Rae RAEGuard EC User manual

RAEGuard
S
EC
Toxic Gas and Oxygen Transmitter
RAEGuard
S
LEL
Combustible Gas Transmitter
RAEGuard
S
IR
Non-Dispersive Infrared (NDIR)
Transmitter
User’s Guide
P/N 033-4117-E00 Rev A August 2009

RAEGuardSEC / LEL / IR User’s Guide
- READ BEFORE OPERATING -
This manual must be carefully read by all individuals who have
or will have the responsibility of using, maintaining, or servicing
this product. The product will perform as designed only if it is
used, maintained, and serviced in accordance with the
manufacturer’s instructions. The user should understand how
to set the correct parameters and interpret the obtained results.
CAUTION!
To reduce the risk of electric shock, turn the power off before
removing the instrument cover. Disconnect the power before
removing the sensor module for service. Never operate the
instrument when the cover is removed. Remove instrument
cover and sensor module only in an area known to be non-
hazardous.
WARNING!
The calibration of all newly purchased RAE Systems
instruments should be tested by exposing the sensors to known
concentration calibration gas before the instrument is used or
put into service. For maximum safety, the accuracy of the
RAEGuardSshould be checked by exposing the sensor(s) to
known concentration calibration gas every three (3) months.
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RAEGuardSEC / LEL / IR User’s Guide
Contents
1. General Information......................................................................... 3
1.1 General Specifications............................................................... 6
RAEGuardSEC Specifications ................................................. 6
RAEGuardSIR Specifications................................................... 7
RAEGuardSLEL Specifications................................................ 9
2. Operation....................................................................................... 10
2.1 Physical Description ................................................................ 11
2.2 Installation and Access Instructions ........................................ 11
Mounting.................................................................................. 12
Instrument Assembly Removal................................................ 13
Electrical Wiring....................................................................... 14
Instrument Assembly Installation............................................. 15
Earth Grounding Instructions................................................... 16
2.3 Display And User Interface...................................................... 18
User Interface .......................................................................... 18
Magnet Key ............................................................................. 18
Using The Magnet Key ............................................................ 19
System Initialization................................................................. 19
Reading Display ...................................................................... 20
Alarm Contacts ........................................................................ 20
2.4 Calibration ............................................................................... 21
Zero Calibration ....................................................................... 22
Span Calibration ...................................................................... 23
2.5 Advanced Menu (EC & LEL) ................................................... 25
2.6 Advanced Menu (IR)................................................................ 31
2.7 Restoring Default Values (EC & LEL) ...................................31
3. Theory of Operation....................................................................... 33
4. Maintenance .................................................................................. 35
5. Troubleshooting............................................................................. 35
Table A: EC Sensor configuration ................................................ 37
6. ModBus/RS-485 Information ......................................................... 38
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RAEGuardSEC / LEL / IR User’s Guide
1. General Information
RAEGuardSEC The RAEGuardSEC is a fixed electrochemical
detector for oxygen and toxic gas (CO, H2S, SO2, NO, NO2, Cl2, O2,
ClO2, NH3, PH3, HCN and ETO). It operates with voltages from 9 to
36 VDC and provides an analog (4 to 20mA) output signal and digital
(RS-485, ModBus) output signal within the corresponding ranges of
gas detection. The RAEGuardSEC uses an interchangeable
electrochemical smart sensor, which can be pre-calibrated
independently offline. Housed in an explosion-proof enclosure, the
RAEGuardSEC is equipped with a local digital display of the gas
concentration and unit of measurement, status LEDs, and function
keys for performing calibration.
RAEGuardSIR The RAEGuardSIR is fixed non-dispersive infrared
(NDIR) detector for hydrocarbon combustible gases, carbon dioxide,
and other gases, It operates with voltages from 9 to 36 VDC and
provides an analog (4 to 20mA) output signal and digital (RS-485,
ModBus) output signal within the corresponding ranges of gas
detection of 0 to 100% LEL or 0 to 50,000 ppm CO2. The RAEGuardS
IR uses a smart NDIR sensor, which can be pre-calibrated
independently offline. Housed in an explosion-proof stainless steel
enclosure, the RAEGuardSIR is equipped with a local digital display
of the gas concentration, status LEDs, and function keys for
performing calibration.
RAEGuardSLEL The RAEGuardSLEL is a fixed, highly poison-
resistant catalytic bead lower explosion limit (LEL) sensor for
combustible gases detection. It operates with voltages from 9 to 36
VDC and provides an analog (4 to 20mA) output signal and digital
(RS-485, ModBus) output signal within the corresponding range of 0
to 100% LEL. The RAEGuardSLEL uses a smart LEL sensor, which
can be pre-calibrated independently offline. Housed in an explosion-
proof stainless-steel enclosure, the RAEGuardSLEL is equipped with
a local digital display of the gas concentration, status LEDs, and
function keys for performing calibration.
