Instruction Manual Series 17CA3000 Chloralert TM Plus Multi-Gas Detector CAPITAL CONTROLS

Transcription

1 Instruction Manual Series 17CA3000 Chloralert TM Plus Multi-Gas Detector CAPITAL CONTROLS

2 These instructions describe the installation, operation and maintenance of the subject equipment. Failure to strictly follow these instructions can lead to an equipment rupture that may cause significant property damage, severe personal injury and even death. If you do not understand these instructions, please call De Nora Water Technologies for clarification before commencing any work at and ask for a Field Service Manager. De Nora Water Technologies, Inc. reserves the rights to make engineering refinements that may not be described herein. It is the responsibility of the installer to contact De Nora Water Technologies, Inc. for information that cannot be answered specifically by these instructions. Any customer request to alter or reduce the design safeguards incorporated into De Nora Water Technologies equipment is conditioned on the customer absolving De Nora Water Technologies from any consequences of such a decision. De Nora Water Technologies has developed the recommended installation, operating and maintenance procedures with careful attention to safety. In addition to instruction/operating manuals, all instructions given on labels or attached tags should be followed. Regardless of these efforts, it is not possible to eliminate all hazards from the equipment or foresee every possible hazard that may occur. It is the responsibility of the installer to ensure that the recommended installation instructions are followed. It is the responsibility of the user to ensure that the recommended operating and maintenance instructions are followed. De Nora Water Technologies, Inc. cannot be responsible deviations from the recommended instructions that may result in a hazardous or unsafe condition. De Nora Water Technologies, Inc. cannot be responsible for the overall system design of which our equipment may be an integral part of or any unauthorized modifications to the equipment made by any party other that De Nora Water Technologies, Inc. De Nora Water Technologies, Inc. takes all reasonable precautions in packaging the equipment to prevent shipping damage. Carefully inspect each item and report damages immediately to the shipping agent involved for equipment shipped F.O.B. Colmar or to De Nora Water Technologies for equipment shipped F.O.B Jobsite. Do not install damaged equipment. De Nora Water Technologies, Colmar Operations Colmar, Pennsylvania, USA is ISO 9001: 2008 Certified READ THE ENTIRE MANUAL BEFORE OPERATING USE ONLY IN ACCORDANCE WITH INSTRUCTION MANUAL WARNING: HAZARDOUS VOLTAGES. PROTECTIVE GROUND (EARTH) TERMINAL WARNING: FAILURE TO INSTALL, SET UP OR OPERATE THE EQUIPMENT IN THE MANNER SPECIFIED BY DE NORA WATER TECHNOLOGIES MAY IMPAIR THE PROPER OPERATION OF THIS EQUIPMENT

3 TABLE OF CONTENTS SAFETY SUMMARY...7 READ FIRST INTRODUCTION General Model Number Breakdown Specifications INSTALLATION Inspection Location and Mounting Receiver Electrical Connections Sensor/Transmitter Electrical Connections FUNCTIONAL DESCRIPTION General Features Sensors/Transmitter Gases Gas Concentration Range Outputs Power Consumption Sensor Cross-Sensitivity Receiver Input Voltage Power Requirements Receiver Outputs Analog Outputs (AO) Digital Outputs (DO) Keypad Push-button Operating Modes Password Display Modes Watchdog Timer Circuit Self-Test Standard Tests Extended Tests Self-test Failure Messages Sensor Check Calibration Mode Security and Safety Password Watchdog Timer Power Failure Battery Operation Operational Alarms Level Mode Latch Delay Event Displays Alarm Displays Status Event Displays Event Queues START-UP & OPERATION Firmware Level Calibration Data Quick-Start

4 4.3.1 Data Entry Configuration Setup Menu Navigation & Defaults Select Sensor Channel Select Sensor Type Enter Sensor Calibration Parameters Configure Alarm Configure Digital Output Return to RUN MODE Menu Sequence Setup Direct Access Password Protected Configure Instrument Name Engineering Units Display Mode Set Time Set Date Change Password Override the Password Default Database Set LCD Contrast Sensor Check Run Self-Test Enter Configuration Code Custom Average Hours Battery Status Software Version Channels Tag Name Sensor Type Alarm (1,2, or 3) Level Mode Latch Delay Analog Output Output Span Zero Mode Calibration (Analog Output Parameters) Calibration (Sensor Parameters) Concentration Span Zero Sensor Data Digital Outputs Source Invert State Comm Port Baud Rate Instrument Address Parity

5 Datalink Enable Datalink Protocol Run Calibration Stop Calibration CALIBRATION Sensor Calibration Setup Source Calibration General Calibration Overview ZERO Calibration Procedure SPAN Calibration Procedure Analog Output Calibration Minimum Output Current Calibration Maximum Output Current Calibration COMMUNICATIONS General Interconnections RS232 Plug Connections RS422/485 Plug Connections Configuring the System Module for Datalink Protocol Message Types Host to Instrument Instrument to Host Transaction Examples Mnemonic-to-Datapoint Cross Reference Database Starting Addresses Instrument Memory Address Scheme Executing Instrument Self Tests Using Datalink Database Prompt-to-Datapoint Cross Reference MAINTENANCE General Routine Maintenance Sensor/Transmitter Replacement Troubleshooting General Troubleshooting Sensor Troubleshooting...83 LIST OF FIGURES Figure 1-1 Basic System Configuration... 9 Figure 1-2 Receiver Data Tag Figure 2-1 Receiver Outline Dimensions Figure 2-2 Sensor/Transmitter Outline Dimensions Figure 2-3 Interconnection Diagram Figure 2-4 Sensor Wiring Figure 3-1 Chloralert Plus Keypad Figure 3-2 Basic Alarm Operation Figure 3-3 Self-Resetting Alarm Operation Figure 3-4 Latching Alarm Operation Figure 4-1 Receiver Data Tag Figure 4-2 Sensor Calibration Tag Figure 4-3 Startup Phases Figure 4-4 Receiver Data-Entry Keypad Figure 5-1 Label & Magnet Orientation Figure 6-1 RS-232 or RS-485 Datalink Module Figure 6-2 RS-232 Plug Connector Figure 6-3 RS-485 Plug Connector Figure 6-4 Floating Point Examples

