Operation Manual Infrared Hydrocarbon Gas Detector SGOES 80016-001 Information and technical data disclosed in this document may be used and distributed only for the purposes and to the extent specifically authorized by ESP Safety Inc. ESP Safety Inc. Reserves the right to change published specifications and designs without prior notice.
Table of Contents INTRODUCTION 4 ORDERING GUIDE 4 SPECIFICATIONS OF SGOES 5 OPERATIONAL CHARACTERISTICS 5 ELECTRICAL CHARACTERISTICS 5 MECHANICAL CHARACTERISTICS 6 APPLICATION 7 OPERATIONAL DESCRIPTION 7 OPERATION CONCEPT 7 OPTICS PROTECTION 8 EXPLOSION PROOF INTEGRITY 8 IMPORTANT SAFETY INFORMATION 8 TRANSPORTATION AND STORAGE 8 PROTECTIVE COVER 8 INTERNAL OPTICS HEATER 8 CAUTIONS AND WARNINGS 10 PHYSICAL INSTALLATION 11 GENERAL WIRING REQUIREMENTS 12 CABLING GUIDELINES 12 24 VDC REQUIREMENTS 12 EARTH GROUNDING 12 POWER CONDUCTOR SIZE AFFECTS CABLE LENGTH. 12 USING SGOES WITH ESP SAFETY UPES MULTICHANNEL CONTROLLER 13 SGOES TO UPES INTERCONNECT 13 SGOES 3 WIRE INTERFACE METHOD 13 SGOES RS-485 MODBUS DIGITAL INTERFACE (DAISY CHAIN) 14 TABLE 1- DESCRIPTION OF FUNCTION AND INDICATIONS AVAILABLE ON THE REAR PCBA 15 INSTALLATION REVIEW PRIOR TO STARTUP 16 STARTUP PROCEDURE 16 HART DEDICATED CONNECTOR 16 RS-485 MODBUS DIGITAL COMMUNICATION AND OPERATION 17 ESP-COMMANDER SOFTWARE 17 CALIBRATION PROCEDURES 17 METHODS OF PERFORMING CALIBRATION 17 CALIBRATION PROCEDURES SGOES OPERATION CONCEPT REVIEW 18 NON-INVASIVE MAGNETIC WAND CALIBRATION PROCEDURE 18 REQUIRED EQUIPMENT FOR NON-INVASIVE MAGNETIC CALIBRATION. 18
NON- INVASIVE CALIBRATION PROCEDURE WITH HART COMMUNICATOR 19 REQUIRED EQUIPMENT FOR HART COMMUNICATOR CALIBRATION PROCEDURE 19 HTTP://WWW.HARTCOMM.ORG 19 RS-485 MODBUS CALIBRATION 21 LAUNCH ESP COMMANDER 21 AVAILABLE FUNCTIONS FOR ESP COMMANDER 21 ANALOG OUTPUT CONFIRMATION 23 APPENDIX I: CALCULATING VALUES 24 SGOES NOMINAL STATIC CONVERSION FORMULA 24 TABLE I-A GAS MEASUREMENT SCALE RANGE 25 TABLE IB-GAS FLASH POINT TEMPERATURES 25 APPENDIX II: ANALOG +4 TO 20MA OUTPUT VALUES BY GAS 26 APPENDIX III RECOMMENDED CALIBRATION GAS MIXTURES 27 APPENDIX V: LOCATION OF THE INSTALLATION SITE 29 APPENDIX VIII: CROSS CONTAMINATION 32 APPENDIX IX: TROUBLESHOOTING 33 APPENDIX X: WARRANTY 34
Introduction ESP Safety Inc. designs and manufactures affordable safety products and protection solutions for industrial safety and fire protection. Our company is committed to partner with our customers, contractors, and Architects in their design process to create a system that best meets the specification. After the system is installed, ESP Safety offers customer assistance via Telephone, Email, or Instant Message. On site commissioning services and field support are available to ensure and maintain the protection of lives and infrastructure in hazardous environments. Our line of industry-leading products, services, and systems benefit society, save lives, and preserve capital resources. Ordering Guide SGOES can detect a number of Hydrocarbon based Gases and Vapors. It can be easily changed for detecting a different gas in the field. For simplicity of ordering and eventual installation, the SGOES is factory prepared and ordered for detection of eight user specified gases. SGOES Model to Order Detected Hydrocarbon Scale Range %LEL Inclusion volume fraction % SGOES-CH4 Methane 0 to 100 0 to 4.4 ± 5% (in the range 0 to 50%LEL) SGOES-C3H8 Propane 0 to 100 0 to 1.7 ± 5% (in the range 0 to 50%LEL) SGOES-C4H10 Butane 0 to 50 0 to 0.7 ± 5% LEL SGOES-iC4H10 Isobutane 0 to 50 0 to 0.65 ± 5% LEL SGOES-C5H12 Pentane 0 to 50 0 to 0.7 ± 5% LEL SGOES-C5H10 Cyclopentane 0 to 50 0 to 0.7 ± 5% LEL SGOES-C6H14 Hexane 0 to 50 0 to 0.5 ± 5% LEL SGOES-C3H6 Propylene/Propene 0 to 50 0 to 0.1 ± 5% LEL SGOES-CH3OH Methanol Vapor 0 to 50 0 to 0.1 ± 5% LEL SGOES-C2H5OH Ethanol Vapor 0 to 25 0 to 0.78 ± 5% LEL 0 to 50 0 to 1.55 ± 5% LEL Limits of Basic Absolute Error Absolute Relative ± 10% (in the range 0 to 100%LEL) ± 10% (in the range 0 to 100%LEL) Introduction Page 4 of 34
Specifications of SGOES Operational Characteristics Gases that can be detected Gas Detected Range Accuracy Response Time (For 100% LEL Methane) Humidity Range Warm Up Time Operating Temperature Storage Temperature Ingress Protection Methane, Propane, Butane, Pentane, Hexane, Isobutane, Cyclopentane, Ethanol. (The target gas is factory configured according to customer request.) 0 to 100% LEL (lower explosive level in air) ±3% LEL, for 0 to 100% LEL 50% full scale < 1.9 seconds 60% full scale < 10.5 seconds 90% full scale < 14.5 seconds Up to 100%, non-condensing (Withstands up to 100% RH for short periods) 10 Minutes -60 o C to +85 o C -75 o C to +185 o C IP66 RFI/EMI Protection EN50081-1 / Class B E> 50270 *Operates with no interference from a 5 watt walkie-talkie keyed (transmitting) at 1 meter Status Indication Tri-color status LED indicates operational mode, fault, and gas Optional SGOES Receiver Displayed Information (Model SSS-903 Illuminated LCD Display) Explosion Proof Labels Electrical Characteristics Input Voltage Power Consumption Output From SGOES Alarm Relays presence. Continuous sensor data Gas Type Measuring Units Three Fixed Alarm Thresholds Graphic display of trending data for Peak Readings and Time- Weighted Average (TWA) of gas concentration 3-30 minutes Class I, Division 1 & 2, Group C & D T4 according to FM 3600. Ex d [ia Ga] IIC T6 Gb Ex d ia IIC T6 +24VDC Nominal (+18 to 32VDC) 7.9 W maximum +4-20mA industry standard analog with embedded HART Digital RS-485 MODBUS RTU HART interface with easy access dedicated connector 3 Dry Contact relays (NO/Form-A) All Relays Contact Rating 1Amp@125VAC/30VDC 2 User Programmed Alarm Relays 1 Fault Condition Relay Specifications Page 5 of 34
