GMA 200-MW4 - GfG Instrumentation

22
GMAZD
200-MW4
Operations Manual
1194 Oak Valley Dr, Ste 20, Ann Arbor MI 48108 USA
(800) 959-0329 • (734) 769-0573 • www.goodforgas.com
Table of Contents
Page
1.
1.1
1.2
2.
2.1
2.2
2.3
2.4
2.5
3.
3.1
3.2
3.3
4.
INTRODUCTION
3
For your safety
Operating information
3
3
GENERAL TRANSMITTER INFORMATION
4
General Description
Measurement procedure and measurement gas feed
Particularities when using a calibration adapter
Transmission response
Unit design
4
4
4
4
5
ASSEMBLY AND INSTALLATION INSTRUCTIONS
Installation location
Installation
Installation of electrical connections
6
6
6
OPERATING INSTRUCTIONS
7
4.1
Commissioning
4.2
Measurement mode
4.2.1
Measuring range underflow
4.2.2
Measuring range exceeded
4.2.3
Operating buttons
4.2.4
Display, LED and horn test [TEST]
4.2.5
Display of operating parameters [INFO]
4.2.6
Sensor service life
4.3
Calibration and adjustment
4.3.1
Zero point calibration
4.3.2
Zero point adjustment with display and keyboard [ZERO]
4.3.3
Zero point adjustment using the ZERO reset button
4.3.4
Zero point adjustment with the ZERO potentiometer
4.3.5
Sensitivity calibration
4.3.6
Sensitivity adjustment with display and keyboard [SPAN]
4.3.7
Sensitivity adjustment with the SPAN potentiometer
4.4
Main and service menu [MENU]
4.4.1
Main menu
4.4.2Service menu
4.5
Displays and messages
4.5.1
Overview of the status LED states and power output signals
4.5.2
Display of special conditions (device start-up and fault)
4.5.3
Displays in service mode and during sensor adjustment
4.5.4
Displays in measurement mode
4.5.5
Priority of displays and messages in measurement mode
4.6
Fault, cause, remedy
5.
6
APPENDIX
7
8
8
8
9
9
9
9
9
9
10
10
10
11
11
11
12
12
12
14
14
14
15
16
16
16
17
Cleaning and care
5.1
Servicing and maintenance
5.2
5.2.1
Visual inspection
5.2.2
Functional check
5.2.3
System check
5.2.4 Repair
Sensor replacement
5.3
Accessories and spare parts
5.4
Sensor specification
5.5
Technical data
5.6
EC declaration of conformity
5.7
17
17
17
17
17
17
17
18
18
19
20
2
1.
INTRODUCTION
1.1 For your safety
These operating instructions refer to the proper use of the product and serve to ensure
personal safety and health. They must be read and followed by all persons that utilize this
product or use, maintain, service and check this product. This product is only able to
perform the tasks for which it is intended, when it is utilized, used, maintained, serviced and
checked in accordance with the information provided by GfG Instrumentation.
The warranty assumed by GfG shall become void if it is not utilized, used, maintained, serviced
and checked in accordance with the information provided by GfG. The aforementioned does not
alter the warranty and liability information contained in the GfG terms of sale and delivery.
1.2 Operating information
The transmitter has been tested for proper operation and display prior to delivery. The calibration
and adjustment was carried out with appropriate testing or calibration gases.
This does not absolve from the responsibility of performing a calibration or, where
necessary, an adjustment following installation.
The ZD 22 transmitter is not approved for use in potentially explosive atmospheres.
CAUTION
The supply voltage may exceed 30 V DC!
The same applies to voltage spikes!
3
2.
GENERAL TRANSMITTER INFORMATION
2.1 General description
A stationary gas warning system consists of a transmitter and a gas measurement and evaluation
unit (GME, not included in the scope of delivery). The transmitter and GME are connected
via a remote measuring cable. The transmitter converts the concentration of gas into an electric
measurement signal and sends it to the analysis unit for further processing.
The ZD 22 transmitter can be optionally equipped with an additional graphic display
with control buttons. The display has a "green" background lighting in measurement mode. The
display color changes to "red" in the event of a fault or alarm in order to provide a visual warning.
Each of the 22 series transmitters is equipped with two status LEDs, which indicate the operating
status of the device. A "green" LED to indicate the operational readiness, and a "yellow" LED to
display a fault or a special condition.
The 22 series transmitter can be equipped either with an analog output current interface or a
digital RS485 interface. The current interface can issue the measurement information with
4-20mA as standard or can, alternatively issue it with 0.2-1mA. The communication of the
digital RS485 interface uses the MODBUS (RTU) protocol.
The electronics assume many tasks which, on one hand, make the operation and servicing easier
and, on the other hand, significantly increase measurement accuracy. The transmitter is
characterized by:




Concentration display (on display version)
Settings at the push of a button without the need to open the housing (on display version)
Compensation of temperature influences
Permanent status display (measuring mode, fault or special state) on the transmitter
2.2 Measurement procedure and measurement gas feed
The ZD 22 transmitter is equipped with an amperometric oxygen sensor based on
an electrochemical oxygen pump cell made of zircon dioxide. If a voltage is applied to the
cell, oxygen ions are pumped from the cathode to the anode. Since the cathode is covered by
a gas diffusion barrier, a saturation current occurs when increasing the voltage. This saturation
current is a measure of the ambient oxygen concentration. The measurement principle is
characterized by high long-term stability and selectivity.