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RAEGuardSEC / LEL / IR User’s Guide
Key features:
•Interchangeable smart electrochemical sensor that can be
calibrated offline
•4 to 20mA analog output signal.
•RS-485 digital communication in ModBus Protocol
•Explosion-proof stainless-steel enclosure for hazardous
environment applications
•Magnetic-key interface eliminates the need to open the explosion-
proof housing when adjusting parameters.
•LCD and status/error LEDs
•LED alarms when High or Low alarm point is reached
•Operation at 9 to 36 VDC
•Two dry contacts (<30V, 2A) normally open (or normally closed),
one for High and Low alarm, another for Fault alarm
Applications:
•Waste water treatment plants
•Petroleum and natural gas fields
•Marine and offshore oil wells
•Refineries and petrochemical plants
•Solvent recovery systems
•Chemical plants
•Industrial safety
•Sewers and pipelines
•Pulp & paper plants
•Heavy industry
•Power plants
•Steel mills
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RAEGuardSEC / LEL / IR User’s Guide
Hazardous Location Classification:
ATEX: II 2G Ex d IIC T6 -40° C < Tamb < +60° C
Complies with EN60079-0 :2004, EN60079-1 :2004
Example Of Name Plate On RAEGuardSModels:
Notes:
Sensor Name is replaced by the actual sensor name.
FGM-1XXXS is replaced by model number.
* < 4
** Optional
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RAEGuardSEC / LEL / IR User’s Guide
1.1 General Specifications
RAEGuardSEC Specifications
Size 7.4" L x 5.9" W x 4.3" H
188mm x 150mm x 109mm
Weight 7.7 lbs
3.5 kg
Detector Off-line pre-calibrated interchangeable smart
electrochemical sensor
Calibration 2-point calibration
Certification ATEX: II 2G Ex d IIC T6 -40° C < Tamb < +60° C
Complies with EN60079-0 :2004, EN60079-
1 :2004
IP Rating IP-65
Power 9 to 36VDC, max 40mA at 24V or 1W
Output 4-20mA
RS-485, baud-rate 4.8, 9.6 or 19.2kb/sec
Sampling Internal diffusion
Display 7-segment, 4-digit LCD and 4 color-coded
alarm LEDs
User Interface Magnetically accessed keys for non-intrusive
calibration and adjustment
Temperature -40° C to 60° C
Humidity 0% to 95% relatively humidity (non-condensing)
Pressure 0.9 to 1.1 Atm
Dry contact Max 30V, 2A
Dry Contacts 30V, 2A, normally open (or normally closed), one for High and Low alarm, another for Fault
alarm
Terminal AWG 24-12
Mounting 2 holes, 5.25" (133mm) from center to center
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RAEGuardSEC / LEL / IR User’s Guide
RAEGuardSIR Specifications
Size 6.6” L x 5.9” W x 4.3” H
168mm x 150mm x 109mm
Weight 7.7 lbs or 3.5 kg
Detector Protected, Off-line pre-calibrated,
interchangeable smart NDIR sensor
Calibration 2 point calibration
Range CO2：0 to 50000 ppm
CH4：0 to 100% LEL
Resolution
CO2：
When CO2< 10000 ppm，resolution is 1 ppm；
When CO2 >10000 ppm，resolution is 1000 ppm
CH4：resolution is 1% LEL.
Response Time
(T90) T90≤30 seconds
Certification ATEX: II 2G Ex d IIC T6 -40° C < Tamb < +60° C
Complies with EN60079-0 :2004, EN60079-1 :2004
IP Rating IP-65
Power 9 to 36VDC, max 60mA at 24V or 1.5W
Output 4-20mA
RS-485
Baud rate: 4.8, 9.6 or 19.2kb/sec
Sampling Internal diffusion
Display 7-segment, 4-digit LCD
4 color-coded LEDs
User Interface Magnetically accessed keys for non-intrusive
calibration and adjustment
Operating
Temperature CO2: -20° C to +60° C
CH4: -40° C to +60° C
Humidity 0 to 95% relative humidity (non-condensing)
Pressure 0.9 to 1.1 Atm
Dry Contacts 30V, 2A, normally open (or normally closed), one
for High and Low alarm, another for Fault alarm
Terminal AWG 24 to 12 (diameter 0.5mm to 2mm)
Mounting 2 holes 5.25" (133mm), from center to center
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RAEGuardSEC / LEL / IR User’s Guide
RAEGuardSIR Default Sensor Settings
Gas Range Resolution Span Gas
Carbon Dioxide (CO2)0to 50,000
ppm
10 ppm or
1000 ppm
2000 ppm to
10000 ppm
Methane (CH4)0to 100%
LEL 1% LEL 20% LEL to
99% LEL
Note: When CO2< 10000 ppm, the LCD displays the reading. When
CO2>10000, the LCD displays X.XE4 (which represents X.X x 104).