Mechanical Characteristics SGOES with the included Mounting Bracket is available in 2 Enclosure Construction Metals Cable Entry Weight With Bracket Physical Dimensions Vibration/Impact Optics Protection Wiring Stainless Steel Grade-316 Aluminum Alloy 2 Cable Entries ¾ NPT Stainless Steel Grade-316 6.5kg Aluminum Alloy 4.2kg 200x200x100mm Weather Proof Cover 14AWG Recommended Included Components SGOES orders when delivered from the factory include: SGOES gas detector Mounting Bracket Magnetic Calibration Wand Dust and Moisture Protective Housing Screw Clamp Connector Kit Gas Calibration Cover Available Options Calibration Kit with Zero and Span Gasses SSS-903 Remote Receiver with visual display of all operational and function characteristics plus LCD TWA display HART Connection Cable Specifications Page 6 of 34
Application Thousands of SGOES units are used in dangerously explosive areas of indoor and outdoor facilities providing reliable detection for a wide range of applications in accordance to IEC60079-14-96 The SGOES is explosion proof, making it the detector of choice for several environments. Industries that choose SGOES for combustible gas detection include: Drilling and Production Platforms Ocean Going Tankers and Vessels Fuel Loading Facilities Refineries Bulk Terminals and Tank Farms LNG/LPG Process and storage Facilities Compressor Stations Pipeline Facilities SGOES has a very low occurrence of false/positive alarms and is ideal for automated warning, control, and suppression system designs used in unmanned and centrally controlled applications. Non-invasive calibrations can be performed in the field using an included magnetic wand or a user supplied Hart communicator. An ESP Safety device driver is available for direct download from the Hart foundation. Calibration can also be performed with an included Windows PC application, ESP Commander. Operational Description The SGOES Combustible Gas Detector from ESP Safety measures the concentration of hydrocarbon gases present in the monitored environment. Each SGOES is factory calibrated to detect one of eight hydrocarbon-based gases (typically methane or propane). The SGOES will activate two alarms when the gas concentrations in the environment reach two independently programmed levels, which are expressed as a percentage of the lower explosive limit (LEL) in air. ESP has designed the SGOES to detect and quantify the presence of hydrocarbons by measuring their absorption of infrared light (IR). Because SGOES does not depend on the presence of oxygen in a mixture of gases, it can function effectively in environments where other sensor technologies cannot, thus it is the de-facto standard for oil platforms that commonly have air temperatures below 44 С, with high waves and ice buildups in excess of 5.5 ft. (170 cm). Moreover, SGOES is not sensitive to inadvertent detection of gases, such as nitrogen, oxygen, carbonic acid, ammonia, and hydrogen sulfide. This makes the SGOES an excellent choice for environments where non-hydrocarbon gases are present and precise monitoring of combustible hydrocarbons like methane and propane is required. All electronics are enclosed in an explosionproof aluminum or stainless steel housing that has been certified by FM-Approvals as an Explosion proof CLASS 1, Division 1 (Zones- 0,1,2 EU) device for use in hazardous locations as defined by the United States National Electric Code (NEC). Operation Concept Operation is based on selective signal disruption by hydrocarbon molecules when an infrared light source is reflected to an optical detector. If no gas is present, the detector will receive all of the energy radiated by the IR source and generating an electrical current. When gas molecules enter the collection chamber, each molecule of the gas blocks the IR energy reducing the output of the detector, which is then processed by the SGOES. Application & Operational Description Page 7 of 34
Optics Protection The weather baffle assembly is UV-resistant, static-dissipating black plastic. The standard is recommended for most outdoor and indoor applications, includes an internal hydrophobic filter Explosion Proof Integrity SGOES is designed to be explosion-proof thus SGOES units installed and in operation must not be modified in any form. All labeling must be intact and visible. All surfaces that are subject to disassembly or removal during installation or maintenance must be installed as detailed in Appendix I and comply with the FM3615 standard when replaced. The enclosure explosion protection marking is: Class I, Division 1 & 2, Group C & D, T4 according to FM 3600. SGOES Explosion proof means are detailed in Appendix VII of this document Explosion protection of SGOES is ensured by: Cabling entering into and out of the SGOES must utilize explosion-proof gland connections. The cable gland should be able to withstand explosion pressure and prevent spread of combustion into the hazardous area. The connection points are marked in the drawings with word Explosion and indicate permissible values of the explosion-protection parameters must comply with FM3615. Limit the enclosure outer temperature to no higher than 135 C. All the bolts securing the parts and enclosure must be sufficiently tightened and prevented from loosening by using spring washers or lock nuts. IMPORTANT SAFETY INFORMATION Be sure to read and understand the entire instruction manual before installing or operating the gas detection system. The products described in this document can be used with a variety of ESP-Safety gas detector models to provide early warning of the presence of a toxic or explosive gas mixture. Proper device installation, operation, and maintenance is required to ensure safe and effective operation. If this equipment is used in a manner not specified in this manual, safety protection may be impaired. TRANSPORTATION AND STORAGE SGOES as packed by ESP Safety Inc. can be transported by any transportation means. Should