GfG IR29, IR29B, IR29D, IR29DB Operation Manual

Operations Manual

Transmitter IR29

Table of contents

For Your Safety

Operating Instructions

General Description

Measuring Methods

Device Design

Type Plate

Installation Site of the Transmitter

Assembly

Installing Electrical Connections

Assembly and Operation with Flow Adapter

Using the RC2 or RC3 operator interfaces

Control Buttons

Display and LED test via RC2 or RC3 operator interfaces

Commissioning

Measuring Mode

Changing the Gas Measuring Channel

Under Range

Over Range

Display of Operating Parameters

Measured Value Histogram

Sensor Lifetime

Device Error

Zero Calibration and Adjustment (ZERO)

Activation

Execution

Sensitivity Calibration and Adjustment (SPAN)

Calibration

Adjustment

Service Menu and Advanced Service Menu

Activate Service Menu

Operation

Layout of the Service Menu

Additional Menu Explanations

Displays and Messages

Display of Special Statuses and Malfunctions

Error Messages of the Main CPU

Error Messages of the Sensor CPU

Displays in Measuring Mode

Displays in Service Mode and During Calibration (Status Messages)

Status of the Status LEDs and the Current Output

Initial Commissioning and Maintenance

Maintenance of Stationary Gas Warning Systems

Regular Functional Tests

Repair

Troubleshooting

5

8

8

9

9

9

4

4

10

10

10

11

11

12

12

12

13

13

13

21

21

23

24

24

25

25

26

26

26

27

27

15

15

15

17

17

17

18

19

2

3

3

1

1

2

Accessories

Connections and Terminal Assignment

IR29 i/Di with 4...20mA Interface and Zener barriers

IR29 i/Di with 4...20mA Interface and Zener barriers from MTL

IR29 i/Di with 4...20mA Interface and SB1

IR29 i/Di with 4...20mA Interface & 3-wire cable (e.g. GMA41)

IR29 /D with 4..20mA Interface & 3-wire cable to GMA200

IR29 B/DB; with RS485 Bus & Four-Wire Cable to GMA200

Measuring Gases and Measuring Ranges

Sensor Specification

Technical Data

Notes IR29

Appendix RC3

Field of Application and Intended Use

Operation

Channel Coding

Changing Batteries

Technical Data

Appendix SB1

Operating Instructions

Device Design

Install Electrical Connections

Technical Data

Declarations of Conformity, Type Examination Certificates

33

33

35

28

29

29

29

30

31

32

32

43

43

43

43

45

46

37

41

41

41

41

41

42

For Your Safety

This user manual states the intended use of the product according to the German Product

Safety Act (ProdSG) and helps to prevent accidents and work-related injuries. It must be read and observed by all persons who operate, service, maintain and inspect this product. This product can serve its intended purpose only if it is operated, serviced, maintained and inspected according to the instructions given by GfG Gesellschaft für Gerätebau mbH.

The warranty provided by the company GfG will become void if the product is not operated, serviced, maintained and inspected in accordance with GfG’s instructions. The above declaration does not affect statements regarding warranties and liabilities in the company

GfG's General Terms and Conditions of Sale and Delivery.


After installation but before commencing operation, gas warning systems must be inspected by an expert to ensure they operate correctly and in accordance with national standards

(commissioning). In Germany, the rules of the employers' liability insurance associations must be followed, "BGR 500, chapter 2.33 section 4.4.".

The transmitter has been tested for functionality prior to delivery. Calibration and alignment took place with appropriate test or calibration gases.

This however does not release you from the obligation to commission the transmitter

with test or calibration gas after installation.

The IR29 transmitter is approved for use in hazardous areas and has an EC type examination certificate from DEKRA EXAM GmbH in accordance with Directive 2014/34/EU.

Certificate: BVS 09 ATEX E 135 X

For the types IR29 i and IR29 Di applies:

Marking:  I M1 Ex ia I Ma

 II 1G Ex ia IIC T4 Ga

-25°C≤Ta≤+55°C

-25°C≤Ta≤+55°C

The following applies to types IR29, IR29 D, IR29 B and IR29 DB:

Marking:  II 2G Ex eb mb ib [ib] IIC T4 Gb -25°C≤Ta≤+55°C

!

CAUTION:

The supply voltage should under no circumstances exceed 30 V

DC! This also applies to voltage peaks!

Operating Conditions:

The transmitter is only admitted to be used under atmospheric conditions, i.e. the operating parameters for temperature and pressure, according to the Technical

Data in the Annex which has to be complied with.

The electrical safety is tested for the use under atmospheric conditions, i.e. up to an oxygen content of typical 21Vol%.

- 1 -

General Description

A fixed gas warning system consists of a transmitter and an evaluation unit (GMA, not included). The transmitter and the evaluation unit are interconnected via a shielded remote measurement cable. The transmitter converts the gas concentration into an electrical measuring signal. The evaluation of the measuring signal proportional to the existing gas concentration takes place at the evaluation unit (GMA).

The extensive electronics assumes various tasks which, on the one hand, facilitates operation and maintenance and, on the other hand, significantly enhances operational safety and measuring accuracy. The transmitter features the following:

•

Measured value display on the display (optional) or on the RC2 operator panel

•

Settings without opening the housing with the remote control RC 2 or RC 3

•

Compensation of temperature influences

•

Ex-protection in temperature range -25 to +55°C

•

Functional test in the temperature range -25 to +55°C [applied for]

•

Permanent status display (operation/fault) on the transmitter

Measuring Methods

The sensors built into the IR29 transmitter operate according to the infrared absorption principle. Alignment to the gas type being monitored takes place using specific optical filters combined with suitable characteristics. The reduced infrared radiation at the position of the detector is converted into an electrical signal. This signal is amplified in the IR29, filtered and used for the display or measured value transfer. Due to its design with two radiation sources, the measurement assembly offers a powerful signaling function and is less sensitive to interfering influences, such as deterioration of the radiators or temperature deviations. Soiling of the optics can also be compensated up to a certain degree. Due to the said design and additionally available temperature and pressure compensation, influence caused by ambient conditions is almost entirely eliminated.

The electronics of the transmitter IR29 converts the measuring signal into a linear measured value output 4..20 mA.

Depending on the sample gas, cross sensitivities with other gases, especially hydrocarbons, may occur.

Variants

The Transmitter IR29 - Meaning of the short description:

Designation 4..20mA

Interface

RS485

Modbus

IR29i

IR29Di

IR29

IR29D

IR29B

IR29DB yes yes yes yes no no no no no no yes yes

Display no yes no yes no yes

Degree of

Protection

Intrinsically Safe

"i"

Increased Safety

"e

- 2 -

Device Design

Retaining Bracket Impact Protection

Measuring

Space

Gas Entry

Under Protective Cap

Display

(optional)

Diffusion opening

Cable Entry

Status LEDs

Type Plate

Terminal Module

Type Plate

Transmitter version details, serial number and ATEX marking

Transmitter

Type designation & serial number

Type Plate IR29

- 3 -

Installation Site of the Transmitter

When determining the installation site, it is important to know the exact ambient conditions and to take them into consideration. In order to receive representative results, the ventilation conditions must be taken into account.

The position of the transmitter in the room must ensure that the gases still reach the sensor even in the event of unfavorable ventilation. If necessary, carry out a measurement, e.g. with ventilation smoke tubes.

When specifying the site of installation, it must be further observed that the transmitter can be accessed for service and calibration tasks.

External influences must also be considered, e.g.

• rainwater, splash water, dripping water, condensate

• the dust content in the atmosphere

The transmitter is protected against the ingress of water or dust to the greatest possible extent.

Special accessories can protect the transmitter against damage in extremely harsh measurement conditions. If desired, the company GfG will gladly advise you about suitable measures.

!

The warranty may become void if the sensor is exposed to ambient conditions which were unknown to the company GfG during the planning phase or delivery.

!

Transmitter types IR29, IR29 D, IR29 B and IR29 DB:

The housing only fulfils the requirements of the EN 60079-0 (table 13) in combination with the IR29 Protection cover (guard). Therefore, the IR29 Protection cover and the device need to be firmly attached.

Assembly

The assembly is carried out step by step in the following sequence:

A

1

I. Loosen the screws "A" and remove the retaining bracket (1). To do so, slightly pull apart the ends of the bracket until the lugs are free.

2

II.

Remove the transmitter (2) from the socket.

Depending on the type, the electrical plug connection is either disconnected or the plug has to be unplugged manually.

- 4 -

B

3

III.

Loosen screws "B", remove and lift the upper part of the base (3) from the lower part (4).

4

C

4

3

IV.

Fasten the lower part (4) into position at the installation site; use the oval holes "C" and the screws provided for this purpose.

A drilling template is supplied in the Annex to assist in the location of the holes.

Subsequently feed the line through the cable gland (fit the shield) and install the single conductors in the terminals X1-X4 (see next chapter).

Assemble in reverse order (steps III-I).

!

CAUTION:

During assembly, some screws must be tightened to a defined torque. An overview can be found in the appendix.

Installing Electrical Connections

The installation of the remote measuring cables and the connection of the electrical installation may only be carried out by a specialist in compliance with the relevant regulations. The installation must be carried out with a protected cable.

