Trolex TX6386 User manual

TX6386 • TX6387 User Manual
TX6386/7-UM-EN-04 3
TX6386 • TX6387 High Visibility and Extra Large Display
Methane Monitor
Contents
1. Product Overview 4
1.1 Operating Features 5
1.2 Application 5
1.3 Dimensions 6
1.4 Technical Information 7
1.5 Electrical Details 10
2. Certification 11
2.1 Europe (ATEX) 11
2.2 Australia (IECEx) 11
2.3 Russia (Customs Union) 11
3. Installing 12
3.1 Safety Precautions 12
3.2 Tools and Test
Equipment Required 13
3.3 Siting Recommendations 14
3.4 Connections 15
4. Setup and Calibration 16
4.1 Controls and Indicators 16
4.2 Output Relays:
Warning Alarm - RL1 and
High Alarm - RL2 21
4.3 Power-up 22
4.4 Self-check and Diagnostics 22
4.5 SP1 and SP2 Buttons 23
4.6 Output Relay - SP1 - Warning
Alarm and SP2 - High Alarm
Adjust 24
5. Operation 25
5.1 Normal Operation 25
6. Calibration 28
6.1 Prepare to Calibrate 28
6.2 Calibrate Zero 29
6.3 Calibrate Span 29
7. Maintenance 30
7.1 Output Signal 30
7.2 Annual Safety Check 30
7.3 Damaged Sensors 31
7.4 Record Keeping 31
7.5 Maintenance and
Calibration Log 32
8. Repair 33
8.1 Local and Remote Sensor -
Replace 33
8.2 Local and Remote Sensor
Filters - Replace 34
9. Spare Parts 34
10. Disposal 35
Disclaimers 36
Trademarks 36
Contact Details 36
Document History 36
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4 TX6386/7-UM-EN-04
1. Product Overview
TX6386 High visibility methane monitor with locally or remotely mounted
gas sensing module - locally mounted gas sensing module shown.
TX6387 Extra large display methane monitor with remote gas sensing
module.
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1.1 Operating Features
• High visibility safety monitoring of methane gas hazards present in the
atmosphere
• High accuracy poison resistant catalytic combustion sensors, calibrated for
methane
• High brightness LED display can be viewed at distance, even in totally dark
conditions.
• Two high visibility display sizes: 20 mm (0.8 inch) - TX6386
OR
100 mm (4 inch) high characters - TX6387
• Periodic self-check routine of all sensor conditions
• Convenient calibration of zero and span
• Signal clamp after gas over-range with manual reset
• Two independent output contacts with adjustable setpoints for local control and
alarms
• Sturdy waterproof construction for use in extreme working environments
• Intrinsically safe for use in Group I hazardous areas
• Optional formats; remote sensors mounted in a compact machined metal
housing for use on machinery where space is limited, also available with
integrally mounted gas sensing modules
1.2 Application
Fixed point methane gas detection for safety monitoring in Group I applications.
