Prosense P Series User manual

PRS‐UM ‐P‐EN‐Rev.0
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2
PRS‐UM‐P‐EN‐Rev.01‐08.2018
WARNING!
This manual must be carefully read by all persons who have or will have the
responsibility for installing, using or servicing this product.
Like any equipment, this product will perform as designed only if installed,
used and serviced in accordance with the manufacturer’s instructions.
Otherwise, it could fail to perform as designed and persons who rely on this
product for their safety could suffer severe personal injury or death.
The warranties made by Prosense with respect to this product are voided if the
product is not installed, used and serviced in accordance with the instructions
in this user guide. Please protect yourself and other by following them.
ImportantRemark
Thedetectorhasbeenfactory‐testedbeforedelivery,thecommissioning
afterinstallationmustincludethezero‐andspan‐adjustment.The
commissioninghastobeterminatedbyafunctiontestofthecompletegas
detectionsystem.

3
PRS‐UM‐P‐EN‐Rev.01‐08.2018
Contents
ForYourSafety...........................................................................................................................................4
StrictlyfollowtheInstructionsforUse...............................................................................................4
Maintenance......................................................................................................................................4
Useinareassubjecttoexplosionhazards.........................................................................................4
Liabilityforproperfunctionordamage.............................................................................................4
IntendedUse......................................................................................................................................4
Introduction................................................................................................................................................6
Detectorbody.............................................................................................................................................7
SensorHead:..............................................................................................................................................7
Installation:.................................................................................................................................................8
Mountingthedetector:..............................................................................................................................9
Electricalconnections...............................................................................................................................10
Cabling......................................................................................................................................................11
Detectorgrounding..................................................................................................................................12
Defaultconfiguration...............................................................................................................................13
DetectorConfiguration.............................................................................................................................14
4‐20mAoutput:.......................................................................................................................................14
DetectorRS485serialcommunication:....................................................................................................14
DetectorRelaymodule:............................................................................................................................16
SystemStatus...........................................................................................................................................18
Firsttimeswitchon(Commissioning)..................................................................................................18
Calibration................................................................................................................................................19
Maintenance............................................................................................................................................20
Proactivemaintenance:........................................................................................................................20
OperationalLife:...................................................................................................................................20
Servicing...............................................................................................................................................21
Sensorreplacement:............................................................................................................................21
Sinterreplacement:..............................................................................................................................21
Sensorheadreplacement:...................................................................................................................21
Generalspecification................................................................................................................................22
Warrantystatement.................................................................................................................................23


4
PRS‐UM‐P‐EN‐Rev.01‐08.2018
For Your Safety
EnsurethatthisOperatingManualisreadandunderstood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OperatingManual.Cautionsappearinthesections/sub‐sectionsofthe
documentwheretheyapply.
Strictly follow the Instructions for Use
Anyuseofthedetectorsrequiresfullunderstandingandstrictobservationofthese
instructions.Thedetectorisonlytobeusedforpurposesspecifiedhere.
Maintenance
ItisrecommendedtoobtainaservicecontractProsensetocarryoutallrepairs.Only
authenticProsensesparepartsshouldbeusedformaintenance.Pleasecheck“Maintenance”
sectionformoredetails.
Use in areas subject to explosion hazards
Equipmentorcomponentswhichareusedinpotentiallyexplosiveatmospheresandhave
beentestedandapprovedaccordingtointernationalorEuropeanregulationsmaybeused
onlyundertheconditionsspecifiedhere.Modificationsofcomponentsortheuseoffaultyor
incompletepartsarenotpermitted.Incaseofrepairsofequipmentorcomponents,the
nationalregulationsmustbeobserved.
Liability for proper function or damage
Theliabilityfortheproperfunctionofthedetectorisirrevocablytransferredtotheowneror
operatortotheextentthatthedetectorisservicedorrepairedbypersonnelnotemployedor
authorizedbyProsenseorifthesensingheadisusedinamannernotconformingtoits
intendeduse.Prosensecannotbeheldresponsiblefordamagecausedbynon‐compliance
withtherecommendationsgivenabove.Thewarrantyandliabilityprovisionsofthetermsof
saleanddeliveryofProsensearelikewisenotmodifiedbytherecommendationsgivenabove.
Intended Use
ThePseriesdetectorsareintendedtobeusedforstationary,continuousmonitoringfor
combustiblegas/airorvapour/airmixturesbelowtheLowerExplosionLimit(LEL)resp.below
10%oftheLELunderatmosphericconditions.Thedetectorsaremarkedbythedevice
categoriesII2G.Thuscanbeoperatedinhazardousareaswithpotentiallyexplosive
atmospheresofzones1and2.Thetypeofprotectionforgasexplosionprotectionaccording
todevicecategory2(zones1or2)isflameproofenclosureandincreasedsafety,"d".The
enclosureprotectionisIP65.
AccordingtotheATEXDirective2014/34/EUthedetectorisanassemblyconsistingofthree
components(SensorHead,enclosureandcablegland),whereallthesethreecomponentsare
typeapprovedaccordingtoATEXDirective2014/34/EUandmarkedbythedevicecategoryII
2G.Thusthisdetectorissuitabletobeoperatedinhazardousareaswithpotentiallyexplosive