6 LIST OF TABLES Table 2-1 Sensor Wiring and Configuration Table 3-1 Gas Cross-Sensitivity Data Table 4-1 Factory Default Database Parameters Table 6-1 System Prompts (Datalink) Table 6-2 Datalink Protocol Table 6-3 Datapoint Types Table 6-4 Database Starting Addresses Table 6-5 Datapoint Addresses Table 6-6 Prompt-to-Datapoint Cross Reference

7 SAFETY SUMMARY GENERAL WARNINGS RETURN OF EQUIPMENT All equipment being returned to De Nora Water Technologies for repair must be free of any hazardous materials. Contact De Nora Water Technologies for authorization prior to returning equipment. INSTRUCTION MANUALS Do not install, maintain or operate this equipment without reading, understanding and following the proper De Nora Water Technologies instructions and manuals, other wise injury or damage may result. ELECTRICAL SHOCK HAZARD Equipment powered by AC line voltage presents a potential electric shock hazard to the user. Make certain that the system power is disconnected from the operating branch circuit before attempting electrical interconnections of service. SPECIFIC WARNINGS ELECTRICAL SHOCK HAZARD Equipment powered by AC line voltage presents a potential electric shock hazard. Servicing of the Chloralert Plus should only be attempted by a qualified electronics technician. WARNING: ELECTRIC SHOCK HAZARD Equipment powered by AC line voltage presents a potential electric shock hazard to the user. Make certain that the system power input and Digital Output replay connections are disconnected from the operating branch circuit before attempting to connect Sensors to the Receiver. (pg.17 ) All alarm operation is temporarily totally disabled during this test. (pg.51) There is no automatic link between this menu entry and the units selected in the Engineering Units menu (refer to section ) or the range selected in the Sensor Type menu. The operator must be careful to select a level value entry that is within the instrument s operating range, otherwise the alarms will not operate. (pg.53)

8 SPECIFIC CAUTIONS After making Sensor/Transmitter electrical connections, care must be taken to replace the Sensor/Transmitter wiring box cover properly. The wiring box is not perfectly square (refer to Figure 2-2) and the cover must be aligned properly to the box in order for the gasket to seal the box properly. (pg.17) In SETUP, ALARM, and DATA modes, gas monitoring continues to take place even though concentration values are not shown on the display. However, when in SETUP, selection of CALIBRATE, SELF-TEST, or SENSOR-CHECK functions will temporarily suspend normal gas monitoring. (pg.24) When power is restored after a power failure, displayed averages will be reset and valid data will not be available until 15 minutes or 8 hours have been accumulated for the STEL and TWA modes respectively. (pg.30) Averaging data will be accumulated from the time the RUN CALIBRATION key is pressed until the calibration process is actually begun by activating the Sensor s magnetic switch. Once Calibration has been activated, data accumulation is sus pended until Calibration is completed. Data accumulation is suspended during SENSOR CHECK, CALIBRATION (begins when the sensors magnetic switch is activated) and SELF-TEST. (pg.30) If the measured gas concentration exceeds the maximum range, the data will be accumulated at the maximum range rate. The average data after the over-range event will be in error for the next averaging period. The over-range event is displayed and may also be retrieved from the data archive. If the instrument is set up such that alarm level 3 is at the maximum range, remote notification of this type of occurrence is possible. (pg.30) The value of the gas concentration entered must be within the range selected from the SENSOR TYPE menu (refer to section ), otherwise an erroneous operation will result. (pg.55) If cleaning of the sensor housing is performed, do not clean the Sensor/Transmitting housing with cleaners containing strong mineral acids or organic solvents such as ketones, chlorinated hydrocarbons, or aromatics. Using such cleaners may damage the housing materials. Cleaning of the sensor housing materials should only be performed using soap and water. (pg.81) Sensor removal must be done by pulling the sensor from the circuit board without rotating or twisting the sensor. Rotation will cause serious damage to the sensor pins. (pg.82) READ FIRST WARNING INSTRUCTION MANUALS Do not install, maintain, or operate this equipment without reading, understanding and following the proper De Nora Water Technologies instructions and manuals, otherwise injury or damage may result. RETURN OF EQUIPMENT All equipment being returned to De Nora Water Technologies for repair must be free of any hazardous materials. Contact De Nora Water Technologies for authorization prior to returning equipment. This instruction bulletin contains general operating information about the Chloralert Plus Multi-Gas Detector as well as instructions for installation and troubleshooting. Read these instructions before starting installation. Save these instructions for future reference

