Riken Keiki PLU-70 User manual

PT9E-0070
Pyrolyzer Unit
(for GD-70D Series)
PLU-70
Operating Manual
Request for the Customers
•Read and understand this operating manual before using the pyrolyzer unit.
•You must operate the pyrolyzer unit in accordance with the operating manual.
•Regardless of warranty period, we shall not make any compensation for accidents and
damage caused by using this product.
The compensation shall be made only under the warranty policy of products or parts
replacement.
•Because this is a safety unit, a regular maintenance for every six months and daily
maintenance must be performed.
•If you find abnormalities in the pyrolyzer unit, please notify them to our local representative
immediately.
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Preface
PLU-70 - 2 -
Preface
Thank you for choosing the pyrolyzer unit PLU-70 designed for dedicated use with our gas detector head
GD-70D series. Please check that the model number of the product you purchased is included in the
specifications on this manual.
This pyrolyzer unit is designed for dedicated use with the gas detector head GD-70D series and must be
used in combination with the GD-70D series as the base unit.
This operating manual explains how to use the pyrolyzer unit PLU-70 installed on the gas detector head.
The basic operating procedures conform to those of the base unit, GD-70D series. This operating manual is
intended as a complement to the GD-70D series operating manual.
For proper use of the pyrolyzer unit, please read and thoroughly understand both this operating manual and
the GD-70D series operating manual before use.
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- 3 - PLU-70
<Contents>
Preface .................................................................................................................... 2
Important Notices on Safety .................................................................................... 4
1. Overview ................................................................................................................. 6
1-1. Product components................................................................................................ 6
1-2. Product specifications.............................................................................................. 7
1-3. List of accessories................................................................................................... 7
1-4. Names and functions for each part.......................................................................... 8
1-5. Block diagram.......................................................................................................... 10
2. Installation ............................................................................................................... 11
2-1. Requirements .......................................................................................................... 11
2-2. Installation of pyrolyzer unit ..................................................................................... 12
2-3. How to wire.............................................................................................................. 16
2-4. How to tube ............................................................................................................. 18
2-5. Relocate .................................................................................................................. 19
2-6. Disposal................................................................................................................... 19
3. How to Operate ....................................................................................................... 20
3-1. Preparation for start-up............................................................................................ 20
3-2. How to start the pyrolyzer unit ................................................................................. 20
3-3. How to exit............................................................................................................... 21
4. Regular Maintenance Mode .................................................................................... 22
5. Maintenance............................................................................................................ 24
5-1. Gas calibration method............................................................................................ 24
5-2. Other adjustments/Cleaning method ....................................................................... 25
5-3. How to replace parts................................................................................................ 25
5-4. Procedures to store the pyrolyzer unit or leave it for a long time............................. 25
6. Troubleshooting....................................................................................................... 26
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Important Notices on Safety
PLU-70 - 4 -
Important Notices on Safety
<Definition of DANGER, WARNING, CAUTION, and NOTE>
DANGER Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury or serious damage to the product.
The use of this symbol is to be limited to the most extreme situation.
WARNING Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury on the human body or object.
CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury or some damage on the human body or objects. It
may also be used to alert against unsafe practices.
NOTE This means "ADVICE" at operation.
<Danger Cases>
DANGER
This is not an explosion-proof unit. You must not use it to detect gases exceeding the lower explosive limit (LEL).
<Warning Cases>
WARNING
Power Supply
Before turning on the pyrolyzer unit, always check that the voltage is properly applied. Do not use an unstable
power supply because it may cause malfunctions.
Need of grounding circuit
Do not cut the grounding circuit inside or outside the pyrolyzer unit or disconnect the wire from the grounding
terminal.
Tubing
The pyrolyzer unit and the base unit, gas detector head, are designed to draw gases around them under the
atmospheric pressure. If excessive pressure is applied to the sampling inlet and outlet (GAS IN, GAS OUT),
detected gases may be leaked from its inside, thus leading to dangers. Be sure that excessive pressure is not
applied to the pyrolyzer unit and the gas detector head while used. Detected gases must be exhausted from the
detected gas exhausting outlet (GAS OUT) on the bottom of the gas detector head to which an exhaust tube is
connected, to a point regarded as a safe place.
