STATUS SCIENTIFIC CONTROLS FGD10A User manual

STATUS SCIENTIFIC CONTROLS
Issue:
16
Date:
7/1/20
Firmware:
V2.4.yy
Installation, Commissioning &
Routine Gas Testing Manual
Gas Detector
Type FGD10A
Oxygen - Toxic Gases
(Relay version)

Declaration of Conformity
We declare that, on the date the equipment accompanied by this declaration is placed on the market, the equipment conforms with all
technical and regulatory requirements of the directives listed below.
Description of Equipment:
The FGD10 Series of Fixed Gas Detectors for the detection of Oxygen, Toxic or Flammable gases.
ATEX Flameproof Certified for use in Group IIC hazardous locations.
Directive 2014/34/EU ATEX
The following harmonised standards were used in support of this declaration:
EN 60079-0:2018 Explosive atmospheres Part 0: Equipment –General requirements
The FGD10 was originally certified to standard EN 60079-0:2006. This standard has been compared with the above harmonised standard
and no significant changes have occurred that are applicable this equipment.
EN 60079-1:2014 Explosive atmospheres Part 1: Equipment protection by flameproof enclosures ‘d’.
The FGD10 was originally certified to standard EN 60079-1:2007 but is considered compliant with the above harmonised standard
because both the instrument housing and GSH4 sensor housing are certified to that standard.
Notified Body for Hazardous Area Certification:
CSA Group Netherlands B.V,
Utrechtseweg 310, 6812 AR,
Arnhem,
Netherlands
Notified Body number: 2813
Notified Body for ATEX Quality Assurance Notification:
SGS Fimko Oy
Särkiniementie 3
Helsinki, 00211
Notified Body Number: 0598
Hazardous Area Certificate Number:
SIRA 08ATEX1031X II 2 G Ex d IIC
T4 (Ta = -20OC + 60OC )
T5 (Ta = -20OC + 50OC ) * T5 & T6 ratings are not valid for
T6 (Ta = -20OC + 35OC ) versions fitted with an externally
mounted sensor.
ATEX Quality Assurance Notification Number:
2056
Place of Manufacture:
Mansfield, Nottinghamshire, UK. Date mark applied –see product
ISO 9001:2015 Quality Management System:
Certificate No. GB93/1938
2014/30/EU –Electromagnetic Compatibility
Harmonised Standards:
EN50270:2006 Electromagnetic compatibility - Electrical apparatus for the detection and measurement of combustible gases, toxic gases
or oxygen.
Authorised Signatory to this declaration, on behalf of the manufacturer:
Name: David Stuttard Title: Managing Director
Address: Status Scientific Controls Ltd, Hermitage Lane Industrial Estate, Kings Mill Way
Mansfield, Nottinghamshire, NG18 5ER, United Kingdom
Signature Date: 14/10/19
Extract from TD18/100

STATUS SCIENTIFIC CONTROLS
Installation, Commissioning & Routine Gas Testing
FGD10A Oxygen / Toxic Gas Detector
TD18/002
Issue:
16
Change Note:
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Page 4
CONTENTS
1. FIRMWARE REVISION.......................................................................6
2. PACKAGE CONTENTS ......................................................................7
3. SCOPE OF THE MANUAL..................................................................7
4. DESCRIPTION....................................................................................8
4.1. RELAYS ....................................................................................10
4.2. ALTERNATIVE GAS TYPES...........................................................10
5. INSTALLATION ................................................................................11
5.1. CABLE ENTRIES.........................................................................12
5.2. MOUNTING AND TERMINAL ACCESS .............................................12
5.3. FGD10A CONNECTIONS ............................................................14
5.4. POWER SUPPLY ........................................................................14
5.5. ANALOGUE OUTPUT...................................................................15
5.6. RS232 OUTPUT ........................................................................15
6. COMMISSIONING.............................................................................16
6.1. APPLYING POWER......................................................................16
6.2. INDICATORS ..............................................................................16
7. INITIAL GAS TESTING.....................................................................17
7.1. ZERO GAS.................................................................................17
7.2. TEST GAS .................................................................................19
7.2.1. Gas connection points .......................................................................... 19
7.2.2. Sampling time ....................................................................................... 20
7.2.3. Suggested calibration gas levels.......................................................... 20
8. SOFTWARE FEATURES..................................................................21
8.1. MENU MODE SELECTION............................................................22
8.1.1. E : 1 –Sensor Zero............................................................................... 23
8.1.2. E : 2 –Sensor Span.............................................................................. 23
8.1.3. E : 3 –Sensor FSD............................................................................... 23
8.1.4. E : 4 –Output Zero (4mA) .................................................................... 23
8.1.5. E : 5 –Output Span (20mA) ................................................................. 23
8.1.6. E : 6 –Decimal Places.......................................................................... 24
8.1.7. E : 7 –Firmware Version ...................................................................... 24
8.1.8. E : 8 –Sensor Selection ....................................................................... 25
8.1.9. E : 9 –Engineer diagnostics................................................................. 26
8.1.10. E : 13 –Relay 1............................................................................... 26
8.1.11. E : 14 –Relay 2............................................................................... 27
8.1.12. E : 15 –Alarm Level 1..................................................................... 27
8.1.13. E : 16 –Alarm Level 2..................................................................... 28
8.1.14. E : 19 –Positive Zero Suppression................................................. 28
8.1.15. E : 20 –Negative Zero Suppression............................................... 29
8.1.16. E : 21 –Toxic Sensor Bias.............................................................. 29
8.1.17. E : 28 –Firmware update................................................................ 30
8.1.18. E : 29 –Relay 3............................................................................... 30
8.1.19. E : 30 –Password........................................................................... 31
8.1.20. E : 31 –Warm-up timer................................................................... 31
8.1.21. E : 47 –Analogue Output FSD ....................................................... 32

