Refrigerant Leak Detecting System

Refrigerant Leak Detecting System
European Refrigeration Controls Catalogue
Catalog Section
Product Bulletin
Issue
PSC
9
PD-GAS-E
9801
Refrigerant Leak Detecting System
Introduction
This range of refrigerant leak detecting systems
is designed for permanent installation. They
monitor refrigerant leakage on a continuous
basis. It provides a valuable warning before
refrigerant leaks impair system efficiency and
running costs and, over time, prevents major
refrigerant loss. Refrigerant wastage and
replenishment are both economical and
environmentally unacceptable.
The refrigerant leak detecting system consists
of:
• A refrigerant detector.
This detector senses refrigerant leakage and
can be used as a stand-alone device or can
be connected to a monitoring unit. Various
detectors for different refrigerants are
available.
Refrigerant Leak Detecting System
• A monitoring unit.
The monitoring unit shows the status of one
or more remote detectors. A wall mount or a
DIN rail mount model is available.
Feature and Benefits
! Two alarm thresholds
Pre-alarm signalling before an alarm is activated
! No on-site calibration
necessary
Easy installation.
! Semi-conductive sensing
element
Long lifetime and long-time stability
! Alarm memory on detector
Possibility to memorise too high refrigerant
concentration
Auto reset or manual reset is field selectable
! Selectable auto reset or
manual reset mode on
monitoring unit
! Up to 10 detectors can be
connected to one monitoring
unit
© 1997 Johnson Controls Inc.
Order No. PD-GAS-E
Multiple detectors can be monitored by one unit.
Makes future expansion very easy.
Catalogue Section 9
Leak Detecting System
Issue 9801
2
Refrigerant detector
Description
Each detector can work as a stand-alone unit,
or can be connected to a monitoring unit for
remote monitoring. (See page 4 and 5)
The detector has 2 relay outputs. The “prealarm relay” contact is closed when the
refrigerant concentration exceeds the “prealarm level”, giving a pre-alarm signalling. When
the concentration exceeds the “alarm level”, the
“alarm relay” is activated.
LED’s indicate the status of the detector, such
as: Power-on, Detector active, Alarm, and
Alarm memory. Each detector is refrigerant
specific. (See selection table on next page and
the application table on page 9).
Three different detector enclosures are
available: Room version (GD2.0 type); Splashproof version (GS2.0 type) and “Safety valve”
version (GR2.0 type).
The detectors are delivered for a specific
refrigerant. Field calibrations are normally not
necessary. (See factory adjusted detection
levels at page 9).
Functioning (See layout drawing and
drawing “relay functioning”)
If the power supply is switched on the green
LED will light up to indicate “power on”. After 4
minutes a yellow LED will light to indicate
“detector active”. The detector is now ready to
sense refrigerant leakage.
If the detected concentration of refrigerant,
exceeds the pre-alarm level, the pre-alarm relay
is activated (terminals 5 and 6) and the LED
“Alarm” is lighted up. If the refrigerant
concentration increases further and exceeds the
“alarm level”, than the “alarm relay” is activated
(terminals 7 and 8).
Fig. 1
Detectors GS2.0/GD2.0/GR2.0
!
Note
The detector has a limited range to detect
different types of refrigerants. It is important
to check the presence of other gases that
may cause an alarm. Such as: Gasoline,
cigarette smoke, liquid cleanings, solvents,
hydrogen from loading batteries, etc.
It is recommended to test the system twice a
year. See page 8 for check and calibration
instructions.
If the concentration decreases, the relays will
switch off, first the alarm relay, then the prealarm relay. The pre-alarm or alarm condition
will be memorised by LED “Alarm memory”.
This LED can be reset by pressing the reset
button under the cover.
Note: It is only possible to reset the alarm
memory if the refrigerant concentration is below
the pre-alarm level. Skip the alarm memory
function by removing Jumper BY2.
!
Note
Fig. 2
Relay Function
The relay contacts should be powered by
max. 24 V ac/dc.
Catalogue Section 9
© 1997 Johnson Controls Inc.
