Honeywell Sensepoint User manual

2106M0525 Iss 2 Nov 05 1
Sensepoint
Gas Detectors
Technical Manual

2106M0525 Iss 2 Nov 05 2

Safety
2106M0525 Iss 2 Nov 05 3
Ensure that this Technical Manual is read and understand BEFORE installing/operating/maintaining
the equipment.
Pay particular attention to Warnings and Cautions.
All document Warnings are listed here and repeated where appropriate at the start of the relevant
chapter(s) of this Technical Manual. Cautions appear in the sections/sub-sections of the document
where they apply.
WARNINGS
Sensepoint is designed for installation and use in Zone 1 or 2 hazardous
areas in Europe. Installation must be in accordance with the recognized
standards of the appropriate authority in the country concerned.
Before carrying out any work ensure local regulations and site procedures
are followed. Appropriate standards must be followed to maintain
the overall certification of the detector.
Access to the interior of the detector, when carrying out any work, must only be
conducted by trained personnel. Switch off and isolate the power supply
to the detector when access is required.Take any necessary
precautions to prevent false alarms.
Never attempt to open a junction box/enclosure or replace/refit the sensor
when flammable/toxic gas is present.
The detector must be earthed for electrical safety and to limit the effects of
radio interference. An earth point is provided inside the unit. Ensure that
all screens/armor are grounded at a single earth star point at the controller
or detector - BUT NOT BOTH - to prevent false alarms due to earth loops.
Take care when handling sensors as they may contain corrosive solutions.
Do not tamper or in any way dis-assemble the sensor.
Do not expose to temperatures outside the recommended range.
Do not expose sensor to organic solvents or flammable liquids.
At the end of their working life, sensors must be disposed of in
an environmentally safe manner. Disposal should be according to local
waste management requirements and environmental legislation.
Alternatively, sensors may be securely packaged and returned to
Honeywell Analytics clearly marked for environmental disposal.
Electrochemical cells should NOT be incinerated as they
may emit toxic fumes.
When replacing the gas detector’s junction box ensure that the correct
gas label is affixed to the replacement enclosure.
Safety

Information
2106M0525 Iss 2 Nov 05 4
Honeywell Analytics 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 Technical Manual.
The reader of this Technical Manual should ensure that it is appropriate in all details for the exact
equipment to be installed and/or operated. If in doubt, contact Honeywell Analytics for advice.
The following types of notices are used throughout this Technical Manual:
WARNING
Identifies a hazardous or unsafe practice which could result in
severe injury or death to personnel.
Caution Identifies a hazardous or unsafe practice which could result in minor
injury to personnel, or product or property damage.
Note Identifies useful/additional information.
Every effort has been made to ensure the accuracy of our documents, however, Honeywell Analytics
can assume no responsibility for any errors or omissions in our documents or their consequences.
Honeywell Analytics greatly appreciates being informed of any errors or omissions that may be
found in the contents of any of our documents.
For information not covered in this document, or there is a requirement to send comments/
corrections about this document, please contact Honeywell Analytics.
Honeywell Analytics reserve the right to change or revise the information supplied in this document
without notice and without obligation to notify any person or organization of such revision or change.
If information is required that does not appear in this document, contact the local distributor/agent
or Honeywell Analytics.
Information

Contents
2106M0525 Iss 2 Nov 05 5
Safety 3
Information 4
Introduction 7
General 8
Installation 9
Location 10
Tools 11
Dimensions 11
Mounting 12
Electrical 13
Cabling 13
Power 15
Wiring 15
All Detectors EXCEPT Oxygen 17
Oxygen Detectors ONLY 17
Accessories 19
Fitting an Outer Filter 19
Maintenance 20
Operational Life 21
Sensor Replacement 21
Junction Box Replacement 23
Changing the Outer Filter 26
Fault Finding 27
Parts 28
Sensors 28
Other Parts 29
Accessories 29
Specifications 30
General 30
Detectable Gases 30
Electrical 31
Physical 31
Certification 31
Applicable Standards 31
Environmental 31
Contents

