haloguardtm ii - Thermal Gas Systems

haloguardtm ii - Thermal Gas Systems
HALOGUARDTM II
MULTI-GAS MULTI-SENSOR MONITOR
INSTRUCTION MANUAL
S E R IA L N O .
M ODEL NO.
T em p . R a n g e
o
1 - = > 60 F
o
2 - = 40 - 60 F
o
3 - = < 40 F
N o . o f S en so rs/G a s T y p e
A - R -1 1
B - R -1 2
C - R -2 2
O u tp u ts
D - R -1 3 4 a
1 - 4 x 3 A R elay s
E - R -1 1 3
2 - 0 - 5 VDC
or 0 - 10 V DC
F - NH3
G - R -1 2 3
H - O x y g en
O p tio n s/A ccesso ries
A - 1 2 0 d B A u d ib le A larm
B - 1 H r. B attery B ack -u p
C - A u to C alib ratio n
L - S tro b e L ig h t
T - T W A In teg ratio n
11285 Elkins Road Bldg. H-1
Roswell, GA 30077
TEL: 770-667-3865
FAX: 770-667-3857
www.thermalgas.com
1
IMPORTANT
READ ENTIRE BOOKLET BEFORE
INSTALLING OR OPERATING
HALOGUARDTM II MONITOR
TABLE OF CONTENTS
1.
2.
3.
4.
5.
6.
7.
Page
3
3
6
7
9
9
10
Unpacking Instructions
Before Installation
Installation
Calibration
Testing
Trouble Shooting
Specifications
FIGURES
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Page
4
4
5
5
5
6
7
8
8
10
11
Dimension Drawing
Upper Circuit Board
Lower Circuit Board
Junction Box Relay Connections
LCD Display Features
Terminal Connectors
Function Jumper Settings
Alarm Jumper Settings
Exposure Limits
Initial Factory Settings
Wiring Diagram
2
UNPACKING INSTRUCTIONS
HaloguardTM monitors are carefully packed, inspected and delivered to the carrier in good condition.
If damage occurs in transit it is the responsibility of the carrier.
Carefully inspect the unit upon receipt. Any damage should be reported to the carrier and an
inspection requested. After inspection by the carrier and your receipt of his acknowledgment as to
the damage, contact us for return authorization (RMA). We cannot file claims for damaged goods
on your behalf, but we will assist you in any way we can.
In order to expedite our work, please provide serial number and purchase date when you call.
WE CANNOT ACCEPT RETURNS WITHOUT PRIOR APPROVAL.
BEFORE INSTALLATION
1. Remove HaloguardTM from carton. Check contents against packing list. If shipment is
incomplete, contact us immediately.
2. The following tools and hardware are required for installation and calibration.
a. Two standard screwdrivers; 1 - medium, 1 - jewelers fine.
b. Needle-nosed electrician’s pliers
c. 9/32” Nut driver
d. (3) No. 10 x 1” Screw - minimal length
e. Digital VOM
3. Select the site for the measurement:
a. Power requirements: Provide a clean source of 115-230 VAC, 50/60 Hz, single phase circuit
rated 15A minimum.
b. Sensor element should be located near potential leaks in a quiet area or downstream from leak
source in area with air movement.
c. Sensor element should be mounted 18” - 24” above the floor for halocarbons and near the
ceiling for ammonia.
d. Make sure the area selected is not subject to flooding, potential impact or severe ambient
temperature and humidity changes (i.e. boiler blow-down or near roll-up doors).
IMPORTANT
SENSOR ELEMENT CAN BE DESTROYED BY IMMERSION IN LIQUIDS OR
EXPOSURE TO SILICONE. COVER SENSOR WITH A PLASTIC BAG WHEN
SILICONE VAPORS ARE PRESENT IN MONITORED AREA. IMMERSION OR
SILICONE EXPOSURE INVALIDATES SENSOR LIFE WARRANTY.
e. Halocarbon and LFL Sensor will respond to presence of alcohol, hydrogen, carbon monoxide,
paint thinner, and many toxic and combustible gases. For accurate refrigerant leak detection
select a location free from above fumes or temporarily disable sensor as above when they are
present.