Normally, the measurement gas passes through diffusion to the gas sensor. However, if a
calibration adapter is attached to the sensor for calibration or adjustment purposes, the following
particularities can be noted on the ZD 22.
2.3 Particularities when using a calibration adapter
To avoid false display values, especially when measuring ranges of oxygen content of less than 5
% vol., connect a gas hose of at least 12 in / 30 cm in length to the calibration adapter gas
outlet. This is the only way to prevent any oxygen molecules from flowing "backwards" to
the sensor with a flow rate of 0.5 l/min. The reason for possible incorrect display values of
low concentrations is due to partial oxygen pressure outside of the calibration adapter.
2.4 Transmission response
The gas indicator and signal delivery are always proportional to the concentration of gas. The
reaction times can be different depending on the sensor type used.
4
2.5 Unit design
ZD 22 without display
Cable inlet
Status LEDs (green, yellow)
Transmitter housing
Type label
Sensor housing
Diffusion opening
ZD 22 with display
Cable inlet
Display with illumination
Control buttons
Transmitter housing
Status LEDs (green, yellow)
Sensor housing
Diffusion opening
The gas sensor and the transmitter electronics are installed in the transmitter housing. The
electronics convert the measurement signal into a gas concentration and indicates it with an
analog current signal of 4-20mA or 0.2-1mA or with a digital RS485 bus signal in the MODBUS
RTU protocol. The gas concentration and status information are displayed on the display
version.
The transmitter can be adjusted by using a multimeter and customer test leads and
two installed potentiometers or, on display version, by using the display and the control buttons.
5
3.
ASSEMBLY AND INSTALLATION INSTRUCTIONS
3.1 Installation location
In determining the place of installation, it is important to know the environmental conditions and
to take this into account when selecting the location. To achieve representative measurement
results, the ventilation conditions must be considered.
The transmitter must be installed in the room so that the gases reach the sensor, even with
unfavorable ventilation. If necessary, calculations must be made, for example with smoke
tubes.
In determining the place of installation always ensure that the transmitter will always be freely
accessible for service and calibration work.
External influences such as those listed below must also be taken into consideration:


Rain water, splash water, dripping water, condensation
The dust in the atmosphere
The transmitter is largely protected against the ingress of water and dust. In very difficult
conditions, special accessories can be used to protect the transmitter from damage. GfG will be
happy to provide you with information regarding suitable measures.
The warranty may become void if the sensor is exposed to environmental
conditions that GfG was unaware of during planning or delivery.
3.2 Installation
In determining the place of installation ensure that the transmitter is always freely accessible for
service and calibration work. The transmitter must be positioned vertically with the sensor
pointing downward.
The transmitter is connected to the analysis unit in accordance with the circuit diagram (see
Installation of electrical connections). To install, release the three Allen bolts and remove the
housing cover. The housing is fastened with three screws. The printed circuit board is inside the
housing. The terminals for the connection to the analysis unit are on the top of the circuit
board.
3.3 Installation of electrical connections
The laying of cables and connection of the electrical installation may only be carried out by a
specialist taking into consideration the relevant provisions. The wire cross-section is based on the
length of the connection cable and the transmitter version. When dealing with the bus version, it
may be necessary to check whether the operating voltage is sufficient to also supply the last
transmitter on the transmitter bus. If necessary, the power supply must be extended with an
additional power source.
For analog data transmission a cable can be used with the wire diameter of 18 AWG gauge, this
is suitable for short distances up to 1,640ft / 500m. For longer distances the wire crosssection has to be 16 AWG gauge. The cable length should not exceed 3,937ft / 1200m.
Wiring diagram:
Terminal for cable connection
1: Data– D0
2: Data+ D1 / 4-20mA / 0.2-1mA
3: 0V GND
4: 24 V DC (15-30 V DC)
Slide switch (Rt)
Terminating resistor for RS485
(Factory setting = OFF)
Following installation, the housing cover must, once again, be sealed and screwed into place.
6
4.
OPERATING INSTRUCTIONS
4.1 Commissioning
The ZD 22 transmitter has been tested for proper operation and display prior to the delivery.
The adjustment is carried out with appropriate testing or calibration gases. Deviations can
occur dependent on the transport, installation and environmental conditions.
Therefore, the gas detection system must be installed by a qualified person and checked for
proper operation.
After switching on, the transmitter requires a 2–3 minutes for:




the self-test, for checking the program and memory
reading and evaluating the device parameters with concurrent memory testing
reading and evaluating the sensor parameters with concurrent memory testing
the stabilizing of the sensor
Version with analog current interface (0.2-1mA):
Directly after switching on, the current interface displays 0.0mA and after 4 seconds displays
0.08mA. In doing so, the green and yellow LEDs are on.
Version with analog current interface (4-20mA):
Directly after switching on, the current interface displays 0.0mA and after 4 seconds displays
1.6mA. In doing so, the green and yellow LEDs are on.
Version with digital Modbus interface (RS485):
With the Modbus version, "Start-up" can be read on the connected analysis unit, e.g. the GMA 200.
For further information, see the Modbus system for the TRM22 operating instructions.
The information regarding the firmware version initially appears in the ZD 22 display. The
measurement range, the unit of measurement, the gas type and the calibration gas
concentration are then displayed. A countdown of the remaining seconds of the run-in phase
can be seen on the display. The ZD 22 automatically switches into measurement mode following
completion of the run-in phase.
The device switches to fault mode if a device error is detected during the start-up phase.
Version with analog current interface (0.2-1mA):
The current interface then displays 0.06mA. An error message appears in the display
(see Display of special conditions section).