9 1.0 INTRODUCTION 1.1 General The Chloralert Plus multifunction gas-leak detector is designed to be used for the detection and monitoring of Chlorine (Cl 2 ) and Sulfur Dioxide (SO 2 ) in ambient air. It also activates audio and visual alarms in the event that the concentration of these gases exceeds programmable preset levels. The basic system consists of the Receiver and one to four Sensor/Transmitters and has provision for additional optional features (refer to Figure 1-1). In use, the sensor assemblies are mounted near the potential sources of leaks or emissions. The receiver assembly may be located up to 1000 ft from the sensor. It converts the signal from the sensor/transmitter to the digital display of gas concentration, activates alarm(s) or other safety devices, transmits 4-20 ma signals for recording or control purposes, and permits serial communication via RS485 or RS232 protocols. The receiver is available as a wall mounted, NEMA 4X enclosure 10.9W x 8.6H x 5.3 inches deep containing a main circuit board, keyboard, and display. The electronics consist of a power supply and signal-processing circuitry for up to four sensor inputs, battery charging circuit for an optional external battery back-up, a malfunction relay and two alarm relays. Support for three separate optional electronics packages is included on the main board: Communications (RS232 or RS485), 4 channels of 4-20 ma analog outputs, and six additional digital output relays (SPST). All relays are rated at 1.5/240VAC. The receiver is supplied with three conduit connectors for sensor, replay, and ac power connections. An additional four conduit connectors for optional accessories are supplied in a separate bag. The sensor includes dedicated transmitter electronics because of individual sensor setup requirements and is currently available in four types (Cl 2 & SO 2 ). A waterproof package (NEMA 4X) consists of a factory-calibrated assembly containing sensor and solid state electronics. The sensors are powered from the receiver which will power 4 sensors for a minimum of 24 hours during a power outage when supplied with the optional back-up battery. Appropriate cable lengths may be ordered separately. A sensor-check (auto-generator) feature is available for each sensor type. It consists of a small gas generator which is assembled on the end of the sensor and is wired in the junction box assembly. This allows testing of the sensor s integrity and verifies that the sensor is functioning properly. Figure 1-1 Basic System Configuration

10 1.2 Model Number Breakdown The following table shows the individual fields of the instrument s model number and the selections available for each. Refer to the receiver s data tag (shown below) for the specific model number configuration of the instrument. 17CA3 Enclosure Standard Wall Mounting 1 Standard With key Locked door 2 Analog Outputs None 0 4 ANO 1 Digital Outputs 3 DO 0 9 DO 1 Design Level A Communications None 0 RS485 1 RS232 2 Sensor Channel - Calibrated with Detector* Not Required Chlorine Sensor - (0-5 PPM) Chlorine Sensor - (0-10 PPM) Chlorine Sensor - (0-50 PPM) Chlorine Sensor with Sensor Check - (0-5 PPM) Chlorine Sensor with Sensor Check - (0-10 PPM) Chlorine Sensor with Sensor Check - (0-50 PPM) Sulfur Dioxide Sensor - (0-10 PPM) Sulfur Dioxide Sensor - (0-20 PPM) Sulfur Dioxide Sensor - (0-100 PPM) * Specify type and quantity of sensor(s) required (4 maximum)

11 1.3 Specifications SYSTEM: Gases Chlorine Sulfur Dioxide Channels/Gases for each receiver Gas Conc. Ranges Ambient Temperature Ambient Pressure: AC POWER: Voltage Range Frequency Range Power Consumption Voltage Dropout Duration Permitted RECEIVER: Signal Relays Annunciators Alarm Levels Alarm Modes Alarm Operation Display Keyboard Diagnostics Security 4 max., channels and gas interchangeable Chlorine: 0-5, 0-10, 0-50 ppm Sulfur Dioxide: 0-10, 0-20, ppm Receiver: -5 to +55 C (23 to 131 F) Sensor: -30 to +55 C (-22 to 131 F) 0.8 to 1.2 atmospheres 93.5 to 276 Vac Hz Receiver- 10 watts nominal, 12 watts max. Electrochemical Sensor/Transmitter- 0.5 watts max. < 20 ms Digital Communication RS 232/485 (optional), 4-20 ma each channel (optional) 3 SPDT Standard, Additional 6 SPST optional Relay contacts rated at 3.15 Amps/240 Vac Optional relays are field replaceable Flashing display indication for concentration alarms and other significant events. Display backlight turned off during battery operation or if battery is faulty. Selectable, 3 programmable concentration alarm levels for each channel. Selectable, TWA, Instantaneous, STEL, and Customer Defined Selectable, normal (self-resetting), latched and delayed. Back-lit LCD, 2 lines x 20 characters Polyester, 20 tactile key position System, power and sensor failure Password-protected

