Dräger Polytron FX User manual

Polytron FX
Operating Manual

1
For Your Safety
Strictly follow the assembly and installation instructions
The instrument must be calibrated at intervals recommended in the operating
manual or more frequently according to specific use and applications.
Do not calibrate the instrument in the presence of an operating radio
transmitter.
Use in areas subject to explosion hazards
The sensor must be screwed in at least 5 threads to maintain the explosion
proof rating.
If the extra port at the 3 or 9 o’clock position is not to be used for wiring
purposes, the supplied plug must be screwed in completely to maintain the
explosion proof rating.
Equipment or components which have been tested and approved according to
the national or European regulations on electrical equipment in rooms subject
to explosion hazards, may be used only under the conditions specified in the
approval.
Modifications of components or the use of faulty or incomplete parts are not
permitted. In the case of repairs to equipment or components of this type, the
national regulations must be observed.
Maintenance
Dräger warrants this instrument to be free of defects in material and
workmanship for a period of one (1) year from date of purchase. Dräger
warrants the sensor for a period of one (1) year from the date of purchase.
Liability for proper function or damage
The liability for the proper function is irrevocably transferred to the owner or
operator to the extent that the transmitter is serviced or repaired by personnel
not employed or authorized by Draeger Service or if the transmitter is used in a
manner not conforming to its intended use.
Dräger cannot be held responsible for damage caused by noncompliance with
the recommendations given above. The warranty and liability provisions of the
terms of sale and delivery of Dräger are likewise not modified by the
recommendations given above.
Draeger Safety, Inc.
For Your Safety

2
Contents
For Your Safety ....................................................................................................... 1
1 Introduction ......................................................................................................... 4
1.1 Intended Use ......................................................................................................... 4
1.2 Design .................................................................................................................... 4
1.2.1 Aluminum Version ................................................................................... 4
1.2.2 Stainless Steel Version .......................................................................... 5
2 Operation ............................................................................................................. 6
2.1 Installation .............................................................................................................. 6
2.2 Replacing the Sensor ......................................................................................... 7
2.3 Change Gas Category of Polytron FX IR ........................................................ 8
3 Menu ..................................................................................................................... 9
3.1 Menu Navigation .................................................................................................. 9
3.2 Changing Parameter Values/Status ................................................................ 9
3.3 Exiting the Menu ................................................................................................ 10
3.4 Menu Items ......................................................................................................... 10
3.4.1 Gas Conc .............................................................................................. 10
3.4.2 Password ............................................................................................... 10
3.4.2.1 Password Adj ....................................................................... 10
3.4.3 Zero Adj ................................................................................................. 10
3.4.4 Span Adj ................................................................................................ 11
3.4.5 FSD Adj .................................................................................................. 11
3.4.6 A1 Adj ..................................................................................................... 11
3.4.7 A2 Adj ..................................................................................................... 11
3.4.8 A1 Lat ..................................................................................................... 11
3.4.9 A2 Lat ..................................................................................................... 11
3.4.10 A1 Acn .................................................................................................... 11
3.4.11 A2 Acn .................................................................................................... 11
3.4.12 Cal Sig .................................................................................................... 11
3.4.13 LCD On/Off .......................................................................................... 11
3.5 Output and Display Variations ........................................................................ 12
4 Maintenance ..................................................................................................... 13
4.1 Calibration .......................................................................................................... 13
4.1.1 Calibration Procedure ........................................................................ 13
4.1.1.1 Zero Calibration ................................................................... 13
4.1.1.2 Span Calibration .................................................................. 14
4.2 Error Messages ................................................................................................. 15
Contents