The yellow fault LED is permanently illuminated.
Version with analog current interface (4-20mA):
The current interface displays 1.2mA. An error message appears in the display
(see Display of special conditions section).
The yellow fault LED is permanently illuminated.
Version with digital Modbus interface (RS485):
With the Modbus version an error message displays on the transmitter and/or
the GME (see Display of special conditions section).
The yellow fault LED is permanently illuminated.
Note:
After the initial commissioning of the transmitter and the run-in phase, a check and, where
necessary, an adjustment of the zero point (ZERO) and, subsequently, also the sensitivity
(SPAN) should take place.
7
4.2 Measurement mode
The green operating LED is permanently on and the yellow fault LED is off when the
measurement mode is operating flawlessly. In measurement mode, the digital display shows
the gas concentration currently being detected. The measurement of the gas concentration
takes place constantly and is being refreshed every
second. The functionality of the electronics is constantly
monitored by various tests such as sensor, processor
and memory tests.
i
4.2.1
In normal measurement mode, a bar chart showing the current gas concentration
complete with the set measurement range is shown on the transmitter display, also in
5 seconds intervals the type of gas and gas unit.
Measuring range underflow
Readings below the zero point are shown in the display as a number preceded with a negative
sign. In the event of a measurement value underflow of 0 to -5% of the measurement range,
the measurement value continues to be shown on the transmitter display or on the analysis unit
(e.g. the GMA 200).
In the event of a measurement value underflow of -5 to -7.5%, the arrows ↓↓↓ are shown
alternatively with the measurement value in the display.
With an underflow of the measured value below the measuring range of -7.5%, the arrows ↓↓↓
appear permanently on the display.
Transmitter with analog current interface 0.2-1mA:
In accordance with the measurement value, the current interface displays a signal within the 0.14
to 0.2mA range.
Transmitter with analog current interface 4-20mA:
In accordance with the measurement value, the current interface displays a signal within th 2.8 to
4.0mA corresponding to the reading.
Transmitter with digital Modbus interface (RS485):
In the Modbus version, the respective measurement value is shown on the transmitter and/or the
GME display (see Display of special conditions section).
4.2.2
Measuring range exceeded
Exceeding the measuring range between 100% and
Exceeding the measuring range between 100% and
112% of the measuring range the arrows ↑↑↑ are
112% of the measuring range the arrows ↑↑↑ are
displayed
displayed alternately
alternating with
with the
the measured
measured value.
value.
Transmitter with analog current interface 0.2-1mA:
In accordance with the measurement value, the current interface displays a signal within the
1.0 to 1.1mA range.
Transmitter with analog current interface 4-20mA:
In accordance with the measurement value, the current interface displays a signal within the
20 to 22mA range.
Transmitter with digital Modbus interface (RS485):
In the Modbus version, the respective measurement value alternating with ↑↑↑ is shown on
the transmitter and/or the GME display (see Display of special conditions section).
Exceeding by even more than 112% of the measurement range, the display
shows permanent arrows ↑↑↑ and a rapidly-flashing yellow status LED.
Transmitter with analog current interface 0.2-1mA:
The current interface displays 1.1 mA.
Transmitter with analog current interface 4-20mA:
The current interface displays 22mA.
Transmitter with digital Modbus interface (RS485):
With the Modbus version, ↑↑↑ is displayed in the display of the transmitter and/or the GME (see
Display of special conditions section).
8
4.2.3
Operating buttons (Display version only)
Using the control buttons on the
and settings adjusted through the menu.
4.2.4
TEST
ZERO
QUIT
INFO
MENU
SPAN
transmitter the unit can be calibrated
Display, LED and test [TEST]
In measurement mode, a display and LED test can be performed through the menu by
briefly pressing the test/zero button.
TEST
ZERO
In doing so, all LEDs are triggered, all segments of the
display are shown and all status LEDs as well as
an audible beep are triggered.
4.2.5
Display of operating parameters [INFO]
During the operating mode, pressing the button
operational parameters in sequence automatically.




INFO
SPAN
briefly shows the following important
Measurement gas
Unit of Measurement
Measurement range
Calibration / test gas concentration
These indicators also appear during the device start-up phase.
4.2.6
Sensor service life
Zircon dioxide sensors have a limited service life. The expected service life of the ZD 22
sensors is up to five years depending on the operating conditions. Once the expected service
life has been reached, the transmitter displays that the sensor should be replaced during the
next service. The display illuminates red and a corresponding message is shown and the
yellow fault LED briefly flashes every five seconds. This has no impact on the measurement
mode and the remaining service life of the sensor.
4.3 Calibration and adjustment
4.3.1
Zero point calibration
When calibrating (checking) or adjusting (setting) the zero point, 100 vol% nitrogen is
used as zero gas. Please refer also to section 2.3 "Particularities when using a calibration
adapter".
Calibration (check):
In this case, a calibration adapter must be screwed on the sensor housing. Through the
calibration adapter, the zero gas can then be applied to the sensor in a pressure-free
manner with a flow rate of approx. 0.5 l∕min. If the display value deviates from zero, the
deviation can be adjusted.
Adjustment of the display:
depending on the transmitter version, the adjustment of the zero point can be performed in
different ways. These options are described next.
9
4.3.2
Zero point adjustment with display and keyboard [ZERO]
To perform the zero point adjustment, press and hold the button
(>3sec.) to change to the service code query. After entering the default
service code "0011" (factory setting), the program"ZERO Adjustment "
activated. This is signal ed by a flashing yellow status LED and transmitters
with analog
interface (4-20mA or 0.2-1mA) by an output signal of 2.4mA
or 0.12mA.
