Intec Controls PolyGard AT-3300 V3 User manual

Customer Services [phone] & (888) GO INTEC
INTEC Controls, 12700 Stowe Dr., Suite 110, Poway, CA 92064
Fax [phone] & (888) FX INTEC
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Specication subject to change without notice.
Printed in USA 150313
March 13, 2015 – Revision
Polygard® is a registered trademark of MSR AT-3300_V3_UserManual
PolyGardAT-3300 V3
Transmitter for Combustible Gases
Serial No. ET03-002
User Manual
April 2009
12700 Stowe Drive, Suite 100, Poway, CA 92064 | Ph: [phone] & (888) GO.INTEC | relevantsolutions.com/inteccontrols
Polygard® is a registered trademark of MSR | AT-3300_V3_UserManual
January 04, 2016 – Revision

Printed in USA 150313
Page 02
1Intended Use...............................................................................................................................3
2Functional Description .........................................................................................................3
2.1 Control Mode.............................................................................................................................3
2.2 Sensor .......................................................................................................................................3
3 Installation....................................................................................................................................4
3.1 Mounting Instructions ................................................................................................................4
3.2 Installation .................................................................................................................................4
4Electrical Connection ............................................................................................................5
4.1 Wiring Connection .....................................................................................................................5
5Commissioning .........................................................................................................................5
5.1 Calibration .................................................................................................................................6
5.1 Manual Calibration ....................................................................................................................6
5.1.1 Zero-point...............................................................................................................................6
5.1.2 Gain .......................................................................................................................................6
5.1.3 Calculation of Control Voltage ...............................................................................................6
5.2 Calculation calibration gas < >target gas (backup calibration) .................................................7
Cross-sensitivity data AT-34XX V3.....................................................................................................7
5.3 Option Relay Output..................................................................................................................8
6Inspection and Service.........................................................................................................9
6.1 Inspections ................................................................................................................................9
6.2 Calibration .................................................................................................................................9
6.3 Exchange of Sensor Element....................................................................................................9
7Troubleshooting .......................................................................................................................9
7.1 Analog Mode .............................................................................................................................9
8Technical Data .........................................................................................................................10
9 Figures..........................................................................................................................................11
10 Notes and General Information...................................................................................14
10.1 Intended Product Application...............................................................................................14
10.2 Installers’ Responsibilities ...................................................................................................14
10.3 Maintenance ........................................................................................................................14
10.4 Limited Warranty..................................................................................................................14
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Page 03
Transmitter with cathalytic bead sensor for combustible gases and vapours
1 Intended Use
The PolyGard gas transmitter with digital processing of the measuring values and temperature compensation
is used for the continuous monitoring of the ambient air to detect the presence of combustible gases and
vapours, such as natural gas, methane, propane, butane and ammonia etc. below the lower explosion limit
(LEL). The transmitter is used for monitoring leakages in gas pipes, gas fan heaters, gas heating systems, gas
engines (block heating stations), gas boilers, gas fittings, gas transfer stations, gas valves, natural-gas fuelling
stations, domestic gas boiler installations, gas operated vehicles in underground car parks etc.
The intended sites are all areas being directly connected to the public low voltage supply, e.g. residential,
commercial and industrial ranges as well as small enterprises (according to EN50 082).
The PolyGard® AT-33XX transmitter must not be used in potentially explosive atmospheres.
2 Functional Description
2.1 Control Mode
Analog mode:
The analog output can be selected as current signal with (0)4-20 mA or as voltage signal (0)2-10 V.
2.2 Sensor
The integrated sensor works according to the catalytic bead principle. The ambient air being monitored diffuses
through a sintered metal disk into the sensor. Here the combustible gases and vapours are burned by catalytic
means at a heated detector element (pellistor). The resulting combustion heat also heats up the detector
element. This heating changes the resistance of the detector element which is proportional to the partial
pressure of the combustible gases.
In addition to the catalytic detector element, the sensor also has a similarly heated inactive compensator
element. Both elements are part of a Wheatstone measuring bridge. Environmental influences such as
temperature, ambient moisture or thermal conductivity of the monitored ambient air affect both elements to the
same extent so that the influences on the measuring signal are almost completely compensated.
The integrated measuring amplifier converts this sensor current into a linear output signal. The zero point
(Zero) and the amplification (Gain) are calibrated by potentiometers.
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Page 04
Certain substances and gases in the monitored ambient can affect the sensitivity of the sensor, or poison the
sensor completely.
The following are currently known:
- polymerising substances, such as ethylene oxide, acrylonitrile, butadiene, styrene, silicone.
