Flammable gases Detectors Model DAX 03F DAX 03F- C DAX 03F- H Note for installation, use and maintenance Version 1.2
Introduction This handbook must be read carefully by any person who has or will have the responsibility for the installation, the use or the maintenance of this product. Warranties provided by DALEMANS will be null and void if installation, use or maintenance of this equipment is not carried out in accordance with this manual's instructions. By respecting these instructions you guarantee your safety and that of the occupants of the buildings or the installations to be protected. Do not hesitate to contact us for any information about the use or maintenance of this product, if possible BEFORE you install it. Each apparatus must be installed, used and maintained according to the instructions, the warnings and the operational limits detailed in this manual. Use only DALEMANS original parts when you assume the maintenance of this product as described in this manual otherwise the performances of the apparatus may be seriously impaired. Any repair or maintenance carried out without observing the procedures described in this manual or without the assistance of our after-sales service could prevent the material from working properly and, consequently, from ensuring the safety of the building occupants. Make sure to always switch off power before carrying out modification operations. Utilization The DAX 03F is a gas detector intended for use in industrial and commercial sectors where potentially explosive atmospheres, zone 1 and 2, can be created. It is designed to react before the gas concentration in the air reaches its Lower Explosive Limit (LEL). Certification - Standards As a manufacturer, Dalemans Company declares that the products described in this note are certified for the hazardous areas on a IP6x ingress protection degree against dust, corresponding to the non aggressive indoor environments, and that it fulfills the requirements of the following directives and standards: 94/9/CE EN 50014 EN 50018 EN 50281-1-1 The indicated product is in conformity with the type tested by the notified body N 0080 (INERIS). Moreover, a total quality assurance is guaranteed by a certified ISO9001 quality system, in accordance with appendix II, paragraph 3 of 90/936/EC directive. 1
Marking Notify body identification code Type x II 2GD EExd EEx IIC d T6 IIC IP6X T6 INERIS03ATEX0126 S/N D3F3GAAB-03001037-2003 Device reference 0492 DALEMANSS.A. rue Jules Mélotte, 27 DAX 03F 4350 remicourt, Belgium Ta : -20..+55 C Un : 2,0V In : 180mA Sensor : DAL17 EEx Classification II : apparatus group for use in flammable atmosphere 2 : category (flammable atmosphere present intermittently) GD : nature of atmosphere (Gas & Dust) EEx d :explosion protection mode (flameproof enclosure) IIC : gas grouping (methane, propane, ethylene, hydrogen, acetylene) T6 : temperature classification T6 - T85 C T4 - T135 C IP6X : ingress protection degree EC type examination approval Nr Serial Nr/year of production Ta : ambient temperature Un : nominal voltage In: nominal current Sensor : type of cell Description The main element of a detector is its measuring cell working according to the principle of catalytic combustion. The cell is made of two electrically heated (400 C) platinum filaments. One of these is covered with an active catalytic layer which has the property to very strongly warm up when it comes in contact with a combustible gas (natural gas, methane, butane, propane, hydrogen, other hydrocarbons, ). This rise in temperature causes an increase in the resistance of the filament which we measure in our central unit. The second filament is used as a passive thermal compensator. The DAX 03F gas detector is composed of two ATEX certified elements: The detection head: enclosure containing the measuring cell The junction box containing the connection terminal block of the detector. Like the whole range of our products, the DAX 03F is approved to the European standards into force by official organizations such as INERIS, ISSEP,... detection head body cell detection head cap o-ring sintered metal filter Diagram 1: Detection head 2
3 Diagram 2: Box, DAX 03F-C
4 Diagram 3: Box, DAX 03F
5 Diagram 4: Box, DAX 03F-H
Installation Positioning the detector Below, you will find a series of recommendations which it is preferable to follow in order to avoid a premature ageing of the detector and to guarantee its optimal operation. IEC 60079-14 standard will also help you in that. These two references are not exhaustive. Consider the following factors when selecting the location to install the detector: The surrounding air: - The detector cannot be in contact with silicones. The risk to be in contact with water or steam. The detector cannot be: - Directly above or below a water point. - Outdoor without any protection against the rain. The unit weight of the gas to be detected: - If the gas is lighter than air, place the detector at the ceiling. - If the gas is heavier than air, place the detector close to the floor. - If the gas unit weight is close to the air unit weight, place detectors at the ceiling and close to the floor. Temperature: - Note that the density of a gas increases if the temperature goes down. - The detector cannot be in places where temperature is outside of its operating range. - For outdoor installation, provide a protection against exposures to direct sunlight. The level of risk of accident. The room ventilation. The detector cannot be: - In air currents. - Near to an air extractor. - Directly in ventilation ducts. Easy access to the detector must be provided because it will have to be handled during