12 Max. Distance Receiver to Sensor/Transmitter: Wires (Xmttr/Receiver) 2 Sample Draw Sensor Check Housing Sensor/Transmitter: Dimensions: Receiver: Battery: Weight: Materials: Dimensions: Weight: Materials: Dimensions: Weight: 1000 ft. None Optional 3.2 in.(w) x 11.0 in.(h)* x 2.2 in.(d) *12.6 in.(h) with gas-generator 1 lb. Electronic Housing Tube-PVC Junction Box-polycarbonate 10.9 in.(w) x 8.6 in.(h) x 5.3 in.(d) 5 lb. Enclosure-polystyrene Clear Front-polycarbonate 10.5 in.(w) x 9.0 in.(h) x 6.5 in.(d) 15 lb. Mounting: Wall ENCLOSURES: NEMA 4X(IP65) OPTIONS: 4 ANO Option Contains circuitry for transmitting four 0-20 ma or 4-20 ma analog current outputs proportional to gas concentration levels. The analog outputs are not isolated since they all share the same circuit common return point (Refer to Figure 2-4). 6 DO Option Contains six additional SPST relay circuits, thus allowing for two relays for each gas channel. Communications Plug-in models for RS232 or RS485 ACCESSORIES: External Battery Sensor Cable Sensor-Check Generators SENSOR: Sensor Type Minimum Detectable Concentration Calibration Mode Includes battery (w/storage case) allowing a minimum of 24 hours of operation Available in any length (in feet) up to 1000 ft. max. Attach to end of sensor. Discharge gas into the sensor to verify sensor and receiver operation. Controlled by the Receiver. Electrochemical (EC) Chlorine: 0.1 ppm Sulfur Dioxide: 0.1 ppm automatic, remote single person, non-intrusive

13 2.0 INSTALLATION 2.1 Inspection The equipment should be inspected for damage that may have occurred during shipment. All damage should be reported to the shipping agent. If the equipment is damaged to the extent that faulty operation may result, contact De Nora Water Technologies before installation. Always reference the complete instrument serial number and model number in all correspondence concerning the equipment supplied. 2.2 Location and Mounting The Model 17CA3000 Chloralert Plus Receiver may be wall-mounted close to the gas sensor(s) or may be located up to 1000 feet from the sensor(s). Refer to Figure 2-3 for the recommended interconnection diagram. Mounting-ears are supplied with the Receiver and the Sensor/Transmitter and may be used for convenient wall-mounting (Refer to Figures 2-1 and 2-2 respectively). The mounting ears may be oriented in several directions to facilitate convenient mounting. It is recommended that both receiver and sensor/transmitter be oriented vertically as shown in Figure 1-1. Mounting screws or any other mounting hardware desired or required is supplied by the customer. The receiver case is supplied, configured with three ½-NPT conduit fittings for customer wiring (Refer to Figure 2-1). The receiver enclosure contains four additional knockouts for attachment of additional conduit fittings. These provide a means of wiring optional features like digital communications, analog outputs, battery backup and alarms. Select a location which gives limited access to unauthorized personnel and where ambient temperature remains within the temperature range specified in section 1.3. The installation area should be well ventilated and provided with a source of heat, if necessary, to ensure that the ambient temperature does not fall below the specified minimum temperature. The selected location must be of sufficient size to provide necessary equipment clearances and to allow easy access for routine inspection and maintenance of the Chloralert Plus Receiver and its gas sensor/transmitters. Refer to Figures 2-1 and 2-2 for outline dimensions of the Chloralert Plus Receiver and Sensor/Transmitter Assembly respectively. Locate the sensor module 12" to 36" (305 to 915 mm) from the floor with the sensor pointed downward. 2.3 Receiver Electrical Connections Electrical wiring including AC power, sensor and alarm relay interconnections should be performed in accordance with the interconnection diagram shown in Figure 2-3. Refer to section 2.4 for detailed sensor/ transmitter assembly wiring. WARNING ELECTRICAL SHOCK HAZARD. Equipment powered by AC line voltage presents a potential electric shock hazard to the user. Servicing of the Chloralert Plus should only be attempted by a qualified electronics technician

14 Figure 2-1 Receiver Outline Dimensions

15 Figure 2-2 Sensor/Transmitter Outline Dimensions

16 Figure 2-3 Interconnection Diagram

17 2.4 Sensor/Transmitter Electrical Connections WARNING ELECTRICAL SHOCK HAZARD. Equipment powered by AC line voltage presents a potential electrical shock hazard to the user. Make certain that the system input and digital output relay connections are disconnected from the operating branch circuit branch circuit before attempting to connect sensors to the receiver. Precautions must be taken to insure that the sensor/transmitter assembly is correctly wired to the receiver. The sensor/transmitter assembly interfaces with the receiver circuitry via the sensor interface, terminal block TB3. This terminal block consists of 12-positions organized into 3 terminals for each of the four possible sensors. Each sensor is wired to a S+, S- and SHD (shield) terminal. WARNING Calibrated Sensors are calibrated to a specific channel on the gas detector and are required to be wired as such Sensor wiring for the Chlorine Electrochemical Sensor is shown in Figure 2-4. The example shown in the figure shows a single sensor wired to terminals S1+ and S1- on TB3. These terminals correspond to CHANNEL 1 in the SETUP-CONFIGURATION-CHANNELS menu selection discussed in chapter 4.0, START-UP AND OPERATION. For a single-sensor system, it is recommended that the sensor be connected to the S1+ and S1- terminals and that it be configured as CHANNEL 1 in the firmware. The sensor wires are polarized and the RED wire must be connected to the + terminal while the BLACK wire connects to the - terminal. As mentioned previously, the figure shows wiring for a single-sensor system. If additional sensors are being used, the suggested wiring configuration is shown in Table 2-1 below. Table 2-1 Sensor Wiring and Configuration Number of Sensors Sensor Terminals Channel 1 1 S1+, S S1+, S1- S2+, S2- S1+, S1- S2+, S2- S3+, S3- S1+, S1- S2+, S2- S3+, S3- S4+, S Although the above table shows recommended wiring, a sensor may be wired to any CHANNEL as long as the configured CHANNEL corresponds to the terminals to which the sensor is wired. For example, a single sensor may be wired to the S3+ AND S3- terminals as long as the CHANNEL 3 is configured for that sensor in the configuration menu. Wiring a sensor to S2+ and S2- terminals and configuring CHANNEL 1 will cause a sensor alarm to be generated. CAUTION After making sensor/transmitter electrical connections, care must be taken to replace the sensor/transmitter wiring box cover properly. The wiring box is not perfectly square (refer to Figure 2-2) and the cover must be aligned properly to the box for the gasket to seal the box properly