STATUS SCIENTIFIC CONTROLS
Installation, Commissioning & Routine Gas Testing
FGD10A Oxygen / Toxic Gas Detector
TD18/002
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Change Note:
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9. CALIBRATION..................................................................................33
9.1. SENSOR CALIBRATION ...............................................................33
9.1.1. Sensor Zero .......................................................................................... 33
9.1.2. Sensor Span ......................................................................................... 34
9.2. ANALOGUE OUTPUT CALIBRATION ..............................................35
9.2.1. Analogue Output Zero........................................................................... 36
9.2.2. Analogue Output Span.......................................................................... 36
10. ERROR CODES................................................................................37
10.1. EXAMPLE 1100 PPM TOXIC SENSOR ...........................................37
10.2. EXAMPLE 25000 PPM TOXIC SENSOR .........................................37
11. COMMUNICATIONS PROTOCOL ....................................................38
11.1. HARDWARE CONNECTIONS.........................................................38
11.2. CONTROL BYTE CONSTANTS......................................................38
11.3. FRAME STRUCTURE...................................................................39
11.4. VARIABLES................................................................................39
11.5. READING A VARIABLE.................................................................40
11.5.1. Read example - read live data........................................................ 41
11.6. WRITING A VARIABLE.................................................................42
12. ROUTINE GAS TESTING..................................................................43
13. SENSOR REPLACEMENT................................................................44
13.1. OXYGEN /TOXIC SENSOR...........................................................44
14. FUSES ..............................................................................................52
15. SPECIFICATION...............................................................................53
16. DIMENSIONS....................................................................................54
17. CERTIFICATION...............................................................................55

STATUS SCIENTIFIC CONTROLS
Installation, Commissioning & Routine Gas Testing
FGD10A Oxygen / Toxic Gas Detector
TD18/002
Issue:
16
Change Note:
1904
Page 6
1. FIRMWARE REVISION

STATUS SCIENTIFIC CONTROLS
Installation, Commissioning & Routine Gas Testing
FGD10A Oxygen / Toxic Gas Detector
TD18/002
Issue:
16
Change Note:
1904
Page 7
2. PACKAGE CONTENTS
The FGD10A is supplied in a box containing the following items:-
Description
Stock No
FGD10A Oxygen / Toxic Gas Detector
Magnetic pen
Installation manual
Calibration certificate
Optional:-
Weather guard
3. SCOPE OF THE MANUAL
This manual relates specifically to the version of the FGD10A gas detector
with the following features:-
•An Oxygen or Toxic sensor for the detection of various gases.
•Output signals in the form of 4 to 20mA and RS232 communications.
•Three control relays each fitted with a single set changeover contacts.