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PRS‐UM‐P‐EN‐Rev.01‐08.2018
atmospheresofzone1andzone2.ThePseriesdetectorscomprisesagassensortypeEx‐
proof(protectiontypeflameproofenclosuredtype).Itmustnotbeoperatedatambient
temperatureslowerthan–20(°C).Themaximumambienttemperatureis50(°C)for
temperatureclassT6.
Nottobeusedinoxygenenrichedatmospheres
InconjunctionwiththecentralcontrollersProsensedetectorswithpreadjusted
alarmthresholdsaudibleandvisiblealarmdevicesorautomaticcountermeasures
canbeactivatedbeforethedetectedgasesorvapourscanformdangerous
flammableortoxicmixtureswithair.
Pleasebealertedinfollowingspecialconditionsmayhaveimpactonmeasuringfunctiondue
tothenatureofmeasuringmethod:

1.Veryhighgasconcentrations
InfraredandPellistorsensorsusedtodetectflammableandtoxicgases.Themeasuring
methodbasedonheatproducedbyreactiononthecatalyticoxidationofaflammablegas
whenpellistorsensorused.Incaseofhighgasconcentrationsthereisnotenoughoxygenin
thesensortoperformoxidationprocesscorrectly.Hencethemeasuringsignaldecreasesat
highgasconcentrationsandevencanleadtomeasuringsignalwithinthemeasuringrange
again.Aconnectedcontrollermustbeoperatedwithalarmdevices,outputs,andalarm
thresholdsoperatingaslatchedifthemeasuringrangeisexceeded.Inthiscasedonotreset
latchingalarmswithouthavingensuredasafeconditionbymeansofanindependentgas
concentrationsmeasurement.
2.Minimumoxygenconcentration
Themeasuringprincipleofheatofreactionneedsaminimumoxygenconcentrationof12%
byvol.,otherwisethemeasuringvalueswillbetoolowbecauseofoxygendeficiency.
3.Long‐termgassingwithmethaneatverylowtemperatures
IftheProsensePseriesflammablegasdetectorsareoperatedapplyingwithmethaneatvery
lowtemperatures,themeasuringsignalatlongtermexpositionmaydecreaseafteralarm
activationandmayleadtomisinterpretation.
Ifagasalarmoccurs,necessaryactionsneedtobetakenimmediately.Thedecreaseofthe
measuringsignalshouldnotmeanthatthegasconcentrationhasbeendecreased.We
recommendtokeepalarmsontheassociatedcontrollersandnottoresetthesealarms
withoutperformingmeasurementwithanindependentgazdetectorstomakesure
conditionsaresafe.

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PRS‐UM‐P‐EN‐Rev.01‐08.2018
Introduction
TheProsensecomprisesagasdetectorbodyandachoiceofsensorsheadsfordetecting
flammablegas,toxicgasandoxygen.TheconstructionofProsenseallowsittobeusedin
hazardousarealocations;itmayalsobeusedinotherareasnotclassifiedashazardous.

Prosensedetectorscanbeconfiguredwithawiderangeofdifferentsensorsmaybeusedto
detectabroaderrangeoftargetgases.Thedetectorcanbeconfiguredwithoptionalrelay
boardfeaturesthreeprogrammablerelaysforcontrollingexternalequipmente.g.alarms,
sirens,valvesorswitches.Thedetectorprovidesanindustrystandard3‐wire,4‐20mAsource
orsinkoutputforconnectiontoadedicatedgasdetectioncontrolsystemorPLC.