there be a high concentration of a Hydrocarbon based gas or a pollutant to which SGOES may have been exposed in transit or storage there should be no contamination of the unit if the packaging remains intact. Protective Cover The black protective cover is provided to prevent debris and water from entering the optics, while allowing gases and vapors to enter readily. Protective Covers are not field-serviceable, but are easily replaceable. The Protective Cover is furnished with a calibration gas nozzle for direct injection of gas to the sensor, allowing the operator to apply gas to the detector without going through the weather baffle. NOTE: Always cover the calibration gas nozzle with the cap during normal operation, and ensure that the cap is not damaged. Internal Optics Heater Each SGOES includes a heating system that will serve to keep the optics free of moisture and increase operating temperature range in extreme cold environments. Application & Operational Description Page 8 of 34
Certifications and Compliance Explosion-proof for Class 1, Div.1, Group B, C, D (T4) Hazardous (classified) locations per FM 3615, 6310 Dust ignition-proof for Class II, Div.1, Group E, F, G Hazardous (classified) locations per FM 3615, 6310 Non-incendiary for Class 1, Div.2, Group A, B, C, D (T4), Class 2, Div.2, Group E, F, G (T4) Hazardous (classified) locations per FM 3611 Performance verified up to 100% LEL methane-in-air atmosphere per FM 6320 Explosion-proof for Class 1, Div.1, Group B, C, D (T4) Hazardous (classified) locations per CSA C 22.2 # 30 and Ex d IIC T4 per CSA E 60079-0-1 Dust ignition-proof for Class II, Div.1, Group E, F, G Hazardous (classified) locations per CSA C 22.2 # 25 Non-incendiary for Class 1, Div.2, Group A, B, C, D (T4), Class 2, Div.2, Group E, F, G (T4) Hazardous (classified) locations per CSA C 22.2 # 213 Performance verified up to 100% LEL methane-in-air atmosphere per CSA C 22.2 # 152 CE 0539 II 2 G Ex d[ia] IIC T4 (Tamb IP 66 75 C) Ex d [ia] IIC T4 (Tamb 75 C) IP 66 1 Ex d [ia] IIC T4 X T= -60 C...75 C IP 66 EN Standards EN 60079-0: 2006 EN 60079-1: 2007 EN 61779-1: 2000 EN 60529: 1991+A1: 2000 EN 50270: 2006. Certifications & Compliance Page 9 of 34
Cautions and Warnings This user guide includes numerous cautions and warnings that are specifically included to prevent injury to personnel and prevent damage to equipment. Care is also taken to include notation of all applicable standards and best practices as appropriate information that may apply to any use or procedure associated with the product. WARNING: TOXIC, COMBUSTIBLE, AND FLAMMABLE GASES OR VAPORS ARE VERY DANGEROUS. USE EXTREME CAUTION WHEN THESE HAZARDS ARE PRESENT. WARNING: Take appropriate precautions, including wearing and use of protective clothing and devices when servicing the SGOES as they may have remnants of corrosive solutions Caution: The installation of SGOES must comply with relevant requirements of the latest edition of the national Electric Code (ANSI/NFPA 70) Caution: Connection Conduit, Barrier Glands, and Epoxy Sealants are to meet EN-50018/IEC 60079-1 Standards Caution: The SGOES detector has no user serviceable parts. If a problem should develop, refer to the Troubleshooting information in Appendix IX. If it is determined that the problem is caused by a manufacturing defect, please return the device to the factory for repair or replacement. Caution: Observe precautions for transport and handling of electrostatic sensitive devices. Caution: SGOES detectors have been tested and approved for use in hazardous areas. However, it must be properly installed and used only under the conditions specified within this manual and the specific approval certificates. Any device modification, improper installation, or use in a faulty or incomplete configuration will render warranty and product certifications invalid. Caution: ESP Safety Inc. Recommends use of shielded cable with 14AWG conductors reaching a span no greater than 6500 ft. (20000 meter) Cautions & Warnings Page 10 of 34
Physical Installation Step 1 (Optional) Locate and securely fasten the mounting Step 2 - Remove one explosion proof Conduit Plug using M16 Hex Wrench support bracket (supplied) in the location to be monitored with usersupplied hardware with power applied. This action is prohibited by regulations of operation in a hazardous area. Step 6 Reattach the SGOES body to rear flange cover. Step 7- The SGOES is to be horizontally mounted in the desired location with the Tri-Color status LED in a clearly visible position Step 3 Remove Rear Flange Cover at 3 locations indicated using M4 Hex Wrench cable Step 4 Attach a user supplied 3/4-inch conduit Gland conveying the appropriate Step 5 Locate the appropriate terminal set for the external control system. Refer to Table 1 for connections and functions X-1 X - X- 3 Caution: The SGOES contains some components that may be damaged by static electricity. Special care must be taken when wiring the system to ensure that only the connection points are touched. WARNING: Do not connect or disconnect the SGOES detector Physical Installation Page 11 of 34