Order No. PD-GAS-E
Leak Detecting System
Issue 9801
3
Layout
Fig. 3
Wiring Diagram
Fig. 4
Selection table
Item code
GD2.0-CFC
GD2.0-HFC
GD2.0-NH3
GS2.0-CFC
GS2.0-HFC
GS2.0-NH3
GR2.0-CFC
GR2.0-HFC
GR2.0-NH3
Refrigerant
CFC/HCFC universal
HFC universal
Ammonia
CFC/HCFC universal
HFC universal
Ammonia
CFC/HCFC universal
HFC universal
Ammonia
Enclosure type
Room, fig 12a
Room, fig 12a
Room, fig 12a
Splash proof, fig 12b
Splash proof, fig 12b
Splash proof, fig 12b
Safety valves, fig 12c
Safety valves, fig 12c
Safety valves, fig 12c
Note: See application table on page 9 and dimension drawings on page 10, 11
© 1997 Johnson Controls Inc.
Order No. PD-GAS-E
Catalogue Section 9
Leak Detecting System
Issue 9801
4
Monitoring units
Description
The Monitoring unit shows the status of one or
more refrigerant detectors (See page 3 and 4).
When the refrigerant concentration as
measured by the detector exceeds the “prealarm level, the “Pre-alarm relay” on the unit is
activated, giving a pre-alarm. When the
measured concentration exceeds the “alarm
level”, the “Alarm relay” on the unit is
activated.
The “Fault relay” is energised when there is a
detector or power supply failure.
LED’s indicate the status of the unit, such as:
Power-on, Detector active, Pre-alarm, Alarm,
and Fault.
Two models are available, a 35 mm DIN rail
version (G27C) and a wall mount version
(G230C).
Functioning
If the power supply is switched on the green
LED will light up to indicate “power on”. After
4 minutes a yellow LED will light up to
indicate the unit is active”. The unit is ready
now to monitor the refrigerant detector(s).
If the concentration of refrigerant, measured
by the detector, exceeds the pre-alarm level,
the pre-alarm relay is activated and the LED
“Pre-alarm” is lighted up. If the refrigerant
concentration increases further and exceeds
the “Alarm level”, than the “Alarm relay” is
activated.
Fig. 5
Monitoring Units, G27C/G230C
Note
When monitoring more than 1 detector, the
position of jumper BY1, on the detector,
should be taken into account. This jumper
should be removed for all detectors except
the last one. (See also wiring examples on
page 6)
When the refrigeration concentration
decreases the relays can be reset by pushing
the “Reset” button in front of the cover.
Note:
It is only possible to reset the relays when the
refrigerant concentration is low enough.
Both models have the possibility to set the
operation mode from manual to automatic
reset.
Model G230C has an additional buzzer build
in which gives an audible alarm. This buzzer
is automatic reset when the refrigerant
concentration decreases.
The proper functioning can be verified by
pushing the “test” button.
Catalogue Section 9
Fig. 6
Relay function
© 1997 Johnson Controls Inc.
Order No. PD-GAS-E
Leak Detecting System
Issue 9801
5
Fig. 7
Wiring G27C
Fig. 8
Wiring G230C
Selection table
Item code
Enclosure type
G27C
DIN Rail Mount
G230C
Wall mount
© 1997 Johnson Controls Inc.
Order No. PD-GAS-E
Catalogue Section 9
Leak detecting system
Issue 9801
6
Wiring and mounting information.
Detector location
Correct placing of the detector is very important.
The detector has to be mounted high (under the
ceiling, not in the ceiling) for refrigerants lighter
than air (Ammonia), and low (20 cm above the
floor) for refrigerants heavier than air (CFC,
HCFC, HFC). The detector must be mounted at
a location where air streams cannot influence
the detector.
!
Warning
When wiring or servicing make sure that
power supply is switched off.
Fig. 9
Catalogue Section 9
© 1997 Johnson Controls Inc.