For intrinsically safe devices (IR29 i/Di), e.g. Helukabel OZ-BL-CY 4X1.5 mm2 or Lapp Kabel

ÖLFLEX® EB CY can be used. According to the manufacturer, these exemplarily selected cables meet the requirements of DIN EN 60079-14 or IEC 60079-14 Section 12.2.2 (VDE 0165

Part 1). In addition, mechanical protection of the installed telemetry cable is required if both intrinsically safe circuits are routed in one cable. This is necessary to prevent the two intrinsically safe circuits coming into contact.

Suitable mechanical protection depends on the operating situation, the installation site and the hazard potential. The shielded PVC data cable UNITRONIC® LiYCY 3 x 1.5mm², for example, is suitable for devices with increased safety (IR29 /D/B/DB).

The conductor cross section is determined by the length of the connection line and the version of the transmitter. Remote measurement cables with a conductor cross section of 0.75 mm can be used for short distances of up to 500 m. The conductor cross section must be 1.5 mm for longer distances of up to 1,000 m.

2

2

- 5 -

The shielding is fitted in the M16x1.5 cable gland. Potential equalization may be required for the transmitter IR 29.

Only the transmitter can be installed in a potentially explosive atmosphere – the evaluation unit and the power supply unit must be installed outside this atmosphere.

If potential equalization of the housing is necessary, the potential equalization terminal can be found at the lower section of the wall holder.

!

!

!

The transmitter may only be installed if there is no gas present.

In possibly explosive areas all electrical lines need to be laid stationary from and to the transmitters IR29 (all types).

Each screwed and secured cable and line gland in the housing wall either has to be closed by a cable or by a plug admitted for this application.

Transmitter types IR29 i/ Di:

The user has to make sure that also in case of an error no higher voltage than Ui =

30V DC may apply on the terminal of the IR29.

Transmitter types IR29, IR29 D, IR29 B and IR29 DB:

The user has to make sure that also in case of an error, no higher voltage than the maximum voltage U m terminal of the IR29.

= 45V DC is indicated on the type plate may apply on the

The current interface (4..20mA) of the "i" version requires its own supply voltage. See chapter

Connections and Terminal Assignment.

- 6 -

Connection Diagram IR29 i/Di

X1: 15…30V DC

X2: GND

X3: 15..30V (+)

X4: 4...20mA (-)

Potential Equalization

Potential

Equalization

4 mm2

Potential Equalization Terminal:

This is located on the side next to the cable gland on the lower part of the wall holder.

The potential equalization must be carried out with a cable cross-section of 4 mm 2 .

Potential

Equalization

4 mm2

Potential Equalization Terminal:

(on IR29 Protection cover)

The potential equalization terminal is positioned laterally on the guard (IR29

Protection cover) beside the cable gland

(pressed in threaded bold M5x12).

Potential equalization must take place with a line cross section of 4 mm 2 .

As shown in the diagram, the wall holder must be fixed horizontally with the cable gland facing to the left, fixed to a wall or suitable support. The impact protection should be directed downwards with the diffusion opening. For alignment, loosen the Allen screw slightly, and then turn the protection.

A different mounting of the transmitter may adversely affect the response time or the weather protection.

After the disassembly of the impact protection, a dust filter may be inserted in the measuring space. When using the dust filter, the response time of the transmitter is extended.

In the diffusion mode, the response time for methane is extended by about 50%.

This value may vary for other gases. Depending on the operation site, it is necessary to check in regular intervals if the dust filter is soiled, in order to guarantee the gas entry.

- 7 -

Assembly and Operation with Flow Adapter

It is possible to mount a flow adapter instead of the impact protection (Sketch see Annex).

With that, it is possible to measure gas sampling in the flow via the gas supply on the IR29 and via a gas outlet on the adapter. The gas should be supplied unpressurised with a volume flow of at least 1l∕min (<2l/min). A lower volume flow adversely affects the response time. The use of a flow controller may be useful in this place. The gas supply should be performed via the gas nozzle on the device; the gas outlet is performed via one of the two gas nozzles on the adapter. The two nozzles on the adapter need to be closed.

Gas supply and drain via the two connections on the adapter may adversely influence the response time. The use of the dust filter during the operation with the flow adapter may adversely influence the response time.

The connection to the gas extraction point may be performed e.g. by a PE or PTFE hose.

Delays in the response time due to the hose length need to be considered.

At an inner diameter of the line of 4mm a delay of the response time of one second per 1.3m line length at a flow of 1l/min would result. In the meantime, the pump and any possible other installations (e.g. condensate trap) additionally need to be considered.

The user has to check the sample lines by suitable measures in regular intervals in order to ensure the functionality.

Using the RC2 or RC3 operator interfaces

!

For service tasks, only the remote control RC 2 (BVS 04 ATEX E 212) should be connected to the transmitter, or the remote control RC 3

(BVS 08 ATEX E 006) in conjunction with an integrated display should be used at the transmitter.

The remote control RC 2 and the IR remote control RC 3 can be used in potentially explosive atmospheres.

Settings of the zero point and display sensitivity (adjustment) can be executed directly at the optionally integrated display at the transmitter IR 29 and the remote control RC 3 or with the connected remote control RC 2.

The buttons and functions of the remote control RC 2 are identical to those of the IR remote control RC 3. Output in the transmitter display takes place in plain text format; output in the remote control RC 2 display occurs in abbreviated form.

See operating instructions 206-000.13 for use of the RC2.

In this manual the outputs are mostly given in the form Display/RC2, e.g. Code/ .

- 8 -

Control Buttons

The functions of the buttons at the remote control RC 2 and the IR remote control RC 3 are identical. The designation of the buttons at the RC 3 can be displayed by briefly pressing the central (oval) button at the display of the transmitter IR 29.

Additionaly, there is a sketch with a key label in the appendix.

Display and LED test via RC2 or RC3 operator interfaces

In measuring mode, briefly press the TEST

ZERO button to trigger a display and LED test. All the LEDs are subsequently activated for two seconds and all the segments of the display are shown.

Commissioning

The transmitter IR29 is tested to ensure it is functioning correctly prior to delivery. Calibration and adjustment takes place with a suitable test and calibration gas. Deviations may be identified depending on the transport, assembly and ambient conditions.

Therefore, the gas warning system must be commissioned and tested by the GfG Service to ensure it functions correctly.

After switching on, the transmitter needs, up to four minutes for:

• loading the internal buffer memory

• the self-test, during which the program and main memory are checked

• the reading and evaluation of the device parameters with simultaneous memory check

• the reading and evaluation of the sensor parameters with simultaneous memory check

• the running-in of the sensor

The memory tests occur during the first few seconds of the switch-on phase. The current interface is set to 1.2 mA, the orange and green status LEDs illuminate. During the second step, the current interface is set to 1.6 mA, the fault LED illuminates and the operation LED flashes. The following is initially shown on the display: Einlesen Geräte-Param. (Reading device

param.) ∕  . The measuring unit, the type of gas, the measuring range and the calibration gas concentration are subsequently shown one after the other at the devices equipped with a display or at the remote control RC 2.

The transmitter IR29 switches to the warm-up phase of the sensor, the fault LED flashes and the operation LED indicates readiness at 5 second intervals by flashing briefly – the remaining time is shown on the display in seconds.

The measuring mode is automatically activated after the warm-up phase.

If a device error is detected during the start-up phase, the transmitter IR29 switches to error mode. The current interface is set to 1.2mA, an error message is shown on the display of the transmitter (if available) or via the remote control RC 2 (sees Displaying special statuses and

malfunctions). The fault LED is permanently lit. The display lighting additionally flashes with display versions.

Note:

Initial commissioning demands adjustment of the zero point (AutoCal ZERO) after the warm-up phase and a subsequent sensitivity test, as well as possible adjustment.

(AutoCal SPAN).

- 9 -

Measuring Mode

The gas concentration is measured continuously. The current interface outputs a linear proportional signal in the range 4mA to 20mA. Transfer function: i

0 - 100 % LEL

∝

4 - 20 mA

The current interface is updated every second.

The functions of the electronics such as the parameter memory or the sensor function are monitored continuously. During the trouble-free measuring operation, the green operating LED will flash every 15 seconds, the yellow malfunction LED is off.

For transmitters with a display, the currently measured value is being shown on the display. For transmitters without a display, the measured value is displayed on the connected operating device RC2.

The resolution of the display and the current interface depends on the gas concentration.

Gas concentration x [%UEG] (lower intervention limit) x ≤ 20.0

20.0 > x ≥ 50.0

X > 50.0

Resolution

[%UEG] (lower intervention limit)

0.2

0.5

1.0

When using an IR29 without a display, the display of the remote control RC 2 changes from gas concentration to gas unit and type of gas at one minute intervals.

When using an IR29 with a graphical display, a pending measured value (>0) is shown as a bar graph, which always displays the current measured value in addition to the numerical display (the measuring gas and measuring unit are shown every

30 seconds instead of the bar graph). With display "0.0", the measuring gas and measuring unit are always displayed instead of the bar graph.

Changing the Gas Measuring Channel

For the MK244-3 it is possible to change between the measuring channels, since the measuring value can only be output via the current interface. By simultaneously pressing the buttons

TEST

ZERO and INFO

SPAN

for three seconds, the active gas channel will be displayed such as:

Display:

Choose gas channel

Gas channel 1

RC2:

CHA.1

Then it is possible to choose one of the two other channels by pressing the arrow buttons and INFO

SPAN

which is confirmed by pressing the central button QUIT

MENU

.