Operation in a gas
Do not operate the pyrolyzer unit in a place where combustible gases or vapors are present. Operating the
pyrolyzer unit in such an environment will lead to extreme dangers.
Pyrolyzer heater (pyrolyzer)
The pyrolyzer heater becomes hot. Do not touch the pyrolyzer heater because your hands may be burnt. Do not
touch the pyrolyzer heater just after power-off because it is still hot.
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Important Notices on Safety
- 5 - PLU-70
<Precautions>
CAUTION
Do not use a transceiver (walkie-talkie) near the pyrolyzer unit.
Radio wave from a transceiver near the pyrolyzer unit or its cables may affect reading. When using a transceiver,
it must be used in a place where it disturbs nothing.
To restart the pyrolyzer unit, you must wait five seconds more before doing it.
Restarting the pyrolyzer unit within five seconds may cause errors.
Attach the dust filter before using the pyrolyzer unit.
Before using the pyrolyzer unit, attach the specified filter to prevent disturbances by possible gas adsorption or air
dust.
A dust filter to be used varies depending on the gas to be detected. For more information on dust filters, please
contact our sales department.
Observe the operating restrictions to prevent condensation inside the tube.
Condensation formed inside the tube causes clogging or gas adsorption, which may disturb accurate gas
detection. Thus, condensation must be avoided. In addition to the installation environment, carefully monitor the
temperature/humidity of the sampling point to prevent condensation inside the tube. In particular, when detecting
a gas which is dissolved into water and corrodes contacted materials, such as a strong acid gas, the gas is
undetectable and furthermore may corrode internal parts. Please observe the operating restrictions.
Do not disassemble/modify the pyrolyzer unit, or change the settings if not necessary.
Disassembling/Modifying the pyrolyzer unit will invalidate the warranty of the performance. Changing the settings
without understanding the specifications may cause alarm malfunctions. Please use the pyrolyzer unit properly in
accordance with the operating manual.
Do not forget to perform a regular maintenance.
Since this is a safety unit, a regular maintenance must be performed to ensure its safety. Continuing to use the
pyrolyzer unit without performing a maintenance will compromise the sensitivity of the sensor, thus resulting in
inaccurate gas detection.
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1 Overview 1-1. Product components
PLU-70 - 6 -
1
Overview
1-1. Product components
<Pyrolyzer Unit (PLU-70)>
<Standard Accessories>
•Operating manual
•Protective rubber cap (to be removed when using the
pyrolyzer unit)
•Dedicated handling lever (for wiring)
•Dedicated U-tube
<Gas Detector Head GD-70D Series (Base Unit: Option)>
* This pyrolyzer unit is designed for dedicated use with the gas
detector head GD-70D series. Use the pyrolyzer only after
installation on the base unit, GD-70D series.
Gas detector head
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1 Overview 1-2. Product specifications
- 7 - PLU-70
1-2. Product specifications
Power Display POWER lamp on (green)
Recommended
Power Cable
Cable of CVV, etc.(1.25sq) - 2-core
Power Supply 24VDC ±10%
Power
consumption
Max. 25 W
Tube Connecting
Hole
Rc1/4 (O.D Φ6-1t half-union for Teflon tube<PP>supplied)
Operating
temperature
0-40°C (at a constant condition)
Operating humidity 30-80%RH (Non-condensing)
Structure Box type/Wall mounted type
External
Dimensions
Approx. 70(W)x120(H)x145(D) mm (projection potions excluded)
Weight Approx. 0.9 kg
Outer Color PLU main unit: grey
Front door: white
1-3. List of accessories
•Operating manual
•Protective rubber cap
•Dedicated handling lever
•Dedicated U-tube
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1 Overview 1-4. Names and functions for each part
PLU-70 - 8 -
1-4. Names and functions for each part
<Appearance>
GD-70D connecting tube
Screw for grounding earth rod
Protective cover for power switch
Power switch
M5 mounting hole
Fan exhaust hole Power lamp
External wire hole
Connector for PoE
GD-70D connecting cable
GAS OUT (Unit: mm)
GAS IN
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1 Overview 1-4. Names and functions for each part
- 9 - PLU-70
<Components of the Pyrolyzer Unit>
<Wall-mounted Unit>
CAUTION
•Each unit consists of precision parts. When a unit is detached, be careful not to drop it. Dropping the
unit compromises its original performance or causes malfunctions.