Order No. PD-GAS-E
Leak Detecting System
Issue 9801
7
Feature list
Detector
Enclosure
Power supply
LED indication
Output relays
Wall mount
DIN rail mount
230Vac
12Vdc
12Vac
Power on
Device Active
Pre-alarm
Alarm
Fault
Alarm memory
Pre-alarm
Alarm
Fault
GD/GS/GR2.0
•
Selectable auto reset/
man reset mode
Build in Buzzer
Alarm test
Test Connector
•
•
•
•
•
•
24V
24V
Monitoring unit
G27C
G230C
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
24V
24V
24V
•
230V
230V
230V
•
•
•
•
•
Optional accessories
Item code
SA 100
© 1997 Johnson Controls Inc.
Order No. PD-GAS-E
Description
Service adapter
Catalogue Section 9
Leak detecting system
Issue 9801
8
Check and Calibration of refrigerant detectors
To check and calibrate the detector you need a
SA 100 service adapter, connected to a
multimeter.
Working of the detector.
The GV value is a voltage proportional to the
measured refrigerant concentration. This “GVvoltage” will increase with an increase in
refrigerant concentration. The offset value (no
refrigerant measured) need to be checked twice
a year.
The pre-alarm level and alarm level are set at a
particular GV-voltage. A (pre-)alarm signal is
activated when the “GV-voltage” exceeds the
(pre-)alarm level.
!
Note
In some cases the detector can give an
alarm at start up of the system. This is no
fault, it indicates that the detector has to be
on for some minutes to stabilise after
storing and transportation. The alarm will go
off after a couple of minutes.
Check and calibrating instructions
The first action is to check the power supply to
the detector at terminal 1 and 2. This should be
12V ac/dc ±15%.
Connect the SA 100 service adapter to the test
terminal and do the check /calibration as
mentioned in the table bellow. Connect a
multimeter to the service module and set the
selector to the DC range
.
Fig. 11
Fig. 10
Selector position
Correct value
Corrective action if value is not correct
5V DC
Offset GV-value
5V ± 0,15V
See table page 9
Alarm level
Pre-alarm level
See table page 9
See table page 9
Replace detector if value is not correct
Adjust the “GV” offset value using the “GV” potentiometer.
Important: The detector has to be powered for at least 1 hour
before checking. Avoid any airflow influence during the test. Zero
setting of the GV offset value has to be done in clean air!
Adjust the Alarm level using the Alarm pot meter.
Adjust the Pre-alarm level using the pre-alarm pot meter
Note: The pre-alarm level is set at a percentage of the Alarm
level. When the alarm level is re-adjusted than the Pre-alarm
level will follow automatically.
Catalogue Section 9
© 1997 Johnson Controls Inc.
Order No. PD-GAS-E
Leak Detecting System
Issue 9801
9
Trouble shooting
Use the SA 100 service adapter, connected to a multimeter
Problem
Check point
Remark
Detector gives no
alarm at gas
influence
Check that the GV-value will
increase at gas influence
When voltage is higher than alarm levels
the alarm relays should be activated
Constant alarm from
detector
• Check the GV-value offset
(See calibration instructions)
If GV value is higher than alarm level,
move the detector to another area with
clean air and calibrate
• Check that no other gases
can cause a false alarm
• Check for EMC problems.
Constant alarm on
monitoring unit
• Check if Jumper BY1 is
mounted at last detector
• If all BY1 jumpers are mounted, a wrong
signal is sent to the monitoring unit
• Check voltage on each
detector (between terminal 3
and 4)
• If detector cable is close to high voltage
wiring, electromagnetic induction can
affect the detector signal
Refrigerant application table and alarm levels
Sensor type
Refrigerant
Pre-Alarm level
Alarm level
Gx2.0- CFC
CFC’s, e.g.:
≈ 300 - 700 ppm
depending on
gastype
≈ 700 - 1200
ppm depending
on gastype
GV = 1,0V
GV = 1,4V
≈ 300 - 700 ppm
depending on
gastype
≈ 700 - 1200
ppm depending
on gastype
GV = 1,0V
GV = 1,4V
≈ 400 - 700 ppm
depending on
gastype
≈ 700 - 1200
ppm depending
on gastype
GV = 1,0V
GV = 1,5V
≈ 150 ppm
≈ 300 ppm
GV = 2,5V
GV = 3,5V
R11, R12, R13, R113,
R114, R500, R502,
R503
HCFC’s, e.g.:
R22, R123, R124,
R142, R401A/B,
R402A/B, R403A/B,
R408A, R409A
Gx2.0- HFC
HFC’s, e.g.:
R23, R32, R125,
R134, R134a, R143a,
R152a, R404A,
R407A/B/C, R410A,
R507
Gx2.0- NH3
Ammonia, R717
Offset
GV
Location
0,35V
Low
0,35V
Low
0,3V
Low
0,2V
High
Note: The indicated values are typical for ambient temperatures at +20°C. To have an exact value you
need to use calibration gas and calibrate at 20°C.
