Honeywell EC-FX-NH3 Manual

Electrochemical Ammonia (NH
3
) Leak Detector
EC-FX-NH3
Instruction and Installation Manual
Part No. 1998M0872
Revision 1
June 2014
Honeywell Confidential & Proprietary This work contains valuable, confidential, and proprietary information.
Disclosure, use or reproduction outside of Honeywell Inc. is prohibited except as authorized in writing. This
unpublished work is protected by the laws of the United States and other countries.

OPERATOR MANUAL
Table of Contents
Table of Contents ................................................................................................. 1
Figures .................................................................................................................2
NoticesandTrademarks ......................................................................................3
Contact Us ............................................................................................................4
Online .....................................................................................................4
Telephone ..................................................................................................4
Symbol Definitions ................................................................................................5
Introduction ..........................................................................................................6
System Description...............................................................................................7
Specifications ............................................................................................7
Installation............................................................................................................9
ALocating the EC-FX -NH3 Sensor ......................................................9
BWiring ...........................................................................................11
Outputs: ...................................................................................... 13
Cable Recommendation:..............................................................14
Operation ........................................................................................................... 16
AStart-up Procedures .....................................................................16
Simple Start-Up Test:....................................................................16
BPushbutton Operation and LED Indicators.................................... 16
Green LED................................................................................... 17
Red LED ......................................................................................17
Yellow LED ..................................................................................17
Green — ON, Red — Fast Blink, Yellow — Fast Blink...................18
SensorCheckTM............................................................................ 20
4/20 mA Loop Test .......................................................................21
Simple Zero Test.......................................................................... 22
Span Calibration Mode ................................................................. 22
Span Calibration ..........................................................................23
Span Signal Formula ................................................................... 25
MODBUS Address Change .............................................................26
C Troubleshooting .............................................................................28
DMaintenance ................................................................................31
EC Sensor Replacement Procedure ...............................................32
ReplacementParts ........................................................................32
Limited Warranty ................................................................................................ 33
Limited Warranty...................................................................................... 33
Exclusions .............................................................................................. 33
Warranty Limitation and Exclusion ............................................................33
Disclaimer of Unstated Warranties............................................................33
Limitation of Liability ................................................................................34
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OPERATOR MANUAL
Figures
Figure 1. Mounting Dimensions ...............................................................10
Figure 2. 4/20 mA Output Wiring Diagram ................................................13
Figure 3. RS-485 Communication and Power Wiring Diagram...................15
Figure 4. LED Blink Sequence .................................................................17
Figure 5. EC-FX-NH3 Detector Components ............................................18
Figure 6. LED Sequence Indicator and Operation Summary ......................19
Figure 7. LCD Module..............................................................................27
Figure 8. Troubleshooting .......................................................................30
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OPERATOR MANUAL
Notices and Trademarks
© 2014 by Honeywell International Inc.
While this information is presented in good faith and believed to be accurate, Honeywell
disclaims the implied
warranties of merchantability and fitness for a particular purpose
and makes no express warranties except as may
be stated in its written agreement with
and for its customers.
In no event is Honeywell liable to anyone for any indirect, special or consequential
damages. The information and specifications in this document are subject to
change without notice.
Manning is a registered trademark of Honeywell International Inc.
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OPERATOR MANUAL
Contact Us
Online
Honeywell Organization WWW Address (URL)
Corporate www.honeywell.com
Honeywell Analytics www.honeywellanalytics.com
To return a product, contact [e-mail] to obtain
an RMA number.
For sales Information, contact [e-mail].
Telephone
Contact us by telephone at the numbers listed below.
Organization Phone Number
Americas
Honeywell Analytics Inc.
Lincolnshire, IL
1-800-538-0363
1-847-955-8200
BW Technologies by Honeywell
Calgary, Alberta, Canada 1- 800-663-4164
Honeywell Analytics Inc.
Brossard, Quebec, Canada 1- 800-563-2967
Asia Pacific Honeywell Asia Pacific Inc.
Seoul, Korea [phone]
Europe/Middle
East/Africa
Life Safety Distribution AG
Hegnau, Switzerland [phone]
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OPERATOR MANUAL
Symbol Definitions
The following table lists those symbols used in this document to denote certain
conditions.
