User Manual

AT-1193 – UserManual

Specifications subject to change without notice. | USA 140403 | Page 1 of 13

PolyGard



AT-1193

Electrochemical Chlorine Transmitter

Serial No. AT03-005

User Manual

October 2011

April 03, 2014 –

Revision

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Page 02

1 Intended Use ........................................................................................................................................ 3

2 Functional Description ....................................................................................................................... 3

2.1 Control Mode ............................................................................................................................... 3

2.2 Sensor ......................................................................................................................................... 3

3 Installation .............................................................................................................................................. 4

3.1 Mounting Instructions .................................................................................................................... 4

3.2 Installation ...................................................................................................................................... 4

4 Electrical Connection .......................................................................................................................... 4

4.1 Wiring Connection ....................................................................................................................... 5

5 Commissioning ...................................................................................................................................... 5

5.1 Correction of the Zero-point at the Analog Output Signal ............................................................ 5

5.2 Calibration ................................................................................................................................... 6

5.2.1 Zero-point ................................................................................................................................ 6

5.3.2 Gain ......................................................................................................................................... 6

5.3.3 Calculation of Control Voltage ................................................................................................. 6

5.4 Option Relay Output .................................................................................................................... 7

6 Inspection and Service .........................................................................................................................

7

6.1 Inspection .................................................................................................................................... 7

6.2 Service and Calibration ............................................................................................................... 7

6.3 Exchange of Sensor Element ...................................................................................................... 8

7 Troubleshooting........................................................................................................................

.

......

.

.....

8

7.1 Analog ..

....... 8

8 Cross-sensitivity Data.......................................................................................................

.

..........

.

......

8

9 Technical Data.....................................................................................................

..

..............................

9

10 Figures ..................................................................................................................................................

11

11 Part Disposal .....................................................................................................................................

13

12 Notes and General Information..........................................................................................................

13

12.1 Intended Product Application ................................................................................................. 13

12.2 Installers’ Responsibilities ..................................................................................................... 13

12.3 Maintenance .......................................................................................................................... 13

12.4 Limited Warranty .................................................................................................................... 13

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Page 03

Electrochemical Chlorine Transmitter

1 Intended Use

The PolyGard



Cl analog/digital gas transmitter AT-1193 with digital processing of the measuring values and temperature compensation is used for the continuous monitoring of the ambient air to detect the presence of

Chlorine gas. Main application ranges are waterworks, sewage plants, swimming pools etc.

The intended sites are all areas being directly connected to the public low voltage supply, e.g. residential, commercial and industrial ranges as well as small enterprises (according to EN50 082).

The PolyGard

®

Technical Data.

Cl

2 analog/digital transmitter must not be used in potentially explosive atmospheres.

The transmitter must only be employed in areas within the environmental conditions as specified in the

2 Functional Description

2.1 Control Mode

The analog output can be selected as current signal with (0)4-20 mA or as voltage signal (0)2-10 V. In the 4-

20 mA mode and without any supplementary options, the AT-1193 also works in the 2-wire technique.

2.2 Sensor

The sensor portion of the transmitter is a sealed electro-chemical cell with three electrodes, sensing, counter and reference. The ambient air to be monitored diffuses through a membrane filter into the liquid electrolyte of the sensor. The chemical process of the measurement is one of reduction where one molecule of the target gas is exchanged for one molecule of oxygen. The reaction drives the oxygen molecule to the counter electrode, generating a DC microampere signal between the sensing and reference electrodes. This signal is linear to the volume concentration of the sensed gas. The signal is evaluated by the connected amplifier and transformed into a linear output signal.

Electrochemical processes always lead by and by to a loss of sensitivity. Therefore regular calibration of zero- point and gain is obligatory. See also section 6.

Caution:

There is a small quantity of corrosive liquid in the sensor element. If in case of damage persons or objects touch the liquid, you have to clean the affected areas as fast and carefully as possible with tap water. Out of use sensors must be disposed in the same way as batteries.

