Consilium PG11 User manual

Operating Manual PG11 / PGE11 Page 1

Operating Manual PG11 / PGE11 Page 2
Warnings
!
It is important that the manual is carefully read in its entirety. The manual shall be read and
understood by those having the responsibility for the Operation and Maintenance of the product. If
the product is not used and maintained in accordance with the manufacturer’s instructions, the
product may not perform as intended.
!
Warranties with respect to the product are voided if the product is not used and maintained as
described in this manual. Warranties are also voided if product is used outside temperature and
vibration certified ranges. Please read the general warnings in the separate chapters.
!
Please see the Abbreviations chapter for a description of abbreviations and foreign words.

Operating Manual PG11 / PGE11 Page 3
Table of contents
1 Product Description and detection principle 5
1.1 Technical Specifications 6
1.2 Dimensions PG11 7
1.3 Dimensions PGE11 8
1.4 Detection principle of PG11 and PGE11 10
2 Safety and Warnings PG11 11
3 Installation 11
3.1 Installation checklist 11
3.2 Preparations and Positioning considerations 12
3.3 Mounting the detector 13
3.3.1 Pole mounting 14
3.3.2 Duct or pipe mounting 14
3.4 Electrical connections and Earthing 16
3.4.1 Booting up the Gas Detector 17
3.4.2 Performing loop test 18
3.5 Environment Shield for PG11 18
3.6 Sunshade 19
3.7 Mosquito net 20
4 Commissioning the Gas Detector 20
5 Operation 21
5.1 Function test 21
5.1.1 PG11 function check with the “Gas Test kit” 22
5.1.2 PG11 Function check with the “Gas Test kit” 23
5.1.3 PG11 Function check using the “Gas nozzle” 23
5.1.4 PG11 Function check with the “Remote Gas Test kit” 24
5.1.5 PGE11 short and medium Function check 26
5.2 Perform a check of the Gas Detector accuracy 27
6 Maintenance 28
6.1 Cleaning of optics - lens and mirror 28
6.2 Inspecting detector for damage 28
6.3 Keeping a stable Zeroing of the Detector 29
6.3.1 The OptoBAS™ function 29
6.3.2 Manual zero adjustment 29
6.4 Self Diagnostics 29

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6.4.1 Downloading Self diagnostics datalog 30
6.5 The Blocking kit - Protection during site Maintenance 30
7 Signal outputs 31
7.1 Detector status flags 31
7.2 Light indicator 32
7.3 Analog Safety output 33
7.4 HART® 34
7.4.1 HART® electrical connection 34
8 Warranty 34
9 Certifications and standards 34
9.1 Directives and standards 34
9.2 Approvals and Certificates 35
9.3 Marking 35
9.3.1 Certification 35
9.3.2 Vendor information 35
9.3.1 Serial number and year of manufacturing 35
9.4 Specific conditions of use 36
10 Troubleshooting 36
11 Accessories and Spare Parts 38
12 Product coding and Ordering information 40
13 The OptoCom™ module 42
14 Abbreviations 43
15 Safety Manual 43
16 Support and Contact details 43

Operating Manual PG11 / PGE11 Page 5
1 Product Description and detection principle
PG11 is an explosion proof rugged Optical Gas Detector for the detection of flammable gases and CO2. The
detector comes calibrated for life from the factory and requires very little effort to install and maintain.
The PG11 is built for long maintenance intervals in very demanding environments such as extreme
temperatures and tough vibrations. It has built in condition monitoring that enables better maintenance
planning and less risk of unplanned shutdowns.
In the figure below, the PG11 Optical Gas Detector has the following parts:
A. Multicolour indicator light.
B. Sapphire lens
C. Sapphire mirror with heating
D. Mounting leg.
E. Two entries for cable glands M20. On request 1/2”NPT, 3/4"NPT, and M25.
F. Cover terminal compartment.
G. Sign plates with certification details.