Symbol Definition
ATTENTION: Identifies information that requires
special consideration.
TIP: Identifies advice or hints for the user, often
in terms of performing a task.
REFERENCE-EXTERNAL: Identifies an
additional source of information outside of this
bookset.
REFERENCE-INTERNAL: Identifies an
additional source of information within this
bookset.
Indicates a situation which, if not avoided, may
result in equipment or work (data) on the system
being damaged or lost, or may result in the
inability to properly operate the process.
CAUTION: Indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury. It may also be used to
alert against unsafe practices.
CAUTION:Symbol on the equipment refers the
user to the product manual for additional
information. The symbol appears next to
required information in the manual.
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OPERATOR MANUAL
Introduction
This manual has been prepared to help in the use and installation of the EC-FX-
NH3 (Electrochemical-Ammonia) Sensor. This manual will convey the operating
principles of the sensor, ensure proper installation, and
demonstrate start-up and
routine maintenance procedures for the sensor.
ATTENTION: This manual must be carefully followed by all
individuals who have or will have the responsibility for using or
servicing the sensor.
Warranties made by Honeywell Analytics with respect to this equipment will
be voided if the equipment is not used and serviced in accordance with the
instructions in this
manual. If in doubt about a procedure, please contact
Honeywell Analytics before proceeding.
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OPERATOR MANUAL
System Description
The EC-FX-NH3leak detector is a three-wire 4/20 mA transmitter/sensor with
RS-485 Modbus RTU
communication. It is designed for low-level ammonia
detection in industrial refrigeration, cold-storage environments, and engine
rooms.
The detector exhibits excellent durability and precision, with negligible
response to common interference gases and changes in relative humidity.
The default alarm level is 25 ppm for the 0
- 100 ppm sensor. The unit exhibits
extremely high reliability with no moving parts.
Monitoring equipment must be configured to indicate
a fault if the signal is
less than 1.5 mA. All signals over 20 mA must be considered high gas
concentrations.
Specifications
Method: Electrochemical (diffusion)
Ranges:
0-100 PPM
0-200 PPM
0-250PPM
Output: Isolated 4/20 mA, 700 ohms max at 24
VDC. Signal output reduces
to 0.5 mA to indicate a
fault condition.
RS-485 Protocol: MODBUS RTU
Accuracy: ±5% of full scale range at temperature of calibration. Contact
Honeywell Analytics for additional details.
Repeatability:<10% of full scale
Response Time (T90): <30 seconds, 90% full scale
Sensor Viability Test: An internal microprocessor
determines the sensor’s
electrical viability every 24
hours (SensorCheckTM). Should the electrical
viability
test fail, a 0.5 mA signal will indicate a fault.
A red LED on the circuit board will indicate if a sensor is degraded electrically,
depleted of electrolyte or
disconnected.
4/20 mA Loop Viability Test: Internal monitoring of
4/20 mA output
impedance.
Operating Humidity: 5%-100% RH (condensing). ATMOS equipped®
enviro-adaptive technology option required for condensing conditions or
refrigerated areas, and all outdoor applications.
Operating Temperatures:
-50
o
F to +120oF (-45ºC to +50ºC).
ATMOS
®
equipped enviro-adaptive technology option required for
refrigerated areas or outdoors.
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OPERATOR MANUAL
Sensor Pressure Limits: Atmospheric ±10%
Power Source: 24 VDC (recommended), 0.5 amp max. 14-26 VDC
acceptable.
Cable Recommendations:
4/20 output: #18/3 shielded cable (Belden #8770 or
equal), cable
runs <1,500 feet.
Modbus RTU (RS-485): For communication cable,
use 24 AWG
twisted pair, shielded (Belden #9841 or
equal), cable runs up to
2,000 feet.
Power Cable Recommendations:
For power cable,
use 14 AWG (Belden #5100UE or equal), cable runs
up to 1,000 feet, for each power supply. Larger power cable and/or
additional power supplies may be
required for longer cable runs
and/or increased
number of sensors. Due to variables such as
sensor
current draw, line loss, and cable size, contact Honeywell
Analytics for help with power requirements.
