration of the instrument to gases other than Methane CAUTION In most cases the concentration of any particular compound that the sensor is exposed to should not exceed the LEL of that compound or sensor damage could occur The concen...

Страница 18: ...2 8 2 Operational Theory Model 1220 Teledyne Analytical Instruments ...

Страница 19: ...ped with the channel modules and control module installed Since the system is intended as a safety monitor for detecting the presence of combustible gases in industrial environments the system enclosure is normally installed in a safe area while the remote sensors are installed at potentially hazardous areas up to 12 thousand feet distant Numerous case options are available however One optional co...

Страница 20: ...on should be used 3 2 3 Electrical Connections The primary power terminals are designated H hot N neutral and GND ground Connections should be made in accordance with these designations All electrical connections are available at the barrier type terminal strips located at the rear of the control unit These facilities are shown on the user interconnection drawing D 67850 WARNING Disconnect primary...

Страница 21: ...ch sensor is 35 i e the cabling and connections should not exceed 35 total or 35 2 17 5 on each side of the sensor See Figure 3 2 Note that the white wire resistance is not a limiting factor in the Loop Resistance i e its resistance is not included in the Loop Resistance measurement To measure the Loop Resistance directly short the RED and BLACK Connections at the Sensor and measure the resistance...

Страница 22: ... external signal can be either 1 a contact closure or 2 a powerline level signal Reactive loads connected to the relay contacts must be equipped with appropriate transient suppression networks to prevent spurious triggering of sensitive alarm circuits Analog output from each channel module should be connected to monitoring equipment as shown in Figure 3 3 Note that the monitoring equipment inputs ...

Страница 23: ...allation of the Control Unit simply requires that it be slid into the system chassis making certain that the circuit board lines up with the connector The circuit may be seated in the connector by tightening the jack screws The six retaining screws may then be reinstalled and the primary power reconnected to the System Chassis 3 3 1 Control Unit Fuses The Control Unit contains three fuses Two 3 Am...

Страница 24: ...t may be configured by changing the installation of the jumpers on the PCB See the following sections for complete jumper installation information The default jumper installation is Three alarms CAUTION HIGH and FAIL may be configured for either fail safe default or non fail safe operation per the following table ...

Страница 25: ...ng line voltage to the external connections Additionally the contact closure can be normally opened or normally closed when the relay is de energized The following tables summarize the jumper settings for the external au dible alarm configurations The internal audible alarm may be disabled by removing JP17 WARNING It is not recommended to remove JP17 unless there is an external audible alarm in us...

Страница 26: ...e accomplished by sliding the module into the chassis until the top and bottom screws can be engaged engaging them tightening the bottom jack screw to reconnect the module and then tightening the top retaining screw WARNING Disconnect power before performing any of the following These operations should only be per formed by a qualified service technician 3 4 1 Removing the Channel Module Cover In ...

Страница 27: ...ove the channel module cover as in section 3 4 1 and add remove the second sensor PCB as shown in Figure 3 4 3 4 4 Configuring the Internal Jumper Connections The Channel Module outputs may be configured by setting the inter nal jumpers In addition there are several factory preset jumpers config ured as shown in the following table Changing the internal jumpers re quires removing the channel modul...

Страница 28: ...older does not flow onto the area where the terminal screws must seat as that can make it difficult to get firm permanent seating of the screws If conduits carrying the sensor leads to the control unit also carry other electrical wiring the sensor leads must be shielded The Channel Modules may support one or two sensors dual sensor option When the dual sensor option is used the two sensors connect...

Страница 29: ...All the green Power LEDs on the channel modules should be illuminated Each channel goes thru the process of a self diagnostics test for the following Checks the power supply 5V output Checks the power supply 15V outputs Checks the power supply 12V outputs Checks the analog outputs Checks for one sensor or two sensor mode Checks for sensor installation Checks that the ADC is responding 3 The Channe...

Страница 30: ...pass LED The Audible Alarm Switch overrides the audible alarm when in the Bypass position The red Bypass LED lights when the audible alarm is bypassed 4 2 3 Fuses For fuse replacement installation see section 3 3 1 and 3 4 3 4 2 4 RS485 Port NOTE This feature is not presently supported contact the factory for application assistance An RS485 port is provided at the 9 pin D sub connector The RS485 p...

Страница 31: ...Multi Channel Combustible Monitor Operation 4 4 3 Teledyne Analytical Instruments Channel Module Front Panel Controls and Indicators ...

Страница 32: ... The red yellow and blue alarm LEDs begin to flash They remain flashing until the alarms are reset or the BYPASS switch is pressed again SELECT Switch Use this membrane switch to access any of the Channel Module s four user configurable modes and their options The four modes are 1 Sensor and Calibration Mode This mode allows you to select sensor 1 S1 or sensor 2 S2 and then set the ZERO and SPAN v...

Страница 33: ...our user configurable modes all arrows allow you to navigate through the options In addition the Up Down arrow keys can be used to set the values shown on the display for ZERO and SPAN and also increase decrease the value of the HIGH and CAUTION alarms CAUTION HIGH ALARM CAUTION HIGH ALARM FAIL FAIL POWER Blue LED indicates a Channel Module or Sensor failure Flashes when bypassed Red LED indicates...

Страница 34: ...the Up Down Arrow Keys C highlighted indicates that the Caution Alarm value can be set by using the Up Down Arrow Keys When the instrument goes into an alarm condition the alarm relay switches If LCH latched was selected the alarm relay remains switched latched even after the alarm condition has been cleared Using this configuration you must press the RESET switch to unlatch unlock the relay When ...

