Honeywell 5704 User manual

System 57
5704 Control System
Operating Instructions

2
MAN0448_Issue 13_01-2010 5704 Control System
005704-M-5001 A03249
Total Environmental Solutions
Ensure that you read and understand these instructions BEFORE
operating the equipment.
Please pay particular attention to the Safety Warnings.
WARNINGS
The items of equipment covered by this manual are:
1. Notdesignedorcertiedforuseinhazardousareas.
2. Designed for indoor use only.
3. Not to be exposed to rain or moisture.
CAUTIONS
1. Use only approved parts and accessories with the 5704 Control
System.
2. To maintain safety standards, regular maintenance, calibration
andoperationofthe5704ControlSystembyqualiedpersonnel
is essential.
IMPORTANT NOTICES
1. HoneywellAnalytics Limited can take no responsibility for installation
and/or use of its equipment if this is not done in accordance with
the appropriate issue and/or amendment of the manual.
2. The user of this manual should ensure that it is appropriate in all
details to the exact equipment to be installed and/or operated. If
in doubt, the user should contact Honeywell Analytics Limited for
advice.
Honeywell Analytics Limited reserve the right to change or revise
the information supplied in this document without notice and without
obligation to notify any person or organisation of such revision or
change.
If further details are required which do not appear in this manual, contact
Honeywell Analytics Limited or one of their agents.

3
MAN0448_Issue 13_01-2010 5704 Control System
005704-M-5001 A03249
MANUAL ISSUE STATUS
The following table indicates the issue status of this manual and of the
individual chapters within the manual
ISSUE 13, JANUARY 2010
Section Pages File Issue
Front Pages 1 to 6 MAN0448A 13
Chapter 1 1-1 to 1-8 MAN0448B 13
Chapter 2 2-1 to 2-26 MAN0448C 13
Chapter 3 3-1 to 3-22 MAN0448D 13
Chapter 4 4-1 to 4-58 MAN0448E 13
Chapter 5 5-1 to 5-20 MAN0448G 13
Chapter 6 6-1 to 6-12 MAN0448H 13
Chapter 7 7-1 to 7-16 MAN0448I 13
Chapter 8 8-1 to 8-14 MAN0448J 13
Chapter 9 9-1 to 9-4 MAN0448K 13
Chapter 10 10-1 to 10-6 MAN0448L 13
Since the 'Front Pages' of a manual contain the above manual issue
status table these pages will always carry the overall issue status of
themanual.Theremainingchapterissueswillreectthelatestissueof
those chapters at the time of print of a manual, e.g., Issue A, B, C, etc.,
for chapters of provisional information and 1, 2, 3, etc., for chapters of
conrmedinformation.
HELP US TO HELP YOU
Every effort has been made to ensure the accuracy in the contents
of our documents, however, Honeywell Analytics Limited can assume
no responsibility for any errors or omissions in our documents or their
consequences.
Honeywell Analytics Limited would greatly appreciate being informed
of any errors or omissions that may be found in our documents. To this
end we include the following form for you to photocopy, complete and
return to us so that we may take the appropriate action.

4
MAN0448_Issue 13_01-2010 5704 Control System
005704-M-5001 A03249

5
MAN0448_Issue 13_01-2010 5704 Control System
005704-M-5001 A03249
MANUAL CONTENTS
Chapter
1. SYSTEM CONCEPT
2. SYSTEM DESCRIPTION
3. CONTROLS AND FACILITIES
4. INSTALLATION INSTRUCTIONS
5. COMMISSIONING AND MAINTENANCE INSTRUCTIONS
6. OPERATING INSTRUCTIONS
7. ENGINEER'S OPERATING INSTRUCTIONS
8. SPECIFICATION
9. ORDERING INFORMATION
10. SPECIAL CONDITIONS FOR SAFE USE ACCORDING TO
EC-TYPE EXAMINATION CERTIFICATE BVS 04 ATEX
G 001 X