- corrosive substances, such as halogenated hydrocarbons.
- catalytic poisons, such as sulphur and phosphor compounds, silicon compounds, metal vapours.
Caution:
There is a small quantity of corrosive liquid in the sensor element. If in case of damage a person or an area
comes in contact with the liquid, the affected person or area must wash the liquid off with water immediately.
Out of use sensors must be disposed in the same way as batteries.
3 Installation
Note:
Avoid any force (e.g. by thumb) on the sensor element during operation or installation. Electronics can be
destroyed by static electricity. Therefore, do not touch the equipment without a wrist strap connected to ground
or without standing on a conductive floor (acc. to DIN EN100015).
3.1 Mounting Instructions
When choosing the mounting site please pay attention to the following:
• The mounting height depends on the gas type to be monitored.
For gases and vapours with a density >air, the transmitter must be located near the ground.
For gases and vapours with a density < air, the transmitter must be located at the highest point
possible. Gas density and mounting height can be read from the table Cross-sensitivity data.
• Choose mounting location of the sensor according to the local regulations.
• Consider the ventilation conditions! Do not mount the transmitter in the centre of the airflow (air
passages, suction holes).
• Mount the transmitter at a location with minimum vibration and minimum variation in temperature
(avoid direct sunlight).
• Avoid locations where water, oil etc. may influence proper operation and where mechanical damage
might be possible.
• Provide adequate space around the sensor for maintenance and calibration work.
Duct mounting
• Mount only in a straight section of duct with minimum air vortex. Keep a minimum distance of 1 m (3,5
feet) from any curve or obstacle.
• Mount only in a duct system with a maximum air velocity of 10 m/s (2000 ft/min) or less.
• Mounting must be performed so that the probe openings are in line with the airflow.
3.2 Installation
• Open the cover. Unplug basic PCB carefully from the bottom part.
• Fix bottom part by screws vertically to the wall (terminal blocks to the ground).
• Plug in the basic PCB at X4 and X5 with care. Replace the cover.
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4 Electrical Connection
Consider static electricity! See 3. Mounting
• Installation of the electrical wiring should only be performed by a trained specialist according to the
connection diagram, without any power applied to conductors and according to the corresponding
regulations!
• Avoid any influence of external interference by using shielded cables for the signal line, but do not
connect the shield.
• Recommended cable analog mode: (20 AWG), max. res. 73 Ω/km (20.8 Ω/1000 ft).
• It is important to ensure that the wire shields or any bare wires do not short the mounted PCB.
4.1 Wiring Connection
• Open the cover. Unplug basic PCB carefully from terminal blocks at X4 and X5.
• Insert the cable, connect cable leads to terminal blocks. See fig. 1 and 2.
• Replug the PCB in the terminal blocks X4, X5. Replace cover.
5 Commissioning
Consider commissioning instructions at any exchange of sensor elements.
Only trained technicians should perform the following:
• Check mounting location.
• Select output signal form: Current or voltage, and starting point 0 or 20%. See fig. 4.
• Check power voltage.
• Check PCB AT-33XX V3 for proper mounting at X4 and X5.
• Check the sensor for proper mounting at the connectors X8 of the PCB AT-33XX V3 (only AT-34XX
V3).
• Calibrate the transmitter (if not already factory-calibrated).
Required instruments for commissioning (calibration) of the transmitter:
• Test gas bottle with synthetic air (20 % O2, 80 % N).
• Test gas bottle with test gas (methane etc.) in the range of 30 – 60 % of the measuring range.
• Gas pressure regulator with flow meter to control the gas flow to 150 ml/min.
• Calibration adapter with tube, (silicon-free, e.g. Viton). Calibration set CALKIT-AT. See fig. 06.
• Digital voltmeter with range 0 – 10VDC, accuracy 1% and a small screwdriver.
Note: Prior to calibration the sensor element must be fully stabilized by applying power voltage for at least 4
hour without interruption.
Please observe proper handling procedures for test gas bottles (regulations TRGS 220)!
Attention: Combustible calibration gases are toxic, never inhale the gas!
Symptoms: Dizziness, headache and nausea.
Procedure if exposed: Take the victim into fresh air at once, call a doctor.
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5.1 Calibration
Depending on the version and the control mode there are three different possibilities to calibrate the
transmitter:
5.1 Manual Calibration
5.1.1 Zero-point
• Connect calibration adapter carefully to the sensor element.
• Apply synthetic air (150 ml/min; 1 Bar (14.5 psi ) ± 10%).
• Wait 2 minutes until the signal is stable, push button “Zero” for 5 seconds.