For example, when the monitor display 1.5E4, it means 15000 ppm;
when the LCD displays 3.6E4, it means 36000 ppm. The LCD on the
RAEGuardSIR CH4displays the %LEL (percentage of LEL) reading.
For example, when the LCD displays 25, it means 25% LEL; when
the LCD displays 75, it means 75% LEL.
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RAEGuardSEC / LEL / IR User’s Guide
RAEGuardSLEL Specifications
Size 6.6” L x 5.9” W x 4.3” H
168mm x 150mm x 109mm
Weight 7.7 lbs or 3.5 kg
Detector Protected, Off-line pre-calibrated,
interchangeable catalytic bead smart LEL
sensor
Calibration 2 point calibration
Range 0 to 100% LEL
Resolution 1% LEL
Response Time
(T90) <15 seconds to 90% of reading to 50% LEL
methane
Certification ATEX: II 2G Ex d IIC T6 -40° C < Tamb < +60° C
Complies with EN60079-0 :2004, EN60079-
1 :2004
IP Rating IP-65
Power 9 to 36VDC, max 60mA at 24V or 1.5W
Output 4-20mA
RS-485, Baud-rate 4.8, 9.6 or 19.2kb/sec
Sampling Internal diffusion
Display 7-segment, 4-digit LCD
4 color-coded LEDs
User Interface Magnetically accessed keys for non-
intrusive calibration and adjustment
Operating
Temperature -40° C to +60° C
Humidity 0 to 95% relative humidity (non-condensing)
Pressure 0.9 to 1.1 Atm
Dry Contacts 30V, 2A, normally open (or normally closed),
one for High and Low alarm, another for
Fault alarm
Terminal AWG 24 to AWG 12 (diameter 0.5mm to
2mm)
Mounting 2 holes, 5.25" (133mm) from center to
center
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RAEGuardSEC / LEL / IR User’s Guide
2. Operation
The calibration of all newly purchased RAE Systems instruments
should be tested by exposing the sensor(s) to a known concentration
calibration gas before the instrument is used or put into service. For
maximum safety, the accuracy of the RAEGuardSEC should be
checked by exposing the sensor(s) to a known concentration
calibration gas, after a period of time.
Calibration should be verified daily during the period of initial use in
the intended atmosphere to ensure nothing is poisoning the
sensor(s). The period of initial use must be of sufficient duration to
ensure that the sensors are exposed to all conditions that might have
an adverse effect on the sensors.
Verify the calibration with a known concentration test gas before use.
This “bump” test is very simple. Recalibrate the unit if readings are
off.
Prior to factory shipment, the RAEGuardSEC is calibrated and tested
using span gas. However, the user should calibrate the instrument
before the first use. After the unit is installed, run for 24 hours, and
calibrated, it is ready for immediate operation. Calibration setting
values for EC sensors are shown as Table A (on page 32).
Kit Accessories include: Calibration Adapter, RAEGuard Magnet
Key, and User’s Guide.
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RAEGuardSEC / LEL / IR User’s Guide
11
2.1 Physical Description
The design of RAEGuardSallows it to be easily mounted and
interfaced to a fixed-point gas monitoring system. The RAEGuardS
EC and LEL are housed in a 7.4" L x 5.9" W x 4.3" H (188mm x
150mm x 109mm) case with two holes 5.25" (133 mm) from center to
center. The RAEGuardSIR’s dimensions vary slightly because of the
sensor size: 6.6" L x 5.9" W x 4.3" H (168mm x 150mm x 109mm).
5.0" (127)
5.24" (133)
Ø3.15"(8)
3/4" -14NPT
7.40" (188)
4.92" (125)
Note: This dimension
is 6.6"(168mm) on the
RAEGuardSIR and
LEL.
Ø 4 1/2" (114.30)
3/4" -14NPT
1.04" (26.4)
4.29" (109.0)

RAEGuardSEC / LEL / IR User’s Guide
2.2 Installation and Access Instructions
WARNING
1. A minimum of 18"(457mm) of explosion-proof conduit
must be used at cable entry in group A and B
atmospheres. CSA requires seals in conduit exceeding 5'
(1.524 m) in group C atmospheres.
2. To prevent ignition of hazardous atmospheres, area must
be free of flammable vapors and supply circuit must be
disconnected before removing cover.
3. For European application, the installation must comply
with the requirements of EN 60079-14.
Mounting
First, decide where the transmitter will be mounted. (Refer to
installation drawing, below.) Drill two holes in mounting surface, with
the center of the holes 5.25"(133mm) apart.