Contents
2106M0525 Iss 2 Nov 05 6

Introduction
2106M0525 Iss 2 Nov 05 7
The Sensepoint gas detector consists of a certified enclosure fitted with a replaceable certified gas
sensor that can be used to detect gas indoors or outdoors in ATEX certified hazardous areas in
Europe, and also in safe areas. It is protected against water and dust ingress to IP65 (IP66 with
Weather housing
fitted).
The detector is supplied with one of 3 types of sensor to monitor different gases present in ambient
air:
• Flammable
• Toxic
• Oxygen
Flammable detector (%LEL) — this version measures flammable gas concentrations below the
Lower Explosive Limit (LEL) of the target gas for which it is calibrated. It features a poison-resistant
catalytic pellistor sensor device which forms part of a bridge measuring circuit.
Toxic detector — detects toxic gas, present in ambient air. Detectors measuring gas in parts per
million (ppm) concentrations are available for detecting carbon monoxide (CO), hydrogen sulfide
(H2S), hydrogen (H2), sulfur dioxide (SO2), nitrogen dioxide (NO2), and ammonia (NH3) gas. The
Toxic and oxygen detectors feature a local amplifier for operation as part of a 4-20 mA circuit.
Oxygen detector — measures oxygen deficiency levels in air in percent by volume (%V/V)
concentrations.
The detector gas type is shown on a label on the enclosure’s lid.
Terminal Block
Earth
Terminal
Earth Plate
Mounting Lug
½”
Cable Entry
NPT
M20
Cable Entry
3/4” Cable EntryNPT
Sensor
Enclosure
Base
(GRP)
Sensor
Lock Nut
Lid Captive
Securing Screws
(4 off)
Cover
Gasket
Earth Continuity
Plate
Introduction

Introduction
2106M0525 Iss 2 Nov 05 8
All versions of the detector are designed for connection to a dedicated controller, e.g. Touchpoint1
or Touchpoint4(contact your distributor for details).
The detector’s construction allows unit dismantling for:
• gas sensors to be easily changed
• cabling to be routed and terminated
• commissioning/maintenance
• accessories to be fitted
The detector’s screw-in sensor cannot be repaired but is replaced as a complete unit.
The certified enclosure acts as a junction box and is fitted with 3 cable entries and a 4-wire terminal
block. The gas sensor is fitted to a tapped hole in the enclosure and is secured with a locknut.
The enclosure features a hinged lid that facilitates installation by a single technician when making
electrical connections/changing the sensor.
The terminal block is used to connect sensor power/signals to an external controller. The three cable
entry positions are fitted with approved seals. An earth continuity plate with earth terminal is fitted
for added RFI protection.
All the detector types can be fitted with a range of accessories, e.g. filter, weather housing, collecting
cone, and calibration gas flow adaptor.
Proper consideration must be made when locating the detector to ensure trouble free operation
throughout its life.
General
This document consists of the following chapters:
• Introduction
• Installation, see page 9
• Maintenance (including fault finding), see page 20
• Parts, see page 28
• Specification, see page 30
• Certification, see page 33

Installation
2106M0525 Iss 2 Nov 05 9
WARNINGS
Sensepoint is designed for installation and use in Zone 1 or 2 hazardous
areas in Europe. Installation must be in accordance with the recognized
standards of the appropriate authority in the country concerned.
Before carrying out any work ensure local regulations and site procedures
are followed. Appropriate standards must be followed to maintain
the overall certification of the detector.
Access to the interior of the detector, when carrying out any work, must only be
conducted by trained personnel. Switch off and isolate the power supply
to the detector when access is required.Take any necessary
precautions to prevent false alarms.
Never attempt to open a junction box/enclosure or replace/refit the sensor
when flammable/toxic gas is present.
The detector must be earthed for electrical safety and to limit the effects of
radio interference. An earth point is provided inside the unit. Ensure that
all screens/armor are grounded at a single earth star point at the controller
or detector - BUT NOT BOTH - to prevent false alarms due to earth loops.
Take care when handling sensors as they may contain corrosive solutions.
Do not tamper or in any way dis-assemble the sensor.
Do not expose to temperatures outside the recommended range.
Do not expose sensor to organic solvents or flammable liquids.
At the end of their working life, sensors must be disposed of in
an environmentally safe manner. Disposal should be according to local
waste management requirements and environmental legislation.
Alternatively, sensors may be securely packaged and returned to
Honeywell Analytics clearly marked for environmental disposal.
Electrochemical cells should NOT be incinerated as they
may emit toxic fumes.
When replacing the gas detector’s junction box ensure that the correct
gas label is affixed to the replacement enclosure.
Cautions The detector’s enclosure is suitable for installation within an
explosive atmosphere as described in EN50014.
Installation must be in accordance with EN60079 and current wiring
regulations of the country where the enclosure is installed.
The marking on the detector cover label must match the ambient
temperature where the enclosure is installed.
The detector enclosure is manufactured from glass-filled polyester
(GFP) and fitted with stainless steel cover fixing screws, neoprene (or
silicone) ‘O’ ring, and brass earth screws.
Installation