Prosensedetectorscomprisesofthemainpartsasshownbelow:




Diagram1:Explodedview

Cover
Body
Mountingplate
Lockinggrubscrew
Fieldcableentriesx2
Sensorheadsocket
Sensorheadbody
Sensorholder
Sinter
Sensorheadcab
Sinternut
Lockinggrubscrew

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PRS‐UM‐P‐EN‐Rev.01‐08.2018
Detector body
Thedetectorenclosurehasthreethreadedentries.Thetwocableentrieseithersideofthe
upperpartofthetransmitterhousingareforconnectingthepowersource,signaloutput
andrelaycontactstoassociatedsignallingequipment.Thebottomentryallowsdirect
connectionofthesensorsocket.Thereisamountingplateincorporatedintothetransmitter
housingallowingforvariousmountingconfigurationoptions.


Diagram2:DetectorbodyandSensorHeadcomponents

1:Sensorheadbody
2:Sensorholder
3:Sensorheadcap
4:Sinternut
5:Sinter
6:Junctionbox–Detectorbody
7:Wallmountingadapter
8:Junctionboxcover
Sensor Head:
TheProsensesensorheaddesignedtodedectflammable,toxicgaeseandoxygen.Theymay
includeNDIRinfrared,pellistororelektrocjemicalsensorsdependingofthetargetgasand
range.

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PRS‐UM‐P‐EN‐Rev.01‐08.2018
Installation:
Gasdetectorsshouldbemountedwhereapotentialhazardofgasismostlikelytobe
present.Thefollowingpointsshouldbenotedwhenlocatinggassensors.
 Whenlocatingdetectorsconsiderthepossibledamagecausedbynaturaleventse.g.
rainorflooding.
 Considereaseofaccesstothegasdetectorforfunctionaltestingandservicing.
 Considerhowescapinggasmaybehaveduetonaturalorforcedaircurrents.
Note:Theplacementofgasdetectorsshouldbedeterminedfollowing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.Theagreementreached
onthelocationofdetectorsshouldberecorded.
Eachgashasdifferentnaturedependingontheirdensity.Thedensityofwhichislowerthan
air,suchashydrogen,methaneorammoniathesensorheadmustbelocatedabovea
possibleleakoratthehighestpointsatwhichmajorconcentrationsofgasmaybefound.
Thegasesandvapourswithadensitygreaterthanair,thesensorheadmustbeinstalled
beneathapossibleleakoratthelowestpointsatwhichsuchgasesandvapoursmaybe
present.
Prosensemayprovidecableglandtogetherwithdetectorinregardstocustomerrequests.
ThecableglandprovidedbyProsensehasATEXcertificationandprovidesatleastIP65level
protection.Thecableglandsareonlysuitableforfixedinstallations.Cablesshallbe
effectivelyclampedtopreventpullingortwisting.Toprovidenecessaryprotectioncable
glendcouplingshouldbefixedwith20Nmtorquewhenusedwiththreesealings;18Nm
whenusedwithtwosealings;16Nmwhenusedwithonesealing.Itisthefinal
assamblers/usersresponsibilitytoensurethethreadedjointbetweencableglandandthe
enclosuremeetalltherequirementsoftheapplicablestandartsfortheassembly.Cable
glandsealingsaresuitableforthecirculartypecables.Ifothershapedcableswillbeusedthe
sealingsshouldbereplacedwithsuitableones.ThecableglandsprovidedbyProsenseare
suitabletousetemperaturerangeinwhichdetectorworks.
Prosensemayprovideplugsandadaptorstogetherwithdetectorinregardstocustomer
requests.TheplugsandadaptorsprovidedbyProsensehaveATEXcertificationandprovides
atleastIP65levelprotection.Thesepartsshouldbemountedtodetectorbodyinsuchaway
thataccidentalrotationorlooseningwillbeprevented.Itisthefinalassamblers/users
responsibilitytoensurethethreadedjointbetweenfittingandtheenclosuremeetallthe
requirementsoftheapplicablestandartsfortheassembly.Foradaptorsandplugswith
nominalsizeofthreadequalorlowerthan25mmaliminiumalloyshallnotbeused.Only
oneadaptorspermittedforeachcableentry;plugsshallnotbeusedwithadaptors.The
plugsandadaptorsprovidedbyProsensearesuitabletousetemperaturerangeinwhich
detectorworks.

9
PRS‐UM‐P‐EN‐Rev.01‐08.2018
Mounting the detector:
Thedetectorshouldbemountedverticallyasthesensorheadpointingdownwards.Detector
hastobemountedsuchthatthesensor'sgasentrancearea.

