INSTRUCTION MANUAL Detcon Model FP-524D PGM MODEL 1 HOUSTON, TEXAS FP-524D MicroSafeTM LEL Gas Sensor FLT ALM ALM 1 2 CAL PGM 2 FP-524D Combustible Gas Sensor (0 – 100% LEL) DETCON, Inc. 4055 Technology Forest Blvd, Suite 100, The Woodlands, Texas 77381 Ph.281.367.4100 / Fax 281.298.2868 www.detcon.com April 22, 2014 • Document #3597 • Revision 1.
Model FP-524D Page left intentionally blank FP-524D Instruction Manual ii
Model FP-524D Table of Contents 1. 2. 3. 4. 5. 6. 7. 8. Introduction ..................................................................................................................................................1 1.1 Description.......................................................................................................................................... 1 1.2 Modular Mechanical Design.........................................................................................................
Model FP-524D List of Figures Figure 1 Sensor Assembly Front View ................................................................................................................ 1 Figure 2 Sensor Cell Construction ...................................................................................................................... 2 Figure 3 Wheatstone Bridge.................................................................................................................................
Model FP-524D 1. Introduction 1.1 Description Detcon Model FP-524D LEL Combustible sensors are non-intrusive “Smart” sensors designed to detect and monitor combustible gases in air. Range of detection is 0-100% LEL (Lower Explosive Limit). The sensor features an LED display of current reading, fault, and calibration status. The Sensor is equipped with a standard analog 4-20mA output.
Model FP-524D Alumina Bead Platinum Wire Catalytic Beads Main Housing Insert Catalyst Printed Circuit Board Gold Plated Pins Construction of Detector Bead Figure 2 Sensor Cell Construction Principle of Operation Method of detection is by diffusion/adsorption. Air and combustible gases pass through a sintered stainless steel filter and contact the heated surface of both the active and reference detectors.
Model FP-524D 1.2 Modular Mechanical Design The Model FP-524D Sensor Assembly is completely modular and is made up of four parts: 1) 2) 3) 4) FP-524D Plug-in Transmitter Field Replaceable Combustible Gas Sensor Connector PCB Splash Guard. FP-524D Plug-in Transmitter The Plug-in Transmitter Module is a microprocessor-based package that plugs into the connector board located in the explosion proof junction box.
Model FP-524D Replacable Sensor Threaded Insert O-ring Main Housing Figure 7 LEL Sensor Housing with replaceable Sensor NOTE: The Field Replaceable Combustible Gas Sensor housing is constructed from 316 Stainless Steel in order to maximize corrosion resistance in harsh environments. Base Connector PCB The base connector board is mounted in the Junction Box.
Model FP-524D 2. Installation 2.1 Operational Guidelines for Safe Use 1. Install sensor only in areas with classifications matching with those described on the approval label. Follow all warnings listed on the label. 2. Ensure that the sensor is properly mounted in a vertical orientation with sensor facing down. Avoid use of Teflon Tape, or any type of non-conductive pipe thread coating on the NPT threaded connection. All NPT connections should remain grounded to the junction box. 3.
Model FP-524D Leak Sources The most probable leak sources within an industrial process include flanges, valves, and tubing connections of the sealed type where seals may either fail or wear. Other leak sources are best determined by facility engineers with experience in similar processes. Ventilation Normal ventilation or prevailing wind conditions can dictate efficient location of gas sensors in a manner where the migration of gas clouds is quickly detected.
Model FP-524D the active detector’s catalytic ability and cause a permanent reduction in the span sensitivity. Examples of typical poisons are: silicone oils and greases, siloxanes (HMDS), H2S, anti-knock petrol additives, and phosphate esters. Activated carbon filters can be used to provide additional protection from poisoning in most cases.
Model FP-524D Proper electrical installation of the gas sensor is critical for conformance to Electrical Codes and to avoid damage due to water leakage. Refer to Figure 10 and Figure 11 for proper electrical installation. NOTE: If a conduit run exits the secondary port, repeat the installation technique shown in Figure 10. In Figure 10, the drain allows H2O condensation inside the conduit run to safely drain away from the sensor assembly.
Model FP-524D mA line when it is not being used. Wiring designations are DC+, DC-, and MA (sensor signal). The maximum wire length between sensor and 24VDC source is shown in the Table below. The maximum wire size for termination in the Junction Box is 14 AWG. Table 1 Wire Gauge vs. Distance AWG Wire Dia. Meters Feet 22 20 18 16 14 0.723mm 0.812mm 1.024mm 1.291mm 1.