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Contents
5 Sensor Principle .............................................................................................. 16
5.1 Operating Principle for DraegerSensor PR and LC ................................. 16
5.2 Contaminating Gases for DraegerSensor PR and LC ............................. 16
5.3 Operating Principle for DraegerSensor IR ................................................. 17
6 Technical Information ..................................................................................... 18
6.1 Approvals ............................................................................................................ 18
6.1.1 Aluminum Version ................................................................................ 18
6.1.2 Stainless Steel Version ....................................................................... 18
6.2 Signal Transmission to Central Control Unit .............................................. 18
6.3 Voltage of Power Supply ................................................................................. 18
6.4 Physical Specifications .................................................................................... 19
6.4.1 Aluminum Version ................................................................................ 19
6.4.2 Stainless Steel Version ....................................................................... 19
6.5 Environmental Parameters .............................................................................. 19
6.6 Ambient Influences ........................................................................................... 19
7 Order Information ........................................................................................... 20
7.1 Replacement Sensors ...................................................................................... 20
7.2 Accessories ........................................................................................................ 20
7.3 Spare Parts ......................................................................................................... 20
Addresses ............................................................................................................. 25

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1 Introduction
1.1 Intended Use
The Polytron FX is an explosion-proof transmitter for the detection of
combustible gases and vapors in ambient air. The transmitter is designed to be
installed in permanent locations and is approved for use in hazardous,
classified areas (See Section 6.1, Approvals).
1.2 Design
The transmitter is powered by 16 to 30 VDC. Gas concentrations, error
messages, and software menu choices are displayed on a 3 digit LCD display.
Access to the software is obtained by tapping a magnetic wand on the glass
viewport at the appropriate arrow indicators. In this way, the instrument can be
configured, calibrated and maintained non-intrusively, so declassification of the
area is not necessary for these procedures.
1.2.1 Aluminum Version
The Polytron FX transmitter is housed in a powder-coated aluminum enclosure
with 3/4” NPT threaded ports located at the 3 and 9 o’clock positions. The
sensor is located at the 6 o’clock position.
Introduction
Intended Use
Design
Figure 1: Polytron FX and Polytron FX IR, aluminum version

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1.2.2 Stainless Steel Version
The Polytron FX transmitter is housed in an enclosure with 3/4” NPT threaded
ports located at the 12 and 6 o’clock positions.
Figure 1a: Polytron FX and Polytron FX IR, stainless steel version
Introduction
Intended Use
Design

6
2 Operation
2.1 Installation
Mount the instrument at the appropriate height for the gas to be detected,
taking into account the density of the gas, air flow patterns in the room, and
personnel considerations. Responsibility for correct placement of the
Polytron FX rests with the end user; if in doubt about placement, consult with
Draeger application engineers.
Polytron FX is a three-wire device powered by 16 to 30 V DC. Wiring terminals
are located on the back of the PCB; pull out the bezel, by grasping the notches
on either side of the display with your fingers and pulling up (Figure 2).
Connect the wires as shown in Figure 3.
Operation
Installation
Figure 3: Connections for 24 V DC power supply/controller
Figure 2: Pulling out the bezel
grasp notches
with fingers
and pull up
CAUTION
Never insert
objects into
finger notches.

7
Wiring to and from controllers/power supplies must be run through sealed
conduit to maintain the explosion-proof status. If only one of the threaded inlet
ports is used for external wiring, the other must be sealed with the blanking
plug included with the unit (Figure 4).
2.2 Replacing the Sensor
To replace the sensor, see Figure 5 for details:
• Declassify the area according to local procedures.
• Turn off power to the unit.
• Remove the housing cover.
• Remove the main PCB, which is attached to the bezel, by grasping the
notches on either side of the display with your fingers and pulling up
(Figure 2).
• Unplug the sensor cable.
• Unscrew the Dräger Sensor.
Installing the Sensor
Figure 4: Wiring through sealed conduit
Blanking
Plug
Conduit

8
Replacing the Sensor
• Insert the sensor wires through the threaded port in the housing.
• Screw the Dräger Sensor into the port. Five threads must be engaged
to ensure explosion-proof status.
• Plug the wires into the socket on the main PCB.
• Re-install sensor electronics by pushing the bezel and main PCB back into
place.
• Screw housing cover back onto the unit, being careful not to damage the
threads. The cover must be screwed on tightly to compress the o-ring to
maintain explosion-proof status.
• Apply power to the unit.
• Calibrate instrument per section 4.1, Calibration.
• Always test a newly-installed sensor with target gas to verify proper operation.
2.3 Change Gas Category of Polytron FX IR
See manual 9023843. This has to be done at the DraegerSensor IR.
Figure 5: Replacing the sensor
Housing Cover
Bezel
Main PCB
Plug wires into socket
on Main PCB
Threaded Port
Sensor Wires
DraegerSensor
PR or LC
Housing
DraegerSensor IR