Group I:
TX6386 and TX6387
Supply Voltage:
12 V dc
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1.3 Dimensions
1.3.1 TX6386 - High Visibility Methane Monitor
1.3.2 TX6387 - Extra Large Display Methane Monitor
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1.4 Technical Information
1.4.1 TX6386 - High Visibility Methane Monitor
1.4.2 TX6387 - Extra Large Display Methane Monitor
1
2
3
1
2
3
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8 TX6386/7-UM-EN-04
1.4.3 Technical Details
Supply voltage 8.5 to 14.4 V dc
Current consumption 160 mA (typical)
Output 2 normally open contacts (held closed when system
is healthy)
Alarm output contacts Contact rating: Maximum current: 1 A
Maximum voltage: 230 V ac
Suitable for switching approved intrinsically safe
circuits
RL1: Warning Alarm - independently adjustable
setpoint (SP1)
RL2: High Alarm - independently adjustable
setpoint (SP2)
Gas detected Methane 0 to 4% v/v
Operating life Greater than 5 years in clean air
Operating temperature
range
-10 to +40°C (14 to 104°F)
Storage temperature -20 to +60°C (-4 to 140°F)
Humidity 95% non-condensing
Housing materials Housing: Polycarbonate / ABS
Gas sensor: Local: Machined stainless steel
Remote: Machined stainless steel
and brass
Gas sensor connection: Flexible armoured conduit
Protection classification Housing: IP65
Gas inlet port: IP54
Weight 450 g (1 lb)
Mounting TX6386: Two 6 mm (0.23 inch) diameter
fixing holes
TX6387: Four 6.5 mm (0.25 inch) diameter
fixing holes
1
2
3
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Cable entries 3 x M20
Electrical connections 4 mm (0.15 inch) barrier/clamp terminals
Conductors A maximum of two per terminal
Conductor size A maximum of 2 x 2.5 mm² (0.003875 inch²)
Terminal torque 2.4 Nm maximum
Display TX6386: 7 segment, high brightness LED,
20 mm (0.8 inch) characters
TX6387: 7 segment, high brightness LED,
100 mm (4 inch) characters
Vibration limits
(BS 2011)
10 to 100 Hz: 0.25 mm (0.009842 inch) peak
100 to 600 Hz: 2 g peak
Impact limits 20 joules (housing)
Ambient pressure limits 1013 mbar ± 100 mbar absolute
Sensing principle Catalytic combustion
Linearity Linear: 0 to 3% v/v
± 0.2% v/v: 3 to 4% v/v
Drift ± 0.25% v/v per month (at 25°C (77°F))
Response time (T90) < 20 seconds
Warm up time < 5 minutes in air or 1% v/v CH4
(to 95% stated accuracy)
Calibration Front mounted potentiometers
Over range If the measured gas concentration exceeds the
calibration range of the sensor, the display will
indicate FAULT
Pellistor protection The supply to the gas sensing element will be
switched off to prevent oxidisation damage
occurring if the gas concentration exceeds safe
limits. The sensor will remain switched off until
reset.
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1.5 Electrical Details
Mining Ex
TX6386 and TX6387 2 wire remote powered
Supply voltage 12 V dc
Supply current 160 mA (typical)
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2. Certification
2.1 Europe (ATEX)
Ex Certificate number: Baseefa 12ATEX0060
Ex Certification code: I M1 Ex ia I Ma (Ta = -20°C to +55°C)
General Conditions of Use: Prior to installation, it is essential
that user refers to the above certificate to ensure that the
termination and cable parameters are fully complied with and
are compatible with the application. Copies of certificates are
available from Trolex.
ATEX Directive (94/9/EC)
2.2 Australia (IECEx)
Ex Certificate number: IECEx TSA 11.0047X
Ex Certification code: Ex ia I Ma
General Conditions of Use: Prior to installation, it is essential
that user refers to the above certificate to ensure that the
termination and cable parameters are fully complied with and
are compatible with the application. Copies of certificates are
available from Trolex.
2.3 Russia (Customs Union)
Ex Certificate number: TC RU C-GB.ГБ05.B.00356
Ex Certification code: PO Ex ia I Ma
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3. Installing
3.1 Safety Precautions
Hazardous Areas
Do not disassemble the High Visibility Methane Monitor or Extra Large Display
Methane Monitor whilst in the hazardous area or use a monitor that has a damaged
housing in the hazardous area.
Evacuation
If a dangerous gas concentration is detected by a monitor, leave the area
immediately.
Flammable
Be aware that some toxic gases are also ‘flammable’ at high percentage
concentrations.
Operating Limits of Catalytic Combustion Sensors
Catalytic combustion gas sensors positively detect the presence of flammable gas.
They rely upon the presence of oxygen in the atmosphere and should only be used
for gas concentrations up to the Lower Explosive Limit (LEL).
After this point, the output becomes non-linear and may erroneously indicate
that the gas concentration is below the LEL. They should not be used in oxygen
enriched or deficient atmospheres.