installation and also during maintenance operation. Its localization must be determined by specialists having the required knowledge. DALEMANS s.a. will be glad to help you in this operation. Detectors locations must be recorded and available for the personnel implied in the safety procedure. Agreement of the installation or any modification of the installation will have to be delivered by an approved organization. Mounting the detector For DAX 03F-H, refer to the note of installation delivered with this type of box. For mounting the detector, use the outer flanges or the fastening channels outside the sealing lip of the junction box. If a metric screw is used, maximum diameter will be M5. If a wood screw is used, the maximum diameter will be 5 mm. For DAX 03F-C, screw head diameter cannot exceed 7.5 mm. The detection head should never be installed pointing upwards. Make sure that water or dust will not block the filter of the detection head and prevent gas from reaching the detector cell. 6
Startup The startup must be carried out by the manufacturer or his local representative. All the operations described hereafter can be carried out only by specialized personnel who will have been trained beforehand exclusively by Dalemans Assembling - Disassembling Replacement of the filter The head of detection is made up of three elements: The detection head body The detection head cap The sintered metal filter To replace the sintered metal filter: Unscrew the detection head cap Replace the worn filter by a new one Screw up the detection head cap Make sure that the detection head is still correctly fastened to the junction box Calibrate the detector Replacement of the detection cell Because the detection cell is sealed in the detection head body, its replacement can only be achieved by changing the whole detection head. To replace the detection head: Inhibit the function of the detector and disconnect it from the detection central unit Open the junction box by removing the screws from the four corners of the lid Disconnect the wires of the detection head from the terminal block inside the junction box Unscrew the detection head fastening nut inside the junction box Fasten the new detection head to the junction box Connect the wires of the detection head on the terminal block inside the junction box Close the junction box Turn on detector power supply and restore its function Calibrate the detector The detection head is shown on page 2 diagram 1 Maintenance (according to Atex directive - appendix II art. 1.0.3.) Regularly remove dust from the detection head and the junction box. To do so, only use a WET rag in order to limit the risk of electrostatic discharges. To mitigate the loss of sensitivity of the detection cell, the explosive gas detection equipment must be calibrated at least once a year, in some cases three to four times a year or even more. This calibration is carried out by the manufacturer or his local representative, with a calibration gas according to the gas to be detected and its explosive limits. See "Assembling - Disassembling" above for replacement of the filter and the detection cell. 7
Wiring Wiring must comply with the local regulations in force. Use a 3 wires cable with sections between 1.5 mm² and 2.5 mm² and a different color for each wire. The section of the wires can vary according to the type of cell which is used and to the distance between the detector and the central unit (refer to the wiring instructions of the central unit). For DAX 03F-H, refer to the installation note of the junction box for stripping the cable, for connection and for earthing the case. Cable Stripping Sealing sheath MAX 8mm 15mm 100mm Diagram 4: cable stripping Wires must be stripped so that the gap between insulation and the metallic edge of terminal connection does not exceed 1mm distance. Cable gland must be tightened on the outer sheath of the cable. Terminal block Open the junction box by removing the 4 screws from the lid. The connection terminal block is inside the junction box. C E N T R A A P C active: RED passive: BLUE common: WHITE C E L L L Diagram 5: connection terminal block 8
+v DAX 03F red DC DC white zero blue ov Diagram 6: Electrical connections Calibration The calibration must be carried out according to the rules of use and by qualified personnel trained by Dalemans exclusively. The detector must have been powered on for 10 minutes before beginning calibration. For the three following steps, it is essential that the atmosphere has no influence on the detector. If the surrounding conditions require it, apply pure air to the cell. Detector power supply adjustment according to its characteristics (see table of cells for characteristics) Zero adjustment on Wheatstone bridge Calibration of the detector To perform a suitable calibration : After power supply has been applied to the detector, the central unit must be powered on for at least 10 minutes. Use a calibration gas mixture : 2,5 % CH4-97,5 % dry air, i.e. 50 % LEL. Apply calibration gas to the detector at a flow rate of 1,5 l/min for a large room and 0,5 l/min for a small room. If necessary, adjust gain according to the calibration gas concentration. In the example above, the reading should be 50 % LEL. Detector must be calibrated in accordance with gas concentration to be measured 9