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Figure 6: Arrows indicate the location of
magnetic contact switches on front display panel
Up
Down Enter
Menu
Menu Navigation
Changing Parameter Values/Status
Exiting the Menu
3 Menu
In the standard operating mode, the Gas Concentration of the target gas will be
displayed. To access the software menu, tap the magnetic wand once against
the glass viewport above the Down arrow. The display shows the first menu
item, Adj Zero. The displays flashes ‘-0-’, ‘Adj’, and then shows the target gas
concentration.
3.1 Menu Navigation
Tap the magnetic wand over the Up and Down arrows to scroll through the
menu selections. If the magnetic wand is held over the switch for
> 0.5 second, this will be considered multiple taps and the menu will scroll.
When you reach the last item (LCD On/Off), the menu will bottom-out, and you
will have to use the Up arrow to scroll back up through the menu.
The active menu item as well as its current value or status will flash on the
display as it scrolls.
NOTE
The instrument is designed for the magnetic wand to be used with the
housing cover in place. If the housing cover is not in place, then the
magnetic wand may not work properly.
3.2 Changing Parameter Values/Status
To enter a new value, or change a status, tap Enter with the magnetic wand
when the desired menu item is displayed. The current value or status will flash
to indicate a change to data entry mode. The Up and Down arrows allow you to
adjust the value of a numerical parameter or to toggle between preset choices.
Once the display shows the desired value or choice, tap Enter to validate the
new parameter. This will take you back to the menu, where you can scroll to
another menu item, if desired.

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3.3 Exiting the Menu
To get back into the standard measurement mode, just scroll to the Gas
Concentration menu item at the top of the menu. The actual gas concentration
will be displayed.
3.4 Menu Items
3.4.1 Gas Conc
Displays the current value of the concentration of the target gas in % LEL.
This field is read-only, and cannot be modified by the operator.
3.4.2 Password
The use of a password is optional with the Polytron FX. A password consists of
a 3-digit number from 000 to 999; a value of 000 disables password protection
and allows anyone to access the software interface. The instrument is delivered
with the password set to 000.
If a password has been set, it must be entered to gain access to the software
menu. Tap the magnetic wand over the Down arrow until the ‘PAS’ menu item is
displayed. The 3-digit LCD will then show ‘000’, with the first zero on the left
blinking. Use the Up and Down arrows to increment or decrement this digit,
then tap Enter. The second (middle) digit will blink, and the correct value should
be set using the Up and Down arrows as before. Repeat the process for the
third digit. Tap Enter when the full password is displayed. If the displayed value
matches the set password, you will gain access to the rest of the menu. If an
incorrect password is entered, the instrument will return to the measurement
mode.
3.4.2.1 Password Adj
Use the Down arrow to scroll to the last menu item, Password Adjust. The
display will show the message ‘PAS’, ‘ADJ’, ‘000’.
NOTE
If a password other than 000 has already been entered,
that number will appear in place of ‘000’.
Tapping the magnetic wand over Enter causes the 3-digit display to flash. Tap
the Up or Down arrows to scroll the value to the desired new password. The
display will stop scrolling at a maximum value of 999 or a minimum of 000; it
will not roll over.
Tap Enter when the desired password is displayed to accept this as the new
password. Once a password is set, you will have to enter it to gain access to the
menu.
3.4.3 Zero Adj
Allows you to adjust the zero reference point of the sensor when no target gas
is present, such as during calibration. See Section 4.1.1, Calibration
Procedure, for details.
Exiting the Menu
Menu Items