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RAEGuardSEC / LEL / IR User’s Guide
Instrument Assembly Removal (EC and LEL)
Prior to service: Make sure power is OFF. Observe all
Hazardous Location Safety procedures.
1. Unscrew the housing lid
from the housing body by
rotating it counter-
clockwise.
A
s shipped, one
of the conduit holes is
covered by the provided
hex-head plug. The other
conduit is shipped with
connected wires.
2. Pull off the retaining clip
to release the
instrument assembly.
3.Tilt the instrument assembly
90˚.
4.Unlock the black 16-pin
connector.
5.Lift the entire instrument
assembly out of the housing.
6.Unlock the white 8-pin
connector.
7.Remove the sensor.
Picture shows
disassembled instrument
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RAEGuardSEC / LEL / IR User’s Guide
Instrument Assembly Removal (IR)
Prior to service: Make sure power is OFF. Observe all
Hazardous Location Safety procedures.
1. Unscrew the housing lid
from the housing body by
rotating it counter-
clockwise.
A
s shipped, one
of the conduit holes is
covered by the provided
hex-head plug. The other
conduit is shipped with
connected wires.
6.Unlock the 12-pin
connector.
2. Pull off the retaining clip
to release the
instrument assembly.
7.Remove the sensor.
Picture shows
disassembled instrument
6.Tilt the instrument assembly
90˚.
7.Unlock the 20-pin connector.
8.Lift the entire instrument
assembly out of the housing.
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RAEGuardSEC / LEL / IR User’s Guide
Electrical Wiring
1. Inside the housing bottom, unplug the two green terminal block
plugs from the terminal block on the PC boards. Note: The
terminal block plugs accept 12 AWG to 24 AWG wire.
2. Lace the wires through the RAEGuardSEC’s wire hole(s) and
connect wires to the corresponding pin numbers of the terminal
blocks:
Terminal Wire Pin#
Alarm Common (COM) 1
High/Low Alarm (ALM1) 2
Fault Alarm (ALM2) 3
RS485A (485A) 4
Block 1
RS485B (485B) 5
4-20 mA Output (4-20mA) 6
Power Supply - Output Common (P-) 7
Block 2
Power Supply + (9 to 36VDC) (P+) 8
Instrument Assembly Installation
1. Plug all terminal block plugs into the correct terminal block headers.
Keep the extra wires as close to the inside enclosure wall as possible.
2. Screw the sensor module to the housing and plug the 8-pin (EC) or 10-
pin (LEL model) or 12-pin (IR model) connector back into its socket.
3. Plug the 16-pin (EC or LEL model) or 20-pin (IR model) connector back
into its socket.
4. Pull off the clip to place the instrument assembly back into the housing
bottom.
5. Tightly screw the housing top to the housing bottom.
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RAEGuardSEC / LEL / IR User’s Guide
Earth Grounding Instructions
External Earth Grounding
Fasten the crimped ground wire with hardware as illustrated below.
The wire should have a minimum cross-section area of 4mm2for its
conductor.
Wire
(Min. 4 mm2
cross-section)
Crimped terminal
M4 flat washer
M4 Split washer
M4 Screw
Internal Earth Grounding
Use the same hardware as shown in the illustration of external earth
grounding. The wire should be no less than the size of the power
lines.
Internal earth
grounding
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RAEGuardSEC / LEL / IR User’s Guide
Finished Grounding Wires
Internal and external grounding are shown here, as well as an
alternate external grounding point. Always follow local electrical
guidelines.
External earth
grounding
Internal earth
grounding
Alternate
grounding
point
17

RAEGuardSEC / LEL / IR User’s Guide
2.3 Display And User Interface
User Interface
The RAEGuardSEC’s user interface consists of four status LEDs, a 4-
digit LCD display, and three keys, [+], [MODE], and [-]. The three
keys are operated by using the Magnet Key.
RAEGuardSEC user interface.
Magnet Key
The RAEGuardSEC has no external switches, but instead uses the
magnetic end of the RAEGuard Magnet Key (p/n 033-2032-000) to
activate switches built into the unit.
Magnet
SIDE VIEW
TOP VIEW
RAEGuard Magnet Key.
18

RAEGuardSEC / LEL / IR User’s Guide
Using The Magnet Key
Using the magnet end of the Magnet Key, briefly touch the glass above
the MODE circle or the triangles labeled [+] and [-]. Then remove the key
straight out and away from the RAEGuardSEC.
RAEGuard Magnet Key touching glass above the [+] triangle.
Important! Never drag the key sideways, or two functions may be
activated.
System Initialization
When the RAEGuardSEC system power is turned on, it initializes and
an “InIt” message appears on the display. As the transmitter is
warming up, each component is checked, and the LEDs blink all at
once. The countdown timer appears on the screen for the warm-up.
19