General Wiring Requirements Caution: All cable/conduit entries must be sealed with an appropriate and certified sealing plug and cable gland. The use of industrial grade, armored field cable is recommended. Cabling Guidelines If installing connection cables in an explosion proof conduit, do not use the same conduit to carry wiring for any other purpose or equipment. Minimum 14 AWG (2.08 mm2) shielded cable conductors are required for optimal performance. The gauge of the wire used determines the maximum distance between the 24VDC (+/- 8VDC) power source. When using MODBUS, power and signal must be separate shielded twisted pair conductors 24 VDC REQUIREMENTS The SGOES detector has a power draw of 7.9 Watts in an active alarm state with all relays active. (Fault, Alarm1, Alarm2) Select a power supply with adequate capability for the calculated load. Ensure that the 24VDC (+/-8) power positive and common connections are from the same source. Warning: System ground must be provided at the point of origination for 24VDC. Failure to do this may result in loss of range and/or signal integrity. Avoid low frequency, high voltage, and nonsignaling conductors to prevent potential EMI problems. Earth Grounding The enclosure of the SGOES must be earthed/grounded for electrical safety and to limit the effects of radio frequency interference. An earth/ground point is provided on the outside of the SGOES Explosion Proof enclosure Use 14 AWG copper, (Stranded, or Solid), wire. Loosen the nut sufficiently to enable wrapping of the wire or wire terminated with a crimped lug around the thread in a U shape. Raise the flat and lock washers and place the wire between the 2 flat washers and ground base. *Note: Earth and System Grounds are separated to prevent ground loop potential plus maintain signal and current output integrity Power Conductor size affects cable length. The SGOES detector must receive a minimum of 24 VDC (+/-8VDC) to operate properly. Wire size requirements are dependent upon power supply voltage and wire length. Refer to Appendix IV for tables of estimated maximum cable runs based upon wire gauge. NOTE: For FM/CSA/ATEX Certified systems using HART communication, the maximum wiring distance is 600 meters / 2000 ft. There are several possible methods to electrically connect an SGOES that are determined by each users application. These can run from a single SGOES running on 24VDC that is operating as a isolated device and is connected directly to a warning system of alarms and/or lights to a network of devices that are connected in series providing RS-485 MODBUS, +4 to 20 ma, and relays to separate devices. Cautions & Warnings Page 12 of 34
Using SGOES with ESP Safety UPES Multichannel Controller The UPES Multichannel Controller is a standalone, rack mountable, controller that can also be interfaced to PLC (Programmable Logic Controller) or DCS (Distributed Control or SCADA) systems. The UPES is equipped with eight interface control modules that can be connected with 16 ESP Safety detection devices. SGOES to UPES Interconnect (In compliance with ANSI/ISA-S50.1-1982 Type 2) SGOES 3 Wire Interface Method (In compliance with ANSI/ISA-S50.1-1982 Type 2) Wiring Requirements Page 13 of 34
SGOES RS-485 MODBUS Digital Interface (Daisy Chain) Wiring Requirements Page 14 of 34
Table 1- Description of Function and Indications Available On The Rear PCBA Connection Receptacle X3 - Pins 1 and 2 Receptacle X3 Pins 3 and 4 Receptacle X3 Pins 5 and 6 Receptacle X3 Pins 7 and 8 Receptacle X4- Pins 1 and 2 Receptacle X4- Pins 3 and 4 Receptacle X4- Pins 5 and 6 Receptacle X4 Pins 7 and 8 Function Relay When Active- (Closed) Fault Indication also annunciated on the enclosure LED as Amber Always active as an output signal. Typical use is measured, as amperage, with Pin- 3 as signal ground and Pin-4 as amperage output with a range of 4 to 20 ma. RS-485 Digital MODBUS Connection Pin 5 is A / Pin 6 is B DC Power Input Pin 7 is common (GND), Pin 8 is +24VDC Alarm 2 Relay When Active- (Closed) Fault Indication also annunciated on the enclosure LED as Red Alarm 1 Relay When Active- (Closed) Fault Indication also annunciated on the enclosure LED as Red RS-485 Digital MODBUS Connection Pin 5 is A / Pin 6 is B DC Power Input Pin 7 is common (GND), Pin 8 is +24VDC Receptical & Connector Pinouts & Functions Page 15 of 34
Installation Review Prior to Startup Once the mounting, cabling, and alarm relay installation has been completed, the SGOES is ready to begin the power-on sequence. Before applying power to the system for the first time, review the steps below: Verify that the SGOES has been properly mounted. Ensure that all conduit / cable gland entries have been tightened and sealed if necessary. Verify that all of the signal wires have been installed correctly. Verify connection of earth/ground to the enclosure. Verify the connections between the SGOES housing and any control room devices and alarm systems. Make sure to turn off or disconnect any external devices, such as Trip Amplifiers, PLC devices or DCS systems, until after the startup sequence has been completed. Once you are ready to begin startup, verify that the power supply is connected properly and verify input voltage with the SGOES disconnected at the source. The SGOES is powered by 24 VDC. Startup Procedure Before the initial power up, remove power from or disconnect all output devices and alarms to prevent actuation. Apply power to the system. Upon first power-up, the SGOES +4-20mA output will be 8mA. Relays for alarm and fault will be in the Active State (relay contacts closed). The Tri-State Status LED will cycle Red, Green Yellow, indicating self-test is being performed. After 40 to 60 seconds the self-test initialization sequence will be completed. At this time the unit will be in the normal operational state will relays off (Open) and Status Indicator Green. Allow the SGOES to warm up for 10 minutes for detection of accurate gas level measurements. If the detected area is gas free, the +4 to 20mA will output +4mA. Digital Data Communication The SGOES provides three digital communication methods: HART (Highway Addressable Remote Transducer) accessible via a dedicated connector that is located on the SGOES housing. Digital RS-485 MODBUS-RTU (Remote Terminal Unit) HART over +4 to 20 ma output HART Dedicated Connector HART is a bi-directional communication protocol that provides data access between intelligent field instruments and host systems. In most applications for SGOES the host is an ESP-Safety specific software application available from the HART Foundation for use on a technician's hand-held HART communicator device. A HART system in considered non-invasive in that the SGOES does not have to be opened or removed from a field installed location. HART communicators and RS-485 devices can access: Information detected gas type The measuring range in PPM or LEL% Value of current gas concentration State and programming of fixed alarm thresholds Calibration Zero Cal Address of the SGOES as used by RS-485 Download of Non-Volatile Memory Start Up Proceedure & Digital Data Communication Page 16 of 34
