INSTRUCTION MANUAL Detcon Model TP-624D PGM MODEL 1 HOUSTON, TEXAS TP-624D MicroSafeTM H2S Gas Sensor FLT ALM ALM 1 2 CAL PGM 2 TP-624D Hydrogen Sulfide Sensor This manual covers the following ranges: 0-20ppm, 0-50ppm, and 0-100ppm DETCON, Inc. 4055 Technology Forest Blvd, Suite 100, The Woodlands, Texas 77381 Ph.281.367.4100 / Fax 281.298.2868 www.detcon.com March 10, 2013 • Document #3532 • Revision 0.
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Model TP-624D Table of Contents 1. 2. 3. 4. 5. 6. 7. 8. 9. Introduction ..................................................................................................................................................1 1.1 Description.......................................................................................................................................... 1 1.2 Modular Mechanical Design......................................................................................................
Model TP-624D List of Figures Figure 1 Sensor Assembly Front View ................................................................................................................ 1 Figure 2 Circuit Functional Block Diagram......................................................................................................... 2 Figure 3 Transmitter Module ...............................................................................................................................
Model TP-624D 1. Introduction 1.1 Description Detcon Model TP-624D hydrogen sulfide sensors are non-intrusive “Smart” sensors designed to detect and monitor H2S in air. Ranges of detection are 0-20ppm, 0-50ppm, and 0-100ppm. The sensor features an LED display of current reading, fault, and calibration status. The sensor is equipped with standard analog 4-20mA and ModbusTM RTU outputs.
Model TP-624D Principle of Operation Method of detection is by diffusion/adsorption. Air and H2S diffuse through a sintered stainless steel filter (flame arrestor) and contact the heated surface of the metal oxide sensor film. As hydrogen sulfide gas molecules react with oxygen ions on the film, there is a decrease in electrical resistance proportional to the gas concentration.
Model TP-624D The transmitter module includes four LED status indicators (see Figure 3). These indicators are labeled FLT, ALM1, ALM2 and CAL. The ALM1 and ALM2 LEDs are illuminated when the sensor is above the corresponding alarm threshold. The FLT LED is illuminated when the sensor is in fault. The CAL LED is illuminated solid when the sensor is completing an AutoSpan calibration.
Model TP-624D 1.3 Relay Outputs The TP-624D includes three 5A Form C relay outputs. Two of these relays are dedicated to alarm outputs, and the third is used to indicate when the sensor is in fault. The common and normally closed contacts on the alarm relays are connected when the gas concentration is below the alarm threshold. If the concentration exceeds the alarm threshold for more than five seconds, then the common and normally open contacts will be connected.
Model TP-624D 2. Installation 2.1 ATEX 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. DETCON, THE WOODLANDS, TEXAS, USA MODEL TP-624D RATED: 22-30VDC, 132 mA @ 24VDC DETCON, THE WOODLANDS, TEXAS, USA MODEL TP-624D RATED: 22-30VDC, 132 mA @ 24VDC detcon, inc. Date Code detcon, inc.
Model TP-624D 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 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. Note: H2S is heavier than air.
Model TP-624D The more common materials that potentially cause problems with the sensors are as follows: Silicone vapors such as those found in greases and lubricants Halide Compounds containing Chlorine, Chlorine Dioxide, Fluorine, HF, HCl, and Bromine Caustic and Acid liquids and concentrated vapors Heavy metals such as tetraethyl lead Heavy and complex VOC gasses The presence of such contaminants in an area does not preclude the use of this H2S sensor technology, although it is likely that the sensor li
Model TP-624D maintained to provide a solid electrical ground path. If Teflon Tape is used the Sensor must be externally grounded using a ground strap. When mounting on a pole, secure the Junction Box to a suitable mounting plate and attach the mounting plate to the pole using U-Bolts. (Pole-Mounting brackets for Detcon Junction Box’s are available separately.) 6.125" 5.5" PGM MODEL NPT Ports 4.6" TP-624D MicroSafeTM H2S Gas Sensor 6.45" 4 1 HOUSTON, TEXAS FLT 3 5.
Model TP-624D Alarm 1 Fault Alarm 2 NOTE: The Detcon Warranty does not cover water damage resulting from water leaking into the enclosure. Customer Wiring Power (+ -) 4-20 mA RS-485 (A,B) Blue Yellow Black White Wiring to H2S Sensor Figure 8 Typical Installation NOTE: Any unused ports should be blocked with suitable ¾” male NPT plugs. Detcon Supplies one ¾” NPT male plug with each J-box enclosure. If connections are other than ¾” NPT, use an appropriate male plug of like construction material. 2.
Model TP-624D high voltage lines or other possible sources of induced interference. Separate conduit runs are highly recommended in these cases. NOTE 3: The supply of power should be from an isolated source with over-current protection as stipulated in table. NOTE 4: A 250 ohm load resistor is needed between the 4-20 mA and the Power ‘-‘ terminals when the 4-20mA signal is not being used.