TEST
ZERO
The display shows the current gas reading (indicated value) and displays
the adjusted zero gas concentration. If the measured gas value is no more
than 10% of the measuring range, the zero point adjustment can be
started with the left button [start]. If the current measured gas value
remains constant during a defined interval of time, the new zero point is
accepted and displayed. Using the right button, the program "ZERO
adjustment" can be aborted and a change back to measuring mode can
be made.
4.3.3
Zero point adjustment using the ZERO reset button
For transmitters without a display, the easiest way to adjust the zero point is to press the
ZERO reset button. To access this button, the transmitter cover has to be removed. Afterwards,
press and hold the button for 3 seconds in order to start the adjustment procedure. The
adjustment procedure is signaled by a flashing yellow status LED and a power output signal
of 2.0mA (or 0.1mA). If the measured value remains constant during a defined interval of
time, the new zero point is accepted. The adjustment process is then automatically finished.
Note:
While waiting for a constant measurement
value, the adjustment procedure can be
shortened by pressing and holding the ZERO
reset button. The hardware immediately
starts the zero point adjustment.
If the current measured value is outside the
permissible limit values, the transmitter
switches back to measurement mode without
having performed the adjustment.
4.3.4
Zero point adjustment with the ZERO potentiometer
For transmitters without a display, the zero point adjustment can be carried out when the
transmitter cover is open on the ZERO pot using a small screwdriver, a multimeter and a test
cable with service plug (see Accessories and spare parts section). The test cable must be
connected to the voltage measuring jacks of the multimeter and the service plug must be
inserted into the service connector of the transmitter (also see note).
As long as the ZERO pot is not turned, a voltage value is shown on the multimeter between
0.2-1V DC, this indicates the current gas measurement in the range of 0-100% of the
measuring range proportional.
Once the ZERO pot is turned the setpoint can be read on the multimeter for the zero point
adjustment. This is signaled by the flashing yellow status LED. It must be turned until a
voltage value of 0.200V is displayed. As long as this setpoint remains unchanged for a
considerable time, the zero point adjustment is started by the transmitter. The yellow status LED
goes off once the adjustment is complete.
The zero point adjustment with the ZERO potentiometer can be performed for display values up to
25% of the measuring range. If the transmitter, despite correct task of the calibration gas, jumps
back to the original (unadjusted) measurement value after the adjustment, this could mean that
the adjustment was not successful due to exceeding the tolerable signal limits or there was
excessive signal noise. This can be a sign that the sensor is defective and should be replaced so
as soon as possible.
10
Note:
If no test cable is available with service plug, the output current (Iout) of the transmitters with
analog interface (4-20mA and 0.2-1mA) can be measured directly between terminal 2 and
terminal 3 (GND). During this current measurement nothing may be connected to terminal 2
except the multimeter during this current measurement. Multimeter in mA scale.
4.3.5
Sensitivity calibration
For calibration (checking) or adjusting the gas sensitivity, a calibration adapter has to be
screwed on the sensor housing. The test or calibration gas is supplied to the sensor without
pressure at a flow rate of approx. 0.5 l∕min via the calibration adapter. Depending on the
measuring range, fresh air or synthetic air can also be used.
The indicated value is shown on the display. A sensitivity adjustment is required if the display value
deviates from the calibration gas concentration.
Adjustment of the display:
Before any adjustment of the sensitivity, the zero point should be checked and if necessary
re-adjusted. The adjustment of the sensitivity can be done in different ways depending on
the transmitter version. Both options are described below.
4.3.6
Sensitivity adjustment with display and keyboard [SPAN]
INFO
To perform the sensitivity adjustment, press and hold the button
(>3sec.) to change to the service code query. After entering the default
service code "0011" (factory setting), the program "SPAN Adjustment " is
activated. This is signal ed by a flashing yellow status LED and transmitters
with analog interface (4-20mA or 0.2-1mA) by an output signal of 2.4mA
or 0.12mA.
SPAN
The display shows the current gas reading (indicated value) and displays
the adjusted test gas concentration (cal gas). After pressing the middle
button [Gas] the test gas concentration can be changed with the left
or right control buttons, and saved with the center control button.
If the measured gas value is at least 7% of the measuring range, the
sensitivity adjustment can be started with the left button [Start]. Once
a stable reading is detected for a defined period, the sensitivity is
adjusted and the new measured value is displayed. Using the right
button, the "SPAN Adjustment" program can be completed and a
change back to measurement mode can be made.
4.3.7
Sensitivity adjustment with the SPAN potentiometer
For transmitters without display the sensitivity adjustment can be carried out when the
transmitter cover is open via the SPAN pot using a small screwdriver, a multimeter and with a test
cable with service plug (see Accessories and spare parts section). The test cable should be
connected to the voltage measuring jacks of the multimeter and the service socket inside the
service connector of the transmitter (also see note).
As long as the SPAN pot is not turned, a voltage value is shown on the multimeter between
0.2-1V DC, this indicates the current gas measurement in the range of 0-100% of the
measuring range proportional.
Once the SPAN pot is turned the setpoint can be read on the multimeter for the sensitivity
adjustment. This is signaled by the flashing yellow status LED. It must be turned until a voltage
value of for example 0.600V (for 50% MR) is displayed. As long as this setpoint remains
unchanged for a considerable time, the sensitivity adjustment is started by the transmitter. The
yellow status LED goes off once the adjustment is complete.