RS-485 MODBUS Digital Communication and Operation The MODBUS interface is used for communication to all ESP Safety Detector models. Up to 480 devices can be connected in a Networked system. MODBUS RTU protocol uses ASCII/Hex data for communication and allows all SGOES functions to be transmitted using this method. MODBUS protocol is a Master-Slaves protocol, meaning a single Master Device (PLC, SCADA, ESP SSS- 903 Receiver, ESP-UPES Controller, or a Windows PC with ESP Commander Software) will send a message to each device to poll, or ask it, for available information, which the device will then return. Each device has a unique identifying address (Set by the user with a HART device or ESP Commander Software) The MASTER device will talk to each device individually at an interval that is also set by the user (Thus the term Poll ) MODBUS is a registered trademark of Schneider Automation Inc. ESP-Commander software SGOES with SSS-903 Receiver By incorporating the SSS-903 the user can have a graphic display for all functions of SGOES plus alarm indications and HART interface. SSS-903 and the SGOES communicate via MODBUS and receive power by using a serial Daisy Chain connection method. Calibration Procedures Warning: Trained staff must perform all calibration procedures. The calibration procedure work area must be a safe distance from any hazardous gas or material. Follow all site safety operating procedures before removing any detector from service. Methods of Performing Calibration There are three methods available to perform calibration of the SGOES Using RS-485 MODBUS with the ESP- Commander control Program (Remote or Bench Test Method) Using a HART Communicator (Non-invasive In Field or Bench Test Method) Using a Magnetic Wand (Noninvasive In Field or Bench Test Method, No Instrument or tools required) Non-Invasive Magnetic Wand Calibration Procedure Warning: All alarms must be disconnected to eliminate the possibility of erroneous alarm activation when performing this procedure Caution: Before the calibration and verification procedure, inspect the SGOES for any mechanical damages to the enclosure and/or elements. Please contact the ESP Safety Inc. service department for further information. The MODBUS interface can also be connected to an ESP-Safety SSS-903 Receiver. RS-485 MODBUS Digital Communications Page 17 of 34
Calibration Procedures SGOES Operation Concept Review The SGOES gas detector operates on the principal of selective absorption of radiation by hydrocarbon molecules. Primary components of the SGOES gas detector consist of optoelectronic and data input compartments within an explosion-proof enclosure. The data input compartment houses infrared sources and receivers along with the signal conditioning electronics. Infrared emissions penetrate into an unsealed compartment where the gas mixture is analyzed. A mirror reflects the infrared emission back into photo detectors in the data input compartment. The signal is amplified and processed for conversion to an output with a current range of 4 to 20 milliamps. The amperage of the output corresponds to a range of measured gas concentrations of 0 to 100% LEL (lower explosive level). Output signals from the SGOES gas detector are available from the clamp terminals mounted inside the explosion-proof data input compartment. WARNING: Do not connect or disconnect the SGOES detector with power applied. This action is prohibited by regulations of operation in a hazardous area. Non-Invasive Magnetic Wand Calibration Procedure Non-Invasive Zero set and Calibration up can be performed on SGOES detectors when installed in the permanent location by using a magnetic Wand included with every SGOES order.. Required Equipment for Non-Invasive Magnetic Calibration ¼ PVC Tubing ESP Safety Zero Gas and Span Gas disposable canister for the appropriate gas. ESP Safety Magnetic Wand Step 1 Remove the dust and moisture protective housing from the SGOES by twisting it in a counterclockwise direction STEP 2 Place the calibration cup onto the SGOES collection chamber with the nipples oriented horizontally. Step 3 Connect the nipple of Sensor s collection chamber to the Zero Gas Cylinder with PVC tubing and purge the SGOES with approx. 1 LPM of Zero gas. (Approx 1 minute) Step 4 While still applying Zero Gas; place the magnetic wand on the SGOES sensor body magnet mark. The Calibration indicator will begin flashing Green after 1 second indicating Calibration Function has started. At this point all alarms have been disabled. Step 5 Place the Wand again to begin Zero Calibration The Indicator will flash RED. If the purge step has been performed this step can be completed after 30 seconds Step 6 Change to the Span Gas Cylinder. Start a flow at 1-2 LPM. Place the Wand after gas has begun flowing to start the Span Gas Calibration. The indicator will begin flashing Green. Step 7 After 4 minutes of Span Gas flow, place the Wand to the sensor to complete the process. The status indicator will glow steady green for normal operation with alarms enabled. Note: If a Span Gas is not detected after 3 minutes the test will automatically abort returning SGOES to normal operation. Magnetic Bangle Calibration Page 18 of 34