Specifications Dimensions Detection head Material Junction box Filter Weight Output signal* Power consumption* Operating voltage* Operating temperature Ambient Humidity Intermittent, non-condensing Pressure Ingress Junction box protection Detection head Junction box Approval Detection head Standards Zone Gas grouping DAX 03F-C Polyester 0.5 W 2.5 V -10 to +40 C IP65 IP6X DAX 03F Polyester Stainless steel 1.4404 (316L) 0.4 W 2 V -20 to +55 C 20 % to 90 % RH 10 % to 99 % RH 90 to 110 kpa IP66 IP6X II 2GD EEx e II T6 II 2GD EEx d IIC T6 DAX 03F-H Aluminium 670 g 950 g 1200g mv Wheatstone bridge II 2GD EEx ed IIC T6 See diagrams Stainless steel 1.4404 (316L) EN50014, EN50018,EN50281-1-1 1, 2, 20 and 21 IIA, IIB, IIC 0.4 W 2 V -20 to +90 C IP66 IP6X II 2GD EEx d IIC T5 II 2GD EEx d IIC T4 * Can vary according to type of cell. Warnings This apparatus is not suitable for use in : atmospheres with more than 21 % oxygen. atmospheres with less than 15% oxygen. atmospheres where oxygen rate is variable. Refer to the local or national regulation relating to the site or the monitored equipment. The operator must have the required knowledge on the actions to take if the gas concentration exceeds the level of alarm. The modification, the disassembling and the total or partial destruction of the detection head and its contents, of the junction box and its contents or of the installation, can involve the invalidation of the whole installation. In particular, no additional drilling is permitted on the junction box of the detector. The existing openings cannot be enlarged. The cable gland can be replaced only by an original part delivered by Dalemans. The connection terminal block inside the case can be replaced only by an original part delivered by Dalemans. No additional contact can be added to the existing connection terminal block. The length of the wires connecting the detection head to the junction box cannot be modified. 10
Precautions Don't open the junction box or the detection head if there is a risk of explosion. Only clean or wipe the detector with a WET rag. Atmospheres higher than 100% LEL can destroy the detection cell in the long run. The detector must be protected from any risk of mechanical impacts The cell can become unusable after long periods of exposures to poisons such as silicones, halogens, heavy metals... Spare parts DAX 03F-C DAX 03F DAX 03F-H Sintered metal filter Junction box Detection head Instructions Manual M20 cable gland Connection terminal block M20 O-ring MEC00000010 BOI00000135 DET00000008 IMP00000005 PRE00000018 BOR00000067 MEC00000012 MEC00000010 BOI00000130 DET00000008 IMP00000005 PRE00000023 BOR00000066 MEC00000012 MEC00000010 BOI00000136 DET00000008 IMP00000005 PRE00000024 BOR00000070 MEC00000012 Troubleshoot The detector gives a non-zero measure : There can be some gas in the atmosphere. Make sure it is not a flammable gas. The detector gives a non-zero measure even though there is no gas in the atmosphere : Adjust zero on the control unit. The detector gives a measure too high or too low : Adjust gain on the control unit. The detector gives a zero measure although there is gas in the atmosphere : Check connections. Make sure that the sintered metal filter is not blocked by dust. Replace the detection cell if pollution has been detected. 11
Glossary EEx e : Increased safety in compliance with european standards EN50014 and EN50019 applying to electrical apparatus in which electrical arcs and sparks do not occur in normal service and in which surface temperatures are controlled below incendive values. EEx d : Flameproof in compliance with european standards EN50014 and EN50018. An enclosure that withstands internal explosion pressures and doesn't transmit any flame to the outside hazardous atmosphere. LEL (Lower Explosive Limit) : maximum gas concentration in the air below which the air-gas mixture can not explode. 94/9/CE : European Council and Parliament directive (23 march 1994) on the approximation of the laws of the member states concerning equipment and protective systems intended for use in potentially explosive atmospheres. EN50014 : Standard applying to electrical apparatus for potentially explosive atmospheres - General requirements. EN50018 : Standard applying to electrical apparatus for potentially explosive atmospheres - Flameproof enclosure "d". EN50019 : Standard applying to electrical apparatus for potentially explosive atmospheres - Increased safety "e". EN50270 : Standard concerning electromagnetic compatibility and applying to electrical apparatus for the detection and the measurement of combustible gases, toxic gases or oxygen. EN50281-1-1 : Standard applying to electrical apparatus for use in presence of combustible dust - Electrical apparatus protected by enclosures - Construction and testing. Table of cells Type DAL-50A DAL-55A DAL17 DAL30 VQ21 DC Current (ma) DC Voltage (V) Power (W) Use 150 ~ 170 160 ~ 180 175 +/- 20 300 +/- 20* 300* +0.050 2.5-0.100 2.0 +0.025-0.075 2,0 +/- 0,1 0.43 0.45 0.35 0.6 0,75 DAX 03F-C DAX 03F + DAX 03F-H * Ensure that the current doesn't exceed the limits of the characteristics of the central unit. 12
Environment The crossed-out wheelie bin logo on this product indicates that you are held to respect the regulation in force on the collection and recycling of waste electrical and electronic equipments. These provisions are intended to preserve the natural resources used for manufacturing this product and to avoid the dispersion of substances potentially harmful for the environment and human health. Therefore, to dispose of your end-of-life product, you MUST hand it over to a designated collection point for the recycling of electrical and electronic equipments. For further information about the collection points in your area, contact your local city office. 13
Notes 14
Rue Jules Mélotte, 27 4350 Remicourt - Belgium Tel: + 32 (0) 19 54 52 36 Fax: + 32 (0) 19 54 55 34 email: internet: info@dalemans-detection.com www.dalemans-detection.com Gas detection