11
If the transmitter, despite correct task of the calibration gas, jumps back to the original
(unadjusted) measurement value after the adjustment, this could mean that the adjustment was
not successful due to exceeding the tolerable signal limits or there was excessive signal noise.
This can be a sign that the sensor is defective and should be replaced so as soon as possible.
Note:
If no test cable is available with service plug, the output current (Iout) of the transmitters with
analog interface (4-20mA and 0.2-1mA) can be measured directly between terminal 2 and
terminal 3 (GND). During this current measurement nothing may be connected to terminal 2
except the multimeter. Multimeter in mA scale.
4.4 Main and service menu [MENU]
The middle button [MENU] must be pressed and held for at least 3 seconds in order to switch to
the main menu and, from there, into the service menu. Access to the main menu is not
protected by an access code.
4.4.1
Main menu
The transmitter remains in measurement mode in the main menu itself and when switching into
the individual menu items. This means that the measurement value recording, processing, and
output continues to function in the background. There is an exception in the service menu, and
this is described in the next section. The main menu is structured as follows:




Transmitter Status
Transmitter Info
Service Menu
Exit
Current system errors, errors in the measurement procedure, service needs and incidents can
be retrieved in the transmitter status. Numbers inside parenthesis can be found after these
groups. These numbers indicate the number of the existing information.
4.4.2
Service menu
To access the service menu, a special access code must be entered. For the
default service menu the code is "1100". Additional functions are available
in an advanced service menu. Only GfG service personnel are permitted
to access the advanced service menu.
The service menu is subdivided as follows:
System settings: This menu contains general settings for the RS485 bus
interface and/or analog interface, language, display contrast, tolerance
range and acoustic alarm.
Sensor settings: This menu contains the settings required for sensor
replacement as well as the selection of the measurement range.
Readout simulation: This menu allows to generate measurement
values without test gas for checking the output signal interface and
the subsequent signal processing.
Within the following subsections, the setting options are described in detail.
12
4.4.2.1
System settings
If the transmitter includes a RS485 bus interface, the Bus address can be
set to a range from 1 to 247 (0 = inactive). However, you are not allowed
to use this bus address several times within the same bus segment.
Bus baudrate can be set to 9600, 19200 or 38400 bauds. By default it is
set to 19200 bauds. The baud rate can be reduced to 9600 bauds for very
long bus lines and increased to 38400 bauds for very many participating
bus stations. The same baud rate has to be set for all bus stations within
one bus segment.
Language can be set to German or English and is relevant for all display
outputs for the menus in particular.
Display contrast can be set from 0 to 100%. This value can vary
depending on the display type and is typically set to 25…40%.
Tolerance band can be set to "ON" or "OFF". If it is set to
"ON" (standard), minor signal deviations of fresh air are indicated as
20.9 vol % O2. The actual measurement value is only indicated when
exceeding or falling below the tolerance range. If this item is set to "OFF",
the actual measurement value is always indicated.
Buzzer volume can be set from 0 to 100%, but is only relevant, if
the transmitter is used to trigger an alarm in case of hazardous gas levels.
Click sound can be set to "ON" or "OFF". If it is set to "ON" (standard), the
internal acoustic alarm produces a short clicking each time a button is
actuated.
If the transmitter is provided with an analog 4-20mA (0.2–1mA)
interface, the menu item Analog interface of the advanced service
menu can be used to adjust and check the current interface.
Iout adjustment: Caution!!! The current interface may only be adjusted
with the help of a very precise ammeter.
Iout test:
The current output can be checked in a range from 0.5 to
24.5mA using this item. Caution!!! It is possible that connected control
devices respond to these test levels.
4.4.2.2
Sensor settings
The following sensor-related settings can only be set in the advanced
service menu:
Sensor replacement: If a gas sensor has been used up and is to be
replaced by a new gas sensor of the same type (MK…), this menu item has
to be used to enter the serial number of the new gas sensor. The sensor
resistance Rk must also be set for certain sensor types (e.g. MK442-1).
When all data are entered, the calibration data of the former sensor are
deleted and replaced by new standard values. In any case, the zero point
and the gas sensitivity of the new gas sensor need to be adjusted.
Measurement range Upon delivery, the transmitter will be set with the
measuring range requested by the customer. However, if another
measuring range is requested later and further measuring ranges are
available for the respective sensor, this menu item can be used to select
another measuring range.
Due to the different limit values of the measuring ranges, the calibration
data of the former measuring range are not adopted. Thus, if another
measuring range is selected, the zero point and the gas sensitivity may
possibly need to be adjusted.
13
4.4.2.3
Measurement value simulation
Thanks to the measurement value simulation, the output signal interface,
transmission of measurement value and subsequent signal processing can
be checked. Over a restricted period of time, measurement values can be
generated without an appropriate test gas being available.
At the beginning, the display still shows the current measured value.
Simulation mode is only started by pressing the left or right key. The
maximum remaining simulation time is then indicated above the keyboard
labeling. If the simulation value is modified with the help of the left or right
key, the remaining simulation time is again set to 5 minutes. The
simulation mode can be terminated by pressing the center key. If no key is
pressed, the simulation mode is terminated upon expiry of the remaining
simulation time and the device automatically switches over to
measurement mode.
4.5 Displays and messages
4.5.1
Overview of the status LED states and power output signals
The various display statuses of both of the status LEDs and the power output signals complete
with a reference to their meaning are listed in the following table.
Green LED
Power output
For description, please see Section ...