4. The wall mounted controller should be installed indoors, approximately five feet above the floor
(or at a location easily visible to operators), in an area with minimal vibration, and with
temperature and humidity changes like sensor location.
IMPORTANT
3
CONSULT LOCAL AND NATIONAL ELECTRICAL CODES FOR ANY SPECIAL
REQUIREMENTS OR RESTRICTIONS BEFORE INSTALLING HALOGUARDTM.
5. Selectors, LCD/LED Displays, and Relays
a. AUTO/MAN Push-button - In the AUTO mode, the HaloguardTM II automatically scans all
active channels in sequence. Manual mode is initiated by pushing the MAN push-button. In
the MAN mode, monitor remains locked in a single channel until manually sequenced to
another channel, by pushing MAN push-button. After 2 minutes, sequencer will
automatically default to AUTO mode.
b. ZERO Push-button - Reads sensor output and sets this value equal to “zero” ambient
condition. ZERO function is inactive when in ANY alarm condition or during RESET (See
Calibration 3c).
c. OFFSCALE Alarm LED and Relay - Factory set at a value 2 - 3 times the full scale.
d. HI Alarm LED/LO Alarm LED and Relays - User adjustable 10% to 100% of Full-scale
value (See Calibration 4.0).
Note: Optional TWA Integration activates LOW Alarm LED and relay when installed.
e. FAULT Alarm LED and Relay - Indicates power failure, out of calibration or sensor failure.
f. POWER - Green LED indicates Haloguard TM is receiving power.
g. RESET - Green LED indicates Haloguard TM in 20 minute RESET mode. During RESET
mode all alarm relays, audible and visual alarms are disabled.
4 1/4”
10 1/2”
7 1/8”

HALOGUARD II CONTROLLER
Figure 1 - Dimensional Drawing
AN1
AN2
AN4
AN3
JP9
JP5
JP6
JP7
JP8
JP1
JP2
JP3
JP4
OFF SCALE
POWER
DISPLAY
HIGH
TEST
LOW
ZERO
FAULT
MAN
RESET
RESET
BRIGHTNESS
MICROPROCESSOR
LED
Figure 2 - Upper Circuit Board
4
PUSH-BUTTON
CHANNEL 1
LOW
HIGH
CHANNEL 2
LOW
HIGH
CHANNEL 3
LOW
HIGH
CHANNEL 4
LOW
HIGH
CHANNEL 5
LOW
HIGH
CHANNEL 6
LOW
HIGH
10
9
8
7
6
5
4
3
2
1
10
9
8
7
6
5
4
3
2
1
10
9
8
7
6
5
4
3
2
1
10
9
8
7
6
5
4
3
2
1
10
9
8
7
6
5
4
3
2
1
10
9
8
7
6
5
4
3
2
1
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
4
5
6
T1 T2 T3
T1 T2 T3
T1 T2 T3
T1 T2 T3
T1 T2 T3
T1 T2 T3
Figure 3 - Lower Circuit Board
Channels 1 - 6
Flashing cursor means Auto Scan Mode
Gas Type (R-11, R-12, R-123, R-134, O 2, etc.)
** CAUTION** (Offscale alarm)
** DANGER!** (Oxygen below 15%)
Instantaneous concentration (PPM, %, %LFL)
8 hr. TWA Concentration
(R-123, NH3)
1
2
3
4
HI ALARM 5
6
7
LO ALARM 8
9
10
FAULT 11
12
OFF SCALE
NC
COM
NO
NC
COM
NO
NC
COM
NO
NC
COM
NO
LO
= Low Battery
Sensor Type
- CMOS (Halocarbon, NH3,, LFL)
- Infrared (Halocarbons)
- Chemical (O2, CO)
Alarm Messages
- LO ALARM
- TWA ALARM
- HI ALARM
- OFFSCALE
ACON
= Auto. Cal. “ON”
LON
= Relay Latch “ON”
Figure 5 - LCD Display Features
Figure 4 - Junction Box Relay
5
INSTALLATION
1. Check power supply. (See Section “Before Installation 3a”)
2. Disconnect power before beginning.
3. To mount HaloguardTM controller:
a. Install No. 10 x 1” screw (minimum) wall fastener at approximate center of desired location.