Theinstalllocation
 shouldbeisolatedfromvibration,directsunlightandhavetemperaturestability
 avoidedexternalinfluencessuchassplashingwater,oil,corrosiveaerosols
 shouldhaveatleast30cmfreespacebeneaththesensorheadtoprovide
accessibilityforcalibrationwork.
 shouldbeinairflowbetweenpossibleleakorcollectionpointandpossiblesourceof
ignition.
Prosensedonotrecommendtoinstalldetectorsto:
 directlyaboveacookingunit,
 directlyaboveasinkunit,
 closetoanextractorunit,
 outdoorwithoutprotectionagainsttherain,
 inplaceswheretemperatureisoutsidetheadmissibleoperatingrange,
 incorrosiveenvironments,
 insideairvents.
 inenvironmentswheresiliconcanbefound.

TheProsensedetectorhasanindependentmountingplateconsistingoftwomountingholes
andtwoholestoattachtodetectorbody.Themountingplatecanbeadjustableontwo
diagonalwayontodetectorbody.Thedetectormaybefixeddirectlytoasurfacemounting.
Followbelowstepstomountthedetector:
1‐ Decidewhichdiagonalwaytouseandadjustmountingplateondetectorbodyif
necessary.
2‐ Checkandmakesuremountingplateiscompletelyfixedtodetectorbody
3‐ Mountthedetectortothesurfaceviausingtwooutermountingholesonmounting
plate.




Diagram3:Detectormountingplate



Wallmountingholes
Detectorbodymountingholes

10
PRS‐UM‐P‐EN‐Rev.01‐08.2018
Themountingplateinstalledinbelowpositionatfactory:

Diagram4:Defaultinstallatonofmountingplate
Electrical connections
Caution:Allelectricalconnectionsshouldbemadeinaccordancewithanyrelevantlocalor
nationallegislation,standardsorcodesofpractice.

Prosensedetectorscanoperatebetween12‐24VDC.Theconnectionsocketlocatedon
mainboardasgivenindiagram8anddetailsgiveninbelowtable2:
Output Usage
V+ Powerinput(+)12VDC–24VDC
V‐ Powerinput(‐)12VDC–24VDC
S CurrentOutputSignal(4mA–20mA)
Tablo1:Detectoroutputportsandtheirusage
Thedetectordesignedtogive4‐20mAcurrentoutputsignal.Itisalsopossibletoget
voltageoutputviausinganadditionalresistor.Belowtable3givesrecommendedresistor
specificationstogetcorrectvoltageoutputfromdetectordependingofthepowersource
level:
DetectorPowerVDC Resistor Signallevel(4mA–20mA)
12VDC–24VDC 250Ω,tolerance%1 1VDC–5VDC
12VDC–24VDC 500Ω,tolerance%1 2VDC–10VDC
Table2:Detectorpowerandtheoutputresistor
Pleaseconsiderthecablelenghtwhenperforminginstallationinthefield.TheProsense
detectorrequiresapowersupplybetween12VDCand24VDC.Makesurethataminimum12
VDCsupplyavailableatthedetectorentranceandconsiderthevoltagedropduetocable
resistanceincaseoflongdistanceapplications.Themaximumloopresistanceinthefield
cableiscalculatedasfollows:
Rloop=(Vcontroller–Vdetectormin)/Idetector


11
PRS‐UM‐P‐EN‐Rev.01‐08.2018
Example;

Diagram5:Fieldcabling
Thecontrollerorpowersupplyissupplyinganominal24VDC(Vcontroller),thedetector
minimumallowablevoltageis12VDC(Vdetectormin),thereforethemaximumallowable
voltagedropbetweenthecontrolleranddetectoris12VDC;thismeansavoltagedropof6V
ineachcore(V+coreandV‐core).Minimumpowerconsumptionofthedetectorwithout
anyoptionalmoduleis1W.Thecurrentrequiredtodrivethedetectorattheminimum
voltageis
(I=P/V)  1.0/12=85mA(Idetector).
Maximumpowerconsumptionofthedetectorwhenoptionalrelaymodulesinstalledandall
relaysareactiveis2.5W.Thecurrentrequiredtodrivethedetectorattheminimumvoltage
(I=P/V)  2.5/12=210mA(Idetector).
So,themaximumfieldcableloopresistance(Rloop)=12/0.21=56Ohms,or28Ohmsper
core,(allowingforcomponentvariations,losses,etc.).
Thefollowingtablesshowthemaximumcabledistancesbetweenthecontrollerand
transmitterassumingavoltagedropof6Vineachcoreandfordifferentcableparameters.
Thetablesareexamplesonlyandactualcableparametersandsourcepowersupplyvoltage
fortheapplicationshouldbeusedtocalculatethemaximumcabledistanceallowedatthe
installationsite.Typicalcabledatafordetectorwithrelaymodule:
Cablesize Cabletype Cableresistance MaximumCablelength(L)
(crosssectionalarea) nearestequivalent Ω/km Meters
0.5mm2 20AWG 36.8Ω/km ~500
1.0mm2 17AWG 19.5Ω/km ~800
1.5mm2 16AWG 12.7Ω/km ~1200
2.0mm2 14AWG 10.1Ω/km ~1500
2.5mm2 13AWG 8.0Ω/km ~1800
Table3:Typicalcabledetailsandmaximumdistanceforcabling
Cabling
Theuseofindustrialgrade,suitablyshieldedfieldcableisrecommended.Thebestpractices
shownthat,screened3cores(plusscreen90%coverage),suitablymechanicallyprotected
coppercablewithasuitableexplosion‐proofgland,or¾”NPTsteelconduit,dependingon
thedistancebetweensignalreceivedorcontrolpanelanddetector0.5to2.5mm2(20to13
AWG)conductorscangivebetterresults.Ensurethecableglandisinstalledcorrectlyand
fullytightened.