TEST

ZERO

Under Range

Measured values below the zero point are displayed as numerical values with a negative sign.

The current interface outputs a signal of between 2.8 mA and 3.9 mA according to the measured value.

If the zero point deviation is too high, the current interface is permanently set to 2.8 mA, and transmitters equipped with a display will permanently show ↓↓↓↓/_ _ _ _ .

- 10 -

Over Range

Transmitters equipped with a display, ↑↑↑↑ ∕  and the measured value are displayed alternately if the measuring range has been exceeded by up to 112.0 %. The current interface provides an output signal between 20...22 mA according to the measured value.

If the measured value exceeds 112.0 % of the measuring range, ↑↑↑↑ ∕  will flash on the display . The current interface is set to 22 mA.

Display of Operating Parameters

During measuring mode, briefly press the INFO

SPAN

button at the remote control RC 2 or RC 3 to automatically display the following important operating parameters one after the other:

1)

•

Measuring Gas

•

Measurement Unit

•

Measuring Range / 

•

Calibration Gas Concentration / 

2)

•

Average value of the last recorded 8 hours

8 h Medium/ 

•

Average value of the last recorded 15 minutes

15 Min. Average /  .



3) If an environmental sensor is installed and activated:

•

Moisture / 

•

Print / 

•

Temperature / 

For transmitters without display, or if it is poorly visible / readable, the parameters can also be displayed in the 7-segment display of the remote control RC2.

For example:

    .

   .

   .

  .

  .

 (         .

  )

- 11 -

Measured Value Histogram

When using a graphical display, it is possible to change to a different display mode. After triggering the display of the operating parameters via the histogram selection.

INFO

SPAN

, briefly press INFO

SPAN

again to display

It is possible to view data of the last 2 hours, 8 hours or 24 hours (select by pressing the TEST

ZERO or INFO

SPAN

button, press QUIT

MENU

to acknowledge your selection). The histogram display mode subsequently appears. It is possible to display average values, maximum values and minimum values by (briefly) pressing the TEST

ZERO

or INFO

SPAN

button again.

Saved measured values are displayed in graphical form instead of the measured value display.

The currently pending measured value is additionally shown in the top section together with the type of gas and gas unit. The histogram is refreshed at regular intervals and can be used as a permanent display mode.

Briefly press QUIT

MENU

or appearing special messages to exit this display mode.

Sensor Lifetime

The IR emitter used has a limited service life. If the signal level falls below 80% of the original value, the transmitter switches the measuring mode off. The error message Sensor error -115-

(unzur. signal level)/  is shown in the display/RC2 . The current interface is set to

1.2mA, the yellow fault LED lights up and the green operation LED flashes quickly.

The display of the fault message can also be an indication of contamination of the optics.

The signal level at the detector may be decreased by impurities. The optics must be checked for impurities and cleaned if necessary.

To carry out the cleaning, see chapter Initial Commissioning and Maintenance - Repair.

If the transmitter continues to display the error message despite clean optics, the transmitter must be replaced.

Device Error

In the event of a fault in the transmitter, the yellow fault LED lights up permanently, the current interface is set to 1.2mA and an error message appears in the display (see chapter

"Displaying special states and malfunctions").

A fault message occurs if, for example, :

• the sensor or the electronics in the transmitter are defective

•

Errors occur during self-monitoring of the device

As soon as the fault has been eliminated, the yellow fault LED goes out.

- 12 -

Zero Calibration and Adjustment (ZERO)

The prerequisite for this inspection is atmospheric air without influencing gas contents.

Synthetic air can also be used for adjustment if the atmosphere is contaminated.

The calibration adapter shown below must be used for checking or adjusting with synthetic air.

The rubberised area must be tightly stretched over the diffusion openings of the impact protection. The calibration adapter can be used to feed the synthetic air without pressure at a flow rate of approx. 0

.

5l∕min. For the complete flushing of the measuring space, a gas feed for at least 90 seconds is required.

If the zero point display deviates in measuring mode, a zero point adjustment is necessary.

After changing the measuring gas (see Service menu and Advanced Service Menu -

Changing the gas type), the zero point must also be checked and reset if necessary.

The AutoCal program automatically adjusts the zero point signal under the above conditions.

Activation

The zero point can only be set via the remote control RC 2 or RC 3 (only possible with transmitter IR29 with a display).

Automatic zero point offset can only be executed after entering access code  if the currently displayed value is 10 % of the maximum measuring range.

An experienced user can activate the zero point setting after entering access code  with a display of up to 15 % of the maximum measuring range. This access code should only be used by fully trained staff of the operator.

If the current zero point display exceeds a value of 15 % of the maximum measuring range and it has been ensured that the display was not caused by the presence of gas, a temporary hour code (valid for max. 1 hour) can be read in the Info ∕  submenu of the service menu

(Zero Code ∕  ) and used to activate zero point setting without restrictions.

Note:

The necessity of the latter measure might be an indicator of a defective sensor and thus of the need to replace the sensor as quickly as possible.

Execution

With the RC3 and the IR29 display or the RC2 keypad, the procedure is carried out in three steps:

1.

2.

Press the TEST

ZERO

button for a longer period (at least 3 seconds) to start activation. After activation, the current interface supplies 2.0 mA throughout the entire process and the fault LED flashes at slow intervals. The following appears on the display: Code ∕  .

The numerical access code  or  must be entered (this access code should only be used by fully trained staff of the operator). Use the TEST

ZERO and INFO

SPAN

buttons to change the number at the current position and QUIT

MENU

to acknowledge the changes. Press the

QUIT

MENU

button for a longer period to delete the last acknowledged number.

3.

After the correct entry, the current measured value and the display Zeroz∕  are alternating on the display . If the measured value remains constant during a time interval of

- 13 -

60 sec., the new zero point is set. The AutoCal program will be automatically terminated with the display Save∕  and changes back to the measuring mode.

Note:

If the current measured value is outside the permissible limits for the respective access code, the display Cal. error no.  ∕   .

 briefly appears at point 3 .

The AutoCal program can be shortened to a constant measured value TEST

ZERO

by pressing the key for a long time (3 sec.) while waiting. The hardware then starts directly with the zero setting.

To cancel the AutoCal program without zero point adjustment during the waiting time, press the key TEST

ZERO briefly.

The following will appear:

The zero point is outside the permitted tolerance range.

MENU

button to acknowledge it .

The following error messages may occur during zero point adjustment:

Display/RC2 Display

Kal.-Fehler Nr. 2



( Cal. error no. 2) ∕   .



Kal.-Fehler Nr. 3

( Cal. error no. 3) ∕   .



(Cancel) ∕  . Press the QUIT

Remark

The gas signal is unstable.

Malfunction LED fast flashing

All error messages must be acknowledged with QUIT

MENU

. After acknowledgement with the unchanged zero point setting, the transmitter returns to measuring mode.

Calibration adapter for IR29 Only for clarification:

Rubberized area of the adapter via the diffusion orifices, which need to be completely covered.

- 14 -

Sensitivity Calibration and Adjustment (SPAN)

For a device without display, the RC2 operating device is required for calibration and adjustment; for transmitters with display, it is also possible to use the remote control RC3.

!

Always observe special safety precautions when handling toxic gases. MAC values indicate hazards caused by toxic gases.

Calibration

First check the set calibration gas concentration by briefly pressing INFO

SPAN

.

The value of the calibration gas concentration should be at least 20% of the measuring range. It is possible to set 10 to 100% of the measuring range (100% LEL).

If the set value of the calibration gas concentration deviates from the available calibration gas, then the calibration gas setting in IR29 must be changed.

To do so, change to the service mode, numeric access code  (or  for trained staff).

Set the concentration of the available calibration gas in the sub item cal. gas/  .

Then quit the service menu with Save∕  , in order to adopt the changes.

Use the IR29 calibration adapter shown above to calibrate or adjust the display sensitivity. The rubberised area must be tightly stretched over the diffusion openings of the impact protection.

The calibration gas needs to be supplied unpressurised with a volume flow of about 0.5

l ∕ min.

via the gas supply. The injection needs to be performed for 180 seconds, 90 seconds for flushing the measuring chamber, another 90 seconds for stabilizing the concentration.

It is possible to calibrate the transmitter directly on site using the RC2. If the display deviates from the calibration gas concentration, it might be necessary to adjust it (sensitivity adjustment).

Adjustment

i

The sensor must be free from calibration gas (zero display) prior to each re-adjustment.

Activation

An adjustment can be performed after having entered the access code  .

If a measured value of >100% is displayed for the calibration, it is not possible to perform an adjustment with the code 0011. Then, a temporary hour code (valid for max. 1 h) can be read in the Info∕  submenu of the service menu (Code∕  ). By doing this, the adjustment can be activated without restrictions, instead of the code 0011. Then, a repeated calibration and afterwards an adjustment might be necessary, if applicable.

- 15 -

Implementation

With the RC3 and the IR29 with display or the RC2 control unit, the procedure is carried out in four steps:

1.