STATUS SCIENTIFIC CONTROLS
Installation, Commissioning & Routine Gas Testing
FGD10A Oxygen / Toxic Gas Detector
TD18/002
Issue:
16
Change Note:
1904
Page 8
Description
FGD10A GAS DETECTOR
FGD10A GAS DETECTOR FITTED WITH
PROTECTIVE WEATHERGUARD

STATUS SCIENTIFIC CONTROLS
Installation, Commissioning & Routine Gas Testing
FGD10A Oxygen / Toxic Gas Detector
TD18/002
Issue:
16
Change Note:
1904
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The FGD10A is an explosion protected ATEX and IECEx certified fixed gas
detector for use in potentially explosive atmospheres. The unit may be
optionally fitted with a protective weather guard as shown in the photograph.
IMPORTANT –When used in hostile environments (e.g. oil platforms
where the instrument is exposed to salt spray or diesel) it is
recommended that the FGD10A is always fitted with its protective
weather guard. The weather guard is attached with tamperproof screws
to ensure that it is not inadvertently removed.
The unit comprises an instrument housing having two cable gland entries
and containing the connection terminals, electronics and display window.
The housing containing the gas sensor has an M27 thread and is screwed
into the bottom of the unit. The sensor housing itself is a certified component
and must not be removed in service.
Behind the display window are:-
•A 4-digit LCD display
•Four magnetically operated switches that are activated through the
display window using a magnetic pen that is supplied with the unit.
•LED indicators for POWER, ALARM & KEY PRESS
The magnetically operated switches allow the unit to be calibrated
whilst power is still applied without the need to remove the cover from
the unit.
The main electrical features of the unit are:-
•Power supply –8 to 24 volts dc (non-intrinsically safe)
•Analogue output –4 to 20mA dc
•RS232 communications output.
•Relay contact outputs for Alarm 1, Alarm 2 and Fault.
•Gland entry threads available –20mm, ½” or ¾” NPT

STATUS SCIENTIFIC CONTROLS
Installation, Commissioning & Routine Gas Testing
FGD10A Oxygen / Toxic Gas Detector
TD18/002
Issue:
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Change Note:
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3.1. Relays
The FGD10A relay version has 3 factory-fitted relays. Each provides a set of
voltage free changeover contacts to perform the following control functions:-
•Alarm Level 1
•Alarm Level 2
•Fault
Versions without relays fitted are also available.
The self-adhesive label on the outer surface of the enclosure indicates
whether or not the relays are fitted as shown below:-
3.2. Alternative gas types
Versions of the FGD10A are available for detection of other gases, fitted with
any of the following sensor types:-
•Infrared (for detecting hydrocarbons and carbon dioxide)
•Pellistor (for detecting hydrogen and hydrocarbons)
GAS DETECTOR TYPE FGD10
CONTROL RELAYS FITTED
GAS DETECTOR TYPE FGD10
NO CONTROL RELAYS FITTED

STATUS SCIENTIFIC CONTROLS
Installation, Commissioning & Routine Gas Testing
FGD10A Oxygen / Toxic Gas Detector
TD18/002
Issue:
16
Change Note:
1904
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4. INSTALLATION
It is important that the correct cable and gland types are used when installing
the FGD10A in a hazardous location.
The cable entry devices and blanking elements of unused apertures shall be
of a certified flameproof type, suitable for the conditions of use and correctly
installed.
With the use of conduit, a suitable certified sealing device such as a stopping
box with compound shall be provided immediately at the entrance to the
flameproof enclosure.
In order to prevent dangerous overloading of the FGD10A gas detector, it is
important that the installer observes the relay contact rating and ensures that
external circuits connected to the relay contacts are suitably protected from
exceeding that rating and associated cabling is adequately rated and suitably
installed.
Guidance on the correct installation of systems is provided by EN60079-14:
2014. It is the responsibility of the installer to ensure compliance with the
relevant standards.
To ensure effective gas detection, the FGD10A must be located at a height
appropriate to the density of the target gas relative to air. For example,
Methane (relative density 0.55) is lighter than air and so it will tend to
accumulate at a high level within a confined space. Whereas Petroleum
(relative density 2.8) is heavier than air and it will tend to accumulate at
around ground level.