Installation
2106M0525 Iss 2 Nov 05 10
Contact with aggressive substances may affect the performance of
these materials.
The detector is intended for use under normal industrial conditions
and must not be installed in an area where extreme vibration may
occur.
The enclosure has been tested to IP66 and with the cover fully
tightened down and the use of suitable cable entry devices will
maintain this protection under normal working conditions, however a
minimum protection of IP64 must be achieved.
This chapter provides the following information about installing Sensepoint:
• locating the detector, see page 10
• tools required, see page 10
• detector dimensions, see page 11
• mounting the detector, see page 11
• cabling, see page 13
• power, see page 15
• wiring, see page 15
• fitting accessories, see page 19
Location
Honeywell can be installed indoors or outdoors.
The following sources give guidance when installing gas detectors:
• EN50073:1999 Guide for selection, installation, use and maintenance of apparatus for the
detection and measurement of combustible gases or oxygen
• International codes of practice
• specifications defining minimum gas detection requirements for specific applications
published by regulatory bodies
Mount the detector where gas is most likely to be present, noting the following points:
• for lighter-than-air gases mount the detector at a high level and preferably with the Collecting
Cone accessory fitted
• mount at a low level for heavier-than-air gases
• if installed outdoors always consider possible damage caused by natural events, e.g. rain or
flooding
• Ensure that a Weather Cover is fitted.
• ensure ease of access to the unit for commissioning and maintenance
• consider how escaping gas may behave due to natural or forced air currents
• check any associated process line conditions — gases may be normally heavier than air, but
if released from a process that is at an elevated temperature and/or under pressure, the gas
may rise rather than fall
• Document the agreed location of detectors

Installation
2106M0525 Iss 2 Nov 05 11
Follow the advice of:
• experts having specialist knowledge of gas dispersion
• experts having knowledge of the process plant system and equipment involved
• safety and engineering personnel
Tools
The following tools are required for installation:
• Hex Key, 4 mm (0.16 in.) A/F — for cover fixing screws.
• 7 mm (0.28 in.) drill — for mounting holes
Note Fixing screws/bolts are not supplied.
Dimensions
The subsequent diagrams show dimensions for Sensepoint.
Note Diagram not to scale

Installation
2106M0525 Iss 2 Nov 05 12
Mounting
Caution The enclosure must be fixed in position using the external mounting
lugs and not mounted using any type of cable entry device.
Sensepoint should be fitted to a flat firm surface suitable for the unit’s size and weight, e.g. a wall,
as follows:
1 Drill two mounting holes in the surface.
The surface should be flat and firm. For sizes, position, etc. see the previous dimension
drawing.
2 Mount the detector using its two mounting lugs.
Use M6 screws/bolts. Mount the unit with the gas sensor pointing downwards to ensure that
dust/water will not collect on the sensor, and to stop gas entering the detector.
Toxic/Oxygen
205.0 mm (8.1”)
76.5 mm (3.0”)
34.0 mm (1.3”)
Sensor
Cap
Enclosure
Sensor
Flammable
195.0 mm (7.7”)
Note Diagram not to
scale

Installation
2106M0525 Iss 2 Nov 05 13
Electrical
Caution Cabling and wiring must be in accordance with the recognized
standards of the appropriate authority in the host country and meet
the electrical requirements of the detector and controller.
Cabling
Cabling may be SWA cable or conduit run. Wire size 1.0 to 2.5 mm2(17 to 14 AWG) max., with
suitable M20 explosion-proof gland, or 1/2 in. NPT, or 3/4 in. NPT steel conduit. Use any of the 3
cable/conduit entries.
The following diagrams show how to earth bond Steel Wired Armored (SWA) cable at enclosures.
The same principles apply to conduit installations. These bonding techniques provide good RFI/
EMC performance. Ground/earth loops must be avoided to prevent false alarms.