Model TP-624D 2.7 Initial Start Up Upon completion of all mechanical mounting and termination of all field wiring, apply system power in the range of 12-28VDC (24VDC typical) and observe the following normal conditions: a) TP-624D display reads “0”, and no fault messages are flashing. b) A temporary upscale reading may occur as the sensor heats up. This upscale reading will decrease to “0” ppm within 1-2 minutes of power-up, assuming there is no gas in the area of the sensor.
Model TP-624D Initial operational tests are complete. Detcon H2S gas sensors are factory calibrated prior to shipment, and should not require significant adjustment on start up. However, it is recommended that a complete calibration test and adjustment be performed 16 to 24 hours after power-up. Refer to span calibration instructions in Section 3.4. TP-624D Instruction Manual Rev. 0.
Model TP-624D 3. Operation 3.1 Programming Magnet Operating Instructions The Operator Interface of the TP-624D gas sensors is accomplished via two internal magnetic switches located above and below the LED display (Figure 11). 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 TP-624D 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 TP-624D Software Flowchart Normal Operation PGM1 (3) PGM2 (3) PGM1 (3) PGM2 (3) Exit Calibration Mode (Auto Span) View Sensor Status Auto Time-Out PGM1/2 (M) PGM1/2 (3) Set AutoSpan Level Set Range AutoTime-out PGM1/2 (M) PGM1/2 (3) Auto Time-Out PGM1/2 (M) PGM1/2 (3) Set Heater Power Auto Time-Out PGM1/2 (M) PGM1/2 (3) Model Type Version X.
Model TP-624D 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. ppm H2S). If the sensor is actively experiencing any diagnostic faults, a “Fault Detected” message will scroll across the display once every minute instead of the units of measure and the gas type.
Model TP-624D concentration is 10ppm for the 0-20ppm range and 25ppm for the 0-50ppm and 0-100ppm ranges. If a span gas containing the recommended concentration is not available, other concentrations may be used as long as they fall between 10% and 50% of selected full-scale range. However, any alternate span gas concentration value must be programmed into the sensor via the “Set AutoSpan Level” menu before proceeding with AutoSpan calibration.
Model TP-624D NOTE 2: If the sensor fails the stability criteria, a “Stability Fault” will be declared and a “Fault Detected” message will be displayed alternately with the sensor’s current reading. The 4-20mA output will be taken to 0mA. The “Stability Fault” bit in Modbus register 40005 will be set. NOTE 3: If the sensor fails the clearing time criteria, a “Clearing Fault” will be declared and a “Fault Detected” message will be displayed alternately with the sensor’s current reading.
Model TP-624D 3.5.1 View Sensor Status View Sensor Status displays all current configuration and operational parameters including: sensor type, software version number, detection range, AutoSpan level, days since last AutoSpan, estimated remaining sensor life, heater power, heater voltage, raw resistance, mA output, input voltage, sensor ambient temperature, serial ID, alarm and fault settings.
Model TP-624D Operating Temperature The menu item appears as: “Temp XX C” Serial ID The menu item appears as: “Serial ID XX” Alarm 1 Level The menu item appears as: “Alarm 1 Level XX” Alarm 1 Ascending The menu item appears as: “Alarm 1 Ascending or Descending” Alarm 1 Latching The menu item appears as: “Alarm 1 Latching or Non-Latching” Alarm 1 Energized The menu item appears as: “Alarm 1 Energized or Non-Energized” Alarm 2 Level The menu item appears as: “Alarm 2 Level XX” Alarm 2 Ascending The menu item
Model TP-624D Set AutoSpan Level is used to set the span gas concentration level that is being used to calibrate the sensor. This level is adjustable from 10% to 50% of selected full-scale range. The current setting can be viewed in View Program Status. The menu item appears as: “Set AutoSpan Level”.
Model TP-624D to scroll “Setting Heater”). After scrolling “Setting Heater”, the sensor will adjust the Heater power. The sequence should require about 2-minutes. When the cycle is complete, the display will revert to the “Set Heater Power” text scroll. NOTE: If the sensor cannot adjust the heater power within 3 minutes an error message, “Can’t set, Reverting to Default”, will be scrolled. Refer to section 6 Troubleshooting Guide.
Model TP-624D previously existing configuration inputs will have to be re-entered if this function is executed. A full 10-second magnet hold on PGM 1 is required to execute this function. From the “Restore Defaults” text scroll, hold the programming magnet over PGM1 until the “▲” prompt appears and continue to hold 10 seconds. The display will scroll “Restoring Defaults”, and then will revert to the “Restore Defaults” text scroll.
Model TP-624D The TP-624D contains two Form C alarm relay outputs. These relays can be configured to change state when the concentration exceeds a set level. The relays can be configured to operate in either energized or nonenergized mode. In non-energized mode, the normally open contact is open if the alarm level has not been reached. In energized mode, the normally open contact is closed if the alarm level has not been reached.
Model TP-624D The fault relay can be configured as either latching or non-latching. In non-latching mode, the relay is deactivated as soon as the fault condition is cleared. In latching mode, the relay remains active even after the fault condition has cleared. Once activated, the relay can only be deactivated by swiping a magnetic programming tool above the PGM1 or PGM2 mark on the TP-624D face plate.