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3 Installation

Note:

Avoid any force (e.g. by thumb) on the sensor element during operation or installation. Electronics can be destroyed by static electricity. Therefore, do not touch the equipment without a wrist strap connected to ground or without standing on a conductive floor (acc. to DIN EN100015).

3.1 Mounting Instructions

When choosing the mounting site please pay attention to the following:

 The specific weight of Chlorine CL

2 is higher than that of air (factor 2.4).

Recommended mounting height is 0.2 m (0.7 ft.) to 0.3 m (1 ft.) above floor.

 Choose mounting location of the sensor according to the local regulations.

 Consider the ventilation conditions. Do not mount the transmitter in the center of the airflow

(air passages, suction holes).

 Mount the transmitter at a location with minimum vibration and minimum variation in temperature (avoid direct sunlight).

 Avoid locations where water, oil etc. may influence proper operation and where mechanical damage might be possible.

 Provide adequate space around the sensor for maintenance and calibration work.

Duct mounting

 Mount only in a straight section of duct with minimum air vortex. Keep a minimum distance of 1 m

(3.5 feet) from any curve or obstacle.

 Mount only in a duct system with a maximum air velocity of 10 m/s (2000 ft/min) or less.

 Mounting must be performed so that the probe openings are in line with the airflow.

3.2 Installation

 Open the cover. Unplug basic PCB carefully from the bottom part.

 Fix bottom part by screws vertically to the wall (terminal blocks to the ground).

 Replug the basic PCB at X4 and X5 with care. Replace the cover.

4 Electrical Connection

Consider static electricity See 3. Mounting

 Installation of the electrical wiring should only be executed by a trained specialist according to the connection diagram, without any power applied to conductors and according to the corresponding regulations

 Avoid any influence of external interference by using shielded cables for the signal line, but do not connect the shield.

 Recommended cable for analog mode: J-Y(St)Y 2x2x0.8 LG (20 AWG), max. loop resistance 73

 /km (20.8  /1000 ft).

 It is important to ensure that the wire shields or any bare wires do not short the mounted PCB.

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4.1 Wiring Connection

 Open the cover. Unplug basic PCB carefully from terminal blocks X4 and X5.

 Insert the cable and connect cable leads to terminal blocks. See fig. 1.

 Replug the PCB in the terminal blocks X4, X5 with care. Replace the cover.

Note: The connection of the power supply at the output signal (X4 pin 4) can destroy the transmitter.

5 Commissioning

Consider commissioning instructions at any exchange of the sensor element as well.

Only trained technicians should perform the following:

 Check mounting location.

 Select output signal form: Current or voltage, and starting point 0 or 20%. See fig. 4.

 Check power voltage.

 Check PCB AT03 for correct mounting at X4 and X5.

Required instruments for commissioning (calibration) of the transmitter:

 Test gas bottle with synthetic air (20 % O

2

, 80 % N) or chlorine-free ambient air.

 Test gas bottle with Cl

2

(ppm) in the range of 30 – 70 % of the measuring range. Rest is synthetic air.

 Gas pressure regulator with flow meter to control the gas flow to 150 ml/min.

 Calibration adapter with tube. Calibration set CONKIT-E/CH-AT. See fig. 5.

 Digital voltmeter with range 0 – 300 mV, accuracy 1%.

 Small screwdriver.

Note:

Prior to calibration the sensor must be connected to the power supply and fully stabilized for at least 6 hours without interruption.

Please observe proper handling procedures for test gas bottles!

Attention:

CL

2 calibration gas is toxic, never inhale the gas

Symptoms: Chemical burn, dizziness, headache and nausea.

Procedure if exposed: Take the victim into fresh air at once, call a doctor.

5.1 Correction of the Zero-point at the Analog Output Signal

The analog output signal is factory set to the zero-point. If necessary, a manual adaptation of the analog signal is possible within 10 sec. after having applied the supply voltage.