12
PRS‐UM‐P‐EN‐Rev.01‐08.2018
CableandEarth/Groundregimes
EffectiveEarth/GroundbondingisimportanttoensuregoodEMCandRFIimmunity.The
followingdiagramsshowexamplesofhowtoearth/groundbondthecableatenclosures.
Thesameprinciplesapplytoconduitinstallations.Thesebondingtechniquesprovidegood
RFI/EMCperformance.Earth/groundloopsmustbeavoidedtopreventtheriskoffalse
signalvariation.TheEarthScreenofthefieldcableshouldbe“tiedtoEarth”orconnectedto
Groundatonepointonly.ItiscommonpractisetoadoptaSTAREARTHconnectionregime
whereallinstrumentationScreensareconnectedatonecommonpoint.TheScreenatthe
otherendofthecableshouldbe“parked”orterminatedintoablankterminal.

Diagram6:Grounding
Detector grounding
EachdetectorhasgroundingscrewwhichutilizesgroundingfordetectormainPCBto
detectorbody.Thescrewshouldbelocatedcorrectyandfixedforalltimes.Incaseofany
maintenanceactivitythisscrewshouldbecheckedandfixedtomakesureforproper
grounding.ItisrecommendedtoutilizeaNo14AWGcopper,(StrandedorSolid),wire.The
followingdiagramsshowwheretoinstallthewireintothegroundscrewoftheenclosure.To
connectgroundingwire,loosenthescrewsufficiently;wrapthewirearoundthescrewina
“U”shape;raisetheclampandplacethewirebetweentheclampandgroundbase;lower
theclampandtightenthescrew.

Diagram7:Detectorgroundingscrew

13
PRS‐UM‐P‐EN‐Rev.01‐08.2018
Default configuration
Prosensedetectorspreconfiguredtoprovidesignalfromanalogoutputdependingonthe
detectorandgastype:
Function Value/Setting Meaning
Signaloutput
2.0mA Fault
2.0mA Warmup
3.0mA Calibration
4.0mAto20.0mA Normalgasmeasurement
22.0mA Maximumoverrange
AlarmRelay1*
Valueisgasdependant Loweralarmlevel
De‐energized Energizesonalarm
ContactNormallyOpen(NO) Closesonalarm
AlarmRelay2*
Valueisgasdependant Higheralarmlevel
De‐energized Energizesonalarm
ContactNormallyOpen(NO) Closesonalarm
FaultRelay*
2.0mA DetectorFault
Energized De‐Energizesonalarm
ContactNormallyOpen(NO) Closesonalarm
(*)Relaysareonlyavailablewithoptionalrelaymodule
Table4:Detectordefaultconfigurationdetails

DetectorMainboardandconnectiondetailsgivenindiagram8:



Diagram8:Detectormainboardandconnections
S
V‐
V+
B
A
SensorConnections
Relaymodule
connections
Address
switches

14
PRS‐UM‐P‐EN‐Rev.01‐08.2018
DetectorhasintegratedRS485Serialcommunicationdevices.Hencebothdigitalandanalog
outputsareavailableonboard.Portdefinitionsaregivenintable6:
Port Usage
V+ Powerinput(+)12VDC–24VDC
V‐ Powerinput(‐)12VDC–24VDC
S CurrentOutputSignal(4mA–20mA)
A RS485SerialcommunicationoutputportA
B RS485SerialcommunicationoutputportB