Model TP-624D 3.6.2 Fault Diagnostic/Failsafe Features Fail-Safe/Fault Supervision Model TP-624D MicroSafe™ sensors are designed for Fail-Safe operation. If any of the diagnostic faults listed below are active, the sensor display will scroll the message “Fault Detected” every 60 seconds during normal operation. At any time during “Fault Detected” mode, holding the programming magnet over PGM1 or PGM2 for 1 second will display the active fault(s). All active faults are reported sequentially.
Model TP-624D Processor Fault If the detector has any unrecoverable run-time errors, a “Processor Fault” is declared. A “Processor Fault” will cause a “Fault Detected” message to scroll once a minute on the sensor display. If a Processor Fault occurs, the 4-20mA signal will be set at 0mA and the “Processor Fault” bit will be set until the fault condition is resolved. Memory Fault If the detector has a failure in saving new data to memory, a “Memory Fault” is declared.
Model TP-624D 4. RS-485 ModbusTM Protocol Model TP-624D sensors feature Modbus™ compatible communications protocol output and are addressable via the program mode. Communication is via a two wire, half duplex RS-485, 9600 baud, 8 data bits, 1 stop bit, no parity, with the sensor set up as a slave device. A master controller up to 4000 feet away can poll up to 256 different TP-624D sensors.
Model TP-624D 03/ 40014 06 Special #4 R/W 03 40015 Calibration Status R 06 40015 Calibration Enable W 03 03 03 03 03 03 03 Function Dependant on Value of 40006 (See Special Register Table) Idle Zero Calibration Started Span Calibration Started Span Set Span Calibration Unsuccessful Set Zero Set Span Signal simulation mode Set FP Bridge Voltage Set TP Heater Power Set IR Gain Two Char of Gas/Units String6 Two Char of Gas/Units String6 Two Char of Gas/Units String6 Two Char of Gas/Units String6 Two
Model TP-624D 5. Service and Maintenance Calibration Frequency In most applications, monthly to quarterly 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. If, after 180 days, an AutoSpan Calibration is not performed, the sensor will generate an AutoSpan Fault.
Model TP-624D Replacement of Transmitter Module a) Remove the junction box cover and remove the Transmitter Module from the Connector PCB. NOTE: It is necessary to remove power to the Junction Box while changing the Transmitter Module in order to maintain area classification. b) Plug the new Transmitter Module into the connector PCB, and reinstall the junction box cover.
Model TP-624D 6. 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 13 Replaceable H2S Sensor Open Heater Probable Cause: H2S sensor has failed Remove H2S sensor wires from the Connector PCB and verify resistance between the black and white wires using an ohmmeter.
Model TP-624D Stability Fault Probable Causes: Failed Sensor, empty or close to empty Cal Gas Cylinder, problems with cal gas and delivery, or no Humidifying Tube used, failure to properly desiccant packet the sensor cell during extended power-off periods. Check Heater Power Setting (should be 240 ± 5mW at 25ºC ambient temperature). Verify use of span gas Humidifying Tube. Check validity of span gas using H2S pull tube or other means (check MFG date on cal gas cylinder).
Model TP-624D Restore Factory Defaults - This will clear the processor’s memory and may correct problem. Remember to reenter all customer settings for range and cal gas level after Restore Factory Defaults. If problem persists, replace the Plug-in Transmitter Module. Unreadable Display If due to excessive sunlight, install a sunshade to reduce glare. Nothing Displayed – Transmitter not Responding Verify condulet has no accumulated water or abnormal corrosion.
Model TP-624D 7. 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 TP-624D 8. TP-624D Sensor Warranty H2S Sensor Warranty Detcon Inc. warrants, under normal intended use, each new H2S sensor (PN 399-800000-000) for a ten year period under the conditions described as follows: The warranty period begins on the date of shipment to the original purchaser and ends ten years thereafter. The sensor element is warranted to be free of defects in material and workmanship.
Model TP-624D 9. Appendix 9.
Model TP-624D Operating Humidity: Operating Pressure: Air Velocity: 5-100% RH (Non-condensing) Ambient ± 10% 0-5 meters/second Mechanical Specifications Mechanical Specifications Dimensions: 10”H (including Splashguard) x 6.1”W x 4.3”D (254mmH x 155mmW x 109mmD) 3 each ¾”NPT Female Input Ports ¼” Mounting Holes (J-box) 5.5” (140mm) Center to Center. Weight: 6 lbs. (2.72kg) (with aluminum j-box) 9 lbs. (4.
Model TP-624D 9.
Model TP-624D 9.3 Revision Log Revision Date 0.0 6/21/2010 0.1 6/25/2010 Changes made Approval Initial Release LBU Changed gas/units register definition. Added note about “Restore LBU Defaults” 0.2 0.3 0.4 Updated Section 2.6 Field Wiring, load resistor Added setting LED Alarm Levels Add notation on use of desiccant pack with sensor cell 04/23/12 08/26/13 03/07/14 LU LU BM Shipping Address: 4055 Technology Forest Blvd, Suite 100, The Woodlands Texas 77381 Mailing Address: P.O.