Activate through pressing the button INFO

SPAN

and holding it for (min. 3 seconds). After the activation, the current interface supplies 2.0 mA throughout the entire following process and the fault LED flashes at slow intervals. The following appears on the display:

Code∕  .

2.

Then, enter the activation code  . Use the

TEST

ZERO and

INFO

SPAN

buttons to change the number at the current position and

QUIT

MENU

to acknowledge the changes. Press the button for a longer period to delete the last acknowledged number.

QUIT

MENU

3.

The display alternates between the current measured value and the display Span∕  .

The instrument now waits until the concentration has risen to at least 80% of the set calibration gas. If the measured value then remains constant during a time interval of

60 seconds, the measured value is automatically used to adjust the sensitivity (display

Speichern (Save)∕  ). The calibration data has now been successfully updated.

4.

However, the transmitter does not switch back to the measuring mode; otherwise, alarms might be triggered by a still pending concentration of calibration gas. The transmitter remains in the adjustment mode, until a decline of the gas concentration and then a stabilization of the display value will be determined. Meanwhile the display

Zero∕  alternating with the current measured value will be displayed. Following the stabilization, the device will switch back to the measuring mode. If no gas decline and stabilization of the measured value is being determined, the device will independently switch back to the measuring mode after three minutes.

Note:

The AutoCal program can be shortened in each phase by pressing the INFO

SPAN

button for a longer period. Speichern ( Save) ∕  appear briefly on the display and the measured value is accepted directly to refresh the sensitivity.

Only press the INFO

SPAN

button briefly to cancel the AutoCal program without setting the sensitivity. Abbruch ( Cancel) ∕  appear on the display and must be acknowledged by pressing the QUIT

MENU

button . Subsequently, it is returned to measuring mode as described under 4.

The following error messages may occur during sensitivity adjustment:

Display/RC2 Display

Kal.-Fehler Nr. 1

( Cal. error no. 1) ∕   .



Kal.-Fehler Nr. 2

( Cal. error no. 2) ∕   .



Kal.-Fehler Nr. 3

( Cal. error no. 3) ∕   .



Remark

No increase in calibration gas has been detected.

The gas signal is unstable

The gas signal is outside the permitted tolerance range.

Malfunction LED fast flashing

Acknowledge the error messages with QUIT

MENU

. The transmitter changes to measuring mode without re-adjustment, the data of the last valid calibration is re-imported, the adjustment must be repeated.

- 16 -

Service Menu and Advanced Service Menu

Activate Service Menu

All-important parameters of the transmitter IR29 can be opened and changed in the service menu. The measuring mode is interrupted when opening the service menu and the device changes to service mode. The special status "Service" is indicated by the slow flashing fault LED and the output signal is set to 2.4 mA. If the user does not press any button, the device automatically exits the service mode after one minute and returns to measuring mode. i

All parameter changes made in the service menu refer to the currently set gas type!

If gas type and parameters are to be changed, the new gas type must first be set before parameter changes for this gas type can take effect. Changing the gas type in the service menu - submenu Gas!

The service menu is available in two different versions.

The standard service menu is opened with access code  . It is not possible to change important settings, such as measuring gas or measuring range end value, here. Such attempts are ignored and the message Gesperrt (Locked) ∕  appears.

The advanced service menu is opened with access code  . All settings can be carried out without restrictions in the advanced service menu. This access code should only be used by specifically trained staff of the operator.

With the RC3 and the IR29 with display or the RC2 control unit, the procedure is carried out in three steps:

1.

Press the QUIT

MENU

button for at least 3 sec. The transmitter changes to service mode. The following appears on the display: Code ∕  .

2.

Now enter the numerical access code  or  . Use the TEST

ZERO and the INFO

SPAN

buttons to change the number at the current position and QUIT

MENU the QUIT

MENU

to acknowledge the changes. Press

button for a longer period to delete the last acknowledged number.

3.

After correct entry, the service menu opens with menu item Gas ∕  . Use the the INFO

SPAN

buttons to select other menu items.

TEST

ZERO and

Operation

To select a menu item, use the TEST

ZERO

and INFO

SPAN keys.

The activation of a desired menu item, or the selection of a prameter, takes place after the selection of

Note:

QUIT

MENU

.

The service menu can be exited either with or without saving the changed parameters.

Several parameters can be changed one after the other without having to store them temporarily. All the parameters previously changed in the submenus are saved when exiting the service menu via the menu item “SAVE”

Exceptions:

1) Changing the type of gas:

If a different type of gas is selected in the “Gas” menu, it is saved immediately, the parameters for this type of gas are activated and the transmitter IR29 restarts with the changed parameters.

2) Setting the date and time: These are stored directly.

17

Layout of the Service Menu

Display Indications Statement

RC2 Display

Language/Time/Bus

0



Info



Settings

Query Device

Information

Zero Band



Gas 1

2



Cal. gas Calibration Gas

Concentration

 

Measuring range 1

Upper Range

Value

Switch Sensor zero band on/off

Sample Gas

Selection



Measured Value

Simulation

Defined values are output to the current interface



Save



Cancel



Exiting the service menu and saving all (changed) parameters

Exiting the service menu without saving all

(changed) parameters

On



Off

Modbus Baud Rate



Modbus Slave Adr 4

Time

 

4

 .



Modbus Format 4





Exit



3

Language

1.2 / 4.0 / 7.8 / 12.0 / 20.0 / 22.0mA/ abort

 .

 /  .

 /  .

 /  .

 /  .

 /  .

 / 

Baud rates 9600,

19200 and

38400

Slave address

1-249 adjustable

8E1 (standard),

8O1 and 8N2

0 Input menu item

1 Only adjustable in the extended service menu

2 The size of the strip is determined by the sample gas.

3 Adjustable only if supported by the device

4 Only for devices with Modbus interface

Act. Date and time

Display language

Exiting the submenu

Each value individually selectable

18

Additional Menu Explanations

Cancel

Exit the service menu without saving the parameters, changes are discarded.

Save

Exit the service menu and save all changes made to the parameters.

Measured Value Simulation

This menu item can be selected to check the functionality of the current interface without gas supply. One of 6 preset mA values (1.2/4.0/7.8/12.0/20.0/22.0) is selected with the arrow keys and confirmed with the middle button. It will be output for up to 5 minutes via the current interface, and then the transmitter changes back to the measuring mode.

The value remains active within 5 minutes, until another value (or also the same value) is being confirmed, or Cancel/ESC is being confirmed. If a value is only selected, it does not influence the current status.

Gas

With this function, it is possible to explicitly select a type of gas; the corresponding parameters are filled into the device parameter memory and are automatically loaded. Only the gases are displayed for which the data are available in the parameter memory.

Note:

If the change to another gas type is confirmed, the transmitter IR29 directly restarts.

The change to a new gas type always requires a calibration and, if necessary, an adjustment of the zero point (AutoCal ZERO) and subsequently a calibration of the sensitivity and, if necessary, an adjustment (AutoCal SPAN).

There are no restrictions for the first zero adjustment after a gas change.

After a gas change, parameters such as measuring range and calibration gas concentration must be checked and adjusted if necessary, since all changes made to the parameters under the original gas type are not accepted.

Measuring Range

The measuring range of the transmitter is fixed, e.g. 0-100% LEL.

The output range of the current interface can be set to 20.0, 25.0, 30.0, 40.0, 50.0, 75.0,

100.0% of the maximum measuring range.

Note:

The change of the output range is only an adjustment of the output signal. The standardized output signal 4...20mA is used for the set output range (Default = 100%).

When reducing the measuring range, the resolution of the measuring value on the current interface is being increased. This will not change the numerical display on the display indicator/RC2.

Example: Measured value = display indicator = 25% LEL

Output range = 100% -> Iout= 4mA+(16mA * 25 %LEL/100% measuring range) = 8mA

Output range = 50% ->Iout=4mA+(16mA * 25 %LEL/50% measuring range) = 12mA

Note: For the second setting (50%) a signal >20mA will already be output for a measuring value of 51%.

19

Cal.Gas

A standard value is preset in % LEL as calibration gas concentration. It must be compared and adapted to the certificate of the sample gas bottle, where applicable.

For all types of gas, the cal. gas can be set from 10% to 100% LEL.

The following instructions are applied to convert V/V to % LEL. It is rounded to one decimal place.

Gas

Methane CH4*1

Propane

C3H8*1

Acetylene

C2H2*1

Butane

Ethanol

C4H10

C2H6O n-Nonan C9H20

LEL[Vol%]

4.4

1.7

2.3

1.4

3,1

0,7

Standard CalGas

3Vol% = 68,2%LEL

1Vol% = 58,8%LEL

1Vol% = 43,5%LEL

1Vol% = 71,4%LEL

Calibration via cross sensitivities

Zero Band

The zero band (tolerance band) of the sensor can be deactivated as required.

With the zero band a measuring value of

±1.2 %LEL is being suppressed. A measuring value from 1.2 to 2.4 %LEL is mapped to the range from 0 to 2.4 %LEL, thus, an abrupt passage is being avoided.

Possible settings:

•

(red) Zero band activated (On/  )

•

(blue) Zero band deactivated (Off∕  )

Info

Retrievable/displayed device information:

•

Sensor type/MK number(Sensor type∕  .

 )

•

Serial number of the sensor (Sensor-Nr.∕  .