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Discrimination
Catalytic combustion sensors can detect a wide range of flammable gases but they
cannot discriminate between individual gases. They will respond to most, or all,
of the flammable components present in the atmosphere without distinguishing
between them.
Contamination
The response of catalytic combustion gas sensors can be affected by air borne
contaminants which will reduce the sensitivity. Substances such as silicones, tetraethyl
lead, sulphur compounds and phosphate esters can cause permanent degradation
(poisoning). Hydrocarbons may also cause temporary inhibition.
Interference
If the atmosphere to be monitored contains a gas that dilutes or displaces the
air, this may reduce the response of catalytic sensors. Similarly, steam laden
atmospheres and condensation can reduce the stability.
High Concentrations of Flammable Gas
Exposure of low concentration catalytic combustion sensors to concentrations of
flammable gas greater than the LEL can affect the sensitivity and zero stability of
catalytic elements and the calibration should be checked after such an exposure.
Toxicity
Be aware that most flammable gases and vapours are also toxic at low
concentrations of LEL.
3.2. Tools andTest Equipment Required
No special tools are needed.
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3.3 Siting Recommendations
Location of Gas Detectors
Each installation needs to be considered in its own right, with reference to safety
authorities and in compliance with mandatory local safety regulations. The sensor
must be operated in accordance with the User Manual to maintain safety, reliability
and to preserve safety integrity where applicable.
It is important that sensors are located in positions determined in consultation
with those who have specialised knowledge of the plant or installation and of the
principles of gas dispersion. Reference should also be made to those responsible
for the engineering layout and topology of the plant as they will be most familiar
with the nature of the potential dangers and the most likely sources of gas release.
It is also important to recognise that the characteristics of the gas source can be
influenced by many factors; including the relative density or buoyancy of the gas,
the pressure at the point of release, the ambient temperature and the ventilation of
the site.
Sensor coverage cannot be simply expressed in terms of ‘number per unit area’.
Sensors need to be sited where they are capable of monitoring those parts of a
plant where gas may accumulate or where a source of gas release is expected
to occur. This way the earliest possible warning of a gas release can be given to
initiate functions, alarm functions or safe evacuation of the premises.
Sensor Management
A very important part of an efficient gas monitoring system is the training of
plant personnel in operation and maintenance of the sensors and the complete
monitoring system. Training can be provided by qualified Trolex application
engineers.
Once a sensor installation is complete, the sensor locations and types should be
formally recorded and a planned test and maintenance procedure instituted.
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3.4 Connections
Dual independent output contacts for remote
signalling and control. Setpoint values for
Warning Alarm - RL1 and High Alarm - RL2
are setup during manufacture to appropriate
levels. The setpoints may be adjusted to
preference.
Standard contact format is Normally Open,
also available in Normally Closed format.
The interconnecting cable between the
sensor and the remote monitoring device
must have steel wire armoured protection or
a braided earth screen.
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16 TX6386/7-UM-EN-04
4. Setup and Calibration
4.1. Controls and Indicators
High Visibility Methane Monitor - TX6386
No Test button. One System Reset button located internally by LED display
Indicator LEDs on front of housing, labelled RL1 (Warning Alarm), RL2 (High
Alarm) and Fault.
Setpoints 1 and 2are adjustable and Setpoint 1 and 2potentiometers are fitted.
Extra Large Display Methane Monitor - TX6387
No Test button. One System Reset button located internally by LED display
Indicator LEDs on front of housing, labelled RL1 (Warning Alarm), RL2 (High
Alarm) and Fault.
Setpoints 1 and 2are adjustable and Setpoint 1 and 2potentiometers are fitted.
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4.1.1 High Visibility Methane Monitor - Exterior
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4.1.2 High Visibility Methane Monitor - Interior
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4.1.3 Extra Large Display Methane Monitor - Exterior
4.1.4 Extra Large Display Methane Monitor - Interior
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20 TX6386/7-UM-EN-04
4.1.5 Extra Large Display Methane Monitor - Controller Details
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