Installation
2106M0525 Iss 2 Nov 05 14
To install cabling use the following procedure:
1 Open the lid of the enclosure.
Unscrew the four M4 captive securing screws, using a 4 mm (0.16 in.) A/F hex key wrench.
The lid is attached to the base by a retaining hinge. Lift the lid vertically away from the
enclosure base and then tilt it away from the base.
2 Fit the field cabling to the enclosure.
Use either of the following:
Conduit - Ensure that a conduit sealing fitting is placed within 18 in. of the enclosure on all
conduit runs.
Cable - using any suitable certified cable entry device.
Use armored multi-core cable, 2-wire plus screen for toxic/oxygen detector, 3-wire for
flammable detector. Cable entry devices must be selected in accordance with the marking
on the certification label on the cover of the enclosure.
Note All unused cable/conduit entries must be sealed with the supplied certified sealing
plug.
Star Ground/Earth Point
+ve
Signal
-ve
Gas Detector
Earth/Ground Point
Enclosure 1 Enclosure 2
To avoid bond
cable screens to ground/earth at the
detector controller, but both
ground loops ONLY
OR NOT

Installation
2106M0525 Iss 2 Nov 05 15
Power
The toxic detector requires a power supply of 16-30 Vdc (at up to 30 mA). Ensure that a minimum
supply of 16 Vdc is measured at the detector, taking into account the voltage drop due to cable
resistance. For example, the nominal DC supply at the control panel has a guaranteed minimum
supply of 18 Vdc. The maximum cable voltage drop allowed is therefore 2 Vdc.
The flammable detector requires 2.9 Vdc to 3.5 Vdc bridge (at 200 mA).
Refer to the control panel manual for allowable maximum cable lengths.
Wiring
Caution An earth point is provided inside the controller. Ensure that all
detector screens/armor are grounded at a single earth star point at
the detector or controller — BUT NOT BOTH — to prevent false
alarms due to earth loops.
All connections are made via the terminal block inside the detector housing.
1 Open the enclosure lid.
Unscrew the four M4 captive securing hex. screws, using a 4 mm (0.16 in.) A/F hex key
wrench. The lid is attached to the base by a retaining hinge. Lift the lid vertically away from
the enclosure base and then tilt it away from the base.
2 Terminate the field wiring.
Cautions All conductors must be fully tightened down within the terminals.
Conductor tightening screws must be below the surface of the
terminal and it is important that the correct sized screwdriver is used.
An oversized screwdriver will break the insulation around the
terminal.
The enclosure is fitted with an earth continuity plate and internal and
external earth studs. A suitable ring-type terminal lug must always be
used to secure the earth conductor.
See the following diagrams for connection details.

Installation
2106M0525 Iss 2 Nov 05 16
3 Close the lid of the enclosure and secure it.
Cautions Ensure there is no moisture inside the enclosure before closing
the lid.
Ensure the seal, between the body and the cover, is correctly
located and is secure.
Ensure the cover is securely clamped to the body of the enclosure.
Use only the captive fixing screws supplied, replacement with
alternative screws will invalidate certification.
Fully tighten the four M4 captive securing hex screws.
4 Carry out one of the following two procedures.
+ Supply (red) Signal (blue)
Screen
(braided wire)
Toxic/Oxygen
Detector
Center Tap
(white)
Non-
Sensitive
Element
(blue)
Sensitive
Element
(brown)
Earth
Terminal
Flammable
Detector