Off
Flashes atth 1 Hz
Off
On
Off
On
Single pulse every 5s To
Flashes at 1Hz
On
On
Flashes at 1 Hz
On
Flashes at 1 Hz
On
Flashes at 1 Hz
Single pulse every 5 s
On
Yellow LED
0.0mA
0.0mA
1.2mA
1.2mA
1.6mA
2.0mA
2.4mA
4-20mA
2.8-22mA
Display of special conditions...
Display of special conditions...
Display of special conditions...
Display of special conditions...
Display of special conditions...
Displays in service mode...
Displays in service mode...
Displays in service mode...
Displays in measurement mode
No.
No.
No.
No.
No.
No.
No.
No.
No.
On
On
On
2.8mA
2.8-22mA
22mA
Displays in service mode
Displays in service mode...
Displays in service mode
No. 307, 308
No. 303-306
No. 301, 302
On
Off
Flashes at 5Hz
4.5.2
001
002
103-113
101
002, 003
204, 205
203
201, 202
309
Display of special conditions (device start-up and fault)
The following table shows the states with a description in which the yellow fault LED lights up and
the 4-20mA current output transmits a signal ≤1.6mA.
For the 0.2-1mA current output the value of the output signal is shown in parenthesis (≤0.08mA).
Behavior during device start-up:
No.
Display
001
Boot V1.07
GfG ZD 22
Error:Flash
002
Boot V1.07
GfG ZD 22
Verify
V1.66
GfG ZD 22
003
004
Warm up
XX
Seconds remaining
Green
LED
Off
Yellow
LED
Flashes
at 1
Hz
Power
output
0.0mA
Off
On
Flashes
at 1
Hz
Flashes
at 1
Hz
On
1.6mA
(0.08mA)
On
1.6mA
(0.08mA)
0.0mA
Cause
Information / Explanation
An error was detected in
the program memory during
the memory check.
Restart the transmitter.
Firmware update is required
if an error message is
displayed again.
Automatic transition to
initialization phase after
approximately 4 seconds.
Automatic transition to
sensor start-up phase after
approximately 3 seconds.
Program and memory tests
in the first seconds of
device start-up.
Initialization
phase of the
transmitter.
Sensor start-up phase.
14
Automatic transition into
measurement mode after
time has elapsed.
Behavior in the event of a fault:
No.
Display
Green Yellow
LED
LED
Single
On
pulse
every 5s
Power
output
1.2mA
(0.06mA)
101
Sensor defective
102
Supply voltage
incorrect
Off
On
1.2mA
(0.06mA)
103
Sensor Uk incorrect
Off
On
104
Sensor Ik < MIN
Sensor Ik > MAX
Off
On
1.2mA
(0.06mA)
1.2mA
(0.06mA)
105
Temp.signal < MIN
Temp.signal > MAX
Watchdog error
Off
On
Off
On
106
1.2mA
(0.06mA)
1.2mA
(0.06mA)
107
FLASH error
Off
On
1.2mA
(0.06mA)
108
RAM error
Off
On
1.2mA
(0.06mA)
109
On
1.2mA
(0.06mA)
110
EEPROM error 1
Off
EEPROM error 2
EEPROM error 2c
EEPROM error 1 + 2
EEPROM error 1 <> 2
Incorrect PCB type
Off
On
1.2mA
(0.06mA)
111
Digital pot error
Off
On
1.2mA
(0.06mA)
112
ADC error 1
ADC error 2
Program sequence
error
Off
On
Off
On
1.2mA
(0.06mA)
1.2mA
(0.06mA)
113
4.5.3
Cause
Information / Explanation
Sensor no longer
responds correctly to gas.
The sensor may be too
old.
The transmitter supply
voltage is either too low
or too high.
Heating voltage for the
sensor is incorrect.
Heating current for the
sensor is too low or too
high.
Temperature measurement
is presumably incorrect.
A hardware error was
detected during the
external watchdog test.
The sensor must be
replaced.
An error was detected in
the program memory during
the memory check.
Defective memory was
detected during the
memory check.
Error in the parameter
memory or when accessing
the external parameter
memory module.
Examine the power
supply and adjust
Restart the device.
Replace the device if the
error message displays
again.
An incorrect printed
circuit board type or
printed circuit board error
was identified.
A hardware error was
detected on the digital
potentiometer.
An error was detected on the
analog-to-digital converter.
A logical process error was
identified during program
processing.
Displays in service mode and during sensor adjustment
The following table shows the states with a description in which the green operation LED lights
up and the 4-20mA current output transmits a signal 2.0-2.4mA.
For the 0.2-1mA current output the value of the output signal is shown in parenthesis
(0.10-0.12mA).
No.
Display
Green
LED
On
Yellow
LED
Flashes
at 1
Hz
Power
output
4-20mA
(0.2-1mA)
201
Zero point
adjustment
(ZERO-Pot)
202
Sensitivity
adjustment
(SPAN-Pot)
On
Flashes
at 1
Hz
4-20mA
(0.2-1mA)
203
Menu item
On
Flashes
at 1
Hz
2.4mA
(0.12mA)
204
Zero point
adjustment
On
2.0mA
(0.10mA)
205
Sensitivity
adjustment
On
Flashes
at 1
Hz
Flashes
at 1
Hz
2.0mA
(0.10mA)
Cause
Information / Explanation
AutoCal program for zero
point adjustment was
activated with ZERO
potentiometer
AutoCal program for
sensitivity adjustment
was activated with SPAN
potentiometer
Service menu was activated
using the keyboard
Zero gas setting
takes place with the
ZERO potentiometer
Zero point adjustment has
been activated using the
keyboard
Sensitivity adjustment
was activated using the
keyboard
15
Calibration gas setting
takes place with the
SPAN potentiometer
Select the menu item. An
automatic return to measurement
mode takes place if no entry is
performed for a period of 1 min.