6
MAN0448_Issue 13_01-2010 5704 Control System
005704-M-5001 A03249
USER NOTES

1-1
MAN0448_Issue 13_01-2010 5704 Control System
005704-M-5001 A03249
5704 SERIES
CONTROL SYSTEM
CHAPTER 1
SYSTEM CONCEPT
CHAPTER 1 - SYSTEM CONCEPT

1-2
MAN0448_Issue 13_01-2010 5704 Control System
005704-M-5001 A03249
CONTENTS
Section Page
1. PRINCIPAL FEATURES 1-3
2. CONSTRUCTION 1-4
FIGURES
Figure Page
1. 5704 Control System 1-6
2. 5704 Control System Over View 1-7
CHAPTER 1 - SYSTEM CONCEPT

1-3
MAN0448_Issue 13_01-2010 5704 Control System
005704-M-5001 A03249
1. PRINCIPAL FEATURES
The 5704 Series Control System is part of the System 57 family and is
designedtomonitoreldmountedindustrialgasdetectors.Theprincipal
features of the system are:
* Provides up to 64 channels of gas detection in a standard 19'' sub-
rack using a 3U card format.
* Provides up to 32 channels of gas detection in a half 19'' sub-rack
using a 3U card format.
* Rackingavailableforbothfrontandrearaccesseldwiring.
* Simpleeldconnectionsforwireupto2.5mm2(14 AWG).
* Four channels per one inch wide card.
* Control cards removable without disturbing other wiring.
* Catalytic bridge or 4 - 20mA input control card versions.
* Alarm change-over relay output options.
* Optional time delayed operation of alarm relays.
* Multi-alarmmodeformaster,zonedandvotedalarms.
* Rising, falling, STEL, LTEL and update alarm outputs.
* Remote inhibit and reset inputs per card.
* Optional 0 - 20mA or 4 - 20mA isolated monitor outputs per
channel.
* Easy to calibrate and operate using a dedicated Engineering
Card.
* EMC compliant.
CHAPTER 1 - SYSTEM CONCEPT

1-4
MAN0448_Issue 13_01-2010 5704 Control System
005704-M-5001 A03249
2. CONSTRUCTION
Thesystemconsistsofindividual1'' (2.54cm)widecards ttedtoa
rigidcustomrackdesignedtotEurorackcabinets.Tworackwidths
are available:
a. 19 inch with 17 card slots to house up to 16 Four Channel Control
Cards and an Engineering Card.
b. Half 19 inch with nine card slots to house up to eight Four Channel
Control Cards and an Engineering Card.
Each sub-rack contains an Engineering Card and a DC Input Card to
make up the rack system
The system is designed to meet the differing customer wiring
congurationsandtoachievethisthecontrolfunctionsaresplitaway
from the relays and eld wiring connections. Four channels of gas
detection therefore consists of:
a. Four Channel Control Card
Each Four Channel Control Card functions independently and
contains all the necessary electronic circuitry to provide the sensor
drive, alarm detection and gas level display for four channels of gas
detection.
There are two types of Four Channel Control Cards, one for catalytic
inputs and the other for 4 - 20mA inputs.
b. Quad Relay Interface Card
The Quad Relay Interface Card provides the interface connections
betweentheControlCardandtherespectiveeldconnectedgas
sensors. In addition, it provides four alarm outputs via the eld
connections.
c. Relay Interface Assembly
Where additional relay contacts are required, an Expansion Relay
Card is attached to the Quad Relay Interface Card. The new
assembly becomes the Relay Interface Assembly and expands the
alarm relays to 16. This combination occupies two interface card
slots and as a consequence limits the number of control cards that
canbettedtotherack.
CHAPTER 1 - SYSTEM CONCEPT