Installation
2106M0525 Iss 2 Nov 05 17
There is a procedure for all sensors except oxygen, and one for oxygen only. The procedure
activates the sensor before putting the detector into service.
All Detectors EXCEPT Oxygen
a. Remove the sensor cap.
Unscrew the cap in a counter-clockwise direction. Refer to the following diagram.
b. Remove the protective disc from inside the sensor cap.
Discard the disc.
c. Refit the sensor cap.
Screw the cap in a clockwise direction. If required fit an accessory. Refer to the instructions
supplied with the item except for fitting outer filters, see page 19.
Oxygen Detectors ONLY
a. Remove the sensor cap.
Unscrew the cap in a counter-clockwise direction. Refer to the following diagram.
b. Remove the protective disc from inside the sensor cap.
Discard the disc.
c. Remove the cell’s protective plug.
The plug is stuck to the face of the sensor’s cell using a light adhesive. Peel the plug off and
discard it.
Sensor Body
Sensor Cap
ac
Counter-clockwise Clockwise
Protective Disc
x
x
x
x
x
x
x x x
x
x
x
x
X
x
x
x
x
x
x
x
x
x
x
x
x
x
X
b
All Detectors
EXCEPT Oxygen

Installation
2106M0525 Iss 2 Nov 05 18
d. Remove the supplied RFI screen and inner filter from the packing bag.
e. Fit the two components to the sensor.
Fit them in the order shown in the diagram. Insert both of them evenly. Push the inner filter
into the neck of the sensor body until its locating tags click into place.
f. Refit the sensor cap.
Screw the cap in a clockwise direction. If required fit an accessory. Refer to the instructions
supplied with the item except for fitting outer filters, see page 19.
Power the unit and check for correct operation of the detector.
Check the gas reading at the controller. Refer to the controller’s user documentation.
e
Protective
Disc
x
x
x
x
x
x
x
x
x
x
x
x
x
X
x
x
x
x
x
x
x
x x
x
x
x
x
X
b
Sensor Cap
Cell
Protective Plug
c
adhesive face
af
Counter-clockwise Clockwise
d
Packing
Bag
RFI
Screen
Inner
Filter
Sensor Body
Cell
Oxygen ONLY
Oxygen ONLY

Installation
2106M0525 Iss 2 Nov 05 19
Accessories
The following accessories are available for use with the detector:
• weather housing
• flow housing
• collecting cone
• filters
Also see page 28.
To fit all the accessories refer to the instructions supplied with the item, except for fitting outer filters,
see the following procedure.
Fitting an Outer Filter
This procedure applies to all types of Sensepoint gas detector. Refer to the following diagram.
1 Remove the sensor cap (or accessory).
Unscrew the cap/accessory in a counter-clockwise direction.
2 Fit the outer filter.
The filter fits inside the Sensor Cap.
3 Refit the sensor cap (or accessory).
Screw the cap/accessory firmly in a clockwise direction.
Sensor Body
13
Sensor Cap
Counter-
clockwise
Clockwise
Outer Filter
2

Maintenance
2106M0525 Iss 2 Nov 05 20
WARNINGS
Sensepoint is designed for installation and use in Zone 1 or 2 hazardous
areas in Europe. Installation must be in accordance with the recognized
standards of the appropriate authority in the country concerned.
Before carrying out any work ensure local regulations and site procedures
are followed. Appropriate standards must be followed to maintain
the overall certification of the detector.
Access to the interior of the detector, when carrying out any work, must only be
conducted by trained personnel. Switch off and isolate the power supply
to the detector when access is required.Take any necessary
precautions to prevent false alarms.
Never attempt to open a junction box/enclosure or replace/refit the sensor
when flammable/toxic gas is present.
The detector must be earthed for electrical safety and to limit the effects of
radio interference. An earth point is provided inside the unit. Ensure that
all screens/armor are grounded at a single earth star point at the controller
or detector - BUT NOT BOTH - to prevent false alarms due to earth loops.
Take care when handling sensors as they may contain corrosive solutions.
Do not tamper or in any way dis-assemble the sensor.
Do not expose to temperatures outside the recommended range.
Do not expose sensor to organic solvents or flammable liquids.
At the end of their working life, sensors must be disposed of in
an environmentally safe manner. Disposal should be according to local
waste management requirements and environmental legislation.
Alternatively, sensors may be securely packaged and returned to
Honeywell Analytics clearly marked for environmental disposal.
Electrochemical cells should NOT be incinerated as they
may emit toxic fumes.
When replacing the gas detector’s junction box ensure that the correct
gas label is affixed to the replacement enclosure.
This chapter describes the following:
• expected operational life of the sensor
• gas sensor replacement, see page 22
• replacing a junction box, see page 24
• changing the outer filter, see page 26
• troubleshooting, see page 26
Maintenance