Operating Manual PG11 / PGE11 Page 6
1.1 Technical Specifications
Detection
technology
Gas Detection by Dual band Optical absorption in target gases.
Solid-state Infrared SafeSource™. Temperature compensated Optical Gas detection for rugged applications
Gases and
maximum
measuring
range
Detector configured from factory for one of the following gases with 100 %vol as maximum range:
●Methane
●Propane
●Ethylene
●Butane
●CO2
●Biogas (mixture of CH4 in CO2)
Ambient
conditions
Temperature
Humidity
Vibration
Severe vibration conditions
Storage: -60 to +85°C / -76 to +185°F
Operating: -40 to +75°C / -40 to +167°F (Desert)
-40 to +65°C / -40 to +149°F (Standard)
-55 to +65°C / -76 to +149°F (Arctic)
0 - 99 %RH
Resistant to shock and vibration.
Tested for mounting on applications such as diesel engines and compressors
(vibrations up to 4G).
Electrical
Cable entry
M20 (standard), M25, 1/2" NPT or 3/4" NPT
Maximum conductor size
2.5 mm² (Stranded), 4 mm² (Solid)
Supply voltage
24 V DC, range 18 - 50 VDC
Power consumption
< 3 W average (standard configuration)
< 5 W average (arctic configuration)
Start-up current
Soft boot-up to keep rush current less than 1 A
Performance
key
characteristics
Accuracy
± 3 %FS*
Repeatability
± 1% FS*
Response time
T90 ≤2 sec, with Environment Shield
T20 ≤0.5 sec, with Environment Shield
Start-up time
Ambient above -20°C
Ambient below -20°C
< 2 minutes,
< 20 minutes
Calibration
Calibrated at the factory, no field calibration shall be done.
Signal outputs
Analog output
Current source or sink 4 - 20 mA
HART® digital communication
RS-485 serial port
Modbus RTU for OptoCom™ modules, Safety protocols or Condition monitoring.
Status indicator light
Multicolour indicator light in front of detector.
Miswiring
protection
The electronics have been designed to withstand powering up the detector with terminal wires accidentally
being swapped.
Self-test
Continuous self-verification of all important functions.
Housing
Housing material
Stainless steel 316
Weight
3.4 kg (3.9 kg with the optional steel rear lid)
Ingress Protection
IP66 and IP67

Operating Manual PG11 / PGE11 Page 7
Approvals
ATEX / IECEx
Ex db eb ib IIC T5 Gb
North America
Class I, Division 1, Groups B, C and D (Pending)
Various
MED, BV, LR, DnV GL, ABS type approvals
Safety Integrity
SIL2, and SIL3 in 1oo2 redundancy setup (Pending)
* The accuracy is specified for room temperature +25°C.
1.2 Dimensions PG11
Mount
Width

Operating Manual PG11 / PGE11 Page 8
Length
and
height
1.3 Dimensions PGE11
The PGE11 comes in three lengths with dimensions shown below.
Mount
Width

Operating Manual PG11 / PGE11 Page 9
Length
and
height

Operating Manual PG11 / PGE11 Page 10
1.4 Detection principle of PG11 and PGE11
PG11 is using an Optical Detection principle. The basic working principle is illustrated in the drawing below
and consists of the following basic parts:
A. Infrared light (2 –6 µm region) is generated at the light source and directed at the
B. sapphire lens focusing the light so it is passing through the
C. gas to be measured. The gas will absorb some wavelengths depending on the type of gas. The
higher concentration of the gas the more light is absorbed. After passing through the gas the
remaining light is
D. reflected by a mirror and back through the gas again reaching the lens directing the light at
E. the light sensors . The light sensors will measure what wavelengths that have been absorbed and how
much light has been absorbed. Based on this information the Gas Detector can decide if the target
gas is above the alarm level .
In addition to the basic principles described above there are more functions in the detector that are
compensating for changes for example by temperature and component aging over time.