 Sensor ).

For serial numbers higher than 9999   is displayed on the RC2.

•

Transmitter software version (Transm.-Fw.-Ver.∕  )

•

Sensor software version (Sensor-Fw.-Ver.∕  )

•

Current interface software version (I

•

Hour code (Code∕  )

4

To

20

-Fw.-Ver.∕  )

•

Transmitter serial number (Fert.-Nr./   )

Note:

The figure displayed under Code∕  corresponds to an access code valid limited in time, which can be activated with the zero point and sensitivity adjustment without limitations, refer to Calibration and adjustment (SPAN & ZERO).

Language/Time/Bus  Language

Possible language settings:

•

German (Deutsch∕  )

•

English (English∕  )

•

Spanish (Espanol∕  )

Hint:

The setting of the language mainly influences on the display of the IR29. The displays of the RC2 remain unchanged, only the display LEL changes to LEL.

Language/Time/Bus  Time

Setting sequence: year, month, day, hour, minute.

20

Language/Time/Bus  Bus

Setting of: Modbus format, slave address, baud rate

This menu is only enabled for the IR29 B/DB. This option is not available in the i-variants, where all setting options are disabled.

Modbus format

The three options 8E1(standard), 8O1 and 8N2 are available for choice.

Modbus Slave Adresse

Modbus slave address

The address of the slave devices can be freely selected from 1 to 249.

Modbus baud rate

Three transfer speeds are available:

9600 bauds (9600 / 9.6), 19200 bauds (19200 / 19.2) and 38400 bauds (38400 / 38.4)

Displays and Messages

The following tables describe the special states in which the yellow fault LED lights up permanently and the current interface <4.0mA is set. For a better diagnosis, the transmitter IR29 without display, the error messages must be read out with the RC2 operator interface.

If the transmitter is to be restarted in the event of an error, it must be disconnected from the power supply for a short time. To do this, simply disconnect the transmitter from the socket and reconnect it after 10 seconds.

Display of Special Statuses and Malfunctions

No Display

Display

RC2

001

002

003

Device Test



Reading in Device

Parameters



Sensor Warm-Up

Seconds

Green

LED

To

Yellow

LED

To

Flashing To

Flashing To

Current

Output

1.2mA

1.6mA

1.6mA

Cause

Program and memory tests at the beginning of system start-up

Start up the system (when starting and after changing the type of gas).

Sensor warm-up phase

Note/Explanation

[p] : permanent

Q] : Acknowledgement necessary

[s] : self-resetting

Automatically switches to the “Display of operating parameters”, and then to the sensor heat-up phase

Switches automatically to measuring mode after expiration

Elapsing Seconds

201

211

↑↑↑

„  “

↓↓↓

"  " 

To

To

To

To

22mA

2.8mA

The gas concentration considerably exceeded the measuring range (≥

112,5% of the measuring range)

[s]

Underrange (< -7.5% of measuring range)

[s]

Zero adjustment is necessary

Note:

The error messages 211 and 201 occur when the extended measuring range (-7.5 to

112.0%LEL) is undercut/exceeded. Before, the "Displays in measuring mode" are displayed according to 210 or 203 or output via the current interface.

21

22

Error Messages of the Main CPU

No. Display

Display

RC2

Green

LED

Yellow

LED

Current

Output

Cause

104 System error -104-

(working memory

defective)

 . 

105 System error -105

(program memory

defective)

 . 


(param. memory

defective)

 . 

109 Sensor error -109-

(communication error sensor CPU)

 .




(communication error

pressure sensor)

 . 


(communication error

humidity sensor)

 . 


(RAM parameter)

 .



Off

Off

Off

Off

Off

Off

Off

Flashes quickly


(unzur. signal level)

 .




(error current

measurement)

 .



Off


(check power supply)

 .



130 System error -130-

(error current

measurement)

 .



Off

Off

To

To

To

To

To

To

To

To

To

To

To

1.2mA

1.2mA

1.2mA

1.2mA

1.2mA

1.2mA

Error during RAM access

Error during ROM access

Error during EEPROM access

(internal)

[p]

Restart the device.

If error message appears

again, replace device

No/failed communication with sensor

No/failed communication with pressure sensor

No/failed communication with humidity sensor


[p] : permanent

[Q] : Acknowledgement required


[s]

Restart the device.



1.2mA

1.2mA

1.2mA

1.2mA

Depending on resistance

Cyclic check of the operating parameters in the RAM miscarried

The signal level is insufficiently low (< 80%) for an exact measurement.

Output error of the current interface or insufficient power supply

Supply voltage <12V, no measuring operation possible

Reading back the current from the current interface supplies actual value ≠

Setpoint

[p]

Restart the device.



[s]

Check optics for soiling, otherwise

Replace device

[s]

Check supply voltage.

Restart the device.



[s]

Check and readjust supply voltage

[s]

Check load or line resistance in signal path

23

Error Messages of the Sensor CPU

No. Display

Display

RC2

120 SenCpu error -120-

(working memory defective)

 . 

121 SenCpu error -121-

(program memory

122 defective)

 . 

ADU error -122-

(Error temperature

measurement)

123

124

125

 . 

ADU error -123-

("stuck at")

 . 

ADU error -124-

(Overrange)

 . 

ADU error -125-

(Underrange)

 . 

Green

LED

Off

Off

Off

Off

Off

Off

Yellow

LED

To

To

To

To

To

To

Current

Output

1.2mA

1.2mA

1.2mA

1.2mA

1.2mA

1.2mA

Cause

Error during RAM access

Error during ROM access

Error A/D converter

(temperature measurement/NTC)

A/D converter

Multiplexer or AD converter defective

A/D converter

Measured value too high

(upper AD converter limit)

A/D converter

Measured value too small

(lower AD converter limit)


[p] : permanent



[p]

Reboot the system.

If the error persists, replace the device.

[s]

Reboot the system.

If the error persists, replace the device.

Displays in Measuring Mode

No. Display

Display

RC2

Green

LED

Yellow

LED

Current

Output

Cause Note/Explanation

[p] : permanent

Q] : Acknowledgement necessary


[s] 203 Measured value

change with

↑↑↑

Measured value "

Change with

Flashes every

15 sec.

Off 20..22mA The gas concentration has exceeded the measuring range

(100...112.5% of the measuring range).

209

210

„  “

Measured value Flashes every

15 sec.

Measured value Flashes every

15 sec.

Off

Off

4...20mA Trouble-free measuring operation

2.8...4mA Underrange of the measuring range (-7.5...0.0% of the measuring range)

[s]

[s]

Zero adjustment necessary

Note:

The states described under no. 203 and no. 210 concern an extension of the evaluation of the

4...20mA output signal to 2.8...22mA, in order to indicate deviations with consideration of tolerances in the standard measuring range.

24

Displays in Service Mode and During Calibration (Status Messages)

No. Display

Display

RC2

301 Menu Item

302

303

304

305

306

ZERO



SPAN



Cal. error

(No conc. change)

  .



Cal. error

(gas not stable)

  .



Cal. error

(Cal. not plausible)

  .



Green

LED

ON

ON

ON

ON

ON

ON

Yellow

LED

Flashing 2.4mA

Flashing 2.0mA

Flashing 2.0mA

Flashes quickly

Flashes quickly

Flashes quickly

Current

Output

2.0mA

2.0mA

2.0mA

Cause

Service menu was activated via keyboard or RC2

AutoCal setting of zero point was activated via keyboard with RC2 or AutoZero key

AutoCal sensitivity setting has been activated by keyboard or RC2

No increase in calibration gas concentration detected during AutoCal sensitivity adjustment

No stable zero gas or calibration gas concentration was detected during AutoCal adjustment.

The zero point or the sensitivity are outside the permitted tolerance range.


[p] : permanent



[s]

Select menu item

If no entry is made for one minute, automatic return to measuring mode

[s]

Automatic termination after successful adjustment

[s]

Automatic termination after successful adjustment

[Q]

Acknowledge with

QUIT

MENU a) Check gas supply b) Gas feed only after calling up the adjustment

[Q]

Acknowledge with

QUIT

MENU a) Stabilize gas supply

[Q]

Acknowledge with QUIT

MENU

Check zero or calibration gas and repeat procedure.

Status of the Status LEDs and the Current Output

For imporved clarity, the following table shows the different displays of both status LEDs and the current output signals as well as their meaning for a transmitter IR29 without a display.

The RC2 keypad is essential for zeroing, adjusting and calling up the service menu on a device without a display.

Green Operation

LED

Yellow Fault

LED on on on on on on flashes every 15 sec. flashes every 15 sec. flashes every 15 sec. flashing flashes quickly from on

Current Output Description see section ... on on

2.8mA

1.2mA

22mA flashes quickly 2.0mA flashing flashing from

2.4mA

2.0mA

20...22mA from from on on on

4...20mA

2.8...4mA

1.6mA

1.2mA

1.2mA

Displaying special states...



Displays in service mode...



Displays in measuring modeNo.






No. 211

No. 001

No. 201

Product No. 304-306

Item No. 301

No. 302, 303.

203

209

210

No. 002, 003

No. 115

No. 104-113, 116-130

25

Fault Messages (system and sensor faults no. 104-130, 201, 211) terminate the measuring mode until they have been eliminated. They appear permanently in the display and are additionally output via the LED code specified above (also for variants without display) and the current interface.