1-5
MAN0448_Issue 13_01-2010 5704 Control System
005704-M-5001 A03249
Inasystemwheretheeldwiringisrequiredtobeconnectedtotherear
of the system, the rack is centrally divided into front and rear sections
by a printed circuit board backplane which provides common signal
routeing between individual Four Channel Control Cards. The control
cardsarettedatthefrontoftherackwhileQuadRelayInterfaceCards
aretteddirectlybehindtheassociatedFourChannelControlCardat
the rear of the rack. The control cards and their respective interface
cards are interconnected by a plug and socket arrangement.
Inasystemwheretheeldwiringisrequiredtobeconnectedtothefront
of a system, the Four Channel Control Cards and Quad Relay Interface
Cards are mounted one above the other in a 6U rack. The backplane
printed circuit board still provides the common signal routeing between
the individual Four Channel Control Cards, but short cables at the rear
of the cards connect each control card to their respective Quad Relay
Interface Card.
Simple calibration and checking of the system is carried out using push
buttons on the Engineering Card tted in each rack. More complex
conguration can be carried out using the RS232 link between the
Engineering Card and an external IBM compatible personal computer
running the engineering interface software.
When a Relay Interface Assembly is used, the resultant four channel
control assembly then takes up two card slots.
Amixtureof5704and5701ControlCardsmaybettedinthesame
System 57 rack.
The 5704 Control System is shown in Figure 1.
CHAPTER 1 - SYSTEM CONCEPT

1-6
MAN0448_Issue 13_01-2010 5704 Control System
005704-M-5001 A03249
Four Channel
Control Card
Quad Relay
Interface Card
DC Input Card
Engineering
Card
8/16-Way
AC to DC PSU
Backplane
Interface
Sensors
PC, Printer or
Engineering Key
Interface Section Control Card Section - RFI Protected
Sub Rack
Figure 1 5704 Control System
RS232
Four Channel
Control Card
Quad Relay
Interface Card
Expansion Relay
Card Front Panel
Blanking Panel
Sensors
Option Module
Alarm Update
MODBUS or
Printing Output
Optional Alarm
Update Panel
*
*
*
*Interconnecting Cable for
Front Access Racks.
CHAPTER 1 - SYSTEM CONCEPT

1-7
MAN0448_Issue 13_01-2010 5704 Control System
005704-M-5001 A03249
Engineering
Card
Front Access
8 or 16-Way
4 x
Sensor
16 x Relay
Relay Interface
Assembly
OR
Figure 2 5704 Control System Over View
Rear Access
8 or 16-Way
MODBUS
Interface
Module
Master Alarm
Update Module
Event Print Module
Blank
Panels
Four
Channel
Control
Cards
Analogue
Output
Modules
4 x Relay
Quad Relay
Interface Card 4 x
Sensor
DC Input
Card
CHAPTER 1 - SYSTEM CONCEPT

1-8
MAN0448_Issue 13_01-2010 5704 Control System
005704-M-5001 A03249
USER NOTES

2-1
MAN0448_Issue 13_01-2010 5704 Control System
005704-M-5001 A03249
CHAPTER 2 - SYSTEM DESCRIPTION
5704 SERIES
CONTROL SYSTEM
CHAPTER 2
SYSTEM DESCRIPTION

2-2
MAN0448_Issue 13_01-2010 5704 Control System
005704-M-5001 A03249
CHAPTER 2 - SYSTEM DESCRIPTION
CONTENTS
Section Page
1. INTRODUCTION 2-3
2. RACKS 2-4
3. CABINETS 2-6
4. FOUR CHANNEL CONTROL CARDS 2-8
4.1 General 2-8
4.2 Control Functions 2-9
4.3 Analogue Output Module 2-9
4.4 Physical Layout 2-10
5. QUAD RELAY INTERFACE CARD AND RELAY
INTERFACE ASSEMBLY 2-11
5.1 General 2-11
5.2 Quad Relay Interface Card 2-11
5.3 Relay Interface Assembly 2-14
5.4 Expansion Relay Card 2-17
6. ENGINEERING CARD 2-18
7. DC INPUT CARD 2-19
7.1 General 2-20
7.2 DC Input Card Rear Access Connections 2-21
7.3 DC Input Card Front Access Connections 2-22
8. AC TO DC POWER SUPPLY UNITS 2-23
8.1 Types of Power Supply Unit 2-23
8.2 Power Supply Unit Upgrades 2-23
8.3 Power Supply Connections 2-23
8.4 8-Way AC to DC Power Supply Unit Layout 2-24
8.5 16-Way AC to DC Power Supply Unit Layout 2-24
8.6 50W Sub-Unit Layout 2-25
8.7 100W Sub-Unit Layout 2-25
9. FRONT PANEL BLANKING PANEL 2-26