Non- Invasive Calibration Procedure With HART Communicator Required Equipment For HART Communicator Calibration Procedure ¼ PVC Tubing ESP Safety Zero Mid Span and Span Gas disposable canister for the appropriate gas. User Supplied Hart Communication Device ESP Safety Hart Connection Cable, Hart Device driver for ESP Safety Products *Available from the Hart Foundation Website http://www.hartcomm.org Step 1 Load the ESP device description driver per the HART device User Guide. Connect the communicator to the HART interface socket of the SGOES using the ESP Safety supplied cable. Apply Power to SGOES and allow it to warm up for at least 10 minutes if it has been powered down. Then turn on the HART. Double Click the HART symbol to establish communication between the devices Step 2 The HART display will cycle through a test mode then change ask for information to create a file of the procedure in the HART Communicator. This can be performed or skipped at the user s choice. To exit the File Storage menu select SAVE. Step 3 HART will now change to the SGOES HOME menu when communication is established. SGOES is automatically determined when the HART and SGOES establish a communication link. THE SGOES menu has the following information that has been sent by the SGOES: 1 Hart Test 2 Device Setup 3 Gas Type: Gas type the detector is programmed for. 4 PV: Present value in %LEL or PPM detected by SGOES 5 SV: First Alarm (Relay) threshold 6 TV: Second alarm threshold 7 4V: Internal Temperature 8 PV Loop Current: Current loop output. Note: Clicking on the pulsing heart will call the help menu Note: Before proceeding: Remove the Protective Cover and install the Calibration Cup. Connect the ZERO gas supply tubing to the nipple of the Cal cup and begin a Purge with Gas flowing at 1-2 LPM for one minute. Note: In the following steps follow the menu prompts on the HART device HART Calibration Page 19 of 34
HART Calibration Menu Tree Magnetic Bangle Calibration Page 20 of 34
RS-485 MODBUS Calibration Several RSP Safety detectors can be calibrated remotely in the field or on a test bench using ESP Commander Note: The following example is for Propane only. Follow the same steps for the gas to be calibrated. Step 1: Before the initial power up, remove power from or disconnect all output devices and alarms to prevent actuation. Apply power to the system. Upon first power-up, the SGOES +4-20mA output will be 8mA Relays for alarm and fault will be in the Active State (relay contacts closed) The Tri-State Status LED will cycle Red, Green Yellow, indicating self-test is being performed. After 40 to 60 seconds the self-test initialization sequence will be completed. At this time the unit will be in the normal operational state will relays off (Open) and Status Indicator Green. Allow the SGOES to warm up for 90 minutes for detection of accurate gas level measurements during calibration procedures. Launch ESP Commander Software Program must be installed on the user supplied PC interfaced to the user supplied RS-485 to USB converter. Select The COM port for the link between the PC and converter ESP Commander will scan for all devices connected (via MODBUS communication protocol) Select the device to be calibrated by ESP Commander Operating Screen Display and Function Available Functions For ESP Commander Device Model Device relay state Device Address Version Serial Number Device Address Assignment Detection Gas Calibration Values Alarm Values Graph of Alarm events Recording of Real Time Data Polling Interval RS-485 MODBUS Calibration Page 21 of 34
Note: The following example is for Propane only. Follow the same steps for the gas to be calibrated Use the pull down to select the gas to match the labeling on the sensor. The gas pull down is pre-programmed with the required LEL for the selected gas. The LEL for Propane is 5% of volume. 5% of Volume equals 100% LEL In this example, as per the labeling on the cylinders, the Zero Gas is Nitrogen, The Span Gas is approx 4.9% of volume and the Mid Span Gas is 2.5% of volume. Enter the highest Span gas value as Pri. Conc- % Vol and the Mid Span as 2.5. After one minute, the Vol. Conc. And LEL windows of ESP Commander should read zero or close to it. Click on the Zero icon to complete the zero cal procedure. If measuring Current loop, the output will equal 4.0mA after setting Zero Cal The Status LED on the SGOES Enclosure will illuminate Green Turn of the Gas Flow on the Zero Cal cylinder when completed. Step 4 SPAN GAS CALIBRATION Attach the Span Gas Cylinder with the mixture value as required. Start a flow into the Calibration cup of 1LPM. After about 60 seconds, the real time display count will level at out approximately 4.9% for Vol. Conc and 98%LEL. The Current loop output will equal 19.6mA. The Alarms will have become active as the thresholds are crossed. The LED on SGOES will turn Red when the first threshold is passed. Turn off the Gas flow from the cylinder before disconnecting any tubing. Step 5 MID SPAN CALIBRATION A second gas with a mixture equal to 50% LEL may be used for calibration of mid span. This would be the value set into the SEC. CONC. %Vol window. Step 2: ALARM THRESHOLDS Next enter the Alarm thresholds in %LEL by entering the value into the edit cells then clicking SET Step 3: Connect tubing between the Zero gas cylinder and SGOES inlet nipple. Using the Zero Gas Cylinder, purge the cup and SGOES detector by passing one Liter of Zero Gas into the sensor. Note when using the ESP Safety Calibration Kit, the preset flow can be dialed as liters per minute (LPM) thus a purge using a flow of 1LPM will take approximately one minute. Attach the Mid Span Gas Cylinder with the mixture value as required. Start a flow into the Calibration cup. After about 60 seconds, the real time display count will level at out approximately 2.5% for Vol. Conc. and 50%LEL. The Current loop output will equal 12mA. The Alarms will deactivate, in this case the alarm set for 60% LEL the thresholds are crossed. The LED on SGOES will turn Red when the first threshold is passed. RS-485 MODBUS Calibration Page 22 of 34