Страница 35: ... alarm settings during the configuration mode and calibration values during Span and Zero operations 4 4 Calibration Procedures 4 4 1 Zero Calibrating a Single Sensor Channel Module NOTE To accomplish the following task two operators are needed Operator one at the Control Unit and operator two at the probe Both operators are involved in the calibration process They must be in constant communicatio...

Страница 36: ...ator Two at the probe 1 A At the Front Panel of the Channel Module to be calibrated a Press SELECT b Use the right or left arrow key to highlight the SPAN option c Press ENTER Result Alarms are deactivated and the SPAN display option flashes 2 B Introduce span gas into sensor 3 A After the reading stabilizes a Press the up or down arrow key until the display reads the value that corresponds to the...

Страница 37: ...graph 4 4 1 beginning with Step 1b and then return here 2 To calibrate the second sensor perform this procedure again begin ning with Step 1b 4 4 4 Span Calibrating a Dual Sensor Channel Module NOTE To accomplish the following task two operators are needed Operator one at the Control Unit and operator two at the probe Both operators are involved in the calibration process They must be in constant ...

Страница 38: ...ds 0 b Press ENTER c Press the up or down arrow key until the display reads the value that corresponds to the value of the certified span gas used NOTE Information about calibration values for various combustible gases appears in Table 1 on page 2 5 and in Section 4 11 on page 4 14 NOTE If you need to adjust the Sensitivity Gauge see Paragraph 4 8 for recommendations d Press ENTER 7 If necessary p...

Страница 39: ...elect the alarm d Use the up or down arrow key to adjust the displayed value to the desired percentage for the alarm selected e Press ENTER 2 If necessary proceed to the previous or next procedure Otherwise press RUN to place the instrument in the analysis mode 4 5 2 Configuring Alarm Relay Settings 4 5 2 1 Setting the Fail safe or Non Fail safe Mode 1 At the Front Panel of the Channel Module to b...

Страница 40: ... analysis mode 4 6 Setting the ID Code 1 At the Front Panel of the Channel Module to be configured a Press SELECT three times to enter the ID Code Mode The current ID code will be displayed b Press ENTER c Use the left and right arrow key to select the digit to be modi fied and the up and down arrow keys to modify the selected digit d Repeat Step c to modify the remaining digits e Press ENTER to s...

Страница 41: ...system will require no attention unless an alarm state occurs In the event of an alarm indication the audible alarm may be silenced in one of two ways 1 Move the AUDIBLE ALARM switch on the system control mod ule to BYPASS This will immediately silence the audible alarm and also prevent an audible indication from occurring should another channel go into an alarm state 2 Press the BYPASS button on ...

Страница 42: ...audible alarm is deactivated To acknowledge a failure condition press RESET This restarts the instrument as if the button has been pressed twice Alternatively you may turn the unit OFF using the button NOTE The reason the failure modes require restarting the instru ment is that once a failure has been detected the unit should not be used until the error is fixed When a failure alarm is detected th...

Страница 43: ...h the instrument should be spanned in accordance with the calibration proce dures when the sensor is exposed to the calibration gas When so adjust ed the instrument will be calibrated to indicate the percent LEL of the selected gas Use the following formula to determine the value to enter during the span calibration procedure V CH4 x CF Where V Value to enter during span calibration CH4 Percent me...

Страница 44: ...s for TAI Combustible Gas Sensor COMPOUND CALIBRATION FACTOR Methane 20 Hydrogen 29 Carbon Monoxide 25 Ethane 28 Ethylene 29 Acetylene 29 Propane 32 Propylene 38 Butane 34 Cyclohexane 53 Heptane 60 Pentane 46 Toluene 56 Ethylene Oxide 37 Methyl Ethyl Ketone 58 Methyl Acrylate 61 Hexane 61 ...

Страница 45: ...5 1 Multi Channel Combustible Monitor Failure and Error Codes 5 Teledyne Analytical Instruments Failure and Error Codes 5 1 Failure Codes ...

Страница 46: ...5 2 5 Failure and Error Codes Model 1220 Teledyne Analytical Instruments 5 2 Error Codes ...

Страница 47: ... scale at constant tempera ture Response Time 90 in less than 15 seconds OperatingTemperature 0 to 50o C TemperatureStability 1 over 10o F Alarms Two Adjustable Alarm Point plus FailureAlarmIndicatorsilluminateat Alarm Setpoint HIGH RED CAUTION AMBER FAIL BLUE Sensor Type Two element catalytic bead anodized aluminumhousing StainlessSteel FlameArrestors SignalOutput Internal LCD Display External 0 ...

Страница 48: ...h screwconnections AlarmOutput Form C Relay Contacts SPDT Recommended Spare Parts List Qty Part Number Description 2 A 12698 Adapter Flow Thru 10 A 11091 Adapter Female 4 B 12093 Detector 5 F 1374 Fuse Type 3AG 1 8A 10 F 229 Fuse Micro 2A 5 F 1379 Fuse Type 3AG 3A 1 C 65446 PCB Front Panel Display 1 C 67479 PCB Constant Current Supply 1 C 65446 PCB Front Panel 1 C 66910 Front Panel With Membrane _...

Страница 49: ...26 934 1500 Fax 626 961 2538 TWX 910 584 1887 TDYANYL COID Web www teledyne ai com or your local representative Drawing List C 67019 Outline Drawing Control Unit A 13450 Outline Drawing Sensing Detector B 68172 Interconnection Diagram Model 1220 C 67478 Schematic Diagram Constant current supply D 65445 Schematic Diagram Model 1220 Front Panel Display D 65442 Schematic Diagram Model 1220 Main PCB ...

Страница 50: ...A 4 Appendix Model 1220 Teledyne Analytical Instruments ...

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