Slip controller over fastener.
b. Remove lower cover from controller to expose lower circuit board. Install two additional
fasteners through holes provided beneath lower cover.
c. Replace cover.
4. Mount sensors in a VERTICAL DOWN position (Oxygen sensors MUST be in vertical down
position to operate properly) on indoor surface with mounting clip provided or in duct work if
provided with mounting flange. Run cable to controller location. Eight feet (8ft.) of cable with
DIN connectors standard; optional extension cables are available.
Refer to FIGURE 3 Lower Circuit Board before proceeding.
DO NOT CUT SUPPLIED CABLE
Maximum Extension wire 300 Feet.
a. Controller is provided with 18” cable with DIN Connector and sensor is provided with 6 1/2’
cable. If cable extension is provided by customer, proceed as follows:
We recommend 3 conductor 18 ga. cable with foil shield, Carol C0455 or equal. Use 3/4”
conduit if required.
To extend sensor beyond the provided length, remove 18” cable with DIN connector from
controller Lower Circuit Board. Splice or solder extension cable to end of 18” cable.
Reconnect extended sensor cable to proper terminal block in lower circuit board of
controller. Start with Channel 1 and connect in sequence until all are connected as follows:
Terminal
T1
T2
T3
Provided
Wire Color
Red
White
Blk./Blk
Extension
Wire Color
Red
White
Black
Function
VDC
Signal
Ground
Figure 6 - Terminal Connection
6
Set HI/LO ALARM jumpers for each sensor at 10. (See Figure 3 and 8 for Lower Circuit Board
settings).
7 Remove cover and face plate from controller using nut driver; remove junction box cover.
Refer to Figures 2,3,and 4 before proceeding
**WARNING**ANALOG OUTPUT IS A DRIVEN SIGNAL-DO NOT CONNECT ANY WIRE WITH
VOLTAGE OR CURRENT TO ANALOG OUTPUT TERMINALS
8
Connect alarm relays (NO or NC) and analog outputs AN 1 thru 4 ((+) SIG and (-) GND if
supplied) where indicated. READ WARNING LAST PAGE
9 Connect power (Connect optional battery back-up if supplied.)
10. For 20 min. after initial power up all alarm relays and audible are automatically disabled. During
initial power up RESET LED will be lit. Whenever power is disrupted, RESET MODE will be
automatic (unless equipped with battery back-up) to protect against false alarms.
6
Due to variations in the ambient (temp. and R.H.) zero calibration must be initially and
periodically checked to assure best performance. (See Calibration Section)
11.LocateSETUP jumpers JP-1 thru 9 on Upper Circuit Board. Select required settings from the
following menu:
JP
JP-1
JP-2
JP-3
JP-4
JP-5
JP-6
JP-7
JP-8
JP-9
FUNCTION
In house ONLY.
Optional AutoCalibration (See 12a)
Set scan rate, 0-10 sec. adjustable (See 12b)
Set gas type and channel (See 12c)
In House Use ONLY. System set-up info.
Set Clock, optional TWA only (See 12d)
In House Use ONLY. (Contact mfg. for changes)
Relay Latch (See 12e)
Optional Audible alarm and jumper storage.(See 12f)
Figure 7 - Function Jumper Settings
12.After selecting from the above, the LCD will show a new mode (SETUP, etc.) and the MAN and
ZERO push-buttons will have new functions.
a. AutoCalibration (Optional) select JP-2, LCD shows ACON. HaloguardTM compares temp.
and RH every 4 hours to compensate for changes in ambient.
b. Scan Rate - Rate is factory set at 4 sec. per active channel. To change, select JP-3, push
ZERO and step to desired rate. Remove jumper from JP-3.