Model FP-524D d) Plug the Transmitter Module into the connector PCB and replace the junction box cover. NOTE: A 6-32 or 8-32 threaded exterior ground point is provided on most junction boxes for an external ground. If the Sensor Assembly is not mechanically grounded, an external ground strap must be used to ensure that the sensor is electrically grounded. 2.
Model FP-524D This adjustment is only required after initial installation and will not be necessary thereafter, except in the event of replacement of the plug-in sensor. Refer to section 3.5.5 to perform this adjustment. NOTE: Refer to section 3.5.5 to set the sensor bridge voltage. 2.
Model FP-524D 3. Operation 3.1 Programming Magnet Operating Instructions The Operator Interface of the FP-524D Series gas sensors is accomplished via two internal magnetic switches located above and below the LED display (Figure 14). The two switches, labeled “PGM1” and “PGM2”, allow for complete calibration and configuration, thereby eliminating the need for area de-classification or the use of hot permits.
Model FP-524D 3.2 Operator Interface The operating interface is menu-driven via the two magnetic program switches located under the target marks of the sensor housing. The two switches are referred to as “PGM1” and “PGM2”. The menu list consists of three major items that include sub-menus as indicated below. (Refer to the complete Software Flow Chart.
Model FP-524D Software Flowchart Normal Operation PGM1 (3) PGM2 (3) PGM1 (3) PGM2 (3) Calibration Mode (Auto Zero) Calibration Mode (Auto Span) View Sensor Status Auto Time-Out PGM1/2 (M) PGM1/2 (3) Set AutoSpan Level Set Gas Factor Auto Time-Out PGM1/2 (M) PGM1/2 (3) AutoTime-out PGM1/2 (M) PGM1/2 (3) Set Cal Factor Auto Time-Out PGM1/2 (M) PGM1/2 (3) Model Type Version X.XX inc Range XXX ppm ## PGM1 (S) PGM2 (S) PGM1/2 (3) #.## PGM1 (S) PGM2 (S) PGM1/2 (3) inc dec #.
Model FP-524D 3.3 Normal Operation In normal operation, the display continuously shows the current sensor reading, which will normally appear as “0”. Once every minute, the LED display will flash the sensor’s units of measure and the gas type (i.e.”% LEL”). If the sensor is actively experiencing any diagnostic faults, a “Fault Detected” message will scroll across the display on the display once every minute instead of the units of measure and the gas type.
Model FP-524D 3.4.2 AutoSpan Material Requirements: -Detcon PN 327-000000-000 MicroSafe™ Programming Magnet - Detcon PN 613-120000-000 Splash Guard with integral Cal Port -OR-Detcon PN 943-000006-132 Threaded Calibration Adapter -Detcon PN 942-520124-050 50% LEL Methane in balance air (recommended) or other suitable span gas containing a certified level of % LEL concentration of combustible gas in air balance. A flow fixed rate of 200-500cc/min is recommended.
Model FP-524D as the display shows the sensor’s “as found” response to the span gas presented. If it fails to meet the minimum in-range signal change criteria within 2½ minutes, the display will report “Range Fault” twice and the sensor will return to normal operation, aborting the AutoSpan sequence. The sensor continues to report a “Range Fault” and will not clear the fault until a successful AutoSpan is completed.
Model FP-524D Alarm 1 Settings Alarm 2 Settings Fault Settings Navigating Program Mode From Normal Operation, enter Program Mode by holding the magnet over PGM2 for 4 seconds (until the displays starts to scroll “View Sensor Status”). Note, the “▼” prompt will show that the magnetic switch is activated during the 4 second hold period. The sensor will enter Program Mode and the display will display the first menu item “View Sensor Status”.
Model FP-524D Sensor Bridge Current The menu item appears as: “Bridge XXXmA” Sensor Bridge Voltage The menu item appears as: “Bridge X.XXVDC Gas Factor The menu item appears as: “Gas Factor X.XX” Cal Factor The menu item appears as: “Cal Factor X.XX” mA Output The menu item appears as: “mA Output XX.XX mA” Input Voltage Supply The menu item appears as: “Voltage XX.