STATUS SCIENTIFIC CONTROLS
Installation, Commissioning & Routine Gas Testing
FGD10A Oxygen / Toxic Gas Detector
TD18/002
Issue:
16
Change Note:
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Cable entries
The cable entry threads are 20mm, ½” or ¾” NPT female.
The FGD10A enclosure is manufactured from die cast aluminium. Therefore,
the use of glands, conduit fittings and blanks made from brass should be
avoided because if moisture is present, bi-metallic corrosion may occur due
to the chemical reaction between the two materials.
Glands and fittings plated with nickel, tin or zinc will provide improved
protection but in harsh environments the use of stainless steel is
recommended.
When connecting the cores inside the unit it is beneficial to use pointed-nose
pliers to carefully guide the cable cores from the cable entries at the rear of
the enclosure towards the pcb mounted terminal connections situated near to
the front of the enclosure.
4.1. Mounting and terminal access
The FGD10A should be mounted and secured using the mounting holes on
the main unit.
Figures 2 and 3 shows details of the FGD10A terminal connections –these
can be accessed as follows:-.
1. Switch OFF the supply to the FGD10A.
2. Release the grub screw located near the lip of the enclosure
cover.
Note: It is not necessary to completely remove the grub screw
to release the enclosure front cover.
3. Remove the enclosure front cover by rotating it several times in
an anti-clockwise direction.
4. Unplug the top display board from within the enclosure by
pulling it forwards. The board is captivated by means of a nylon
wire in order to prevent it falling from the unit –take care to
ensure that the board is not damaged during installation. See
Figure 1.
5. The terminals can now be accessed.
Store the front cover such that it cannot be damaged or the thread
contaminated with dirt.

STATUS SCIENTIFIC CONTROLS
Installation, Commissioning & Routine Gas Testing
FGD10A Oxygen / Toxic Gas Detector
TD18/002
Issue:
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Change Note:
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Figure 1 –Unplugging the display board for
connection purposes

STATUS SCIENTIFIC CONTROLS
Installation, Commissioning & Routine Gas Testing
FGD10A Oxygen / Toxic Gas Detector
TD18/002
Issue:
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FGD10A connections
Figure 2 –Armoured Cable Gland Installation
Figure 3 –EEx d Conduit Installation
4.2. Power Supply
Important
Connect
enclosure
earth-point
to a high
integrity
earth
ATEX certified Ex d armoured
cable glands
-+
PSU
-+
Aout
0V Rx Tx
RS232
Armoured cable
Armoured cable
Mount vertically
as shown
N/O
COM
N/C
Relay 1
Alarm 1
N/O
COM
N/C
Relay 2
Alarm 2
N/O
COM
N/C
Relay 3
Fault
Important
Connect
enclosure
earth-point
to a high
integrity
earth
ATEX Certified compound-filled
conduit seals (stopping boxes)
-+
PSU
-+
Aout
0V Rx Tx
RS232
Conduit
Conduit
Mount vertically
as shown
N/O
COM
N/C
Relay 1
Alarm 1
N/O
COM
N/C
Relay 2
Alarm 2
N/O
COM
N/C
Relay 3
Fault

STATUS SCIENTIFIC CONTROLS
Installation, Commissioning & Routine Gas Testing
FGD10A Oxygen / Toxic Gas Detector
TD18/002
Issue:
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Change Note:
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The FGD10A is powered from an 8 –24 volt dc, 5 W maximum output
supply. This may be either:-
a) An independent supply powering one or more units.
b) A supply that is an integral part of a control card within a monitoring
panel.
4.3. Analogue Output
The analogue output provides a means of indicating to external equipment
(e.g. data loggers, remote displays, control cards) the gas levels currently
being detected by the system. The output is in the form of the industry
standard 4 to 20mA current source.
The analogue output is factory set such that 4mA represents zero gas and
20mA represents the full scale gas level of the FGD10A.
Figure 4 –Analogue Output
4.4. RS232 Output
This output is designed to be compatible with a PC fitted with an RS232
serial communications port. Suitable software is available for installation in
the PC. Contact Status Scientific Controls Ltd for details.
Note - The amplifier and
power supply may be
contained on the same
control card.
FGD10
0V
A+
0V
12-24V DC
Control
Unit
I (4-20mA)
PSU