Operating Manual PG11 / PGE11 Page 11
2 Safety and Warnings PG11
!
PG11 Optical gas detector is certified for and intended for use in potentially hazardous areas. Install
and use the gas detector in accordance with the appropriate local or national regulations.
!
The gas detector shall be properly Earthed to protect against electrical shock and minimize electrical
interference.
!
Test gases may be combustible. Refer to Material Safety Sheets for appropriate warnings.
!
The detector shall be installed and operated by trained and qualified personnel only.
!
Do not open the detector housing, the warranty is not valid if it is open. There are no user
serviceable parts or settings inside. Return to service point for service or repair.
3 Installation
!
The area for which the detector will be installed shall be in accordance with the certification of the
detector and with the standards of the appropriate authority in the country concerned.
!
If the service temperature of the installation may exceed 70 °C, ensure the following:
●Cable glands are certified for the given temperature range.
●Cables are suited for use at temperatures above 78 °C.
!
The usage of unqualified glands, cables or conduits are considered hazardous.
3.1 Installation checklist
Below is the recommended procedure for installing the detector PG11:
1. Check that the detector is mounted in a horizontal orientation with tight bolts as described in section
“3.3 Mounting the detector”.
2. Verify correct wiring of the terminals as described in “3.3 Electrical connections and Earthing”.
3. Check that cable gland is suitable type and certification
4. Verify cable shielding has been correctly terminated.
5. Verify correct Earthing to external Earthing point on the Detector housing as described in “3.4
Electrical connections and Earthing”.

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3.2 Preparations and Positioning considerations
PG11 is a point gas detector and should be placed as close to a potential leaking point as possible. However,
each installation is different from another, and detailed considerations must be done locally in order to get
the best coverage for detection. Below are some general matters to consider:
●The detector should be placed where maintenance, such as cleaning of optics can easily be
performed.
●The relative weight of the target gas compared to air must be taken into account when deciding the
optimum installation height. Methane is lighter than air and in this case the gas detector may have to
be placed above a potential leak source. In case of the other hydrocarbons such as Propane being
heavier than air, could accumulate lower levels and might be better detected by placing Detectors at
lower levels - in many instances close to the floor.
●The concentration of a gas cloud will quickly reduce with the distance from the leak source. The
detector should therefore be placed as close as possible to potential leakage sources.
●In spaces where there are two main components of gas then it is recommended to use two gas
instruments in accordance with HAZOP studies or a Detector that is sensitive to both gases. The
Optical Methane Detector will for most heavy hydrocarbons react very strongly and might be
suitable.
●The detector should not be mounted in areas where it can be drenched by water.
●Also, the fact that gas quickly dilutes when released into the air, and the impact of wind must be
considered. As illustrated below with a leak point at position A, the gas will spread in the direction of
the wind and be detected at position C (downstream), but not detected at position B. The wind speed
has no effect on the detector.

Operating Manual PG11 / PGE11 Page 13
3.3 Mounting the detector
Below, PG11 is shown securely mounted with M8 mounting screws, nuts and washers. The PGE11 is
mounted with the same solution.
PGxx11 should be mounted with the longitudinal axis in the horizontal direction as illustrated below. At the
same time, it can be rotated in any direction around this longitudinal axis. The reason for these requirements
is that such a position will reduce the accumulation of contamination on the optical parts (lens and mirror).
Correct Incorrect
Wall mounting of the detector is most often seen, while it can also be mounted flat or in the roof as illustrated
below. In the example below the detector is mounted in a C-bar structure.

Operating Manual PG11 / PGE11 Page 14
3.3.1 Pole mounting
Below is an illustration of the PG11 with the “ Mount kit Pole ”mounted to a pole with a diameter of about Ø60
mm or 3”.
3.3.2 Duct or pipe mounting
If installed in a ventilation duct or pipe, it is recommended to use the “Duct flange kit” as shown in the
illustration below. To get better gas coverage inside the duct it is recommended to use the PGE11 with the
extended gas sensing section as shown below.
The mounting is done by fixing the flange (A) to the installation. Attach the gasket and the mounting bracket
(B). The PGE11 (C) is slided onto the mounting bracket and fixed with two bolts and the support bracket (D).
The Duct flange kit is supplied with a nozzle (E) to allow gas testing to be performed without removing the
detector from the duct flange. The below table shows three possible configurations mounting the Duct flange:

Operating Manual PG11 / PGE11 Page 15
PG11
mounted in
the Duct
flange kit
Detector can easily be removed from the duc t to
perform a Gas test.
Nozzle not used for gas testing.
PG11
mounted in
Duct flange
with gas test
line
connected to
the nozzle
Installed with the Nozzle installed in the front of the
PG11, and a flexible tube connected from the nozzle
to the Duct flange. With the Environment shield
installed this solution works well doing gas with tests
when the air is flowing in the duck. Without the
Environment shield it is more difficult to do the Gas
test since the gas is faster diluted and therefore very
high flow on the test gas is required.
PGE11
Mounted in
Duct Flange
kit. Through
the rigid gas
pipe a gas
test can be
performed
Installed with a rigid gas pipe.
Can be challenging to perform gas tests if there is air
flow in the duct.

Operating Manual PG11 / PGE11 Page 16
3.4 Electrical connections and Earthing
The PGxx11 chassis shall be connected to local Clean Earth . Use one of the two external Earthing points
(M4x5) illustrated in point Aleft drawing below using an Earthing cable ring lug . The electrical terminals are
located inside the rear lid in point B, opened by unscrewing the three screws fixing it. M20 cable entries Con
both sides of the Detector. The other dimensions M25, 1/2" NPT and 3/4" NPT are supplied on request at
order. The right side of the terminals Dare occupied with internal wiring, and on the left side Eare the
terminals (pin 1 at the top and pin 5 at the bottom) to be wired according to table 1 . Fis the internal Earth
point for an M4x4 screw for the connection of a cable lug.
!
To avoid the risk of corrosion, use quality fasteners for the connection of the earthing. Avoid the use
of aluminium, magnesium, titanium or zirconium. A lock washer or similar should be used to ensure
secureness of the electrical connection.
The termination compartment inside the rear lid is equipped with Phoenix Contact MPT 2,5 - 3248125 Push
in style connectors, accommodating wires of cross section 0.14mm² (AWG 26) to 2.5mm² (AWG14)
(4mm²/12AWG for single conductor wire). Wires should be stripped to expose min 8mm, max 10mm
conductor. Insert rigid conductors or conductors with ferrules into the conductor shaft. The contact spring
opens automatically and provides the required pressure force against the current bar.
The wiring of the Detector shall be done in accordance with table 1 .

Operating Manual PG11 / PGE11 Page 17
Table 1. Specifications of terminals.
Terminal
(detector
wire color)
Signal type
Specification
Cable requirement
1 (white)
Power, Positive
supply voltage
24 VDC
According to site requirements
and Table 2. Min. cross section:
0.14mm²
Max. cross section:
2.5mm² (Stranded)
4mm² (Solid)
2 (brown)
Power, Supply
voltage return
0 VDC
3 (green)
Analog Safety
signal
Analog 0 - 20 mA DC signal overlayed
with a HART signal. Signals levels
described in table 4 . The HART signal
is not interfering with the analog DC
signal and is described in a separate
chapter.
Maximum impedance 500 Ω .
4 (yellow)
RS-485 A
Two wires for connection to digital RS-
485 serial communication, Modbus
RTU.
Industrial communication cable
with shielded twisted pair.
Min/max cross section 0.14/2.5
mm² (stranded) or max 4 mm²
(Solid)
5 (grey)
RS-485 B
EARTH
External Earth
point
External grounding shall be used when the detector is installed in an Ex-
zone.
Internal Earth
point
Normally not used. Shield of the cable is typically connected to instrument
earth in the central control cabinet and is normally not terminated at the
detector.
If extra RFI protection is required, and the installation's grounding
principles/regulations allow it, the shield can be terminated to local ground
via the internal earth point at the detector.
Table 2. Minimum voltage to PG11 shall be 18 VDC. Examples of cable and maximum length.
Cable cross section
0.5 mm²
0.75 mm²
1 mm²
1.5 mm²
2.5mm²
Voltage drop
~5.8V
Max cable length*
133 m
200 m
250 m
400 m
650 m
* For a nominal power of 24 V. Longer cable can be used with higher supply voltage.
3.4.1 Booting up the Gas Detector
When turning on the power to the Gas Detector it has a boot-up time of 60 seconds. During this time the
Detector will run self diagnostics and if the indicator is configured to be active it will show yellow light. After
this boot-up time the Detector is ready to detect gas, but for a very precise testing of gas accuracy the
Detector should be allowed for another 20 minutes warm up time