Model FP-524D When the status list sequence is complete, the display will revert to the “View Sensor Status” text scroll. The user can either: 1) review list again by executing another 3-4 second hold, 2) move to another menu item by executing a momentary hold over PGM1 or PGM2, or 3) return to Normal Operation via automatic timeout of about 15 seconds (the display will scroll “View Sensor Status” 4 times and then return to Normal Operation). 3.5.
Model FP-524D Table 2 Gas/Cal Factors Gas Acetaldehyde Acetic Acid Acetic Anhydride Acetone Acetylene Alkyl Alcohol Ammonia n-Amyl Alcohol Aniline Benzene Biphenyl 1,3-Butadiene Butane iso-Butane Butene-1 cis-Butene-2 trans-Butene-2 n-Butyl Alcohol iso-Butyl Alcohol tert-Butyl-Alcohol n-Butyl Benzene iso-Butyl Benzene n-Butyric Acid Carbon Disulphide Carbon Monoxide Carbon Oxysulphide Cyanogen Cyclohexane Cyclopropane Factor 1.66 1.84 2.17 1.93 1.76 1.96 0.79 3.06 2.54 2.45 4.00 1.79 1.71 1.93 2.20 2.
Model FP-524D Set Cal Factor is used to make the appropriate signal sensitivity adjustment when the cal gas is a gas other than methane. This is necessary because the catalytic bead sensor has different signal strengths for each combustible gas and all reading calculations are made based on a reference to methane. The cal factor value is adjustable from 0.2 to 5.0. It represents the translation between the cal gas and methane gas, where methane has a normalized cal factor = 1.0.
Model FP-524D 3.5.6 Signal Output Check Signal Output Check provides a simulated 4-20mA output. This simulation allows the user to conveniently perform a functional system check of their entire safety system. This signal output simulation also aids the user in performing troubleshooting of signal wiring problems. The menu item appears as: “Signal Output Check”.
Model FP-524D AutoSpan: AutoSpan Settings are lost and user must perform new AutoSpan (Section 3.4.2). 3.5.8 Alarm 1 and 2 Settings The FP-524D has the ability to set alarm levels that are displayed on the front of the sensor via the LED’s ALM 1 and ALM 2. These alarm LEDs can be set as latching or non-latching. In non-latching mode, the LED is deactivated as soon as the sensor alarm condition is cleared. In latching mode, the LED remains active even after the alarm condition has cleared.
Model FP-524D Hold the magnet over PGM1 or PGM2 for 3 seconds to accept the new value (until the display starts to scroll “Saved”). Move to another menu item by executing a momentary hold, or, return to Normal Operation via automatic timeout of about 15 seconds (the display will scroll “Fault Settings” 4 times and then return to Normal Operation). 3.6 Program Features Detcon FP-524D combustible gas sensors incorporate a comprehensive set of diagnostic features to achieve Fail-Safe Operation.
Model FP-524D Zero Fault If the sensor drifts below –10% LEL, the “Zero Fault” will be declared. A “Zero Fault” will cause a “Fault Detected” message to scroll once a minute on the transmitter display and drop the 4-20mA output to 0mA. The sensor should be considered “Out-of-Service” until a successful AutoZero calibration is performed. Range Fault – AutoSpan If the sensor fails the minimum signal change criteria during AutoSpan sequence (Section 3.4), the “Range Fault” will be declared.
Model FP-524D 4-20mA Loop Fault If the sensor detects a condition where the 4-20mA output loop is not functional (high loop resistance or failed circuit function) a “4-20mA Fault” is declared. A “4-20mA Fault” will cause the “Fault Detected” message to scroll once a minute on the ITM display. If a Loop Fault occurs, the 4-20mA signal will be set at 0mA until the fault condition is resolved. If the 4-20mA current loop is still out of tolerance, contact Detcon at Service@detcon.
Model FP-524D 4. Service and Maintenance Calibration Frequency In most applications, quarterly to biannual zero and span calibration intervals will assure reliable detection. However, industrial environments differ. Upon initial installation and commissioning, close frequency tests should be performed, weekly to monthly. Test results should be recorded and reviewed to determine a suitable calibration interval. Visual Inspection The Sensor should be inspected annually.
Model FP-524D Replacement of the Connector PCB NOTE: It is necessary to remove power to the junction box while changing the connector PCB in order to maintain area classification. a) Remove the junction box cover and remove the transmitter module from the connector PCB. b) Remove the black, white, blue, and yellow wires coming from the combustible gas sensor from the connector PCB. c) Remove the output wiring from the connector PCB terminals labeled DC+, DC-, and MA.