AutoCal adjustment
of the zero point
AutoCal adjustment
of the sensitivity
4.5.4
Displays in measurement mode
The following table shows the states with a description in which the green operation LED lights up
and the 4-20mA current output transmits a signal 2.8-22mA.
For the 0.2-1mA current output the value of the output signal is shown in parenthesis (0.14-1.1mA).
No.
Display
↑↑↑
Green
LED
On
Yellow
LED
Flashes
at
5Hz
Power
output
22mA
(1.1mA)
↑↑↑
On
Flashes
at
5Hz
22mA
(1.1mA)
↑↑↑ alternating with
On
Off
20-22mA
(1.0-1.1mA)
Measurement value
On
Off
4-20mA
301
permanent
302
permanent
303
the measurement
value
304
Cause
Measurement value
On
Off
306
Measurement value
alternating with
On
Off
307
Permanent
On
308
Permanent
309
Sensor replacement
required
↓↓↓
↓↓↓
↓↓↓
4.5.5
The gas concentration has
exceeded the measurement
range of the transmitter
electronics
The gas concentration has
significantly exceeded the
measurement range (Gas ≥
112.5% MR)
The gas concentration has
exceeded the measurement
range (100 to 112% MR)
Fault-free measurement
mode
(0.2-1mA)
305
Information / Explanation
Underflow of the measurement
range (-5.0 to 0.0% MR)
3.2-4.0mA
(0.16-0.2mA)
2.8-3.2mA
(0.14-0.16mA)
Underflow of the measurement Zero point calibration is
useful
range (-7.5 to -5.0% MR)
On
2.8mA
(0.14mA)
Underflow of the measurement Zero point calibration is
range (below -7.5% MR)
necessary
On
On
2.8mA
(0.14mA)
On
Single
pulse
every 5s
2.8-22mA
(0.14-1.1mA)
Measurement signal has fallen
below the measurement range
of the transmitter electronics
Expected service life of the
sensor is exceeded.
Zero point calibration is
necessary and sensitivity
must be checked
Sensor replacement or
adjustment required
Priority of displays and messages in measurement mode
The display of statuses with lower priority are overwritten by displays with higher priority.
The statuses with lower priority are not reset.
Priority
Status
Significant measurement range overflow (ambiguity)
Slight measuring range overflow
Measurement range underflow
Sensor replacement
For description, please see Section ...
Displays in service mode
No. 301, 302
Displays in measurement mode No. 303
Displays in service mode
No. 305 - 308
Displays in measurement mode No. 309
Sensor fault no. 101 and the transmitter fault no. 102 - 113 stop the measuring operation
with their respective messages.
4.6 Fault, cause, remedy
Fault
Cause
Remedy
Zero point can no longer be set
Sensitivity can no longer be set
Output current has dropped to 0mA
Sensor defective
Sensor defective
Defective fuse or electronics
Line interrupted
Replace sensor
Replace sensor
Replace printed circuit board
Re-establish connection
16
5.
APPENDIX
5.1 Cleaning and care
External soiling on the transmitter's housing can be removed with a damp cloth. Do not use
any solvents or cleaning agents!
5.2 Servicing and maintenance
The servicing and maintenance includes a regular visual inspection, functional check and
the system check as well as the repair of the gas warning system.
5.2.1
Visual inspection
The visual inspection should take place regularly, at least once per month, and consist of the
following activities:
- Check the indicator light and the status messages,
e.g. operation display "On", alarm and fault display "Off"
- Check for mechanical damage and outer soiling
5.2.2
Functional check
The functional check can be carried out at intervals dependent on the risk of the gas to be
monitored. For gas detection systems used for the measurement of toxic gases and oxygen 6
months is recommended.
This includes the following activities:
-
Visual inspection according to section 5.2.1 of this operating manual
Check and assessment of measurement value displays
Triggering the alarm thresholds
Triggering of test functions for display elements, visual and audible signaling device without
triggering the switching functions
- Check of stored messages, faults and maintenance requirements.
5.2.3
System check
The system check must be performed at regular intervals. The period must not exceed 1 year.
This includes the following activities:
- Functional check according to section 5.2.2 of this operating manual
- Check of all safety features including the triggering of switch
functions
- Check of the parameterization through a target / actual comparison
- Check of the messaging and logging devices
5.2.4 Repair
The repair includes all repair and replacement work. They may only be performed by the
manufacturer and by persons who have been authorized by the manufacturer,
GfG Instrumentation. Only original spare parts as well as original assemblies that have been
tested and approved by the manufacturer may be used.
5.3 Sensor replacement
The transmitter cover must be removed in order to replace the sensor. Once power is
removed, the sensor cables can then be removed from the terminals 5-8. The printed
circuit board must then be pulled out of the guide so that the old sensor can be
unscrewed. The assembly of the replacement sensor takes place in reverse order. Only a sensor
of the same type may be used for this purpose. Furthermore, the serial number must be
entered into the service menu of the transmitter once it has been installed and commissioned.
17
5.4 Accessories and spare parts
1.
2.
3.
4.