Operating Manual PG11 / PGE11 Page 18
3.4.2 Performing loop test
The PG11 can perform a loop test through the HART of MODBUS interfaces. The loop test allows for the
Operator to Manually set the analog signal output to a selected value for a limited time. Please consult the
corresponding HART chapter of this Manual for instructions.
3.5 Environment Shield for PG11
Dirt, dust, snow and liquids gathered on the lens and mirror will reduce the amount of IR light used for
detecting gas. If more than 55% of the IR light is blocked due to contamination of the optics, the detector will
give an EARLY CLEAN OPTICS WARNING. The optics should then be cleaned as described in section
“Cleaning optics”. If more contamination is allowed to accumulate without cleaning, the detector will go into
FAULT when more than 70% of the IR light is blocked. How fast dirt is accumulating on the Optics depends
on how dirty the environment is.
The PG11 comes by default with an Environment Shield . It is recommended to use the environmental shield
in most cases. This will reduce the effects of rain, snow, dirt and water spray from eg. fire extinguishing
systems. The optics of the PG11 is heated and the environmental shield will enhance the effect by keeping
the heat more localized inside the sensing section of the PG11. The result is a more robust solution against
thick mist and rapid temperature changes.
For severe humid applications (>99% RH), it is recommended to use the Hydrophobic filter. See the full list of
accessories in chapter 11 Accessories and Spare Parts.
Environment Shield for PG11 consists of one compact unit fitting into the gas sensing section as illustrated
below. The Environment Shield has been designed for optimum performance of the detector.
The Environment Shield for the PG11 consists of one compact unit fitting into the gas sensing section as
illustrated below. The Environment Shield has been designed for optimal performance of the detector. The
illustration below shows how the Environment Shield is easily slotted into the sensing section of the PG11.
Before inserting the Environment shield visually inspect that it is free of dirt or any blocking substances. Make
sure it is inserted all the way in.

Operating Manual PG11 / PGE11 Page 19
3.6 Sunshade
The PG11 can be fitted with a screen or roof keeping it from being exposed to direct sunlight heating the
detector up, or from snow, sand or similar that can accumulate on the detector. The sunshield is fitted as
illustrated below. The sunshield is fixed with the same screws as the Detector.
The Sunshade is slided in from the front.
The Sunshade is secured with the same screws as
the Detector mounting.
The accessory Sunshade extension included in the
Sunshade kit can be used to give extra shielding in
some applications, but is normally not used for
horizontal mounting.
For wall or pole mounting it is recommended to use
the Sunshade extension to shield the detector from
direct sunlight, rain and snow.

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3.7 Mosquito net
The accessory Mosquito net can be fitted to the Gas Detector to prevent insects from blocking the optics.
The Mosquito net (A) is fitted on the outside of the detector nose and secured with the screw (B). It is
recommended to use the accessory Gas nozzle (C) for easier access when performing Function tests with
gas. The Mosquito net can also be used in combination with the Environment Shield for a combined splash
and insect protection.
4 Commissioning the Gas Detector
Below is the recommended procedure for commissioning the detector PG11:
1. Turn on power to the Gas Detector. The Detector will run self-diagnostics and warm up as described
in section “3.4.1 Booting up the Gas Detector”
2. Verify Status indicator light alarm levels, and change if necessary. The default settings might be
different from site alarm levels. Light indicator described in chapter 7.2 Light indicator.
3. Perform the Gas Detector Safety Function test as described in “5.1 Function test”.
4. Verify that the Site Safety System is receiving the gas signal from the Gas Detector.
5. With all steps passed this concludes commissioning of the Gas Detector.