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3.4.4 Span Adj
Allows you to adjust the displayed gas concentration to match the known
concentration of an applied calibration gas. For example, if a 50% LEL
calibration gas is applied to the sensor, the Span Adj value should be adjusted
to 50 once the sensor reading has stabilized. See Section 4.1.1, Calibration
Procedure, for details.
3.4.5 FSD Adj
The Full Scale Deflection is fixed at 100% LEL for the Polytron FX and
Polytron FX IR or 10% LEL for the Polytron FX LC.
3.4.6 A1 Adj
This menu item is not active for the Polytron FX.
3.4.7 A2 Adj
This menu item is not active for the Polytron FX.
3.4.8 A1 Lat
This menu item is not active for the Polytron FX.
3.4.9 A2 Lat
This menu item is not active for the Polytron FX.
3.4.10 A1 Acn
This menu item is not active for the Polytron FX.
3.4.11 A2 Acn
This menu item is not active for the Polytron FX.
3.4.12 Cal Sig
Calibration signal is the signal that is transmitted by the 4 to 20mA output
anytime you access the software menu. It is user-selectable. The two
possibilities are:
a steady 3 mA signal
an oscillating 3 to 5mA signal with a frequency of 1 Hz
The default value is a steady 3 mA signal.
3.4.13 LCD On/Off
This feature allows you to turn the LCD output off if the desired, effectively
turning the Polytron FX into a non-display instrument. The 4 to 20mA output
remains active independent of the LCD state. If the LCD is Off, pressing the
Down arrow when in measurement mode still gives you access to the software
functions.
Menu Items

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3.5 Output and Display Variations
The following table shows the status of the 4 to 20 mA output, and the LCD
display for various conditions.
Condition Analog Output LCD Display
Warming-up actual signal actual signal
After warm-up actual signal actual signal
After power outage actual signal actual signal
New sensor installed actual signal actual signal
Sensor removed signal “pls con snr”
Hardware fault signal “flt”
Microprocessor lock-up signal frozen display
In menu maintenance signal menu function
In cal modes maintenance signal cal function displays
The “actual signal” means the unmodified real-time signal in the circuit.
The maintenance signal is the 3 to 5mA oscillating signal, or the steady 3 mA
signal chosen in the “cal sig” menu function.
Output and Display Variations

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4 Maintenance
4.1 Calibration
4.1.1 Calibration Procedure
Calibration of this unit must be performed at regular intervals as detailed in the
sensor data sheet.
DraegerSensor IR:
If the zero signal has drifted significantly, or a calibration fails: calibrate the
DraegerSensor IR first (see manual P/N 9023843), then continue with the
calibration procedure for Polytron FX.
4.1.1.1 Zero Calibration
• Attach the pressure regulator to the nitrogen (N2) or Zero Air calibration gas
cylinder.
DraegerSensor PR and LC:
• Fit the calibration adapter tightly to the end of the sensor.
Draeger Sensor IR:
Maintenance
Calibration
Figure 7: Calibration

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• Connect the tubing to the barbed fitting of the sensor.
• IMPORTANT: Turn the gas on and allow to flow for at least one minute before
proceeding.
• Scroll through software menu to Zero Adj and tap Enter. The current zero
value will be displayed.
• Wait for the zero to stabilize.
• If the display is not already reading zero, trim the stabilized value to zero on
the display using the Up and Down arrows.
• Accept the value by tapping Enter with the magnetic wand.
• Turn off the gas flow and remove the calibration adapter from the sensor, or
disconnect tubing.
NOTE
Ambient air can be used to zero the sensor instead of nitrogen or
Zero Air if the area is known to be free of the target gas or any gas
to which the sensor may be cross-sensitive (as listed on the
sensor data sheet). In this case, no cylinder or calibration
adapter is needed for the zero calibration.
4.1.1.2 Span Calibration
WARNING
Never adjust the span before completing zero adjustment. Performing
these operations out of order will cause the calibration to be faulty.
• Attach the pressure regulator to the calibration gas cylinder.
DraegerSensor PR and LC:
• Fit the calibration adapter tightly to the end of the sensor.
Draeger Sensor IR:
• Connect the tubing to the barbed fitting of the sensor.
• IMPORTANT: Turn the gas flow on and allow to flow for at least one minute
before proceeding.
• Scroll through software menu to Span Adj and tap Enter. The span value will
be displayed.
• Wait for the span value to stabilize.
• Using the Up and Down arrows, trim the stabilized value to the calibration gas
concentration that is being applied to the sensor. If the sensor has reached
the end of its life, the span value will not be able to be reached. In this case,
replace the sensor.
• Accept the value by tapping Enter with the magnetic wand.
• Turn off the gas flow and remove the calibration adapter from the sensor, or
disconnect tubing.
Calibration