Mounting hole: A hole for wall-mount.
Terminal plate: A power terminal (2P).
Lock lever: A lever to lock the PLU main unit.
Wall-mounted unit
PLU main unit
GAS IN
For tubing to the gas detector head
Power lamp
Lock lever
Inside the PLU main unit
(with the front cover open)
Pyrolyzer heater
Fan
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1 Overview 1-5. Block diagram
PLU-70 - 10 -
1-5. Block diagram
<Electric Diagram>
<Tubing Diagram>
Controller
(CPU)
Flow Sensor 2
Bypass flow rate
Flow Sensor 1
Total flow rate
POWER INPUT(DC:24V)
Power supply part
Pyrolyzer
(Pyrolyzer heater)
PL-70
Fan
Display
(POWER lamp)
Power supply circuit
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2 Installation 2-1. Requirements
- 11 - PLU-70
2
Installation
2-1. Requirements
Not only the first-time users but also the users who have already used the product must follow the operating
precautions.
Ignoring the precautions may damage the pyrolyzer unit, resulting in inaccurate gas detection.
<Precautions for Installation Sites>
< Precautions for System Designing >
Using a stable power supply
The pyrolyzer unit must be provided with the following power supply.
Power supply voltage 24 VDC ±10% (the terminal voltage of the pyrolyzer unit)
Allowed time of
momentary blackout
Up to 10 millisecond
(To recover from the momentary blackout for 10 milliseconds or more, restart the
pyrolyzer unit.)
To ensure continuous operation and activation, install a UPS outside the pyrolyzer unit.
Others Do not use it with a power supply of large power load or high-frequency noise.
Use a line filter to avoid the noise source if necessary.
CAUTION
•Install the pyrolyzer unit near the base unit, gas detector head GD-70D series. Since the pyrolyzer
unit is a precision device like the gas detector head, the precautions for installation sites shall conform
to those of the gas detector head. (See the operating manual for the GD-70D series.)
CAUTION
•After you receive the pyrolyzer unit, start using the pyrolyzer immediately.
CAUTION
•An unstable power supply and noise may cause malfunctions or false alarms.
•The designing of a system using the pyrolyzer unit must reflect the contents of the operating manual
of the base unit, gas detector head GD-70D series, and the descriptions in this section.
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2 Installation 2-2. Installation of pyrolyzer unit
PLU-70 - 12 -
Heat radiation designing
•Do not block the ventilation holes when you install the pyrolyzer unit on or under the gas detector head.
It is recommended that installation points of the sets should be away from each other for 10 mm or more.
Intervals between installation points must be at least 5 mm.
•When it is installed in the closed instrumentation board, attach ventilation fans above and below the
board.
2-2. Installation of pyrolyzer unit
CAUTION
•Install the pyrolyzer unit near the base unit, gas detector head GD-70D series. See the
descriptions in this section and the gas detector head GD-70D series operating manual before
carrying out installation.
•Before installing the pyrolyzer unit, remove the protective rubber caps from GAS IN and GAS
OUT. If the pyrolyzer unit turned on with the rubber caps remaining while the installation, applied
overload may damage the pump and sensor. Do not forget to remove the caps.
CAUTION
•When the internal temperature of the pyrolyzer unit reaches about 60°C, a trouble alarm is issued
by the gas detector head, resulting in a halt of the pyrolyzer heater. Since the internal
temperature rises to ten-odd degrees higher than the ambient temperature, take care not to let
the ambient temperature exceed 40°C. Provide a clearance of 30 mm or more above the
py
rol
y
zer unit to
p
revent a rise in the internal tem
p
erature.
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2 Installation 2-2. Installation of pyrolyzer unit
- 13 - PLU-70
<Install Dimension and Maintenance Space>
CAUTION
•The installation points of the pyrolyzer unit PLU-70 and the gas detector head GD-70D series
should be away from each other for 80 ±5 mm (with a clearance of 5 to 15 mm).
It is recommended that installation points of the sets should be away from each other for 10 mm
or more. Intervals between installation points must be at least 5 mm.