Model FP-524D 5. Troubleshooting Guide Refer to the list of failsafe diagnostic features listed in Section 3.6.2 for additional reference in troubleshooting activities. Listed below are some typical trouble conditions and their probable cause and resolution path. Figure 16 Replaceable Combustible Gas Sensor Sensor Current/Voltage Fault Probable Cause: Plug-in sensor has failed Remove plug-in sensor and verify resistance between PIN 5 and PIN 7 and PIN 2 and PIN 4 using an ohmmeter.
Model FP-524D Probable Causes: Failed sensor, cal gas not removed at appropriate time, problems w/ cal gas and delivery, or Background combustible gases preventing clearing Confirm that no combustible gasses are present in background. Check bridge voltage (should be 2.7 +/- 0.2VDC). Check validity of span gas and flow rate (check MFG date on cal cylinder). Make sure correct cal factor and gas factor is set Check for obstructions through stainless steel sinter element (including being wet).
Model FP-524D Faulty 4-20mA Output If sensor has a normal reading with no faults displayed, and the 4-20 mA signal output is 0mA…. Check that wiring is properly connected at terminal blocks and through to controller inputs. The 4-20mA output loop must be closed (resistance of < 1000 ohms) to avoid the Loop Fault. Perform a “Signal Output Check” sequence via Section 3.5.6 and verify 4-20mA output with current meter.
Model FP-524D 6. Customer Support and Service Policy Detcon Headquarters Shipping Address: 4055 Technology Forest Blvd, Suite 100, The Woodlands Texas 77381 Mailing Address: P.O. Box 8067, The Woodlands Texas 77387-8067 Phone: 888.367.4286, or 281.367.4100 Fax: 281.292.2860 • www.detcon.com • service@detcon.com • sales@detcon.com All Technical Service and Repair activities should be handled by the Detcon Service Department via phone, fax or email at contact information given above.
Model FP-524D 7. FP-524D Sensor Warranty Plug-in Combustible Gas Sensor Warranty Detcon Inc. warrants, under normal intended use, each new plug-in combustible gas sensor (PN 370-201600000 (Uses p/n 365-037020-160 in shipping container)). The warranty period begins on the date of shipment to the original purchaser and ends 2 years thereafter. The sensor element is warranted free of defects in material and workmanship.
Model FP-524D 8. Appendix 8.1 Specifications Sensor Type: Continuous diffusion/adsorption type Matched-Pair Catalytic Bead type True plug-in replaceable type Sensor Life: 3-5 years typical Measuring Ranges: 0-100% LEL Accuracy/ Repeatability: ± 3% LEL in 0-50% LEL range, ± 5% LEL in 51-100% LEL range Response Time: T50 < 10 seconds, T90 < 30 seconds Performance Testing: Complies with CSA C22.2 No. 152-M1984, ANSI/ISA S12.
Model FP-524D 1000 ohms maximum loop load @ 24VDC 0mA All Fault Diagnostics 2mA In-Calibration 4-20mA 0-100% full-scale 22mA Over-range condition Status Indicators: 4-digit LED Display with gas concentration, full-script menu Prompts for AutoSpan, AutoZero, Set-up Options, and Fault Reporting Faults Monitored: Loop Fault, Input Voltage Fault, Zero Fault, Sensor Fault, Processor Fault, Memory Fault, Calibration Fault(s) Cable Requirements: Power/Analog: 3-wire shielded cable Maximum distance is 13,300
Model FP-524D 8.
Model FP-524D 8.3 Revision Log Revision Date 0.0 06/22/10 1.0 12/02/10 1.1 06/21/11 1.2 1.3 1.4 04/23/12 10/31/13 04/22/14 FP-524D Instruction Manual Changes made Initial Release Made previous section 2.7 into 2.8 and inserted new section 2.7. Added CSA note in section 3.4.2 and section 8.1. Revised note in section 3.5.5. Revised section 2.1. Changed spare part 365-037020-160 to 370-201600-000 and referenced that it is same part in shipping container Updated Section 2.6 Field Wiring, load resistor.
Model FP-524D Shipping Address: 4055 Technology Forest Blvd, Suite 100, The Woodlands Texas 77381 Mailing Address: P.O. Box 8067, The Woodlands Texas 77387-8067 Phone: 888.367.4286, 281.367.4100 • Fax: 281.292.2860 • www.detcon.com • sales@detcon.com FP-524D Instruction Manual Rev. 1.