After successful calibration the measuring signal is corrected automatically. Depending on the
selected signal starting point the measuring signal shows the following values:
Signal start at 2 V or 4 mA 40 mV = 0 ppm
Signal start at 0 V or 0 mA 0 mV = 0 ppm
If the zero-point is out of the admissible range (> 20 mV at starting point 0% / > 60 mV at starting
point (20%) before calibration, there is no correction of the measuring signal. The sensor has to be
replaced.
• Remove calibration adapter carefully by turning lightly. Check the sensor for correct mounting!
5.1.2 Gain
• Connect calibration adapter carefully to the sensor element.
• Apply calibration test gas (150 ml/min; 1 Bar (14.5 psi) ± 10%).
• Wait two minutes until the signal is stable, adjust control voltage with potentiometer ”Gain” until the
signal corresponds to the calculated value ± 3 mV, see calculation section 5.2.3.
• Remove calibration adapter with a careful light turn. Check the sensor for correct mounting!
By limiting the gain factor, calibration will not be possible any more when the sensitivity of the sensor
reaches a residual sensitivity of 30 %. Then the sensor has to be replaced.
5.1.3 Calculation of Control Voltage
Signal start 2 V / 4 mA
Control voltage (mV) = 160 (mV) x test gas concentration (% LEL) + 40 (mV)
measuring range (% LEL)
Signal start 0 V / 0 mA
Control voltage (mV) = 200 (mV) x test gas concentration (% LEL)
measuring range (% LEL)
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Example:
Measuring range 100 % LEL
Test gas concentration 40 % LEL (methane)
Control voltage: Signal start 2 V / 4 mA 104 mV
Control voltage: Signal start 0 V / 0 mA 80 mV
Signal start 2 V / 4 mA Signal start 0 V / 0 mA
160 (mV) x 40 (% LEL) + 40 (mV) = 104 mV 200 (mV) x 40 (% LEL) = 80 mV
100 (% LEL) 100 (% LEL)
5.2 Calculation calibration gas < >target gas (backup calibration)
ÜWGas = KALGas x ( KGas / ÜGas) ÜWGas = Target gas % LEL
KALGas = Calibration gas % LEL
K
Gas = Factor relative sensitivity % LEL calibration gas
Ü
Gas = Factor relative sensitivity % LEL target gas
Example:
Calibration gas 30% LEL/Methane
Target gas Propane
30 % LEL/methane x (100/63) 47.6% LEL/Propane
The factor of the relative sensitivity can be read from the table cross sensitivity data.
Cross-sensitivity data AT-33XX V3
Type of gas/vapour Chemical mark
Sensitivity1%
% LEL/Methane
LEL/
% v/v
Gas Density
Air = 1
Mounting
high
Acetone
(CH3)2CO
50
2.60
2.00
Floor
Acetylene
C2H2
47
2.00
0.90
Ceiling
Benzene
C6H6
44
1.30
2.70
Floor
Cyclohexane
C6H12
44
1.30
2.91
Floor
Ethylene
CH2
81
2.30
0.98
Ceiling
Ethane
C2H6
82
3.00
1.05
Floor
Ethyl Alcohol
C2H5OH
75
3.30
1.59
Floor
Ethyl Acetate
CH3COOC2H5
46
2.20
3.04
Floor
Ethylene Oxide
C2H4O
52
2.60
1.52
Floor
Hydrogen
H2
107
4.00
0.07
Ceiling
JP8 25 0.7
JET_A 46 0.7
Methane CH4100 4.40 0.55 Ceiling
Methanol CH3OH 84 6.70 1.11 Floor
n-Butane C4H10 51 1.80 2.11 Floor
n-Heptane C7H16 44 1.05 3.46 Floor
n-Hexane C6H14 46 1.02 2.98 Floor
n-Octane C8H18 38 0.95 1.66 Floor
Propane C3H863 1.70 1.55 Floor
n-Pentane C5H12 50 1.40 2.49 Floor
1according to information of the sensor manufacturer.
The table does not claim to be complete. Other gases can have an influence on the sensitivity, too.
7KHindicated sensitivity data are only standard values referring to new sensor elements.
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5.3 Option Relay Output
The two relays are activated in dependence of the gas concentration. If the gas concentration exceeds the
adjusted alarm threshold, the corresponding relay switches on. If the gas concentration falls below the
threshold minus hysteresis, the relay switches off again.
The contact function for relay 2, NC (normally closed) or NO (normally open), can be selected via the jumper
NO/NC. See fig 1 and 3. Relay 1 is equipped with a change-over contact.
Via the MODBus interface the two alarm thresholds and the hysteresis are freely adjustable at the PC within
the measuring range. The procedure can be read from the user manual “MODBus Software”.