 Jumper 0-20 % for signal start has to be set (= 4 mA or 2 V).

 Connect digital voltmeter (300 mV) at test pint “Test” (measuring signal ~ 40 mV = 4.0 mA).

 Switch on the operating voltage.

 Each pressing on the “Zero” push-button increases the signal by + 0.5 mV (0.05 mA). Press the button repeatedly until the measuring signal reaches 40 ± 0.2 mV. After 44mV the signal starts again at 36 mV. The correction is only possible within the 10 seconds after having switched on the power supply. An impulse pause of more than 10 sec. cancels the release of the correction function.

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Gas Transmitter


Page 06

5.2 Calibration

Manual calibration is only possible if the transmitter is equipped with the push-button “Zero” and the potentiometer “Gain” (= version for manual calibration).

5.2.1 Zero-point

 Connect digital voltmeter to pin “Test”.

 Connect calibration adapter carefully to the sensor element.

 Apply synthetic air (150 ml/min; 1 Bar (14.5 psi) ± 10%), or Chlorine (Cl

2

)-free ambient air.

 Wait 2 minutes until the signal is stable, push button “Zero” for 5 seconds.

After successful calibration the measuring signal is corrected automatically. Depending on the selected signal starting point the measuring signal shows the following values:

Signal start at 2 V or 4 mA

Signal start at 0 V or 0 mA

40 mV = 0 ppm

0 mV = 0 ppm

If the zero-point is out of the admissible range (> 20 mV at starting point 0% / > 60 mV at starting point 20%) before calibration, there is no correction of the measuring signal. The sensor has to be replaced.

 Remove calibration adapter carefully by turning lightly. Check the sensor for correct mounting

5.3.2 Gain

 Connect digital voltmeter to pin “Test”.

 Connect calibration adapter carefully to the sensor element.

 Apply calibration test gas Cl

2

(150 ml/min; 1 Bar (14.5 psi) ± 10%).

 Wait three minutes until the signal is stable, adjust control voltage with potentiometer ”Gain” until the signal corresponds to the calculated value ± 2 mV, see “5.3.3 Calculation of Control Voltage”.

 Remove calibration adapter with a careful light turn. Check the sensor for correct mounting

By limiting the gain factor, calibration will not be possible any more when the sensitivity of the sensor reaches a residual sensitivity of 30 %. Then the sensor has to be replaced.

5.3.3 Calculation of Control Voltage

Signal start 2 V / 4 mA

Control voltage (mV) = 160 (mV) x test gas concentration Cl

2 measuring range Cl

2

(ppm)

(ppm) + 40 (mV)


Control voltage (mV) = 200 (mV) x test gas concentration Cl

2 measuring range Cl

2

(ppm)

(ppm)

Example:

Measuring range

Test gas concentration

Control voltage: Signal start 2 V / 4 mA

Control voltage: Signal start 0 V / 0 mA

20 ppm

10 ppm Cl

2

120 mV

100 mV


160 (mV) x 10 (ppm) + 40 (mV) = 120 mV mV 20 (ppm)


200 (mV) x 10 (ppm) = 100

20 (ppm)

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Page 07

5.4 Option Relay Output

The two relays are activated in dependence of the gas concentration. If the gas concentration exceeds the adjusted alarm threshold, the corresponding relay switches on. If the gas concentration falls below the threshold minus hysteresis, the relay switches off again.

The contact function for relay 2, NC (normally closed) or NO (normally open), can be selected via the jumper NO/NC. See fig 1 and 3. Relay 1 is equipped with a change-over contact.

Via the ModBus interface the two alarm thresholds and the hysteresis are freely adjustable at the PC within the measuring range. The procedure can be read from the user manual “ModBus Software”.

The following parameters are factory-set.

