detcon inc. Detcon MicroSafe ™ IR-522 Combustible Hydrocarbon Sensor (0-100% LEL) Operator’s Installation & Instruction Manual December 2, 2013 • Document #2272 • Version 1.4 CAUTION: Before operating the Model IR-522 sensor, read this manual thoroughly and verify that the configuration of default factory settings are appropriate and correct for your application.
Table of Contents 3.0 Description 3.1 Principle of Operation 3.2 Application 3.3 Specifications 3.4 Operating Software 3.5 Installation 3.6 Start-up 3.7 Calibration 3.8 Status of Programming, Calibration Level, and RS-485 ID 3.9 Program Features 3.10 Display Contrast Adjust 3.11 Optical Sensor Replacement 3.12 Trouble Shooting Guide 3.13 Spare Parts List 3.14 Warranty 3.15 Service Policy 3.16 Software Flow Chart 3.17 Revision Log Model IR-522 Combustible Hydrocarbon Sensor PG.
.0 DESCRIPTION Detcon MicroSafe™ Model IR-522, combustible hydrocarbon gas sensors are non-intrusive “Smart” sensors designed to detect and monitor combustible hydrocarbon gas in air over the range of 0-100% lower explosive limit (LEL). One of the primary features of the sensor is its method of automatic calibration which guides the user through each step via instructions displayed on the backlit LCD. The sensor output is a standard 4-20 mA signal.
Porous Membrane H H H H C H C H H H Optical Sample Gas Chamber Optical Filter Optical Filter Reference Detector Active Detector Lamp 3.0.2 Microprocessor Control Circuit The control circuit is microprocessor based and is packaged as a plug-in field replaceable module, facilitating easy replacement and minimum down time.
3.0.4 Explosion Proof Enclosure The sensors are packaged in a cast metal explosion proof enclosure. The enclosure is fitted with a threaded cover that has a glass lens window. Magnetic program switches located behind the transmitter module face plate are activated through the lens window via a hand-held magnetic programming tool allowing non-intrusive operator interface with the sensor. Calibration can be accomplished without removing the cover or declassifying the area.
tained, excessive loss in useable signal eventually gives way to noise and unstable readings. The optical sensor may, over long periods of time (3-7 years), lose its IR lamp source filament, and in this case an optical sensor modular replacement is required. The IR-522 has an extensive list of Fault Diagnostics to alert and pin-point operational problems. See section 3.9.
Electrical Classification Class I; Groups B, C, D; Div. 1. Response Time T50 < 15 seconds; T90 < 35 seconds Clearing Time 90% < 35 seconds Repeatability ± 3% FS Range 0-100% (lower explosive limit) LEL Operating Temperature -40° to +175° F Accuracy ± 3% FS Sensor Warranty 5 year pro-rated Power Consumption Normal operation = 86 mA (2.1 watts); Max = 102 mA (<2.5 watts) Zero Drift < 5% per year Output Linear 4-20 mA DC Input Voltage 11-28 VDC 3.
3.4.3 Program Mode The program mode provides a program status menu, allows for the adjustment of alarm set point levels, and the selection of the calibration gas level setting.. 3.4.3.1 Program Status The program status scrolls through a menu that displays: * The gas type, range of detection and software version number. The menu item appears as: “LEL 0-100 V6.0” * The calibration gas level setting.
Density - Placement of sensors relative to the density of the target gas is such that sensors for the detection of heavier than air gases should be located within 2-4 feet of grade as these heavy gases will tend to settle in low lying areas. For gases lighter than air, sensor placement should be 4-8 feet above grade in open areas or in pitched areas of enclosed spaces.
4 3/4" 6 1/8" 5 1/2" 3/4" NPT 3/4" NPT Figure #2 8 1/4" 1/4" Dia. Mounting Holes Rainshield/ Splashguard 2 1/8" 2" Base Connector Board Figure #3 4-20 mA Output VDC Power In mA RED BRN WHT BLK YEL BLU Sensor 3.5.5 Remote Mounting Applications Some sensor mounting applications require that the gas sensor head be remotely mounted away from the sensor transmitter. This is usually true in instances where the gas sensor head must be mounted in a location that is difficult to access.