•The PLU-70 must be installed on the LEFT of the gas detector head GD-70D series.
(170)
(30)
(150)
Leave the diagonal line area so that the installation space is reserved.
(300)
PLU-70
(Left)
Gas detector
head
(Right)
PLU-70
(Left)
Gas detector
head
(Right)
(Unit: mm)
Maintenance space Maintenance space Maintenance space Maintenance space
Maintenance space
Maintenance space
When installing by using 2 screws When installing by using 3 screws
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2 Installation 2-2. Installation of pyrolyzer unit
PLU-70 - 14 -
<Installation of Wall-mounted Unit>
Attach the wall-mounted unit in the installation surface using two or three M5 screws.
Recommended mounting screw
Length of 8 mm or more
Flat washer of Φ10 mm or less (small round)
After the wall-mounted unit is attached to the wall, install the PLU main unit on the wall-mounted unit.
<Detaching and Attaching PLU Main Unit>
Attaching PLU Main Unit
At the position of 10 mm above the wall-mounted unit, press the
PLU main unit onto the wall-mounted unit. Be sure to fit both side
hooks of the wall-mounted unit in the grooves of the PLU main
unit.
Then press down the PLU main unit to fix it. The lock at the
bottom of the PLU main unit clicks to fix it properly. Make sure
that the top center of the wall-mounted unit is above the PLU
main unit as viewed from front.
CAUTION
•Install the unit so that its surface is in intimate contact with the wall-mounted unit. A space
between the unit and the wall-mounted unit may invite unnecessary vibrations and noises.
Make sure that the top of the
wall-mounted unit is above the
PLU main unit.
10mm
When pressing the PLU main
unit, align the side mark with the
hook of the wall-mounted unit for
smooth installation.
The lock clicks.
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2 Installation 2-2. Installation of pyrolyzer unit
- 15 - PLU-70
Detaching PLU Main Unit
While pushing the sky blue lever toward the wall-mounted unit,
hold up the PLU main unit.
If you cannot move the PLU main unit, insert a larger flathead
screwdriver while pushing the lever, and you can easily detach it
as shown below. Do not rotate or move up and down the flathead
screwdriver. Simply insert it into the wall-mounted unit.
CAUTION
•Be careful not to drop the PLU main unit when
detaching it. Also, check the secure installation of the
PLU main unit after attaching it to the wall-mounted
unit. If the PLU main unit is not securely installed, it
might fall, causing an unexpected injury or a damage
of the unit.
•Turn the power off before detaching or attaching the
PLU main unit.
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2 Installation 2-3. How to wire
PLU-70 - 16 -
Left side
PLU-70 Right side
Gas detector head
GD-70D
Dedicated
communication cable
2-3. How to wire
<Figure of Terminal Plate>
1 2
+ -
24VDC
<Connecting to the Gas Detector Head>
Connect the PLU-70 and the gas detector head using a dedicated communication cable extending from the PLU-70.
•Install the PLU-70 on the left and the gas detector head on
the right when viewed from the front.
•Before making the connection, ensure that the PLU
communication connector on the gas detector head is ready
for use.
•The dedicated communication connector is a lock type.
Check that the connector is firmly locked when you attach it.
Unlock the connector before you detach it.
CAUTION
•Be careful not to mistake the wall-mounted unit of the pyrolyzer unit with that of the gas detector head
GD-70D series because they have different numbers of terminals (2P for the PLU-70 and 10P for the
gas detector head).
•Install wiring for the pyrolyzer unit in the same way as for the gas detector head. For "Specifications of
Terminal Plate," "How to Connect to Terminal Plate," "How to Clamp Cables," and "Grounding," see
the operating manual of the gas detector head GD-70D series and install wiring accordingly.
Use the dedicated
handling lever.
<Communication Cable Connector>
Lock
Insert the dedicated
communication cable
into the connector of
the gas detector head.
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2 Installation 2-3. How to wire
- 17 - PLU-70
NOTE
<Use of the PLU Communication Connector on the Gas Detector Head GD-70D Series>
•Insert a small flathead screwdriver into a gap where the lug of the communication connector cover is
protruding, and pull it up in the direction of an arrow in the figure to remove it. Be careful not to damage the
connector pins inside by pushing in the flathead driver.