Gas Sampling: Diffusion method is standard.
Enclosure: NEMA 1, gasketed, #16-gauge steel
(standard) or stainless steel
models are available.
NOTE: The EC-FX is for use in non-classified areas only.
Weight: 3 lbs.
Dimensions: 6" high x 4" wide x 3.5" deep
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OPERATOR MANUAL
Installation
A Locating the EC-FX -NH3 Sensor
Because each sensor is a point measurement, it is very important that the
sensor be located properly.
One of the most important considerations when installing EC
sensors is that they must be easily accessible for calibration and
maintenance. As a general rule, locate sensors no closer than one
foot from the ceiling.
If the primary application is personal protection
(representative
concentration reading that an
employee would be exposed to), mount the
sensor at
a height in the breathing zone of the employees. It would typically
be about five feet off the ground, which also allows easy access.
If the primary application is the fastest possible leak
detection, mount the
sensor near the potential leak
sources. In the case of ammonia, this is
usually near
the ceiling as ammonia vapor is lighter than air. In certain
refrigeration applications, ammonia vapors from an NH3 leak will remain at a
low elevation. In
these cases, leak detection will take longer if the sensor is
mounted at high elevation and the indicated
concentration will not be
representative of personnel
exposure. Higher mounting locations can also
complicate access to the sensor for required calibration and maintenance.
For more information on
sensor mounting locations for different leak
scenarios,
please contact Honeywell Analytics.
General Mounting Considerations:
•Should be easily accessible for calibration and maintenance.
•Mount the sensor close to a potential leak source.
•If personnel protection is the primary application, mount in the
“breathing zone”.
•Protect sensor from water, excessive humidity, and wash-down.
•Take air movement and ventilation patterns into account.
•If mounting sensor outdoors, consider prevailing wind direction and
proximity to the most likely source of leaks. Protect the sensor from
sun and rain as much as possible.
•Never mount the sensor in CA (controlled atmosphere) rooms because
normal atmospheric level of oxygen is required for operation.
•For highly critical locations, more than one sensor should be installed
in each room.
•To prevent electrical interference, keep sensor and wire runs away
from mercury vapor lights, variable speed drives, and radio repeaters.
•Protect sensor from physical damage (fork lifts, etc.).
•Do not mount the sensor over a door in a refrigerated area.
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OPERATOR MANUAL
Figure 1. Mounting Dimensions
•Sensor must be mounted vertically.
•Never mount flat on a ceiling.
•Enter enclosure only through existing hole in bottom.
•Always make a drip loop in the conduit (see Figure 1).
Blast Freezers: Never mount sensor above the coil. The ideal location,
when possible, is below the
bottom of the coil. Try to put in return air and
protect
the unit from being damaged by product loading and unloading.
Keep it away from warm, moist air during
defrost. Usually four or five feet off
the ground is the
best location.
Penthouses:
•Multi-Coil (defrost one coil at a time): In this case the
best location is
usually in the center of the penthouse
four or five feet above the
grate.
•Single Coil (or when all coils defrost at the same time):
In this case
high moisture conditions can occur and
the sensor should be
mounted one foot above the
grate.
Engine Rooms: The sensor should be
mounted in a cool part of the room, if
possible. Keep the sensor away from hot air exhausting from electric
motors
or other machinery. Usually the best location is four or five feet above the
floor in a location where
the room exhaust fan will move air across the sensor
from the potential leak source.
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OPERATOR MANUAL
Ceiling-Hung Evaporators: When mounting Manning EC sensors near
evaporators, mount the
sensor no higher than two feet below the top of the
evaporator coil. DO NOT mount in high air flow (1,200 feet/ minute
maximum). NEVER mount the
sensor on evaporators as vibration can
damage the
sensor.
Other Locations: When mounting Sensors in locations such as roof top air
units, duct-
work, attic spaces, makeup air intakes, etc., contact Honeywell
Analytics for application assistance and recommendations.
B Wiring
Figure 2 on page 13 presents 4/20 mA output wiring information for the EC-
FX-NH3 sensor. Figure 3 on page 15 presents
RS-485 communication wiring
information for the
EC-FX-NH3 sensor.