Table5:Detectoroutputportsandtheirusage
Detector Configuration
TheProsensededecorhasthreedifferenttypesofconnectiondependingoninstalled
boards:
1.Single4‐20mAoutput(defaultoption)
2.RS485Modbusserialcommunicationoutput
3.3‐Relayoutputs
4-20 mA output:
Thedefaultconfigurationprovidessingle4‐20mAsignaloutput.Prosensedetectorscanbe
connectedtocontrolpanelsonthemarkethaving4‐20mAinputsignal.Signalwiringfrom
detectorandthecontrolpanelshouldbecarriedoutbyshieldedcables.Wirescrosssection
dependsonthedistancebetweenthecontrolpanelandthedetector.Thedetailsgivenin
powercablingarevalidaswellforsignaloutput.Werecommendtousevaluesgivenintable
4(seepage13)ascablingbestpractices.

Pleaseavoidanyinterruptionincaseanyjunctionsonwires.Theshieldistobegrounded
fromthecontrolpanelsideonlyandneverconnecttheshieldtothedetector.Pleasemake
sureclutchingorcrimpingaparatsarenotloosenoroxidized.

Iftheanalogoutputshortcutduetoanerrortheoutputwillbedroppedto2mAasdetector
hasaselfdefendingmechanismimplemented.Analogoutputwillbeautomatically
deactivatedifanalogoutputwouldnotbeusedasportleftemptyornoconnection(or
incorrectconnection)madetoit.
Detector RS485 serial communication:
DetectorhasintegratedRS485Serialcommunicationdevices.TheRS485communicationAB
portsarelocatedinanothersocket.IfonlyRS485serialcommunicationwillbeused
connectiontodetectorshouldmadeby4wirethat2forpower(V+,V‐)and2forRS485
(A,B).IfbothRS485Serialcommunicationandanalogoutputwillbeusedthen,5wireshould
beused(V+,V‐,S,A,B).Thetotallenghtoftheconnectionlineshouldnotexceed1000

15
PRS‐UM‐P‐EN‐Rev.01‐08.2018
meters.ThewiringfordetectorsutilizedwithRS485boardshouldbedonebyusing
connectioncableEIARS4852corewireswithsection0.22/0.35mm2andshielded.
Nominalcapacitybetweenthewires<50pF/mandnominalimpedance120Ohms.

Detectorswillbewiredindaisychain(bus)mode.Werecommendnottousestarmode
connectionduetonegativeimpactofinterference.Eachdetectorshouldhaveunique
addressnumberinthechain.Thedetectorswouldnotberecognisedbycontrolpanelif
sameaddressgiventothem.Detectorscanhaveaddressesbetween1to63.Addresszero(0)
isreserved.TheaddressofdetectorcanbeadjustedviausingDIP‐Switchsetontheboard:

Diagram9:RS485Modbusserialcommunicationaddressandswitchposition
Thelastdetectorinthechainshouldhave120OhmsRS485terminationresistor.Theresistor
isalreadyimplementedontheboardbydefaultbutnotactivated.Usershouldactivatethe
terminationresistorviausingtheterminationpinoncetheinstallationcompleted:



Diagram10:RS485Modbusserialcommunicationmoduleendoflinejumper
12345
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
29
25
26
27
30
28
RS485termination
p
ins

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
Thepowerconnectionwerecommendtouseseperate2wirecablewithspecificationgiven
earlierinthisdocument(seeElectricalConnectionssectionatpage11).Oncethecablingis
completedpleasecheckeachdetectorhasatleast12VDCpower.
Detector Relay module:

ProsenseprovidesoptionalrelaymodulesforProsensedetectors.Therelaymoduledetails
aregivenbelow:





Diagram11:Relaymodule

Therelayboardhas3relayoutputs:
Port Usage
Fault FaultRelayoutput
Al1 Alarm1Relayoutput
Al2 Alarm2Relayoutput
Table6:Relaymoduleoutputportsandtheirusage

FaultRelayoutputpins
Alarm1,Alarm2andFaultLEDs PowerLED
Alarm1Relayoutputpins
Alarm2Relayoutputpins
Mainboardconnection
RelayoutadjutmentpinsNO/NC
SW1andSW2
Alarmleveladjustmentpins

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AlloutputpinslocatedonProsenseIRdetectorcanbeusedsimultanously.Thatmeansuser
canuseallrelayoutputs,analog(4‐20mA)outputandRS485digitaloutputatsametimeif
implementationequipmentallowstheirusage.
Eachrelayhas3pinstoadjusthowtobehaveincaseofalarmwhichare
NO:NormallyOpen
NC:NormallyClose
Therelayoutputpinpositionsshownbelow:

NormallyOpen(NO)

NormallyClose(NC)
Table7:Relayoutputpinpositions

TheFaultrelayissettoNO(NormallyOpen–Energised)andenergised.Hencefaultrelay
LEDisalwaysactive.Itdoesnotmeanthatthereisafaultondetector.IfthepowerLEDis
activeandfaultLEDisoffitmeansthatthereisafaultconditiononthedetector.Thefault
relaywillbede‐energizedincaseofpowerfailure.