18 Figure 2-4 Sensor Wiring

19 3.0 FUNCTIONAL DESCRIPTION 3.1 General The 17CA3000 Chloralert Plus normally consists of two distinct elements, the sensor/transmitter and the receiver. The sensor/transmitter is located near potential sources of gas leaks or emissions while the receiver is located remotely in a control room, although in some instances, they may both be located at the same site. Both elements of the device have inputs and outputs. The sensor/transmitter is powered by the receiver to operate the electronics as well as the sensor, it transmits a multiplexed frequency-modulated (FM) signal to the receiver. This conditioned sensor signal is a function of the gas concentration being monitored by the sensor. The receiver accepts the sensor/transmitter input, converts it to a display of the gas concentration, activates alarms and other safety devices, and transmits an analog output current signal (if so configured) for recording or control purposes. Additionally, setup and configuration data are available via an optional remote serial data communications port. The receiver may also receive information such as that needed for a set up and calibration from an external computer via this datalink (Refer to section 6.0). The receiver is also used to set up the database for the various alarm functions and the required calibration information. Several alarm modes are available; Instantaneous, STEL, TWA, or Custom. It also provides information during the calibration procedure about the status of the calibration as it proceeds. The main board in the receiver contains the power supply for all sensor/transmitters, the microprocessor, three (standard) programmable alarm relays and associated electronics. Four optional features are available: Four 0-20 ma or 4-20 ma ANALOG OUTPUTS for transmission of the gas concentration levels. Six additional DIGITAL OUTPUT relays RS232 or RS485 Communications Port Battery Backup The purpose of this chapter is to give an overview of some of the features of the 17CA3000. For actual operational and data-entry procedure, refer to section Features Sensor/Transmitter Gases Presently, the system is designed to monitor two gases: Chlorine Sulfur Dioxide Gas Concentration Range The Chloralert Plus uses frequency to transmit the sensor/transmitter information to the receiver. The accuracy for any given concentration is then determined by the concentration used for calibration

20 Outputs The output of the sensor/transmitter is wired directly to a terminal block in the receiver so care should be taken that the sensor is correctly connected to the receiver (refer to section 2.4). If the sensor/transmitter is connected incorrectly, no damage will occur but the LED indicator on the sensor/transmitter will not light and the LCD display on the receiver will indicate BAD ID. The output of the sensor/transmitter consists of two multiplexed frequencies which provide information for ambient temperature and sensed gas concentration. Refer to section for additional information Power Consumption Nominal power requirement for the sensor/transmitter is approximately 0.5 watts per individual sensor Sensor Cross-Sensitivity The sensor may also be responsive to gases in sampled air other than the target gas. The degree of the sensitivity may cause an error in the concentration reading of the target gas. Table 3-1 below shows the typical concentration errors to be expected when a chlorine sensor is exposed to the indicated concentrations of interference gases. Gas Table 3-1 Gas Cross-Sensitivity Data Concentration (ppm) CF Equivalent (ppm) Carbon Monoxide Hydrogen Sulphide 15 approx Sulphur Dioxide 5 0 Nitric Dioxide 35 0 Nitrogen Dioxide 5 approx. 5 Hydrogen Hydrogen Cyanide 10 0 Hydrogen Chloride 5 0 Ethylene Receiver Sensor response to an instantaneous change of 50% relative humidity would be a chlorine equivalent of approximately +/-0.5 ppm lasting for 2 minutes with no permanent effect. Longerterm changes in relative humidity (>5 minutes) have no effect Input Voltage The receiver is designed to operate on any voltage between 93.5 and 276 Vac without the need for the customer to make adjustments should he decide to change voltage sources. The sensor/transmitter is powered by the receiver Power Requirements Overall system power requirements range from 10 to 14 watts and varies depending on which system features are activated. Optional backup power is available to provide power during AC power losses. Battery life is at least 24 hours with all sensors and options active. Battery charge is automatically maintained by the receiver and no operator intervention is required