The following parameters are factory-set.
Alarm threshold 1 = Relay 1: 10 % LEL
Alarm threshold 2 = Relay 2: 20 % LEL
Switching hysteresis: 5 % LEL
Specifications subject to change without notice. | USA 151203 | Page 8of 14
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Page 09
6 Inspection and Service
6.1 Inspections
Inspection, service and calibration of the transmitters should be done by trained technicians and executed at
regular intervals. We therefore recommend concluding a service contract with MSR or one of their authorized
partners.
6.2 Calibration
(See section 5.1 and 5.2)
•At commissioning and at periodic intervals determined by the person responsible for the gas detection
system (recommendation every 12 months).
•After exchange of the sensor
•If in case of operational or climatic influences the sensitivity of the sensor falls below 70 % in
operation, calibration will not be possible any more. Then the sensor has to be changed.
6.3 Exchange of Sensor Element
Consider static electricity! See point 3.
Sensor should always be installed without power applied:
•Unplug basic PCB AT-33XX V3 carefully from the bottom part.
•Unplug old sensor from the PCB.
•Take the new sensor out of the original packing.
•Plug in the sensor element into the PCB ET03 at XB7/XB8.
•Replug the PCB AT-33XX V3 into terminal blocks X4, X5 carefully.
•Calibrate according to section 5.
7 Troubleshooting
7.1 Analog Mode
Trouble Cause Solution
Jumper 0-20 % not set Check jumper position
Power voltage not applied
Measure tension at X4:
Two-wire: Pin 1 (+) and 4 (-)
Three-wire: Pin 1 (+) and 2 (-)
PCB AT-33XX V3 not plugged in
correctly at X4 and X5
Replug PCB correctly
Output signal < 3 mA / 1,5 V
and/or control voltage < 30 mV
only for starting signal 2V/4 mA
Wire break Check the wiring
Output signal > 22 mA /220 mV Short-circuit Check the wiring
Sensor element not calibrated Calibrate sensor element
Control voltage does not reach
the calculated value Sensor sensitivity < 30 % Replace sensor element
Power voltage not applied Measure tension at X4
No reaction of the output signal
in spite of gas concentration Signal (Pin 4) not wired correctly Check the wiring
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Page 10
8 Technical Data
General sensor performances
Gas type Combustible gases/ vapours
See Ordering Information
Sensor element Ex sensor, catalytic bead
Pressure range Atmosphere ± 20 %
Storage temperature range 5 °C to 30 °C (41 °F to 86 °F)
Storage time Max. 6 months
Mounting height Depending on gas type
AT-33XX V3
Measuring range 0 - 100 % LEL
Detection limit 0,5 % LEL
Accuracy ± 1 % of signal/methane
Repeatability ± 2 % of signal/methane
Long-term zero drift < 5 % measuring range/year
Long-term sensitivity drift < 2 % measuring range/month
Response time t90 < 10 sec./methane
Life expectancy > 3 years/normal operating environment
Temperature range - 10 °C to + 40 °C (14 °F to 104 °F)
Humidity, continuous 15 – 90 % RH non condensing
Humidity, intermitted 0 – 99 % RH non condensing
Electrical
Power supply 16 - 28 VDC/AC, reverse polarity protected
Power consumption (without options) 35 mA, max. (0,85 VA)
Output signal
Analog output signal
Selectable: Current / tension
Starting point 0 / 20 %
(0) 4 – 20 mA, load ≤ 500 Ω,
(0) 2 - 10 V; load ≥ 50 k Ω
proportional, overload and short-circuit proof
Serial interface
Transceiver RS 485 / 19200 Baud
Protocol, depending on version MSR_DT05 or MOD_Bus
Physical
Enclosure* Stainless steel V2A
Enclosure colour* Natural, brushed
Dimensions* (H x W x D) 113 x 135 x 45 mm /(5.35 x 4.5 x 1.8 in.)
Weight* Approx. 0,5 kg (1.1 Ibs.)
Protection class* IP 55
Mounting* Wall mounting, pillar mounting
Cable entry Standard 1 x M 20
Wire connection Screw-type terminal min. 0,25, to. 2,5 mm2
24 to 14 AWG
Wire distance Current signal ca. 500 m (1500 ft.)
Voltage signal ca. 200 m (500 ft.)