Step 6: Turn off the Gas flow from the cylinder before disconnecting any tubing. Finally, remove the Calibration cup and allow the SGOES to normalize. At this point all alarms should be off. The Status LED will be Green. The Current Loop output will equal 4.0mA. ANALOG OUTPUT CONFIRMATION Zero Gas Confirmation of +4 to 20mA Values 1. An LEL value of 0.0% will correspond to a + 4 ma output reading. 2. During the initial warm-up period of 90 minutes, the 4mA output value should be periodically monitored to confirm the reading remains stable 3. (+4mA means no gas is detected) 4. It is not necessary to flow Zero gas during the entire warm-up period. If the environment is known to be free of any potential hydrocarbons, simply allow the detector to sit idle with gas off and power on and check periodically. 5. Remove the Protective Cover and attach the Calibration Cup. Span and Mid Gas Confirmation using +4-20mA. 6. Attach the Span Gas 7. Open the valve of the gas cylinder Allow the gas to flow for at least 2 minutes before checking the current output for LEL Range. 8. An LEL value of top range for the selected gas will correspond to a 20 ma output reading. If the %LEL of the target gas is not listed in Table IA consult Appendix I to calculate the expected current output value. Analog +4 to 20mA Confirmation of Calibration Page 23 of 34
Appendix I: Calculating Values SGOES Nominal Static Conversion Formula Nominal conversion of the SGOES employs the following formula: Ii =16Сi /CMAX +4 Ii is the output current value, in ma; Ci is the concentration value for the gas analyzed, % LEL C MAX is the maximum value of converted concentration, % LEL.). To determine the concentration of the detected gas in %LEL, calculate by the formula: Ci = 6.25(Ii-4) Under calibration with standard gas mixture, the measuring concentration of the detected component (in %LEL) is calculated by the formula: Ci = 100 Cpasp/Cp Cpasp is the value of the converted range of the detecting component concentration labeled on the cylinder of a specific control gas mixture Cp is the upper value of the converted gas range of the detecting component equaling 100% LEL Calculation of absolute error The absolute error is calculated using the formula: Са= Сi-Сd Сi gas analyzed indication under i is a control gas mixture in %vol and %LEL. Сd real concentration of detecting component under I control gas mixture supplying %vol and % LEL Example Using a control gas mixture labeled 61.7 LEL. The Calculated value %LEL resulted 60% LEL. Calculate the measurement error of absolute error: Са=61.7 LEL-60%LEL =1.7 LEL Thus the absolute error of this gas mixture is equal to 1.7 LEL. Relative error estimate of gas analyzer is calculated by formula: б= Сi-Сd/ Сdх100 using the above to determine absolute error. б=61.7-60/60х100=2.8% The calibration results are considered accurate if the basic error of gas analyzer calculated by the formulas given above in all calibrating points does not exceed limits of Table 1-A Appendix I: Calculation Values & Conversion Formulas Page 24 of 34
Table 1-A Gas Measurement Scale Range SGOES Model Detected Hydrocarbon Scale Range %LEL Inclusion volume fraction,% Limits of Basic Absolute Error Absolute Relative SGOES-CH4 Methane 0 to 100 0 to 5 ± 5% (in the range 0 to 50%LEL) SGOES-C3H8 Propane 0 to 100 0 to 2.1 ± 5% (in the range 0 to 50%LEL) SGOES-C4H10 Butane 0 to 50 0 to 0.7 ± 5% LEL SGOES-iC4H10 Isobutane 0 to 50 0 to 0.65 ± 5% LEL SGOES-C5H12 Pentane 0 to 50 0 to 0.7 ± 5% LEL SGOES-C5H10 Cyclopentane 0 to 50 0 to 0.7 ± 5% LEL SGOES-C6H14 Hexane 0 to 50 0 to 0.5 ± 5% LEL SGOES-C3H6 Propylene/Propene 0 to 50 0 to 0.1 ± 5% LEL SGOES-CH3OH Methanol Vapor 0 to 50 0 to 0.1 ± 5% LEL SGOES-C2H5OH Ethanol Vapor 0 to 25 0 to 0.78 ± 5% LEL 0 to 50 0 to 1.55 ± 5% LEL Table 1-B-Gas Flash Point Temperatures Detected Boiling/Vapor Point at Flash Point Hydrocarbon 1 atmosphere Methane (CH4) -165 O C -188 O C Propane (C3H8) -42 O C -104 O C Butane (C4H10) -0.5 O C -108 O C Isobutane -11 O C (ic4h10) Pentane (C5H12) 36 O C -49 O C Cyclopentane 49 O C -37 O C Hexane 69 O C -23 O C Propylene/Propene -48 O C -108 O C Methanol Vapor -64 O C 11 O C Ethanol Vapor NA 13 O C ± 10% (in the range 0 to 100%LEL) ± 10% (in the range 0 to 100%LEL) Appendix I: Table 1A Detection Ranges & Table IB Gas Flash Point Temperatures Page 25 of 34
Appendix II: Analog +4 to 20mA Output Values by Gas Gas Type Methane 0-5% Propane 0-2.1% Hexane 0-0.5% Butane 0-0.7% Isobutene 0-0.65% Pentane 0-0.7% Propylene 0-1.0% Cyclopentane 0-0.7% Correspondence of SGOES analog output under the different concentration of gas mixture. %/LEL 0%/0LEL 0.5%/10lel 1%/20lel 1.5%/30lel 2%/40lel 2.5%/50lel 3%/60lel 3.5%/70lel 4%/80lel 4.5%/90lel 5%/100lel 4 ma 5.6 ma 7.2 ma 8.8 ma 10.4 ma 12 ma 13.6 ma 15.2 ma 16.8 ma 18.4 ma 20 ma 0%/0LEL 0.21%/10lel 0.42%/20lel 0.63%/30lel 0.84%/40lel 1.05%/50lel 1.26%/60lel 1.47%/70lel 1.68%/80lel 1.89%/90lel 4 ma 5.6 ma 7.2 ma 8.8 ma 10.4 ma 12 ma 13.6 ma 15.2 ma 16.8 ma 18.4 ma 20 ma 0%/0LEL 0.1%/10lel 0.2%/20lel 0.3%/30lel 0.4%/40lel 0.5%/50lel 4 ma 5.6 ma 7.2 ma 8.8 ma 10.4 ma 12 ma 0%/0LEL 0.14%/10lel 0.28%/20lel 0.42%/30lel 0.56%/40lel 0.7%/50lel 4 ma 5.6 ma 7.2 ma 8.8 ma 10.4 ma 12 ma 0%/0LEL 0.13%/10lel 0.26%/20lel 0.39%/30lel 0.52%/40lel 0.65%/50lel 4 ma 5.6 ma 7.2 ma 8.8 ma 10.4 ma 12 ma 0%/0LEL 0.14%/10lel 0.28%/20lel 0.42%/30lel 0.56%/40lel 0.7%/50lel 4 ma 5.6 ma 7.2 ma 8.8 ma 10.4 ma 12 ma 0%/0LEL 0.2%/10lel 0.4%/20lel 0.6%/30lel 0.8%/40lel 1%/50lel 4 ma 5.6 ma 7.2 ma 8.8 ma 10.4 ma 12 ma 0%/0LEL 0.14%/10lel 0.28%/20lel 0.42%/30lel 0.56%/40lel 0.7%/50lel 4 ma 5.6 ma 7.2 ma 8.8 ma 10.4 ma 12 ma Methanol 0%/0LEL 0.55%/10lel 1.1%/20lel 1.65%/30lel 2.2%/40lel 2.75%/50lel 0-2.75% 4 ma 5.6 ma 7.2 ma 8.8 ma 10.4 ma 12 ma Ethyl alcohol 0%/0LEL 0.31%/10lel 0.62%/20lel 0.93%/30lel 0-0.78 4 ma 5.6 ma 7.2 ma 8.8 ma Appendix II: Analog Output Values By Gas Table Page 26 of 34