Electrical wiring must comply with all applicable
codes. Plant equipment that
may be involved and
operating conditions should be discussed with local
operating personnel to determine if any special needs should be taken into
account.
Almost all start-up problems are due to improper wiring or monitor
configuration. Please follow these
guidelines carefully.
Do not pull sensor wiring with AC power cables. This will cause electrical
interference. Be sure there are no breaks or splices in sensor wiring runs.
If cable runs cannot be made without a splice, all connections must be
soldered. Soldering should be done using a rosin flux to tie the connecting
ends of sensor wires to ensure a positive and long-lasting contact.
Ground the shield at the main control panel. Connect the shield wire in the
sensor terminal block labeled
SHLD. Tape all exposed shield wire at the
sensor to
insulate it from the enclosure.
All penetrations into a refrigerated room should be
sealed to prevent
condensate from forming in the
conduit and dripping into the sensor
enclosure.
Make drip loops for cables going into sensor
housings. When heated
enclosures are used, follow
the special mounting instructions on the
enclosure
(…This End Up).
Mount sensor enclosures through the flange holes as shown in
Figure 1, and always mount vertically.
4/20 mA output: Always use three conductor,
insulated, stranded, shielded
copper cable.
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OPERATOR MANUAL
RS-485 output: Always use two conductor twisted pair, insulated, stranded,
shielded copper cable for
the communication cable. Use two conductor,
insulated, stranded cable for sensor power.
With RS-485, the communication cabling of the
network is “daisy chained”, with
multiple devices
(sensors, relay modules, etc.) communicating along the same
pair of wires. If used with the AirAlertTM 96d controller, up to 32 devices can be
wired in series per channel (up to three channels).
Refer to the controller manual for specific wiring details.
When many sensors are connected to one set of power cables, total
current draw may
exceed cable recommendations and/or cause
considerable line-loss. Contact Honeywell Analytics for
recommendations on power cable sizing and
additional power
supplies.
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OPERATOR MANUAL
Figure 2. 4/20 mA Output Wiring Diagram
Electrical Power: 24 VDC regulated, 30 mA. With
an ATMOS® equipped
enclosure the current draw is
400 mA max.
Respect minimum voltage requirements.
Outputs:
ATTENTION: The EC-FX-NH3 detector is
shipped with a 100
ohm, 1/4 watt resistor in the green, four position terminal block,
across the
Signal and Ground terminals (see Figure 3). This
resistor is needed to “fake out” the 4/20 mA loop if using the
Modbus RTU output. Only remove this
resistor if using the 4/20 mA
output.
•4/20 mA: Circuit board mounted sensor provides a
linear 4/20 mA
output. Monitoring equipment may
have a maximum input
impedance of 700 ohms.
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OPERATOR MANUAL
•RS-485: MODBUS RTU communication protocol.
Cable Recommendation:
•4/20 mA output: Use #18/3 shielded cable (Belden #8770 or
equivalent). Length of cable to sensor
should be no greater than
1,500 feet.
•RS-485 output:For communication cable, use 24 AWG
twisted pair,
shielded (Belden #9841 or equal), cable runs up to 2,000 feet. Avoid
“T-taps” if possible. Do
not exceed 65 feet per T-tap. Do not exceed
130 feet
total of all T-taps (per channel). For power cable, use 14
AWG (Belden #5100UE or equal), cable runs up
to 1,000 feet, for
each power supply. Larger power cable and/or additional power
supplies may be
required for longer cable runs and/or increased
number of sensors. Due to variables such as sensor current draw,
line loss, and cable size, contact Honeywell Analytics for help with
power cable
requirements.
Monitoring: The EC-FX-NH3 ammonia
detector may be monitored by the GM-
JR, AirAlertTM 96d, or other
appropriately configured system. For 4/20 output,
monitoring equipment must be configured to indicate a fault if the signal is
below 1.5 mA. All signals over
20 mA must be considered a high gas
concentration, not a fault condition.
NOTE for PLC applications: The signal output load can range
from 0 to 700 ohms, where the maximum load resistor at a 24 VDC
supply
is 700 ohms and the maximum load resistor at a 10 VDC
supply is 267 ohms. Any load outside these
values will indicate a
fast flash on the red LED while
in operation or this test mode during
normal
operation. The error LED will blink fast at any time if the
signal output cannot source the necessary
current.