Specifications subject to change without notice. | USA 151203 | Page 10 of 14
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Page 11
Guidelines EMC Directive 2004 / 108 / EWG
CE
Options
Relay output
Alarm relay 1 (switch threshold 10 % LEL) 30 VAC/DC 0,5 A, potential-free, SPDT
Alarm relay 2 (switch threshold 20 % LEL) 30 VAC/DC 0,5 A, potential-free, SPNO/SPNC
Power consumption 30 mA, (max. 0,8 VA)
Warning buzzer
Acoustic pressure 83 dB (distance 200 mm) (0.7 ft.)
Frequency 2,3 kHz
Power consumption 30 mA, (max. 0,8 VA)
LCD-Display
LCD Two lines, 16 characters each, not illuminated
Power consumption 10 mA, (max. 0,3 VA)
Heating
Temperature controlled 3 °C ±2°C (37.5 °F ± 3,6 °F)
Ambient temperature - 30 °C (- 22 °F)
Power supply 18 - 28 VDC/AC
Power consumption 0,3 A; 7,5 VA
* Indications only for option "stainless steel", for further types see datasheet AT-DT Enclosure.
9 Figures
Application: Analog mode
Fig. 1
Controller
Transmitter
ADTX3
0 VDC
4-20 mA
24 VDC
X4
1
2
3
4
5
6
7
0 VDC
24 VDC_Out
24 VDC
Analog_Out
4-20 mA_Inp
Bus_A
Bus_B
X5
R1 2
3
4
5
1
R2
Option
Relay
NO NC
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Page 12
PCB ADT03
Fig. 3
Terminal block
Selection analog output signal
Fig. 4
Jumper 0- 20 % Jumper V-A Output signal
Not set Not set 0 – 20 mA
Set Not set 4 – 20 mA
Not set Set 0 – 10 V
Set Set 2 – 10 V
54321
1234567
X5
X4
7
6
5
4
3
2
1
4
2
3
1
5
R2
X4
V-A
NO NC
XA3-1 XA3-2
Gain
ET03_001
0-20%
Test
Bridge
Connector
Service Tool
R1
X5
Zero
Option
Relay
Anal. Output
= V DC
= mA
Anal. Output
Start Point
= 20 %
= 0 %
Function Relay R2
NO/NC
= NC = NO
Option
Manual
Calibration
Sensor
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Calibration adapter
Fig. 5
Type: CONKIT-COMB-AT
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10 Notes and General Information
It is important to read this user manual thoroughly and clearly in order to understand the information
and instructions. The PolyGard® transmitter must be used within product specication capabilities. The
appropriate operating and maintenance instructions and recommendations must be followed. Due to on-
going product development, INTEC and MSR reserves the right to change specications without notice.
The information contained herein is based upon data considered accurate. However, no guarantee is
expressed or implied regarding the accuracy of this data.
10.1 Intended Product Application
The PolyGard®transmitter is designed and manufactured for control applications and air quality compliance
in commercial buildings and manufacturing plants (i.e. detection and automatic exhaust fan control for
automotive maintenance facilities, enclosed parking garages, engine repair shops, warehouses with
forklifts, re stations, tunnels, etc.).
10.2 Installers’ Responsibilities
It is the installer’s responsibility to ensure that all PolyGard®transmitter is installed in compliance with all
national and local codes and OSHA requirements. Installation should be implemented only by technicians
familiar with proper installation techniques and with codes, standards and proper safety procedures for
control installations and the latest edition of the National Electrical Code (ANSI/NFPA70). It is also essential
to follow strictly all instructions as provided in the user manual.
10.3 Maintenance
It is recommended to check the PolyGard®transmitter regularly. Due to regular maintenance, any
performance deviations may easily be corrected. Re-calibration and part replacement in the eld may be
implemented by a qualied technician and with the appropriate tools. Alternatively, the easily removable
plug-in transmitter card with the sensor may be returned for service to INTEC Controls.
10.4 Limited Warranty
MSR-Electronic-GmbH and INTEC Controls warrants the PolyGard®transmitter for a period of two
years, 12 months normal exposure for the sensor, from the date of shipment against defects in material
or workmanship. Should any evidence of defects in material or workmanship occur during the warranty
period, INTEC Controls will repair or replace the product at their own discretion, without charge.
This warranty does not apply to units that have been altered, had attempted repair, or been subject to
abuse, accidental or otherwise. The warranty also does not apply to units in which the sensor element
has been overexposed or gas poisoned. The above warranty is in lieu of all other express warranties,
obligations or liabilities.
This warranty applies only to the PolyGard®transmitter. INTEC Controls or MSR shall not be liable for
any incidental or consequential damages arising out of or related to the use of the PolyGard®transmitter.
If the PolyGard® transmitter needs to be returned to INTEC Controls for service, an RMA number must be
obtained prior to sending.
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