21 Receiver Outputs The outputs of the receiver fall into two categories Analog - gas concentration data as a linear current output Digital - relay contact-closure Analog Outputs (AO) An optional 4-20 ma or 0-20 ma analog output linearly proportional to sensed gas concentration is available on terminal block TB1 for each sensor channel. The analog output specifications are given below: Feature Specification Max. Number 4 Rated Signal Range 0-20 ma or 4-20 ma Control Range ma No-Load Voltage to 24 V Load Range 900 ohms Filter Time Constant 50 ms Output Measurement Error < +/ ma Temperature Coefficient < +/-0.02 ma/ C The analog outputs are not isolated since they all share the same circuit common return point (Refer to Figure 2-4) Digital Outputs (DO) Three SPDT relay outputs are standard on the Chloralert Plus main circuit board. Access to normally open (NO) and normally closed (NC) contacts is provided via terminal block TB2. A circuit board with an additional six output relays with SPST normally open (NO) contact arrangement is available as an option to provide additional alarm functionally, if desired. Contact outputs are available on TB1. The inputs that control the digital output (DO) relays are selected by the operator using the receiver s SETUP-CONFIGURATION-DIGITAL OUTPUTS mode (Refer to section ). The Chloralert Plus is able to be configured by the customer to allow control of all DO s by a single input or to allow each DO to be controlled by a different input. The operator should maintain a listing of the functions assigned to each digital output. The need for separate relays for each channel depends on the device connected to the relay and the location of the various sensor/transmitters. If each of these is mounted remotely in different locations then each channel requires dedicated relays to alert attending personnel of a gas release. The normal/delayed option allows the operator to cope with output surges that are due to electrical pickup rather than a genuine gas exposure. This mode is only important whenever the alarm is set to instantaneous concentration, not TWA or STEL. This alarm delay may be used to eliminate alarms during power-up (refer to section 4.3), thereby eliminating false alarms Keypad Push-button The keypad contains a total of 20 push-button arranged in a 4-row x 5-column matrix. The keypad layout is shown in Figure

22 1 ABC 2 DEF 3 ALARM GHI 4 JKL 5 MNO 6 ACK DATA PRS 7 TUV 8 WXY 9 LETTER SETUP QZ 0 ENTER Figure 3-1 Chloralert Plus Keypad Operating Modes The following four modes of operation may be selected: RUN - displays concentration data SETUP - setup menu ALARMS - active alarm/events queue DATA - historical alarm/events queue When the power is first applied, the unit activates in the RUN mode. In this mode, the display shows active gas concentration information. SETUP, ALARM, and DATA modes can be selected by pressing the appropriate key on the front panel keypad. These keys are used to toggle between the respective modes and RUN. Since the RUN mode has no key associated with it, PRESSING THE RESPECTIVE MODE KEY AGAIN RETURNS THE UNIT TO THE RUN MODE. For example, in order to return to RUN mode from any of these operating modes, the user must press the current mode key again (i.e., if in SETUP mode and the SETUP key is pressed, the operating mode returns to the RUN mode). CAUTION In SETUP, ALARMS, and DATA modes, gas-monitoring continues to take place even though concentration values are not shown on the display. However, when in SETUP, initiation of CALIBRATION, SELF-TEST, or SENSOR CHECK functions will temporarily suspend normal gas-monitoring Password When the receiver initializes to the default parameters, password-protection is disabled and the operator must automatically enter the SETUP menu by pressing the SETUP key. Password-protection may be enabled, if desired, by entering the SETUP mode and selecting the CONFIGURE-INSTRUMENT-CHANGE PASSWORD menu item (Refer to section 4.4). The user may then enter a numerical or alphanumerical password. If password-protection is enabled, the user will be required to enter his password whenever attempting to enter the SETUP mode

23 Display Modes The receiver has a 2 line, 20 character per line LCD display with a character height of 0.19 in. (4.86 mm). The display mode may be selected as either AUTO or MANUAL using the CONFIGURATION menu in the SETUP mode. If an alarm occurs with the display in either mode, the display will change to the 4-channel summary mode automatically. The difference between the AUTO and MANUAL modes is described below: MANUAL- Advance through the available channel display (if more than one channel is active), including the 4-channel summary, by pressing the right or left arrow keys. AUTO- Automatically scrolls through the available channels, advancing to the next channel every 3 seconds, but skips the 4-channel summery Two types of data displays are possible in the RUN mode: 4-channel Summary Single-channel Summary When using the 4-channel summary display, each line is divided into two 10-character groupings, one for each channel. This display mode is not available if the AUTO display mode has been selected. Channel number, gas identification and instantaneous gas concentration in ppm are displayed simultaneously as shown below: 1 CL O CL NH 0.12 The single-channel display mode shows the same data for the selected channel in addition to the channel s 10-character TAGNAME, short-term exposure limit and either time-weighted average (TWA) or custom gas concentrations (depending on which has been selected). A typical display is shown below: CH1 TAGNAME 1.23 STEL: TWA: 7.89 When in operation, the instrument selects the appropriate display mode using the following guidelines: Single-Channel Display a. If only one CHANNEL is active (refer to section ) b. If MANUAL mode is selected to show a single CHANNEL c. During alarm if only one CHANNEL is active 4-Channel Summary a. If all CHANNELS are OFF b. If MANUAL mode is selected to show the 4-CHANNEL summary c. During alarm if more than one channel is active. If desired, the arrow keys may be used to select the single-channel display mode to show information for the CHANNEL in active alarm. If in single-channel mode, the display reverts to the 4-channel summary mode if a second alarm occurs