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Error Messages
4.2 Error Messages
Error Code Condition Solution
Pls Con Snr No sensor is connected, 1) Connect sensor
sensor connection is bad, 2) Check to ensure sensor
or sensor “bead” is open is seated in connector
3) Contact Draeger Safety
technical service
Snr Err Sensor EEPROM data Contact Draeger Safety
is corrupted technical service
Flt Hardware fault Contact Draeger Safety
technical service
AFE Err Wrong software version 1) Install most recent AFE
installed in the Analog software
Front End (AFE) 2) Contact Draeger Safety
technical service
AFE Out AFE microcontroller is out Contact Draeger Safety
of its socket, technical service
or not installed

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5 Sensor Principle
5.1 Operating Principle for DraegerSensor PR
and LC
The DrägerSensor is a transducer for measuring the partial pressure of
combustible gases and vapors contained in ambient air. It uses the heat-of-
combustion principle.
The monitored air diffuses through the sintered metal disc into the sensor.
There the mixture of combustible gases and vapors are catalytically combusted
at a heated detector element (pellistor). The monitored air supplies the Oxygen
required for the combustion. Due to the resulting heat-of-combustion, the
detector element gets hotter. This increase in heat causes a change of
resistance in the detector element, which is proportional to the concentration
of the mixture of combustible gases and vapors in the monitored air.
In addition to the catalytically active detector element, there is an inactive
compensator element. Both elements are parts of a Wheatstone bridge.
Thus environmental effects like changes in temperature or humidity are
almost entirely compensated.
5.2 Contaminating Gases for DraegerSensor PR
and LC
Vaporous silicon- and lead-compounds, sulfurous compounds such as
hydrogen sulfide and sulfur dioxide, phosphorous compounds such as
phosphine. Acidic vapors such as hydrogen fluoride, hydrogen chloride,
hydrogen bromide and halogenated organic compounds such as refrigerants
and tri- or tetrachloroethene.
A calibration check might be necessary, if the sensor was exposed to a high
concentration of combustible gases or vapors for an extended period of time
or to contaminants as listed above.
Sensor Principle
Operating Principle for DraegerSensor PR and LC
Contaminating Gases for DraegerSensor PR and LC
Principle of operation
1 Sintered metal
2 Detector bead
3 Sensor housing
4 Compensator bead

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5.3 Operating Principle for DraegerSensor IR
The DrägerSensor IR infrared gas sensor is a gas transmitter designed to
determine the concentration of gases and vapors in the ambient air. The
principle of measurement is based on the concentration-dependent absorption
of infrared radiation in measured gases.
The monitored ambient air diffuses through sintered material into the
flameproof housing of a measuring cuvette. The broad-band light emitted by the
radiator passes through the gas in the cuvette and is reflected by the cuvette
walls from where it is directed towards the inlet window of a dual element
detector. One channel of the detector measures the gas-dependent light
transmission of the cuvette (measuring channel), the other channel is used as
reference. The ratio between measuring and reference signal is used to
determine the gas concentration in the cuvette. The cuvette is heated to avoid
condensation of the atmosphere’s moisture content.
Internal electronics and software are used to calculate the concentration. As an
output signal, the gas sensor emulates the half bridge of a catalytic Ex sensor.
Die to its robust design and the measuring method the gas sensor has long
maintenance and calibration intervals (see manual 9023843, Maintenance).
A gas sensitivity drift is practically excluded by the infrared-optical principle of
measurement and in addition, the zero point stability is enhanced by an
automatic tracking system.
Operating Principle for DraegerSensor IR