Status Messages are special messages that are triggered by special functions and interrupt the measuring operation. The messages 304, 305, 306 must be acknowledged, all other messages and statuses are self-resetting after a certain time. The transmitter then automatically resumes measuring operation.

Initial Commissioning and Maintenance

The DIN EN 60079-29-2 "Gas detectors – Selection, installation, use and maintenance of detectors for flammable gases and oxygen" as well as the relevant national rules and regulations must be observed. In Germany, these include "Explosion Protection Regulations", the leaflet T 023 (BGI 518) "Gas warning devices for explosion protection - use and operation" and the BGR 500, Part 2, Chapter 2.33 "Operation of systems for handling gases", 4.4 Testing of gas warning devices. During initial commissioning, gas warning devices must be checked for function by an expert after installation. (see DIN EN 60079-29-2 Section 8.9 and leaflet BGI 518

/T023 Section 8.1). Maintenance includes inspection, servicing, calibration and adjustment, as well as regular functional tests and repairs. Tests must be carried out by an expert. The result must be confirmed in writing.

According to the instruction sheet BGI 518 / T023 - "Gas warning devices for explosion protection: Application and operation", the application and operation includes the following:

• Maintenance of stationary gas warning systems

• Regular functional test

Maintenance of Stationary Gas Warning Systems

Monthly visual inspection (section 9.1 T023):

- Mechanical damage

- Contamination e.g. by dust

- Condensation due to moisture

As well as control of the:

- Protection devices of the transmitters

- Diffusion orifice of the transmitters

- Gas sampling system, gas processing (if available)

Regular Functional Tests

Tests must be carried out by an expert. The result must be confirmed in writing.

Function checks (section 9.2. T023) Interval: 4 months

Scope of functional checks:

- Calibration (measured value display) using zero and calibration gas

- Adjustment of zero point and sensitivity adjustment with zero or calibration gas

- Response Time

- Output functions (interfaces and displays)

- Error Messages

System checks (section 9.3) Interval: 1 year

26

It is recommended to entrust GfG customer service with these tasks.

Repair

This includes all repair and replacement work. Only use original spare parts and assemblies tested and released by the manufacturer.

If during the regular inspections of the gas warning system or by reviewing a warning or fault message a contamination of the optics of the IR29 is detected, it must be cleaned as described below:

1) Remove the impact protection, if necessary remove the dust filter.

2) Visual inspection of the sapphire disc and mirror

3) It is recommended to use a lint-free cloth and isopropyl in order to clean the mirror and the sapphire disk. If any other cleaning agents are used, first make sure that they are compatible with the device materials (sapphire glass, PA12, PA6 and PE).

Troubleshooting

No measuring signal at current interface:

If no measuring signal is output via the current interface, check the amount of the supply voltage and the polarity of the connections.

If the transmitter is disconnected from the base, the current interface will provide a 1.2mA fault signal if it is connected correctly. Once this state is established, the transmitter can be connected. During the warm-up time the value of the current interface should change to 1.6mA, after the warm-up time to 4mA. If this is not the case, the communication between socket and transmitter may be disturbed. An optical check of the plug connection and cleaning of the contacts with a suitable cleaner (e.g. contact WL Universal cleaner for electronics).

No display indication:

Press the "Test" button on the RC2/RC3. All pixels of the display are controlled. If the display shows no reaction or if areas of the display remain bright, the display is defective. Repairs can only be carried out by the manufacturer or the service staff.

The display is not part of the safety chain, all settings can also be performed via the RC2.

No display in RC2 and no response to key operation:

Replace the RC2 battery. If the error persists, the communication between RC2 and IR29 may be disturbed. Optical control of the connectors, test the connecting cable. If all these points are

“no fault found”, test the RC2 on another transmitter, if applicable.

If the same effect is being observed, the RC2 is probably defective – return the RC2 to the manufacturer. If the RC2 works with another transmitter, the error is in the IR29 – return the

IR29 transmitter.

No bus communication:

•

Check the bus settings in the GMA and in the transmitter (baud rate, address, bus format).

•

Check the measurement loop configuration in the GMA.

•

When using the GfG-GMA, check the selected connection (TRM-Bus1 or TRM-Bus2).

•

Check the voltage supply of the transmitter.

•

Check the polarity of the data lines on the transmitter and on the evaluation unit.

•

Check if there is a cable break or a short circuit on the data line.

•

Check the number and position of the terminating resistors; there may only be one terminating resistor on the last device of the bus.

27

Transmitter does not start / error 116, 118,130

Visual inspection of the contacts in the connector. Check if one of the pins is twisted, soiled or dented in the socket in the base (i.e. shorter than the others).

This can result in no or only poor contact between the socket and the transmitter.

If one of the pins is shortened, the only remedy will be to replace the base.

If contact is poor, clean socket and plug, e.g. with electronic cleaner or isopropanol.

Accessories

Remote Control RC2

Connection cable for RC2 / cable length 2m




Remote control RC3, channel 16 (default)

Remote control RC3, channel 01-15

IR29 calibration adapter to adjust the transmitter

IR29 flow adapter to measure gas samples

Dust Filter 40mm

Dust Filter 20mm

Guard

Supply Module SB1

Best. -No.

2800201

2800210

2800211

2800212

2800213

2910230

On Request

2910220

2910221

2900331

2900332

On Request

2910210

Spare Fuse 63mA for SB1 (F4, F5, F6) 2900381

The storage conditions for RC2, RC3 and SB1 can be found in the corresponding operating instructions or extracts from the operating instructions.

The same temperature ranges apply for the calibration adapter, flow adapter and dust filter as for the IR29 transmitter (-25°C to +60°C; recommended 0°C to +30°C).

Furthermore, the accessories need to be stored clean, dry and free from corrosive influences.

28

Connections and Terminal Assignment

IR29 i/Di with 4...20mA Interface and Zener barriers

IR29 i/Di

Transmitter (+) VCC

X1 15...30V DC (behind the Zener barrier)

X2 Transmitter (-) GND

4...20mA (+)

X3 15...30V DC (behind the Zener barrier)

X4 4...20mA (-) GND

X4

X3

X2

4...20mA

15-30V DC

Supply according to the

Zener barrier spec. mA

X1 max. Resistance see technical data

Supply according to the

Zener barrier spec.

IR29 i/Di with 4...20mA Interface and Zener barriers from MTL

IR29 i/Di

Transmitter (+) VCC

X1 22...27V DC (before of the Zener barrier)


4...20mA (+)

X3 22...27V DC (before of the Zener barrier)

X4 4...20mA (-) GND

X4

X3

4...20

Type: MTL 7787P+ / 7728P+

7787P+

4 2

3 1

22-27V DC

Max. Resistance see technical data

X2

X1

7728P+

4 2

3 1

22-27V DC

Transmitter Supply mA

Terminal assignment MTL7700 series according to EPS7700 Rev6

140410

29

IR29 i/Di with 4...20mA Interface and SB1

IR29 i/Di

Supply by SB1


X4 4...20mA (-) GND

SB1 see chapter

accessories

X4

X3

X2

X1

4...20 mA

GND

VCC

SB1

X1 VCC

X2 GND

X3 4..20mA

X4 VCC (Transmitter)

X5 GND (Transmitter)

X6 VCC (4...20mA)

X7 Signal (4...20mA)

X7

X6

GfG SB1

X3

X2

X1

Current Interface

Max. 270 Ω

X5

X4

Supply

22-30V DC mA

!

Note on installation:

The transmitter is supplied via terminals X1 and X2. The current interface is supplied via X3 and supplies the 4...20mA signal via X4. Transmitter and current interface are two galvanically separated circuits which communicate via optocouplers. If this communication is disturbed, e.g. because X1 or X2 is not connected or the transmitter is not connected to the socket (terminal), the current interface outputs

1.2 mA if voltage is already present.

30

IR29 i/Di with 4...20mA Interface & 3-wire cable (e.g. GMA41)

IR29i/Di

Supply via the GMA


X3 Bridged to X1

X4 4...20 mA output

X4

X3

X2

X1

4...20 mA

GND

VCC

GMA41

AL1

AL2

24V

GND

4-20mA

GND

24V

(+)

(-)

GND

Quit

AL3

Sensor

IN diges

OUT

4...20mA

!

!

CAUTION!

To create the necessary bridge X1-X3, the wiring must be made with stranded wire.

The two conductors in X1 must be professionally pressed into a common, sufficiently dimensioned ferrule.

The use of different conductors (solid wire and stranded wire) is not permitted!

The use of several solid wires in one ferrule is not permitted!

CAUTION!

This type of connection interconnects two intrinsically safe circuits.

The IR29 i/Di thereby loses its intrinsic safety; operation in hazardous areas is not permitted!