Description
Calibration adapters for ZD 22 transmitter
Service test cable w/service plug for ZD 22 transmitters
MK435-1 Replacement sensor for 0..2 vol.% O2 (oxygen)
MK442-1 Replacement sensor for 0..25 vol.% O2 (oxygen)
5.5 Sensor specification
MK395-1 Zircon dioxide sensor for oxygen O2
Measuring range / resolution:
Measuring accuracy:
Reproducibility:
Time setting
t90:
Pressure influence
80...500 kPa:
15...80 kPa:
Influence of humidity 0...99 % r.h.:
Temperature influence-4 to +122°F:
Flow velocity
0...6 m/s:
Cross sensitivities:
Expected service life:
0.1...25 vol.% / 0.1 vol.%
0.25 vol.%
0.1 Vol.%
< 5 sec
< 0.05 % of measurement value per 10kPa
< 2.0% of measurement value per 10kPa
negligible
negligible
negligible
approx. –1.1 vol.% @ 40 vol.% CO2
approx. –0.1 vol.% @ 1000 ppm CO
approx. 0.11 vol.% @ 1000 ppm NO2
approx. –0.03 vol.% @ 1000 ppm SO2
approx. –0.2 vol.% @ 1000 ppm CH4
0.0 vol.% @ 400 ppm H2S
0.0 vol.% @ 20 0ppm NH3
4 - 5 years
MK435-1 Zircon dioxide sensor for oxygen O2
Measuring range / resolution:
Measuring accuracy:
Reproducibility:
Time setting t90:
Pressure influence 80...500 kPa:
15...80 kPa:
Influence of humidity0...99 % r.h.:
Temperature influence
-20 to
+50°C:
Expected service life:
0.01...2 vol.%
200ppm
100ppm
< 5 sec
< 0.05 % of measurement value per 10kPa
< 2.0% of measurement value per 10kPa
negligible
negligible
4 - 5 years
MK442-1 Zircon dioxide sensor for oxygen O2
Measuring range / resolution:
Measuring accuracy:
Reproducibility:
Time setting t90:
Influence of humidity 0...99%r.h.:
Temperature influence -20 to +50°C:
Expected service life:
0.1...25 vol.% / 0.1 vol.%
0.5 vol.%
0.1 Vol.%
< 30 sec
negligible
negligible
4 - 5 years
18
Part No.
2000209
2220201
On request
On request
5.6 Technical data
ZD 22
Type designation:
Ambient conditions
Operating temperature:
Storage temperature
Humidity:
Pressure:
Power supply
Operating voltage:
Power consumption:
Sensors
Fuses:
Measuring range and
measurement gas:
Measurement gas feed
Display & operating
elements
Status LEDs:
Display, buttons:
Auto ZERO key:
Potentiometer:
Service connector
Design:
Analog output:
Digital input:
Signal output
analog:
or analog:
or digital:
Connector cable
Cable inlets:
Connection terminals:
Cable (analog):
Cable (digital):
Housing
Protection class:
Material:
Dimension:
Weight:
Approvals/tests
Electromagnetic
compatibility:
-4 to +122°F / -20 to +50°C (sensor dependent)
-13 to +140°F / -25 to +60°C (recommended +32 to +86°F / 0 to +30°C)
-5 - 95%r.h. non-condensing (sensor dependent)
80 - 120kPa (sensor dependent)
24V DC
(15-30V DC allowable)
typ.120mA / max.140mA @ 24V DC (MK442)
typ.130mA / max.160mA @ 24V DC (MK395, MK435)
typ.150mA / max.180mA @ 24V DC (4…20mA version with MK395, MK435)
250mA (not changeable)
Sensor dependent
Diffusion
Green for operation and yellow for fault or service
2.2″ graphic display and 3 function buttons (on display version)
For ZERO adjustment
For ZERO and SPAN adjustment (optional)
3.5mm stereo jack socket (internally located)
0.2-1.0V corresponding to 0-100% range for sensor
calibration for For configuration and firmware update
4-20mA (max. load: 150Ω/400Ω/650Ω @12V/18V/24V supply)
0.2-1mA (max. load: 4K5/9K3/14K1 @12V/18V/24V supply)
RS485; half duplex; max. 38400 bauds; Modbus protocol,
Slide switch for 120Ω termination resistor
1 or 2 units of M16 x 14 AWG (for cable diameter 4.5 - 10 mm)
4 units (for 28...13 AWG gauge conductor cross-section)
3-wire e.g. LiYY 3 x 18...16 AWG gauge or LiYCY
4-wire e.g. LiYY 4 x 18...16 AWG gauge or bus line Y(St)Y 2x2x0.8
*1
IP54 according to IEC 60529
Plastic
3.8 x 5.5 x 2in / 96 x 140 x 49mm (W x H x D) with sensor
6oz or 8 oz / 175g or 220g (display version)
DIN EN 50270:2006 Interference:
Immunity:
Type class I
Type class II
Explanation regarding*1: Bus line Y(St)Y 2x2x0.8 is only suitable for supplying several bus transmitters with power using the same cable
via short cabling distances. The possible distance depends on the quantity and local distribution
of the transmitters on the bus cable.
19
5.8 EC declaration of conformity
20
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GfG Instrumentation, Inc.
1194 Oak Valley Dr.
Suite 20
Ann Arbor, MI 48108
USA
US/Canada: US/Canada Fax: International: International Fax: Website: (800) 959-0329
(734) 769-1888
+1 734 769 0573
+1 734 769 1888
www.goodforgas.com
Worldwide Manufacturer of Gas Detection Solutions
Rev. 1 (11/10/16)
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