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6 Technical Information
6.1 Approvals
6.1.1 Aluminum Version
UL DraegerSensor PR ...................... Class I, Div 1, Group B, C, D
DraegerSensor IR ........................ Class I, Div 1, Group B, C, D
Class II, Div 1, Group E, F, G
CSA DraegerSensor PR ...................... Class I, Div 1, Group B, C, D
ATEX .................................................................................................................. EEx d IIC
DraegerSensor LC and PR II 2 D T135(Ta = -40 to +80°C)
T85 (Ta = -40 to +40°C)
II 2 G T4 (Ta = -40 to +80°C)
T6 (Ta = -40 to +40°C)
DraegerSensor IR II 2 D T135(Ta = -40 to +65°C)
T85 (Ta = -40 to +40°C)
II 2 G T4 (Ta = -40 to +65°C)
T6 (Ta = -40 to +40°C)
CE marking ................. Electromagnetic Compatibility (Directive 89/336/EEC)
6.1.2 Stainless Steel Version
ATEX .................................................................................................................. EEx d IIC
DraegerSensor LC and PR II 2 G 135°C -20°C Ta +60°C
85°C -20°C Ta +40°C
II 2 D T135 -20°C Ta +60°C
T85 -20°C Ta +40°C
DraegerSensor IR II 2 G T6 -20°C to +60°C
II 2 D T80 -20°C to +60°C
CE marking ................. Electromagnetic Compatibility (Directive 89/336/EEC)
6.2 Signal Transmission to Central Control Unit
Analog ........................................................ Transmission by 3-core shielded cable
– Measurement current ...........................................................................4 to 20 mA
– Transmitter fault ............................................................................................. <2 mA
– Maintenance Signal ................................................. 4 ± 1 mA, 1 Hz modulation
or steady 3 mA signal (user selectable)
6.3 Voltage of Power Supply
Operating Voltage ............................................................................... 16 to 30 VDC
In-rush Current .......................................................................... 160 mA for 40 msec
Operating Current (maximum) .................................................... 90 mA @ 24 VDC
Connector accepts 16 to 22 gauge wire AWG (0.5 to 1.5 mm2)
Technical Information
Signal Transmission to Central Control Unit
Voltage of Power Supply

19
6.4 Physical Specifications
6.4.1 Aluminum Version
Enclosure ......................................................................................... NEMA 4X (IP66)
Size ............... L x W x D approx., FX PR 6.5” x 4.5” x 4”; (165 x 115 x 100mm)
FX LC 7.2” x 4.5” x 4”; (185 x 115 x 100mm)
FX IR 11.5” x 4.5” x 4”; (295 x 115 x 100mm)
Weight approx. ..................................................... FX PR, FX LC 3.3 lbs. (1.5 kg)
FX IR 4.2 lbs. (1.9 kg)
6.4.2 Stainless Steel Version
Enclosure ......................................................................................... NEMA 4X (IP66)
Size ........... L x W x D approx., FX PR 6.6” x 5.1” x 4.7”; (170 x 130 x 120mm)
FX IR 11.6” x 5.1” x 4.7”; (295 x 130 x 120mm)
Weight approx. .................................................................... FX PR 7.1 lbs. (3.2 kg)
FX IR 8.0 lbs. (3.6 kg)
6.5 Environmental Parameters
Temperature ............................. FX PR, FX LC –40 to 175 °F, (–40 to 80 °C)
FX IR –40 to 150 °F, (–40 to 65 °C)
Pressure ............................................. 20.7 to 38.4 in. of Hg (700 to 1300 mbar)
Humidity .................................................................... 5 to 95% RH, non-condensing
Maximum Air Velocity ............................................................. 19.5 ft/s (6 m/s)
6.6 Ambient Influences
See sensor data sheets.
Physical Specifications
Environmental Parameter
Ambient Influences