24 Watchdog Timer Circuit The watchdog circuit is intended to let the operator know that the microprocessor has stopped running. The circuit requires a constant input pulse from the microprocessor that only occurs during proper operation. If the input pulses stop for more than a second, the watchdog circuit will disable all of the relays and cause the display backlight to flash. In the event that this should happen, restore normal operation by momentarily removing and re-applying AC power from the unit thereby allowing the unit to cycle through its start-up procedure Self-Test An optional self-test feature is available in the SETUP-CONFIGURE-INSTRUMENT-SELF TEST menu item. This feature permits testing of the functional integrity of the receiver and some of its electronics. This test causes the system to be checked for basic operation and proper output. Once initiated, it operates automatically without further operator intervention (except for the keypad test where user-action is required) as long as the appropriate data was entered in the SETUP-CONFIGURE-INSTRUMENT-SELF TEST menu item. The self-test sequence verifies that the unit is operating properly and is divided into two sections: Standard - runs on all units Extended - requires entry of the Configuration Code (refer to section ) CAUTION In SETUP, ALARMS, and DATA modes, gas-monitoring continues to take place even though concentration values are not shown on the display. However, when in SETUP, initiation of CALIBRATION, SELF-TEST or SENSOR CHECK functions will temporarily suspend normal gas-monitoring Standard Tests The standard test sequence that is performed on all units is as follows: SELF-TEST DISPLAY SELF-TEST KEYPAD SELF-TEST NVRAM SELF-TEST RAM SELF-TEST DIGITAL OUTPUTS The test runs automatically once initiated, however, user-action is required as the keypad self-test is performed. The user is prompted to press the appropriate keypad buttons in the sequence from upper left to lower right on the keypad. The display will indicate which button is to be pressed. Once the keypad self-test is completed, the test will resume automatic operation Extended Tests In order for extended tests to be run on optional instrument configurations, a CONFIGURATION CODE must be entered. The CONFIGURATION CODE indicates the receiver s configuration. The CONFIGURATION CODE must be entered in the SETUP-CONFIGURE-INSTRUMENT-ENTER CONFIG CODE menu item prior to

25 initializing the self-test procedure. It is an 8-digit code, with each digit being either 1 or 0, depending on whether an option is present or not. The positions of the digits to be entered correspond to the options below: 4 ANO 6DO RS232/ RS485 Comm Ext. Battery Kit CH1 CH2 CH3 CH4 To enter the proper configuration code, enter a 1 in the position corresponding to the option if that option is present. (Be certain to enter only the digit 1, any other entry will be interpreted as a 0 by the system.) Enter a 0 if the option is not present. For example, the CONFIGURATION CODE for a receiver with 4 analog outputs, RS232 communication, and external battery kit, and 1 sensor connected to S1+ and S1- terminals on the sensor interface TB3 (Refer to figure 2-3 or 2-4) is shown below: ENTER CONFIG CODE The last four entries in the CONFIGURATION CODE correspond to the sensor channels in the instrument that have the ability to perform the optional SENSOR CHECK routine. Entries in these positions are only required to run the sensor check (refer to section ) and are not required for the SELF-TEST to function properly. If the configuration code that has been entered indicates that the appropriate option is present, the extended self-test routine will be performed in the following sequence: NOTE: Rx and Tx need to be connected for communications ports self test to work. SELF-TEST ANALOG OUTPUTS SELF-TEST OPTL DIGITAL OUTPUTS SELF-TEST COMMUNICATIONS PORTS SELF-TEST BATTERY Self-test Failure Messages Most tests simply exercise the hardware and do not detect an error, and therefore, do not generate an error message. The messages for the tests that do detect failure are given below. The test will stop at a failure and wait to the ENTER key to be pressed in order to proceed with the remaining tests. The self-test may be run in two modes: Single Repeat The SINGLE mode performs the SELF-TEST sequence only once, then returns the unit to the RUN mode if no problems occurred

26 The REPEAT mode continues to cycle through the SELF-TEST sequence until terminated by the operator. When in REPEAT mode, the DISPLAY and KEYPAD self-tests are only performed during the first cycle and are skipped thereafter. In REPEAT mode, the display indicates the number of successful passes through the self-test cycle. If an error occurs while in REPEAT mode, the self-test will stop and the display will flash and indicate the nature of the error and the cycle-number during which the error occurred, as shown below: NVRAM FAILURE PASS COUNT = 3 RAM FAILURE PASS COUNT = 3 COMM PORT FAIL PASS COUNT = 3 BATTERY FAILURE PASS COUNT = 3 The operator may record the error and continue the REPEAT mode by pressing the ENTER key. At the end of each cycle, the user is given the option to exit the REPEAT mode by pressing the ENTER key. This capability is indicated on the display as shown below: PRESS ENTER TO STOP PASS COUNT = 21 Normal sensor data-processing is interrupted when in the self-test mode, therefore it is recommended that the use of the REPEAT mode be limited to isolating a suspected problem area by testing it multiple times. Once the problem had been investigated or confirmed, press ENTER to exit the SELF-TEST REPEAT mode Sensor Check The Chloralert Plus includes an optional SENSOR CHECK feature that may be used to verify the integrity of the sensor and its associated electronics. This check may only be performed on channels that have been configured with the optional sensor check gas generator (refer to Parts Lists ). The channels on which the check will be run must be selected by making the appropriate entry in the last four digits of the configuration code (refer to section ). NOTE In order for the SENSOR CHECK to function properly, the sensor CHANNEL must contain the optional SENSOR CHECK gas generator and the channel entries in the CONFIGURATION CODE must correspond to the channels on the sensor interface terminal block (TB3) to which the sensors are wired. For example, if a single-sensor system has its sensor wired to S3+ and S3- on TB2, then the 1 entry in the CONFIGURATION CODE must be placed in the CH3 position, otherwise an error will result. The ten minute test consists of generating a test gas using the sensor check gas generator and detecting the gas with the sensor. If the generated test-gas is detected within a certain concentration range, the test is considered successful and the unit will automatically revert to the RUN mode. The sensor check test is valid whenever the background concentration exceeds 0.5 ppm