Alarm threshold 1 = Relay 1: 5 ppm

Alarm threshold 2 = Relay 2: 8 ppm

Switching hysteresis: 1 ppm

6 Inspection and Service

Inspection, service and calibration of the transmitters should be done by trained technicians and executed at regular intervals. We therefore recommend concluding a service contract with IN

TEC

Controls or one of their authorized partners.

According to EN 45544-4, inspection and service has to be executed at regular intervals. The maximum intervals have to be determined by the person responsible for the gas warning system according to the legal requirements. IN

TEC

Controls recommends checking the PolyGard Transmitter every three months and maintaining it every 12 months. If different intervals are indicated, always consider the shortest interval.

Inspections and services must be documented. The date for the next maintenance has to be affixed to the transmitter.

6.1 Inspection

The PolyGard Transmitter should be checked regularly by a competent person. The following has to be checked in particular:

 Maintenance/ calibration interval not exceeded.

 Visual inspection of the transmitter including cable for damage etc.

 Remove dust deposits, especially at the gas inlet.

6.2 Service and Calibration

When performing the maintenance you have to do the calibration and the functional test in addition to the inspection.



Calibration: See section 5.

 Functional test: Check the output signal at the test pins during calibration.

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Page 08

6.3 Exchange of Sensor Element

Consider static electricity See point 3.

Sensor should always be installed without power applied:

 Unplug basic PCB AT03 carefully from the bottom part.

 Unplug old sensor element from the PCB.

 Take the new sensor out of the original packing.

 Plug the sensor element in the PCB.

 Replug the PCB AT03 in the terminal blocks X4, X5 carefully.

 Calibrate according to section 5.

7 Troubleshooting

7.1 Analog Mode

Trouble Cause

Output signal < 3 mA / 1,5 V and/or control voltage < 30 mV

Jumper 0-20 % not set only for starting signal 2V/4 mA Power voltage not applied

Solution

Check jumper position

Measure tension at X4:

Two-wire: Pin 1 (+) and 4 (-)

Three-wire: Pin 1 (+) and 2 (-)

Replug PCB correctly

PCB AT03 not plugged in correctly at X4 and X5

Wire break

Output signal > 22 mA /220 mV Short-circuit

Control voltage does not reach the calculated value

Sensor element not calibrated

Sensor sensitivity < 30 %

No reaction of the output signal in spite of gas concentration

Power voltage not applied

Signal (Pin 4) not wired correctly

Check the wiring

Check the wiring

Calibrate sensor element

Replace sensor element

Measure tension at X4

Check the wiring

8 Cross-sensitivity Data

The cross sensitivity can be read from the table Technical Data (see section 9). The table doesn’t claim to be complete. Other gases can have an influence on the sensitivity, too. The indicated sensitivity data are only standard values referring to new sensor elements.

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Page 09

9 Technical Data

General sensor performances

Gas type

Sensor element

Measuring range

Temperature range

Pressure range

Humidity

Storage temperature range

Storage time

Mounting height

Stability & resolution

Repeatability

Long-term output drift

Response time

Life expectancy

Cross sensitivity

1

Carbon monoxide, CO

Hydrogen, H

2

Nitrogen dioxide, NO

2

Nitrogen monoxide, NO

Sulphur dioxide, SO

2

Electrical

Power supply

Power consumption (without options)

- Analog mode

Output signal

Analog output signal

Selectable: Current / tension

Starting point 0 / 20 % t

Chlorine (Cl

2

)

Electrochemical, diffusion

0 - 10 ppm (factory set)

0 – 20 ppm (optional)

- 10 °C to + 45 °C (14 °F to 113 °F)

Atmosphere ± 15 %

15 – 95 % RH non condensing

5 °C to 30 °C (41 °F to 86 °F)

Max. 6 months

0.2m (0.7ft.)

± 0,1 ppm

± 2 % of reading

< 2% signal loss/year

90

35

5

< 90 sec.