•The communication connector cover is a one-piece component of covers for a dedicated communication
cable for the PLU and a LAN cable. Since the cover can be easily split, use it in a way that suits your needs.
Keep the cover attached to the connector while it is not connected.
•When you attach the cover, first fit the lug to the gas detector head base unit and then push in the cover.
CAUTION
•Do not hang the communication cable.
•The communication cable connector has a lock feature. Unlock the connector before you detach it.
Pulling out a locked connector may result in a trouble such as breaking of the wire.
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2 Installation 2-4. How to tube
PLU-70 - 18 -
2-4. How to tube
<Connecting to the Gas Detector Head>
To use the gas detector head GD-70D series and the pyrolyzer unit PLU-70 in combination, install tubes to
realize a flow in the following direction:
GAS IN -> PLU-70 -> Gas detector head GD-70D series -> GAS OUT
. Please use the dedicated U-tube supplied with the pyrolyzer to connect between the PLU-70 and the gas
detector head (between the PLU-70 OUT and the gas detector head IN).
CAUTION
•Making incorrect tube connections may result in inaccurate gas detection. Double-check the tube
connections for errors.
No error message is displayed in particular even if the dedicated U-tube is connected incorrectly
(i.e., from the gas detector head to the PLU-70).
•Use the dedicated U-tube supplied with the pyrolyzer unit to connect between the PLU-70 and
the gas detector head. Using other components invalidates the warranty of the performance.
CAUTION
•Install tubes between the pyrolyzer unit and the gas detector head GD-70D series, putting the
pyrolyzer unit in front of the gas detector head.
•Like the gas detector head, the pyrolyzer unit has a Rc1/4 thread inside of the sampling
inlet/outlet (GAS IN, GAS OUT), to which polypropylene unions are normally attached. Connect
the tubes basically in the same way as for the gas detector head. (See the operating manual for
the GD-70D series.
)
Bottom
GAS IN
GAS OUT
From the PLU-70 to the gas detector head
(
Dedicated flow
p
ath
)
Left side
PLU-70
Right side
Gas detector head
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2 Installation 2-5. Relocate
- 19 - PLU-70
2-5. Relocate
When the pyrolyzer unit is relocated, select a new place in accordance with "Precautions for installation
site" and "2-2. Installation of pyrolyzer unit".
For information on wiring and tubing, see "2-3. How to wire" and "2-4. How to tube". The unpowered time
must be minimized when the pyrolyzer unit is relocated.
2-6. Disposal
When the pyrolyzer unit is disposed of, it must be treated properly as an industrial waste in accordance with
the local regulations.
CAUTION
•When you use a relocated or stopped/stored detector again, do not forget to perform a gas
calibration. For information on readjustment including gas calibration, please contact our sales
department.
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3 How to Operate 3-1. Preparation for start-up
PLU-70 - 20 -
3
How to Operate
3-1. Preparation for start-up
Before connecting a power supply, read and understand the following precautions. Ignoring these
precautions may cause an electric shock or damage the pyrolyzer unit.
•Check that the pyrolyzer unit and the base unit, gas detector head GD-70D, are connected properly (using
dedicated cables and tubes).
•Connect the pyrolyzer unit to a grounding circuit.
•Check that the wiring (power supply wiring) is connected to external power source properly.
•Check that the power supply voltage is compliant with the specifications.
•Check that the dust filter is attached properly.
3-2. How to start the pyrolyzer unit
•Before turning on the power switch, check that the pyrolyzer unit
is installed properly.
•The power switch is protected by a cover to prevent access to it
in a normal time. To turn ON/OFF the power switch, rotate the
switch cover. (Return the switch cover to the original position
after the switching is completed.)
•Turn ON the power switch.
The power lamp blinks (and starts to stay lit in an hour).
•First turn on the power switch of the pyrolyzer unit PLU-70, and
then turn on the power of the base unit, gas detector head
GD-70D series. Check that the gas detector head enters the
initial clear status and has been started.
•During the start-up procedure, check that the pyrolyzer unit
connection indicator appears on the LCD display of the gas
detector head.
When the switch cover
is closed
When the switch cover
is open
OFF ON
Pyrolyzer unit connection indicator
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