Refer to figure 5 before proceeding
c. Channel and Gas Type - See initial factory setting chart for channel set-up To change,
select JP-4, push ZERO and sequence to channel (1 thru 6) desired, push MAN to initiate gas
type menu, push ZERO and scroll to gas type desired (Note: “None” selected will skip
channel). Proceed to next channel and follow same process. When finished, remove jumper
from JP-4.
d. TWA Integration, (Optional). HaloguardTM calculates an 8 hr. TLV-TWA, displays this
value on LCD, activates LO alarm LED and relay if preprogrammed PPM value is exceeded.
(Must be powered up for 8 hrs. to build data base before operating).
e. Relay Setup - Factory setting is Unlatched Mode; The alarm LEDs and relays will return to a
normal status when gas concentration goes below setpoint. To select Latched Mode place
jumper on JP-8. Press RESET button to release alarm or check for false alarm (Note: Alarm
will be disengaged for 20 minutes).
f. Audible Alarm - JP-9 is factory installed to activate alarm circuit. To silence alarm remove
JP-9 jumper.
12. Trim Optional analog outputs by pushing TEST button and turning potentiometers on AN 1 thru
4 (see Figure 2 Upper Circuit Board) until output measures 5.0 or 10.0 VDC as required.
CALIBRATION
1. The Haloguard has been factory calibrated under standard conditions (70oF, 65% R.H.). Due
to variations in the ambient (temp. and R.H.) zero calibration must be initially and
periodically checked to assure best performance.
TM
7
2. The HaloguardTM should be powered up (operated continuously) for 24 hours before
calibration.
Remove Alarm Setpoint Jumper from all active channels before beginning calibration.
3. Calibrate with a digital VOM as follows:
HALOCARBON AND LFL SENSORS “ZERO” CALIBRATION
ZERO CALIBRATION MUST BE COMPLETED FOR EACH SENSOR
(1 thru 6)
a. With VOM on 1 VDC scale, place VOM probe on T2 (+) and T3 (-) Test points (see Figure
3 Lower Circuit Board).
Select MAN mode with push-button, sequence to first channel. Adjust potentiometer to the
left of the terminals with screwdriver until it reads 1.0 VDC. Push ZERO. Sequence to
subsequent active channels and follow same procedure for each channel. Haloguard TM
automatically returns to scanning mode after 2 minutes or press TEST button to start
scanning.
Note: Zero calibration is not necessary for oxygen sensors.
b. LCD display adjustment changes brightness - Adjust potentiometer (See Figure 2 Upper
Circuit Board).
4. Alarm Setpoints Adjustment - (See Figure 3 - Lower Circuit Board) Place jumper on
appropriate alarm point to initiate visual and audible alarm relays.
Jumper Settings
Low/High
10
9
8
7
6
5
4
3
2
1
Range
0 - 300
300
270
240
210
180
150
120
90
60
30
Range
0 - 1000
1000
900
800
700
600
500
400
300
200
100
GAS
R-11
R-12
R-22
R-123
R-134a
R-500
R-502
TLVTWA*
•
1000
1000
50
1000
1000
1000
CEIL
1000
•
•
•
•
•
•
PEL
•
1000
1000
•
1000
1000
•
Other exposure limits are pending.
TLV-TWA = 8hr./day, 40hr./wk. avg. Short term exposures should not
exceed 3 - 5 times the TWA for more than 30 min./day.
* ACGIH Trademark.
Figure 9 - Exposure Limits
Figure 8 - Alarm Jumper Settings
8
Oxygen alarms are preprogrammed at 19.5% (LO) and 15% (HI);
(Optional) TWA Intregation, LO alarm is pre-programmed to the TLV-TWA for specified gas. Off
Scale - Preprogrammed at 2 - 3 times full scale.
SPAN CALIBRATION
Span calibration is not required for operation in typical machine room environments. Optional
Span Gas Calibration Kits are available upon request. Instructions for calibration are included with
kit.