Remote Transmitter IR-522-RT Remote Sensor IR-522-RS Figure #4 56 1234 RED BRN WHT BLK YEL BLU RED BRN WHT BLK YEL BLU 3.6 START UP Upon completion of all mechanical mounting and termination of all field wiring, apply system power and observe the following normal conditions: a) IR-522 “Fault” LED is off. b) A reading of 0% LEL should be indicated upon conclusion of a 12 second “warming up” cycle. Note 1: If the display contrast needs adjustment, refer to section 3.10. 3.6.
A magnetic programming tool (see figure 5) is used to operate the switches. Switch action is defined as momentary contact, 3 second hold, and 30 second hold. In momentary contact use, the programming magnet is waved over a switch location. In 3 second hold, the programming magnet is held in place over a switch location for 3 or more seconds. In 30 second hold, the programming magnet is held in place over a switch location for 30 or more seconds.
NOTE 2: When a “cal fault” occurs, the sensor microprocessor retains its previous calibration references. Zero calibration is complete. 3.7.2 Calibration Procedure - Span CAUTION: Verification of the correct calibration gas level setting and calibration span gas concentration is required before “span” calibration. These two numbers must be equal. Calibration consists of entering the calibration function and following the menu-displayed instructions.
3.7.3 Additional Notes 1. Upon entering the calibration menu, the 4-20 mA signal drops to 2 mA and is held at this level until you return to normal operation. 2. If during calibration the sensor circuitry is unable to attain the proper adjustment for zero or span, the sensor will enter into the calibration fault mode which will activate fault alarm functions (see section 3.
Calibration Fault If during calibration the sensor circuitry is unable to attain the proper adjustment for zero or span, the sensor will enter into the calibration fault mode and cause the display to alternate between the sensor’s current status reading and the calibration fault screen which appears as: “CAL FAULT.2”. The following conditions will cause a calibration fault: 1 - Zero calibration cannot converge. 2 - Auto span cannot converge (too noisy or too unstable).
3.11 OPTICAL SENSOR REPLACEMENT PROCEDURE Should the optical gas sensor element (part number 370-365871-212) require replacement, use the following procedure: 1 - (A) If the sensor is mounted in a classified area, system power to the transmitter must first be removed before proceeding further. (B) If in an unclassified area, remove front enclosure cover and unplug transmitter module. 2 - Remove lower half of sensor housing using an alan wrench (3 screws).
Bad 4-20 mA output 1. Check that wiring is connected to correct terminal outputs. 2. Swap with a known-good transmitter to determine if transmitter is faulty Unstable output/Sudden Spiking/Nuisance Alarms 1. Check condulet for accumulated water. 2. Check transmitter and Terminal PCB for abnormal corrosion. 3. Determine if problem correlates with condensation cycles. 4. Add/change Detcon condensation prevention packet. 5. Check for unstable power supply. 6. Check for inadequate grounding. 7.
Programming Magnet Enclosure glass lens cover Plug-in control circuit Rain Shield Spash Guard Calibration Adapter IR Connector Board Enclosure less cover IR Sensor Housing Assembly Condensation Prevention Packet (replace annually) Field replaceable plug-in optical sensor 3.14 WARRANTY Detcon, Inc., as manufacturer, warrants each NDIR optical plug in sensor (part no.
3.16 SOFTWARE FLOW CHART AUTO ZERO LEGEND PGM1 - program switch location #1 PGM2 - program switch location #2 (M) - momentary pass of magnet (3) - 3 second hold of magnet (30) - 30 second hold of magnet INC - increase DEC - decrease # - numeric value AUTO SPAN PGM1 (3) PGM2 (3) CALIBRATION 1-ZERO 2-SPAN PGM1 (3) PGM1 (M) NORMAL OPERATION PGM2 (30) PGM2 (M) VIEW PROG STATUS SET CAL LEVEL PGM1 (3) PGM2 (M) PGM1 (3) PGM2 (M) PGM2 (3) PGM2 (3) LEL 0-100 V#.