27 CAUTION Initiation of the sensor check feature will temporarily suspend normal gas-monitoring. The sensor check may be run in two modes: Manual Auto MANUAL mode requires only that the proper CHANNEL(S) be selected as described above. When the operator is ready to run the check, TEST NOW is selected from the SETUP- CONFIGURE-INSTRUMENT-SENSOR CHECK-MANUAL menu and the checking begins immediately. Selecting AUTO from the SENSOR CHECK menu performs the check in a periodic manner. This allows the SENSOR CHECK to run automatically to start at a pre-determined time and to be performed at specific intervals. If AUTO operation is desired, entries must also be made for the START and INTERVAL parameters (refer to section for parameter entry format). Once all entries have been made, selecting ENABLE will activate the AUTO mode. When in AUTO mode, a power failure occurring during SENSOR CHECK will cause it to be terminated. It will restart automatically after the power failure when the next start time is reached. For example, if the unit is programmed to start SENSOR CHECK at 2 PM and a power failure occurs at 2:01 PM, the next SENSOR CHECK will be performed the following day at 2 PM, assuming power has been restored. Results of the SENSOR CHECK are logged in the event-queue for later retrieval. Typical messages that would appear during and after the SENSOR CHECK are shown below. These messages would alternate with the displayed gas concentration data resulting from the gas supplied by the SENSOR CHECK. Display of the SENSOR CHECK results lasts for five minutes after the SENSOR CHECK is complete: 1 SENSCHK 2 SC PASS 3 SC FAIL 4 CL 3.45 Where SENSCHK = Sensor Check in Progress SC PASS = Sensor Passed Sensor Check SC FAIL = Sensor Failed Sensor Check In the event that a channel indicates a problem as a result of performing this test, refer to section 7.0 for troubleshooting or maintenance procedures. A sensor check failure will not shut the unit down. Once the results of the sensor check have been cleared from the display, normal operation will continue Calibration Mode Before running the calibration procedure, the operator must configure the unit for calibration using the CONFIGURE-CHANNELS-CALIBRATION menu selection by selecting the span, concentration and zero for each channel intended to be calibrated. The sequence that occurs when RUN CALIBRATION is selected is shown in section 5.0. Calibration can be aborted at any time by pressing the SETUP-STOP CALIBRATION function. Calibration is conducted automatically by exposing the sensor to the calibration gas for up to 5 minutes once the receiver has been placed in the RUN CALIBRATION mode (refer to section 4.4). The receiver will evaluate the incoming signal and determine if its value and the response times are in the proper ranges. The receiver then has the option to accept or reject the calibration based on that comparison. This mode of calibration can be achieved even when the sensor/transmitter is remotely located and only one person carries out the calibration. The LED indicator located on the sensor/transmitter body will indicate whether a calibration has been accepted or not. The operator will know immediately whether or not the calibration

28 has been successful without having to return to the receiver. The receiver s display will also provide this information when the operator returns to the receiver once all sensors have been calibrated. This method of calibration permits a single operator to carry out all the calibration by setting the instrument to RUN CALIBRATION and exposing the sensor to the calibration gas without opening the sensor/transmitter or having to make adjustment at either the receiver or the sensor/transmitter. Calibration sources are connected to the sensor such that during calibration the gas feed to the sensor is completely controlled. Calibration is aborted if: A power failure results in loss of power to the sensor/transmitter A level alarm occurs between selecting RUN CALIBRATION and activating the sensor s magnetic switch The watchdog timer detects a microprocessor malfunction during calibration Refer to section 5.0 for a detailed description of the calibration process Security and Safety Password The receiver may be configured so that entry of a password is required to gain entry to the SETUP menu (refer to section ). This may be desirable to prevent accidental or malicious change of programmed information Watchdog Timer A processor watchdog timer monitors processor operation and determines if a failure has occurred (refer to section ). Processor malfunction during calibration results in the calibration being aborted. Should this occur, the old calibration data is retained while the display indicates information regarding the nature of the problem Power Failure A loss of power results in two modes of operation: Units with battery backup - normal operation continues uninterrupted Units without battery backup - the units will shut down and start up automatically, without alarms, when power is restored Units with battery backup will automatically switch to battery power in the event of a main power failure and the unit will continue to operate in its normal mode Battery Operation During normal AC powered RUN mode operation, the battery condition (if so equipped) is checked every hour on the hour. The state of the battery may be seen by checking the SETUP- CONFIGURE-INSTRUMENT-BATTERY STATUS menu selection. Under certain conditions, the display backlight will be shut off to conserve power or signal a faulty battery. These conditions are: If an AC power failure is detected If AC power is present but the battery is determined to be faulty The battery will provide power for the unit for a minimum of 24 hours in the event of a power failure. Refer to section for more information on backup battery operation status Operational Alarms Operational alarms may occur during the monitoring of the ambient air in the RUN mode. The alarms automatically appear in a quadrant of the LCD display, the location depending on which sensor channel caused the alarm condition