2-3
MAN0448_Issue 13_01-2010 5704 Control System
005704-M-5001 A03249
CHAPTER 2 - SYSTEM DESCRIPTION
1. INTRODUCTION
The 5704 Series Control System is a microprocessor based system
which displays the reading and status of connected gas detectors.
The system provides complex alarm handling facilities with a full
maintenance capability.
AracksystemisttedwithanumberofFourChannelControlCards
each with an associated Quad Relay Interface Card which provides the
necessary sensor input and optional relay output connections. A Relay
Interface Assembly may be used to expand the number of relay outputs
available for each of the Four Channel Control Cards. Simple alarm
handling and operation is provided by each channel control card.
Complex alarm handling is achieved by communication between a
speciednumberofcontrolcardsviathebackplaneoftherack.
An Engineering Card is tted to each rack and provides control of
the rack backplane communications, control card interrogation and
facilitates maintenance.
In small systems power supplies, auxiliary power supplies and battery
back up systems can be connected to the rack via a DC Input Card. In
heavily populated installations of more than eight Four Channel Catalytic
Control Cards, power supplies are connected to each individual Four
Channel Catalytic Control Card via its interface card.

2-4
MAN0448_Issue 13_01-2010 5704 Control System
005704-M-5001 A03249
CHAPTER 2 - SYSTEM DESCRIPTION
2. RACKS
Each rack assembly contains a sub-rack, Engineering Card, DC Input
Card, key kit and where necessary an interconnecting cable.
Dependentuponconguration,thecontrolsystemishousedinoneof
fourstandardsizesub-racksasfollows:
a. Full 19 inch wide by 3U high - Part Number 05701-A-0511,
  forreareldwiringconnections.
b. Full 19 inch wide by 6U high - Part Number 05701-A-0501,
  forfronteldwiringconnections.
c. Half 19 inch wide by 3U high - Part Number 05701-A-0512,
  forreareldwiringconnections.
d. Half 19 inch wide by 6U high - Part Number 05701-A-0502,
  forfronteldwiringconnections.
All four versions have two separate chambers. One is sealed against
electromagnetic interference and contains the control cards while the
other chamber contains the relay interface cards. A backplane between
the two chambers provides a path for signal routeing between individual
control cards and the Engineering Card.
Typical Eight Card Rear Access Rack - Front View

2-5
MAN0448_Issue 13_01-2010 5704 Control System
005704-M-5001 A03249
CHAPTER 2 - SYSTEM DESCRIPTION
Typical Eight Card Front Access Rack
(Relay/Interface Chamber Front Cover Removed)
Typical Eight Card Rear Access Rack - Rear View

2-6
MAN0448_Issue 13_01-2010 5704 Control System
005704-M-5001 A03249
CHAPTER 2 - SYSTEM DESCRIPTION
3. CABINETS
Two wall mounted cabinets are used to house:
a. the full width 16 card front access rack,
(Part Number 05701-A-0451)
b. or the eight card half width front access rack.
(Part Number 05701-A-0452)
A front door on each cabinet provides security and dust protection, while
a clear panel in the door allows the channel card displays to be viewed
when the door is closed. The base of each cabinet contains a selection
ofpreformedknockoutcableglandentries.Aremovableplateisxed
to the inside of the cabinet for mounting accessories.
Cabinet