31

IR29 /D with 4..20mA Interface & 3-wire cable to GMA200

X1

Transmitter (+) VCC

Supply via the GMA Supply GMA mA

GND

GMA200


24V

X5 4...20 mA output 24V

GND

Reset1

Reset2

X5

GND

Iout1

Iout2

X2

X1

4...20 mA

GND

VCC

IN1

24V

GND

IN2

D1+

D0-

DGND

D1+

D0-

DGND

D1+

D0-

DGND

IR29 B/DB; with RS485 Bus & Four-Wire Cable to GMA200

Supply GMA mA

GND

GMA200

X2 GND

X3 D1+

X4 D0-

X5 VCC

X6 GND

X9

X8

X7

X6

X5

X4

24V

24V

GND

Reset1

Reset2

GND

X7 D1+

X8 D0-

X9 terminating resistor

X3

X2

X1

Iout1

Iout2

IN1

24V

GND

IN2

GND

VCC

D0-

D1+

!

D1+

D0-

D0-

D1+

D0-

DGND

D1+

DGND

DGND

Transmitter types IR29B and IR29DB:

The non-intrinsically safe internal bus terminating resistor (120Ω) is activated by a jumper at terminals X8 and X9. Only one wire bridge may be connected. No voltage may be applied to terminal X9.

32

Measuring Gases and Measuring Ranges

Measuring Gas methane propane acetylene*

Methane*, propane*, acetylene* n-butane n-Nonan ethanol

2-propanol

Measuring Range

Standard

0 - 100% LEL

0 - 100% LEL

0 - 100% LEL

0 - 100% LEL

0 - 100% LEL

0 - 100% LEL

0 - 100% LEL

0 - 100% LEL

100%UEG according to DIN EN 60079-20-1: 2010

Methane CH4 n-Butane

C4H10 n-Nonan C9H20

2-Propanol

C3H8O

4.4% by volume

1.4% by volume

0.7% by volume

2.0% by volume

Measuring Range Smallest

/ Largest

10% UEG / 100%UEG

10% UEG / 100%UEG

10% UEG / 100%UEG

10% UEG / 100%UEG

10% UEG / 100%UEG

10% UEG / 100%UEG

10% UEG / 100%UEG

10% UEG / 100%UEG

Propane

C3H8

Acetylene

C2H2

Ethanol

C2H6O

MK Number

242-1, 244-3

243-1, 244-3

244-1

244-3

243-1, 244-3

242-1, 244-3

243-1, 244-3

243-1, 244-3

1.7% by volume

2.3% by volume

3.1 % by volume

Sensor Specification

MK242-1 Infrared sensor for flammable gases and vapors

Measuring Range

Disbandment

Tolerance Band

Response Time

Pressure750 ...1200mbar:

Compensated (uncompensated)

Humidity0%

Temperature-25

Cross sensitivities

@ 50%UEG:

...95% r.h.:

...+55°C:

Expected service life

0.0...100%UEG

0.2..1.0%UEG

± 1.2%UEG t50 ≤ 20sect90 ≤ 50 sec @ CH4 (methane)

<1.1%(1.5%) of CH4 indication per 1% change in pressure

(regarding 100kPa) max. ± 2,0 %UEG or ± 10% of the display (with respect to 0%r.F. @40°C) max. ± 2,0 %UEG or ± 10% of the display (regarding 20°C) gas task

0,85Vol% C

3

H

8

CH4-display0

ca.153%UEG

2,20Vol% CH

1,15Vol% C

1,0Vol% C

3

H

0,75Vol% C

1,15Vol% C

0,5Vol% C

6

2

4

H

2

4

= 50%UEG

H

8

O ca.89%UEG

H

H

14

0,7Vol% C

5

H

12

2

ca.0%UEG

8

O ca.43%UEG

6

O ca.105%UEG ca.30%UEG ca.97%UEG

They can vary from sensor to sensor and depend on the gas concentration.

6 years


Measuring Range

Disbandment

Tolerance Band

Response Time



Humidity0%

Temperature-25

Cross sensitivities

@ 50%UEG:

...95% r.h.:

...+55°C:


0.0...100%UEG

0.2..1.0%UEG

± 1.2%UEG t50 ≤ 21sect90 ≤ 50 sec @

C3H8

(propane)

<0.2%(1.2%) of C3H8 display per 1% change in pressure,

(regarding 100kPa) max. ± 2.0 %LEL or ± 10% of the display (relative to 0%R.F. @40°C) max. ± 2.0 %LEL or ± 10% of the display (relative to 20°C) gas task

0,85Vol% C

3

2,20Vol% CH

2

H

4

H

8

C

3

H

8

-Anzeige

= 50%UEG ca.17,6%UEG

2

ca.0%UEG 1,15Vol% C

1,55Vol% C

0,5Vol% C

6

0,7Vol% C

5

2

H

6

O ca.47%UEG

H

14

H

12 ca.19%UEG ca.37%UEG


6 years

33


Measuring Range

Disbandment

Tolerance Band

Response Time

Pressure750...1200mbar:


Humidity0% ...95% r.h.:

Temperature-25...+55°C:

Cross sensitivities

@ 50%UEG:


0.0...100% UEG

0,2..1,0% LEL

± 1.2% LEL t50 ≤ 21sect90 ≤ 50 sec @

C2H2

(acetylene)

<0.6%(1.4%) of C2H2 display per 1% change in pressure, (with respect to

100kPa) max. ± 3,0 % LEL or ± 10% of the display relative to 0% r.h. @40°C) max. ± 2.0 % LEL or ± 10% of the display (regarding 20°C) gas task

0,85Vol% C

3

H

2,20Vol% CH

1,15Vol% C

2

4

H

8

C

2

H

2

-Display

ca.0%UEG ca.0%UEG

2

= 50%UEG


6 years


Measuring Range

Disbandment

Tolerance Band

Response Time



Humidity0% ...95% r.h.:

Temperature-25...+55°C:

Cross sensitivities

@ 50%UEG:


0.0...100% UEG

0,2..1,0% LEL

± 1.2%UEG t50 ≤ 20sect90 ≤ 50 sec @ CH4 (methane) t50 ≤ 26sect90 ≤ 57 sec @ t50 ≤ 21sect90 ≤ 50 sec @

<1,1%(1,5%) the CH

<0,2%(1,2%) the C gas task

0,85Vol% C

3

H

2,20Vol% CH

4

2

H

8

CH

3

H

<0,6%(1,4%) the C

2

4

4

C

3

C

2

-Display

H

8

H

2

(propane)

(acetylene)

C

3

H

8

-display per 1% pressure change, (referred to 100kPa)

8

- display per 1% pressure change, (referred to 100kPa)

H

2

- display per 1% pressure change, (referred to 100kPa) max. ± 3,0 %UEG or ± 10% of the display relative to 0% r.h. @40°C) max. ± 2,0 %UEG or ± 10% of the display (regarding 20°C)

-Display

ca.153%UEG = 50%UEG

C

2

H

2

-Display ca.0%UEG

= 50%UEG ca.17,6%UEG ca.0%UEG

1,15Vol% C

0,5Vol% C

0,7Vol% C

5

6

2

ca.0%UEG ca.0%UEG = 50%UEG

H14 ca.30%UEG ca.19%UEG ca.0%UEG

6 years

H12 ca.97%UEG ca.37%UEG ca.0%UEG


MK247-1 Infrared sensor for CO2

Measuring Range

Disbandment

Tolerance Band

Response Time

Pressure:

Humidity:

Temperature:

Cross sensitivities

@ 50%UEG:


0,00...10,00 Vol%

0.01..0.1 vol%

- t50 ≤ 30sect90 ≤ 130 sec @ CO

2

(carbon dioxide)

750...1200mbar:

0%...95% r.h.

-25...+55°C

Gas task

0,85Vol% C

8

CO

2

-Display

ca.0Vol%

2,20Vol% CH

1,15Vol% C

3

H

2

4

H ca.0Vol%

2

ca.0Vol%


6 years

34

Technical Data

Device Types IR29i and IR29Di

Measurement Function

Measuring principle: infrared absorption

Output signal: 4...20mA (max.load without Zener barrier :500Ω @18V or 800Ω @≥24V)

600Ω @22V - 30V)

Power Supply

(max. load with Zener barrier: 450Ω @22V or 550Ω @≥24V)

(max. load with GfG SB1:

Supply voltage:

Maximum supply current:

18...30V DC @supply intrinsically safe

22...27V DC @supply via Zener barrier (RL* max = 250 Ω)

22...30V DC @supply via GfG transmitter supply module SB1

< 50mA

Climatic Conditions

Temperature (storage): −25...+60°C or 0...+30°C (recommended)

Temperature (operation): −25...+55°C (see also sensor specification)

Air pressure: 750.. 1200mbar (see also sensor specification)

0..100% r.h. (non-condensing)

≤ 21.0% by volume

Humidity:

Oxygen content of the atmosphere:

Case

Dimensions: (132.5 - 152.5) x 75mm (L x Ø) **

Mounting surface min. 161mm x 133mm; height 118mm

Weight: approx. 950 grams

Housing material: stainless steel, polycarbonate, PA12, POM

Housing protection class:

IR29i / Tue: IP 67

IR29Di with rotatable display: IP 40

Approvals and Tests

Marking and type of protection:  0158

 I M1 Ex ia I Ma -25°C≤Ta≤+55°C

 II 1 G Ex ia IIC T4 Ga -25°C≤Ta≤+55°C

EC type-examination certificate: BVS 09 ATEX E 135 X

Electrical parameters for intrinsically safe connection

Intrinsically safe supply circuit: Connection via terminals X1 and X2

Maximum input voltage: Ui DC 30V

Maximum internal capacity: Ci 11nF

Maximum internal inductance: Li negligible

**)

Intrinsically safe signal circuit: Connection via terminals X3 and X4

Maximum input voltage: Ui DC 30V

Maximum internal capacity: Ci 1.8nF

Maximum internal inductance: Li negligible

The intrinsically safe signal circuit is safely galvanically isolated from the intrinsically safe supply circuit up to a sum of the peak values of the nominal voltages of 60V.