© 1997 Johnson Controls Inc.
Order No. PD-GAS-E
Catalogue Section 9
Leak detecting system
Issue 9801
10
Dimensions (mm)
Fig. 12a
GD2.0 Detector
Fig. 12c
GR2.0 Detector
Fig. 12b
GS2.0 Detector
Fig. 12d
Mounting dimensions
A. Connector
CFC/HCFC/HFC: Male 1/2” Flare
NH3: Male R1/2”
Catalogue Section 9
© 1997 Johnson Controls Inc.
Order No. PD-GAS-E
Leak Detecting System
Issue 9801
11
83
45
118
Dimensions (mm)
12
43
53
70
Fig. 13
G27C Monitoring Unit
Fig. 14
G230C Monitoring Unit
© 1997 Johnson Controls Inc.
Order No. PD-GAS-E
Catalogue Section 9
Leak detecting system
Issue 9801
12
Specifications
Power supply
Frequency
Power consumption
Ambient operating
conditions
Storage temperature
Operating (storage) humidity
Detector cable
Terminals
Dimensions
Relay ratings
Directives
Accuracy
Alarm level
Pre-alarm level
Material
Protection class
Weight (g)
Max number of connected
detectors
230Vac/12Vdc +10%/-15%
G230
12Vac/dc ± 15%
G27C
12Vac/dc ± 15%
GD/GS/GR2.0
50/60 Hz
GD/GS/GR 2.0 3W
2W
G27C
12W
G230
0 to +50°C
G230C/G27C
0 to +50°C
GR2.0
-20 to +50°C
GD/GS2.0
-40 to +70°C
10 to 90%RH (non condensing)
2
4 x 0,75mm , Max. 50 m, Screened cable
2
4 x 1,5mm , Max. 150m, Screened cable
2
Screw type max. wire thickness 2,5 mm
See drawings on page 10,11
GD/GR/GS
G27C
G230C
Pre-Alarm
SPST:
SPST:
SPDT:
relay
24Vac/dc, 1A
24Vac/dc, 1A
230Vac, 2 (0,5)A
Alarm relay SPST:
SPST:
SPDT:
24Vac/dc, 1A
24Vac/dc, 1A
230Vac, 2 (0,5)A
Fault relay
SPST:
SPDT:
24Vac/dc, 1A
230Vac, 2 (0,5)A
Low voltage:
73/23/EEC
EMC:
89/336/EEC
± 15% of adjusted (pre-) alarm level. See page 9
See application table at page 9 for factory setting
See application table at page 9 for factory setting
ABS/PC mixture
G27C
Polycarbonate
G230C
Polycarbonate
GD2.0/GS 2.0
PC, Brass (CFC,HCFC,HFC models)/ Steel
GR2.0
(NH3 models).
IP 30
G27C
IP 65
G230C
IP 21
GD2.0
IP 54
GS/GR 2.0
155
G27C
1570
G230C
235
GD2.0
280
GS2.0
485
GR2.0
95
SA100
10
The performance specifications are nominal and conform to acceptable industry standards. For applications at conditions beyond
these specifications, consult the local Johnson Controls office or representative. Johnson Controls shall not be liable for damages
resulting from misapplication or misuse of its products.
Johnson Controls International, Inc.
Headquarters:
European Headquarters:
European Factories:
Branch Offices:
Milwaukee, WI, USA
Westendhof 8, 45143 Essen, Germany
Lomagna (Italy), Leeuwarden (The Netherlands) and Essen (Germany)
Principal European Cities.
This document is subject to change
Catalogue Section 9
Printed in Europe
© 1997 Johnson Controls Inc.
Order No. PD-GAS-E
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