Appendix III Recommended Calibration Gas mixtures LEL 100% SGOES Analyzed Component 5% Methane (CH 4 ) 2.1% (1.167ppm) Propane (C 3 H 8 ) Calibration Gas Volumetric Fraction % %LEL Zero Mid Span Span Allowed Basic Error Limits for: Nitrogen 2.5±0.25 4.7±0.25 ±0.04% 0% LEL 50%LEL 94% LEL Nitrogen 1.05±0.05 1.9±0.16 ±0.015% 0% LEL 50% LEL 92% LEL 1.6% (0.77ppm) 1.6% (0.6723ppm) 1.5% (3.425 ppm) 1.1% (0.312ppm) 1.1% (0.312ppm) 2% (6ppm) 6 % (0.458PPM) Butane (C 4 H 10 ) Isobutane (i-c 4 H 10 ) Pentane (C5H12) Cyclopentane (C 5 H 10 ) Hexane (C 6 H 14 ) Propylene (C 3 H 6 ) Methanol (СН 3 ОН) Nitrogen 0.35±0.04 0.64±0.06 ±6 % 0% LEL 27.3% LEL 40%LEL Air 0.3±0.1 0.55±0.1 0%LEL 19%LEL 34.4%LEL ±0.03 % Air 0.35±0.04 0.63±0.07 ± 0.03 % 0%LEL 23%LEL 42%LEL Air 0.35±0.07 0.63±0.07 ± 0.03 % 0%LEL 32%LEL 55% LEL Air 0.250±0.025 0.45±0.025 ± 0.01% 0%LEL 23%LEL Nitrogen 0.50±0.05 0.90±0.1 ± 5 % 0.083%LEL 0.15%LEL Air 1.33±0.14 2.47±0.23 ± 5 % 0%LEL 34%LEL 41% LEL Scale Range (0-50) % LEL 17%LEL 20.5%LEL 3.3% (1.746ppm) Ethyl Alcohol (С 2 Н 5 ОН) Scale Range (0-25) % LEL Ethyl Alcohol (С 2 Н 5 ОН) Scale Range (0-50) % LEL Air 0.39±0.04 0.7±0.08 ± 5 % 22%LEL 5.5%LEL 40%LEL 10%LEL Air 0.75±0,08 1.40±0.15 ±5 % 21.5%LEL 40%LEL Note: All Calibration Gases are recommended to be a single Mixture of the volumetric fraction with the volume balance to be air or Nitrogen as indicated. Appendix III: Calibration Gas Mixtures Page 27 of 34
Appendix IV: Maximum Cable Lengths For Analog Connection *Using 24VDC Supply Wire Gauge Resistance Ω/100m Resistance /Ω Max Max Meters Max Feet 18 AWG (0.823mm 2 ) 2.14 17.12 800 2600 16 AWG (1.31mm 2 ) 1.34 17.42 1300 4200 14 AWG (2.08mm 2 ) 0.845 16.9 2000 6500 Appendix IV: Cable Length Page 28 of 34
Appendix V: Location of The Installation Site Caution: The customer must make the determination where to locate the SGOES detector to best perform the required detection as an FM-Class 1 device. ESP Safety recommends mounting the SGOES in a location that affords easy access for occasional inspection or repair. WARNING: Class I Locations- The SGOES Detector is FM-Global certified as an Explosion proof CLASS 1, Division 1 (Zones-0, 1, 2 EU) device for use in hazardous locations as defined by the United States National Electric Code (NEC). The United States National Electric Code (NEC) defines hazardous locations as those areas "where fire or explosion hazards may exist due to flammable gases, vapors, flammable liquids, combustible dust, ignitable fibers or flying ignitable debris. According to the NEC a class one device may be used in the presence of flammable gases or vapors in the air. An example would be natural gas or gasoline vapor. When these materials are found in the atmosphere, a potential for explosion exists which could be ignited if an electrical or other source of ignition is present. Some typical Class I locations are: Petroleum refineries Gasoline storage and dispensing areas Drycleaning plants where vapors from cleaning fluids can be present Spray finishing areas Aircraft hangars Fuel servicing areas Utility gas plants Operations involving storage and handling of liquefied petroleum gas or natural gas. Appendix V: Installation Location Page 29 of 34
Appendix VI: MAINTENANCE REQUIREMENTS Routine maintenance consists of regular visual inspections and zero adjustment for SGOES, as required by user site procedures. In case optical components have been highly contaminated rendering normal operation of SGOES impossible a fault condition will be set. Repeat start-up. If after 1 minute the output will not reach a value of 4 ma then fall back to zero value, it should be assumed that the collection and optic chamber are fowled. Turn off the power and clean the optical components with alcohol and a scratch resistant cloth or chamois. If a fault condition repeats contact the ESP Safety Service Department for assistance. Zero setting for SGOES should not deviate 2% to 3% of LEL after power on and warm up. This indicates a zero drift may have occurred. Contact the ESP Service Dept. for further instructions if this should occur. It is normal to perform a field Zero Calibration on the unit at the installed site. This can be easily performed with the magnetic wand. Refer to the calibration section of this manual for procedure. Appendix VI: Maintenance Page 30 of 34
Appendix VII Hart Menu Tree Appendix VII: Hart Menu Tree & Functions Page 31 of 34
Appendix VIII: Cross Contamination WARNING: Some gases, typically found in industrial environments, can cause a crossinterference response on the sensor. The table below provides some examples: GAS PPM GAS PPM3 Methane 25,000 = 0 Ammonia 500 = 1 Ethane 5,000 = 0 Diesel Fuel 1,000 = 0 Hexane 5,000 = 0 Dimethyl Sulfide 4.4 = 0 Propane 5,000 = 0 Ethylene 200 = 0 Butane 5,000 = 0 Freon 12 1,000 = 0 Carbon Monoxide 800 = 0 Hydrogen 1,000 = 8 Carbon Dioxide 5,000 = 0 Methyl Mercaptan 10 = 5 Carbon Disulfide 14 = 0 Sulfur Dioxide 300 = 0 Methanol 500 = 5 Toluene 32 = 0 Isopropanol 500 = 3 Ethanol 500 = 5 Appendix VIII: Cross Contamination Page 32 of 34
Appendix IX: Troubleshooting The SGOES is a very stable and reliable device that in most circumstances provides years of trouble free operation. If for any reason an unforeseen issue should arise, refer to the following table for possible solutions. Possible Problem Possible Source Remedy No Status LED No power supply Detach the base with the cable entry from the SGOES enclosure and make sure that the terminals are supplied with a voltage of 24±6 VDC. Appendix IX: Troubleshooting Page 33 of 34
Appendix X: Warranty Appendix X: Warranty Page 34 of 34