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OPERATOR MANUAL
Figure 3. RS-485 Communication and Power Wiring Diagram
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OPERATOR MANUAL
Operation
A Start-up Procedures
Before applying power, make a final check of all wiring for continuity, shorts,
grounds, etc. It is usually best to disconnect external alarms and other
equipment from the sensor until the initial start-up procedures are
completed. SensorCheckTM is initiated each time the unit is powered up.
After power-up, allow 24 hours for the system to
stabilize before testing the
sensors. As sensors are typically located a distance from the controller or PLC,
Honeywell Analytics recommends that the mA signal be calibrated with the control
system.
Simple Start-Up Test:
•One person exposes each sensor to a small amount of ammonia.
•The second person stays at the control unit to
determine that each sensor,
when exposed to
the gas fumes, is connected to the proper input and
responds, causing appropriate alarm
functions.
B Pushbutton Operation and LED Indicators
The EC-FX-NH3has an internal pushbutton that is utilized for navigation of test
functions and
operating modes (see Figure 5, Note 5). It also has a group of LEDs
(green, red, yellow
— see Figure 3 on page 15) that blink in specific sequences to
indicate sensor
operation modes. A summary of sensor operation modes and
corresponding LED blink sequences is
shown in Figure 6. The pushbutton must
be pressed
the correct number of times and at the correct rate.
When a multi-press sequence must be performed, the button
must be pressed rapidly
and evenly, lifting one’s finger completely
from
the actuator for each consecutive press.
•For press and hold activations, one’s finger must always be applying
a down pressure
without disruption for the specified time in order to
activate the desired mode.
•See complete details of each operation in other parts of
the manual.
The EC-FX-NH3 has been designed with three distinct test mode procedures that
are
triggered by the appropriate push button action. These test modes include
Manual SensorCheckTM,
Simple Zero Test, and 4/20 mA Loop Check.
The fourth operation puts the unit into Calibration Mode to allow for testing
with a certified calibration gas standard and to provide information for
appropriate span adjustments, if required.
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OPERATOR MANUAL
Figure 4. LED Blink Sequence
SLOW BLINK
MEDIUM BLINK
FAST BLINK
CONTINUOUS ON
Green LED
Solid ON — all modes except Cal. and 4/20 mA calibration.
Slow Blink — Calibration mode.
Red LED
Solid ON — Possible catastrophic failure on the circuit board. The 4/20 mA
signal will vary depending on the exact failure. In the event of corrupted
data, calibration values and Modbus ID may be lost but the gas sensor and
4/20 mA output circuit would still be operational. In the event of a CPU
failure, a 0.5 mA fault signal is output from the sensor. All other functions
and devices would be inoperable (optional LCD, network, pushbuttons,
etc.). Contact Honeywell Analytics for technical support.
Slow Blink — Near death, possible dried up or disconnected sensor. A
0.5 mA fault signal is output from the sensor during this error event. A
replacement sensor should be ordered at this time.
Medium Double Blink — Possible weak sensor. Sensor is nearing the end
of its useful life. Although the sensor may pass the span calibration or
detect the presence of ammonia, frequent attention and increased
calibration checks are strongly recommended until the sensor is replaced.
Fast Blink — Possible 4/20 mA loop failure or load resistance too high.
Check output impedance and ensure it is between 10Ω and 700Ω
referenced to ground. In addition, ensure power supply voltage is within
specified operating range.
Yellow LED
Solid ON — During Sensor CheckTM.
Medium Double Blink — During 4/20 mA (0.5 mA low) test.
Fast Blink — During 4/20 mA (22 mA high) test and during failed (22 mA
high) test.
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OPERATOR MANUAL
Green — ON, Red — Fast Blink, Yellow — Fast Blink
4/20 mA loop test failed the 22 mA high extremity. Check output impedance
and ensure
it is between 10Ωand 700Ωreferenced to ground. In addition,
ensure power supply
voltage is within specified operating range.
Figure 5. EC-FX-NH3 Detector Components
18