STATUS SCIENTIFIC CONTROLS
Installation, Commissioning & Routine Gas Testing
FGD10A Oxygen / Toxic Gas Detector
TD18/002
Issue:
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Change Note:
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Commissioning
Following completion of the installation:-
a) Replace the top display board using the locating pins on the
underside of the board to ensure that it makes connection with the
remainder of the electronics - see Figure 1.
b) Ensure that the front cover has not been contaminated with dirt -
paying particular attention to the thread. Replace the cover by
rotating it several times clockwise until it reaches its limit then
secure using the grub screw –do not over tighten.
4.5. Applying power
Once the installation is complete and the covers are secure then power can
be applied. The power source should be between 8 and 24 volts dc.
When power is first applied to the FGD10A, an initialisation procedure is
performed as follows:
All segments on the LCD are shown
:
8.8:8.8
The software version is displayed
:
1.0.0
The manufacturer code is displayed
:
SSCL
The sensor type is displayed
:
O2
The detected gas level present is displayed and the FGD10A becomes
operational.
4.6. Indicators
Three LED indicators are visible from the front panel of the instrument.
These are:
Colour
Identity
Operation
Red
Alarm
Illuminates when either alarm level has been reached.
Green
Power
Always ON when power is connected.
Yellow
Key press
Illuminates when the magnetic switches are operated.

STATUS SCIENTIFIC CONTROLS
Installation, Commissioning & Routine Gas Testing
FGD10A Oxygen / Toxic Gas Detector
TD18/002
Issue:
16
Change Note:
1904
Page 17
Initial Gas Testing
FGD10A units are factory calibrated as detailed on the calibration certificate
supplied with the instrument. However, it is always advisable after installation
to confirm that the instrument reads zero with no gas present and responds
accurately when presented with an appropriate concentration of the target
gas.
The FGD10A display becomes operational within 60 seconds however, the
sensor should be allowed to stabilise for the period specified on the
associated calibration certificate before attempting to check the zero setting
and gas response.
4.7. Zero gas
With no gas present check that the instrument reads zero on the display *.
a) If the instrument reads zero then no adjustment is required and gas
response testing may now be carried out as described in Section 0
b) If the instrument does not read zero then adjustment of the zero setting
is required as described in Section 5.1.1. - Sensor Zero.
c) If the analogue signal is connected to an associated control panel,
confirm that when the FGD10A display reads zero, the control panel
display also reads zero or, adjust as necessary in accordance with the
control panel manufacturers’ instructions.
* Note –If there is the possibility of a background gas being present then zeroing of
the detector should be carried out using a test gas cylinder of air in nitrogen.

STATUS SCIENTIFIC CONTROLS
Installation, Commissioning & Routine Gas Testing
FGD10A Oxygen / Toxic Gas Detector
TD18/002
Issue:
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Change Note:
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Figure 6 –Arrangement for Application of a Certified Test Gas
Certified
Test Gas
Cylinder
Remote
Sampling Point
6mm O.D.
Sampling Tube
Calibration
Adaptor
Metal sampling adaptor, Stock No. SS336
Without weatherguard
With weatherguard
Flow Regulator
(1 Litre/min)

STATUS SCIENTIFIC CONTROLS
Installation, Commissioning & Routine Gas Testing
FGD10A Oxygen / Toxic Gas Detector
TD18/002
Issue:
16
Change Note:
1904
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Test gas
Figure 6 shows a typical arrangement for the application of a certified test
gas.
The purpose of the test gas response check is to confirm that that the
reading on the instrument corresponds with the test gas concentration.
a) If the instrument reads correctly then no adjustment is required.
b) If the analogue signal is connected to an associated control panel,
confirm that the reading corresponds with that on the FGD10A or adjust
as necessary in accordance with the control panel manufacturer’s
instructions.
c) If the above checks are satisfactory then the installation is now
complete.
d) If the instrument does not read correctly then adjustment of the sensor
span setting is required as described in Section 5.1.2. - Sensor Span.
4.7.1. Gas connection points
Certified test gas can be applied either:-
a). directly to the FGD10A via the appropriate sampling/calibration adaptor.
or
b). remotely, by connecting a test gas sampling tube to the appropriate
sampling/calibration adaptor and installing a test point at the remote end of
the tube.
Method b) avoids the need to gain direct access to the unit in order to carry
out routine gas testing. The sample tube should be taken to a convenient
point and sited such that the risk of contamination is minimised. A means
must be provided to ‘cap off’ the tube when not in use in order to prevent
blockage.
The weather guard is provided with a 6mm O.D. push in tube connector to
allow connection of a gas sampling tube. Firstly, remove the blanking plug by
depressing the coloured plastic ring whilst pulling on the plug; now push in
the gas sampling tube. The standard fitting is a push fit connector for 6mm
O.D tubing. The connector is screwed into a 1/8” BSP thread; other fittings
are available on request.