> 2 years/normal operating environment

Concentration (ppm)

300

300

20

Reaction (ppm Cl

0

~ 20

0

2

)

18 - 28 VDC/AC, reverse polarity protected (2wire mode only VDC)

22 mA, max. (0.6 VA)

(0) 4 – 20 mA, load  500  ,

(0) 2 - 10 V; load ≥ 50 k  proportional, overload and short-circuit proof

1

The table doesn’t claim to be complete. Other gases, too, can have an influence on the sensitivity. The mentioned cross sensitivity data are only reference values valid for new sensors.

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Physical

Enclosure stainless steel Type 5

Enclosure colour

Dimensions (W x H x D)

Weight

Protection class

Mounting

Enclosure Plastic, Type A

Flammability

Enclosure colour

Dimensions (W x H x D)

Weight

Protection class

Mounting

Cable entry

Wire connection

Wire distance

Guidelines

Stainless steel V2A

Natural, brushed

113 x 135 x 45 mm (5.35 x 4.5 x 1.8 in.)

Approx. 0.5 kg (1.1 Ib.)

IP55

Wall mounting, pillar mounting

Polycarbonate

UL 94 V2

Light grey RAL 7032

94 x 130 x 57 mm (3.7 x 5.12 x 2.24 in.)

Approx. 0.3 kg (0.6 Ib.)

IP 65

Wall mounting

Standard 1 x M 20

Screw-type terminal: 0.25 to 2.5 mm

24 to 14 AWG

2

Current signal ca. 500 m (1500 ft.)

Voltage signal ca. 200 m (500 ft.)

EMC Directive

CE

2004 / 108 / EEC

Approvals

Enclosure Type A

Warranty

Relay output

Alarm relay 1 (switching threshold 5 ppm)

Alarm relay 2 (switching threshold 8 ppm)

Power consumption

Heating

Temperature controlled

Ambient temperature

Power consumption

UL 508A

Two years material and workmanship,

12 months normal exposure for sensor element

Options

30 VAC/DC 0.5 A, potential-free, SPDT

30 VAC/DC 0.5 A, potential-free SPNO/SPNC

30 mA, (max. 0.8 VA)

3 °C ±2°C (37.5 °F ± 3.6 °F)

- 40 °C (- 40 °F)

0.3 A; 7.5 VA

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10 Figures

Application: Analog mode

Fig. 1

Controller

4-20 mA

24 V

0 V

7

Bus_B

6

5

Bus_A

4-20 mA_Inp

1

4 Analog_Out

2

3

2

1

X4

24 VDC_Out

0 V

24 VDC

3

4

5

X5

Transmitter

AT-1193

Two-wire connection

-

4 - 20 mA output signal without options

Page 11

Do not connect power supply at this pin.

(0 VDC, 24 VAC or 0VAC will destroy the transmitter.)

Controller

4-20 mA

24 V

0 V

7

6

5

4

3

2

1

X4

Bus_B

Bus_A

4-20 mA_Inp

Analog_Out

24 V_Out

R1

Option

Relay

0 V

24 VAC/DC

R2

Transmitter

AT-1193

Three-wire connection

- VDC output signal

- 0 – 20 mA output signal

- Relay output

- LCD display

- Heating

1

4

5

X5

2

3

Do not connect 24 VAC at pin 2 and pin 4 or +24 VDC at pin 2 and 0 VDC at pin 4!!

Short-circuit = R 10 Ohm burns up!!

Analog_Out

0 VAC/DC

24 VAC/DC

5 10

4

3

2

1

X4

Transmitter

AT-1193

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CL

2

Gas Transmitter


PCB

Fig. 3

3

2

5

4

7

6

1

X4

Anal. Output

= V DC

= mA

Manual

Calibration

Zero

Anal. Output

Start Point

= 20 %

= 0 %

0-20%

X5

1

2

3

4

5

Option

Relay

AT-1193

Selection analog output signal

Fig. 4

Jumper 0- 20 %

Not set

Set

Not set

Set

Calibration adapter

Fig. 5

Type: CONKIT-E/CH-AT

Jumper V-A

Not set

Not set

Set

Set

Output signal

0 – 20 mA

4 – 20 mA

0 – 10 V

2 – 10 V

X4

Page 12

Terminal block

X5

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Page 13

11 Part Disposal

Since August 2005 there are EC-wide directives defined in the EC Directive 2002/96/EC and in national codes concerning the waste electrical and electronic equipment and also regarding this device.