TESTING
1. The Haloguard TM should be tested periodically and 30 minutes after each alarm level condition
has been corrected.
a. Alarm Test - Push and hold TEST button; alarm relays, lights, audible and remote
alarms (if equipped) will activate. Analog outputs will go full scale.
b. Reset Test - Push RESET button; alarm relays, audible and remote alarms (if equipped) will
become inactive for 20 minutes. RESET LED will be green.
TROUBLESHOOTING
The most frequent cause of nuisance alarms is improper set-up, primarily due to:
a. Too short a warm-up time before Zero Calibration.
b. Poor sensor location.
To check Zero Calibration, fill a clean plastic trash bag with clean outside air, tie off with twist-tie,
let sample stabilize inside for 15 - 20 minutes, and insert sensor into bag.
Follow Zero procedures under “Calibration” Section. Remove sensor from bag and observe LCD
response.
If PPM then moves higher, look for possible sources of interfering gases (See “Before Installation”
section 3e). and relocate sensor.
We wish to aid with any problems you might experience with the HaloguardTM line of products.
When contacting Thermal Gas Systems, Inc. Service Department, your assistance is requested to
provided the following information.
1. Model Number and Serial Number.
2. Description of problem.
3. Remove faceplate from Upper and Lower Circuit Board (Figures 2 and 3) . Advise jumper
positions.
4. Remove Junction Box cover (Figure 4). Advise where Alarm wires are connected.
5. Using (Figure 3 Lower Circuit Board) as a guide, measure voltage between +V and GND.;
SIG and GND, for all active sensors. Write down values.
6. Using LCD Display (Figure 5) as a guide, observe the LCD as it scrolls. Write down values.
7. Advise the condition of all LED’s on the faceplate.
9
SPECIFICATIONS
Technology:
CMOS - Ceramic Metal Oxide
Semiconductor
Oxygen - Electro Chemical
Response Time:
Operating Conditions:
CMOS Sensor -20oF to +120oF Non-condensing
Oxygen Sensor +40oF to +110oF Non-condensing
Controller
0oF to +120oF Non-condensing
Electrical Supply: 115-230 VAC, 50-60Hz
Output Signal:
Std. 4 x 3A Dry Contact Relays
(either NO or NC)
Opt. 4 x 0 - 5 VDC Analog
Alarm Outputs:
Three Level Contact Closure
Readout:
Digital Meter, Displayed in PPM
Gas Type, Range and options.
Accuracy:
10% Full Scale (CMOS)
1% Electrochemical (Oxygen)
Ranges:
Fault Diagnostics: Indicator Light or Readout for
Malfunction which include:
(See Figure 5)
Materials:
Controller
Polystyrene, NEMA 12/13, IP65
Design
CMOS Sensor PVC and porous PP
0 - 1000 ppm CFC, HCFC, HFC
0 - 300 ppm NH3,, HCFC (Opt)
0 - 20% LFL Flammability
0 - 25% Oxygen
Channel
< 1 Minute per sample point
Weight:
Controller:
4 lbs. (Add 2 lbs. optional battery)
Dimensions:
Controller
10-1/2” W x 7-1/8” H x 4-1/4”D
Initial factory settings are:
1
2
3
4
5
6
Gas
Sensor
Type
Full Scale
PPM
TWA Alarm
Level
Figure 10 - Initial Factory Settings
GLOSSARY
1.
2.
3
4.
5.
6..
PEL- Permissable Exposure Limits - The employee’s average short term exposure in any 8hr work shift, which shall not be exceeded.
CONTROLLER - Processor mounted on wall which includes LCD Display, LED Alarms
Relays, and other functions
CEIL-The concentration that shall not be exceeded during any part of the work day.
SPAN - A full-scale reading on the LCD display.
TLV-TWA - The time -weighted average concentration for a normal 8 hr. work day and a
40 hr. work week, to which nearly all workers may be repeatedly exposed, day after day,
without adverse effect.
ZERO - An indication on the display indicating the presence or non-presence of CFC’s,
HCFC’s or HFC’s.
10
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