ThealarmrelayssettoNO(NormallyOpen–De‐Energised)positionatfactory.

ThealarmlevelsarealsoadjustableviausingSW1andSW2alarmlevelpins.Alarmlevelsare
definedaspercentageinLELforflammablegases.Thealarmlevelscanbeadjustedusing
jumperstoswitchSW1andSW2.Possibleoptionsaregivenintable9:

SW1 SW2 Al1Level Al2Level
Open Open 10LEL 15LEL
Open Closed 10LEL 20LEL
Closed Closed 20LEL 25LEL
Closed Open 20LEL 40LEL
Table8:Alarmlevelpinpositions
Oxygendetectors:
Foroxygendetectorstheoutputvaluesandmeaningsaredifferentasoxygenisnaturally
availableinatmosphere:
Port Usage
Fault FaultRelayoutput
AL1 Alarm1Relayoutput‐LowerlevelforOxygen
AL2 Alarm2Relayoutput‐HigherlevelforOxygen
Table10:RealymoduleoutputmeaningsforOxygendetectors

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Alarmlevelsarealsodifferentasgiveninbelowtable:
SW1 SW2 Al1Level Al2Level
Open Open 19%vol 23%vol
Open Closed 19%vol 22%vol
Closed Closed 18%vol 22%vol
Closed Open 18%vol 23%vol
Table11:Alarmlevel(%Vol)pinpositionsforOxygendetectors
System Status
TheProsenseIRdetectorshasoneLEDonmainboardtoshowactualstatusofthedetector.
InnormalconditionswhieldetectorworksproperlytheLEDblinkswith1secondperiod(one
blinkinasecond).IfdetecorisinfaultconditionLEDilluminateswith250msperiod(four
blinksinasecond)andthedetectoranalogoutputgives2mAonSport.Ifdetectorcouldnot
getenoughpower(lowerthan12VDC)itwillalsoraisefaultstatus.
First time switch on (Commissioning)
WARNING
ThefollowingprocedurerequiresthedetectorCovertoberemovedwhilecarryingout
supplyvoltagechecks.Thereforetheappropriatepermitstoworkshouldbesoughtin
preparation.

PriortocarryingoutanyHOTWORKensurelocalandsiteproceduresarefollowed.
Ensurethattheassociatedcontrolpaneloutputactuationisinhibitedsoastopreventfalse
alarms.
Caution:Thefollowingprocedureshouldbefollowedcarefullyandonlyperformedby
suitablytrainedpersonnel

1. Removethedetectorcover
2. Configurethedetector'sanalogueoutputsignalandpowerinputconnectionsdone
correctly
3. Checkthatallelectricalconnectionsareterminatedcorrectly
4. SwitchOntheexternalpowersupplytofeedthedetector
5. UsingaDigitalMultiMeter(DMM),checktheSupplyVoltageattheterminalsV+(24V)
andV‐(0V),thisshouldbeaminimumsupplyvoltageof12VDC(Maximumsupply
voltageis24VDC)
6. CheckLEDstatusondetectormainboard.LEDwillbeluminatedrightafterappying
power.
7. WaittwominutesandconfirmthatLEDblinkingwithonesecondperiod.
8. SwitchOfftheexternalpowertothedetector.
9. Fitthecoverandmakesurenonofthecablescauseanobstructionwhilefittingcover
10. Switchonexternalpowertothedetector.

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Calibration
Itisrecommendedtoperiodicallycarryoutcalibrationtoensurecorrectoperation.
Calibrationshouldbedonebyapersonwhotrainedandcertifiedbylocalorinternational
authorities.

Prosensedetectorcalibrationincludestwostepswhicharezeroandspancalibration.During
thecalibrationbothstepshavetobecompleted.Otherwisethecalibrationwouldnotbe
savedandvaluesinvalidatedbydetectorinternalcontrolmechanism.Detectorshouldbe
poweredandstabilizedforatleast30minutesbeforecalibration.Zerocalibrationshouldbe
donebycleanairorN2gasdependingofthedetectorandsensortype.Spancalibration
shouldbedonebyspecificgascombinationsandlevelsdependingofthedetectorand
sensortype.PleasecontactProsensetogetzeroandspancalibrationgasdetails.