*) series resistance of the GfG transmitter supply module or the Zener barrier

Length depending on sensor configuration; without sealing plug

35

Device Types IR29, IR29 D, IR29 B and IR29 DB

Measurement Function

Measuring principle: infrared absorption

Output signal for

IR29 and IR29D: 4...20mA (max.load without Zener barrier :500Ω @18V or 800Ω @≥24V)

Power Supply for IR29B and IR29DB RS485 two-wire interface

Supply voltage:

Maximum voltage: 45V DC

Supply voltage: 18V DC ... 30V DC

Maximum supply current: 70mA

Signal circuit (4-20mA) 30V DC Rated voltage

Signal circuit (RS485) 20V DC Rated voltage


Temperature (storage): -25...+60°Cor 0...+30°C (recommended)

Temperature (operation): -25...+55°C (see also sensor specification)

Air pressure: 750..1200mbar (see also sensor specification)

Humidity:

Oxygen content of the atmosphere:

Case

0..100% r.h. (non-condensing)

≤ 21.0% by volume

Dimensions: (132.5 - 152.5) x 75mm (L x Ø) **

Mounting surface min. 161mm x 174mm; height 118mm

Weight: approx. 1100 gram

Housing material: stainless steel, polycarbonate, PA12, POM

Housing protection class:

IR29 / D/ B/ DB: IP 67

IR29 D/ DB with rotatable display: IP 40


Marking and type of protection:  0158

 II 2G Ex eb mb ib [ib] IIC T4 Gb -25°C≤Ta≤+55°C

EC type-examination certificate: BVS 09 ATEX E 135 X

**) Length depending on sensor configuration; without sealing plug

GfG Gesellschaft für Gerätebau mbH

Klönnestraße 99 - D-44143 Dortmund

Telephone:

Fax:

Web:

Email:

+49 (0)231 - 564 00-0

+49 (0)231 - 564 00-895 www.gasmessung.de [email protected]

Firmware Version 1.20

224-000.20_BA_IR29.do

Last updated: 09 July 2018 Subject to change

36

Notes IR29

Mounting accessories

Dust Filters

Flow Adapter or Impact Protection

37

Overview Torques

38

39

40

Appendix RC3

Field of Application and Intended Use

The RC3 control unit can only be used to operate the IR29 transmitters with display.

The RC3 operator interface is powered by a lithium battery, which must not be replaced in hazardous areas.

The RC3 operator interface is approved for use in potentially explosive atmospheres and has an EC type-examination certificate issued by DEKRA EXAM GmbH in accordance with

Directive 94/9/EC (ATEX100a) with the following

Certificate: BVS 08 ATEX E 006

Certification:  I M1 Ex ia I Ma

 II 1G Ex ia IIC T6 Ga -20°C≤Ta≤+55°C

Operation

The button assignment of the RC 3 can be shown on the display of the device by briefly pressing the central button.

Middle Button

Quit

Menu

Left Button

Test

Zero

Right Button

Info

Chip i

The receiver software only responds to activations >0.6 sec. to avoid unintentional or incorrect operation.

Channel Coding

The RC3 is factory coded on channel 16. This allows any IR29 transmitter to be operated.

Channels 1-15 can be factory coded in RC3 and transmitted on request. In this way it is possible to group devices that can only be operated via a separate channel.

The RC2 control unit is not affected by these settings.

Changing Batteries

CAUTION: Never open the device in potentially explosive atmospheres to change the lithium battery.

41

When inserting the new lithium batteries, always observe their polarity. These batteries should only be obtained from the company GfG, i.e. the device manufacturer. Internal monitoring ensures that only batteries which meet the demands of the Type Examination are used. The battery type is: VARTA CR 2430.

Technical Data

Type Designation:

Climatic Conditions:

Power Supply:

Housing:

RC3 for the operation: -20...+55°C | 5...95% r. F. | 700...1300hPa

Lithium battery Typ: VARTA CR 2430

U n

=3V

Material: plastic

C=280mAh

Dimensions: 44 x 61 x 15 mm (W x H x D)

Weight: 20 g

Protection class: min. IP20

Approvals and Tests:

Marking and type of protection:  I M1 Ex ia I Ma

 II 1G Ex ia IIC T6 Ga -20°C≤Ta≤+55°C

EC type-examination certificate: BVS 08 ATEX E 006 (without measuring function)

42

Appendix SB1


The transmitter supply module SB1 is used to limit the voltage and current of nonintrinsically safe circuits to intrinsically safe values. The non-intrinsically safe circuits are galvanically connected to the intrinsically safe circuits.

A transmitter IR29 connected to the transmitter supply module type SB1 is supplied intrinsically safe. The signals of the IR29 transmitter are read out via a 4-20mA interface and forwarded to an evaluation unit outside the hazardous area. The transmitter supply module is optimally designed for the supply of the transmitters IR29i and IR29Di.

The transmitter supply module SB1 must be installed outside hazardous areas and has an

EC type-examination certificate issued by DEKRA EXAM GmbH in accordance with Directive

94/9/EC.

For the SB1 applies:

Certificate: BVS 11 ATEX E 164

Certification:  II (1) G [Ex ia Ga] IIC -20°C≤Ta≤+55°C

Device Design

Please refer to the table "Technical data" for the maximum values of the voltage, current and power in the intrinsically safe circuits (U

0

, I

0

, P

0

) as well as the maximum permissible values of the connected capacities and inductances (C

0

und L

0

). The values listed in the table apply to one of the two barrier branches that must be observed separately (relating to PA). Observe the current or voltage additions when interconnecting.

Install Electrical Connections

Input circuit Only for connection to a non-intrinsically safe circuit

(terminals X1, X2 and X3) with a safety-related maximum voltage of U m

= 253 V AC

Output circuit

(terminals X4 and X5)

Signal circuit

(terminals X6 and X7)

In ignition protection class 'intrinsically safe' [Ex ia Ga]

In ignition protection class 'intrinsically safe' [Ex ia Ga]

Interchangeable fuses

From the

Control

Unit

Characteristics of the circuits: linear (see Technical data)

Characteristics of the circuits: linear (see Technical data)

To transmitters

Supply circuit

Signal

circuit

!

When mounting the transmitter supply module please consider that the connector cables of the not intrinsically safe electric circuit in the SB1 are conducted with a distance of at least 6mm clearance in air to the connector cables of the intrinsically safe electric circuit and accordingly the connector of the display (con1).

43

!

!

The transmitter supply module is equipped with three exchangeable prefuses. When replacing the fuses, ensure that only fuse type 164050.0,063

(I

N

=63 mA) from SIBA is used.

(See Technical data)

As the intrinsically safe circuits are galvanically connected to the earth potential, potential equalization must be provided throughout the entire intrinsically safe circuits.

Potential Equalization:

This is located next to the cable entries on the bottom side.

Potential equalization must take place with a line cross section of

4 mm 2 .

Potential Equalization

44

Technical Data

Device types: SB1

Power Supply

Supply voltage: 22V DC...30V DC


Temperature (storage): −25...+60°C

Temperature (operation): −20...+55°C or 0...+30°C (recommended)

Air pressure: 0...200kPa

Humidity: 0...100% r.h. (non-condensing)

Case

Dimensions: 98mm x 96mm x 48mm (L x W x H) without cable entry

Weight: approx. 300 gram

Housing material: ABS

Housing protection class: IP 54

Interchangeable Back-up Fuses

Guy: 164050.0,063

Rated current: 63 mA

Rated breaking capacity: 35A @ 250VAC

Melt integral (I2ts): 0,0007

Checked: IEC 60127


Manufacturer: SIBA

Certification:  II (1) G  0158

Ignition protection class: [Ex ia Ga] IIC -20°C≤Ta≤+55°C

EC Type Examination certificate: BVS 11 ATEX E 164

Electrical parameters for non-intrinsically safe connection

Not intrinsically safe supply: X1:

X2:

+22V DC ... +30V DC

GND

Non-intrinsically safe signal circuit: X3: 4...20mA

Maximum fault voltage: Um253V AC

Electrical parameters for intrinsically safe connection

Intrinsically safe supply circuit: X4:

X5:

Maximum output voltage: U

Maximum output current: I

0

Maximum output power: P

Maximum switchable capacity: C

0

0

Maximum switchable inductance: L

0

0

Maximum output current: I

Maximum switchable capacity: C

Maximum switchable inductance: L

0

0

0

0

Maximum output power: P

0

Intrinsically safe signal circuit: X6:

X7:

Maximum output voltage: U

+19V DC

GND

21 V DC

161 mA DC

844 mW

180 nF

1 mH

4…20mA +

4…20mA -

21 V DC

161 mA DC

844 mW

180 nF

1 mH

45

Declarations of Conformity, Type Examination Certificates

46

47

48

49

50

51

52

53

54

No results