For private households there are special collecting and recycling possibilities. For this device isn’t registered for the use in private households, it mustn’t be disposed this way. You can send it back to your national sales organization for disposal. If there are any questions concerning disposal please contact your national sales organization.

Outside the EC, you have to consider the corresponding directives.

12 Notes and General Information

It is important to read this user manual thoroughly and clearly in order to understand the information and instructions. The PolyGard

®

transmitters must be used within product specification capabilities. The appropriate operating and maintenance instructions and recommendations must be followed.

Due to on-going product development, MSR and IN

TEC

Controls reserve the right to change specifications without notice. The information contained herein is based upon data considered to be accurate. However, no guarantee is expressed or implied regarding the accuracy of this data.

12.1 Intended Product Application

The PolyGard

®

Cl

2 transmitters are designed and manufactured for control applications and air quality compliance in commercial buildings and manufacturing plants.

12.2 Installers’ Responsibilities

It is the installer’s responsibility to ensure that all PolyGard

®

transmitters are installed in compliance with all national and local codes and OSHA requirements. Installation should be implemented only by technicians familiar with proper installation techniques and with codes, standards and proper safety procedures for control installations and the latest edition of the National Electrical Code (ANSI/NFPA70). It is also essential to follow strictly all instructions as provided in the user manual.

12.3 Maintenance

It is recommended to check the PolyGard

®

transmitter regularly. Due to regular maintenance any performance deviations may easily be corrected. Re-calibration and part replacement in the field may be implemented by a qualified technician and with the appropriate tools. Alternatively, the easily removable plug-in transmitter card with the sensor may be returned for service to IN

TEC

Controls.

12.4 Limited Warranty

MSR-Electronic-GmbH and IN

TEC

Controls warrants the PolyGard

®

transmitters for a period of (2) years from the date of shipment against defects in material or workmanship and 12 months normal exposure for sensor element. Should any evidence of defects in material or workmanship occur during the warranty period, IN

TEC

Controls will repair or replace the product at their own discretion, without charge.

This warranty does not apply to units that have been altered, had attempted repair, or been subject to abuse, accidental or otherwise. The warranty also does not apply to units in which the sensor element has been overexposed or gas poisoned. The above warranty is in lieu of all other express warranties, obligations or liabilities.

This warranty applies only to the PolyGard

PolyGard

®

transmitters.

®

transmitter. MSR-Electronic-GmbH and IN

TEC

Controls shall not be liable for any incidental or consequential damages arising out of or related to the use of the

If the PolyGard® transmitter needs to be returned to IN

TEC

Controls for service, an RMA number must be obtained prior to sending.

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User Manual

PolyGard

AT-1193

Electrochemical Chlorine Transmitter

User Manual

Electrochemical Chlorine Transmitter

1 Intended Use

2 Functional Description

3 Installation

4 Electrical Connection

5 Commissioning

6 Inspection and Service

7 Troubleshooting

8 Cross-sensitivity Data

9 Technical Data

10 Figures

11 Part Disposal

12 Notes and General Information

Related manuals

Table of contents

User Manual

PolyGard

AT-1193

Electrochemical Chlorine Transmitter

User Manual

Electrochemical Chlorine Transmitter

1 Intended Use

2 Functional Description

3 Installation

4 Electrical Connection

5 Commissioning

6 Inspection and Service

7 Troubleshooting

8 Cross-sensitivity Data

9 Technical Data

10 Figures

11 Part Disposal

12 Notes and General Information

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Table of contents