Tocalibratethedetector,useanappropriatespangascylinder,constantflowregulatorand
ProsenseGasCap.Theflowratesusedforcalibrationgasareasfollows:
Gas Flowrate(L/Min)
CleanairorN2forzeroing 0.5to1.0
Falmmable(Catalytic) 0.5to1.0
O2 0.5to1.0
H2S 0.5to1.0
CO 0.5to1.0
H2 0.5to1.0
Flammable(IR) 0.4to0.6
CO2IR 0.4to0.6
Table9:Gasflowratesforcalibration

CalibrationproceduremayvarydependingontheProsensedetectormodel.IfProsenseGas
Monitorsoftwareavailableforcalibration,firstenablecommunicationbetweendetectorand
computerviasettingthefirstaddressswitchtoONposition.Thengivecleanair(N2forIR
sensors)gastosensorheadtoperformzero.ItwouldbebettertofollowtheADCvaluein
graphtoseeandmakesuresensorhasbeenstabilized.Thenpress“SetZero”buttontostart
zeroing.Detectorwillautomaticallysetthezerolevel.Followingzeroingapplythespangas
immediatelly.Gasconcentrationmayvarydependingofthegasandsensortype.For
flammablegaseswithPellistorandCatalyticsensörs30LELmethanestabilizedwithcleanair
(O2andN2);forflammablegaseswithIRsensors50LELmethanegasstabilizedwithN2should
beused.Applythegastothesensorandwaitatleast2minutes.AlsomonitorADCvalueon
graphtomakesuresensorreadinghasbeenstabilized.Thenpress“SetSpan”buttontostart
spancalibration.Itisnecessarytocontinueapplyinggaswhiledetectorautomaticallysetsthe
spanlevel.Itmaytakeanothertwominutestocomplete.Formoreinformationpleaseseethe
ProsenseGasMonitorsoftwareuserguide.

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IfProsenseGasmonitorsoftwareisnotavailablefollowbelowprocedurestepbystep.
Otherwisethecalibrationwouldnotbecompletedandnonofthevaluesrecorded.
1‐ Putdetectorincalibrationmode.Toenablecalibrationmodethelastswitchon
addressswitchboardshouldsettoON.IfitwasOFFitshouldneedtosettoON.Ifit
wasalreadyONitshouldneedtosetfirstOFF,then10secondslatersettoON.
2‐ Applyzerogas(cleanairorN2dependingofthedetectorandsensortype)tothe
sensorforzeroing.TheLEDonmainboardwillsolidfor75secondsandthanitwill
returntonormalspeed(1secondperiod).OnceLEDreturnedtonormalflashingspeed
zeroingiscompleted.
3‐ Applyspangasandwait75seconds.
4‐ SetlastswitchtoOFFpositiontostartspancalibration.
5‐ Detectorwillsetspanlevelautomatically.TheLEDonmainboardwillsolidfor75
secondsandthanitwillreturntonormalspeed(1secondperiod).OnceLEDreturned
tonormalflashingspeedspancalibrationiscompleted.
Itisnotpossibletoperformonlyzerooronlyspancalibration.Itshouldbedoneingiven
order.Analogoutputwillsetto3mAlevelduringcalibrationstepsperformed,alarmsandfault
statusorrelayswillbedeactivated.Ifyouwantomonitoranalogoutputviausinga
multimeteryoumustusearesistorwhileseriallyconnectingthemultimeter.Otherwise
detectorwillthinksomeonehasdidshortcircuitonanalogoutputhenceitwillenablesaving
modeandsetoutputlevelto2mA.
Maintenance
Proactive maintenance:

Allgasdetectorsincludingbothforflammableandtoxicgasesshouldhavetopassa
functionaltestandcalibrationeverythreetosixmonthsaccordingtoEN60079‐17industiral
standarts.Thetestresultsandcalibrationreportsshouldberecordedinmaintenancebooks.
Operational Life:

Flammablegassensormadebyusingthepellistorsthatsufferfromalossofsensitivitywhen
inthepresenceofpoisonsorinhibitors,e.g.silicones,sulphides,chlorine,leador
halogenatedhydrocarbons.Thepellistorsarepoisonresistanttomaximizethe
operationallifeoftheCatalyticflammablesensor.Atypicaloperatinglife,subjecttothe
presenceofpoisons/inhibitorsis36months.

TheNDIR(infrared)flammablegassensorisnotaffectedbythementionedpoisonshence
hasalongerlifespan.
