Manning EC-F2 NH3 Ammonia Sensor Instruction and Installation Manual

EC-F2-NH
3
Sensor for
Ammonia
Instruction and
Installation Manual
Rev H
MOUNT ENCLOSURE THIS END UP.
DO NOT BLOCK PERFORATED VENT HOLES.
®
SENSOR
®
Manning EC-F2-NH3 Sensor 18341 ECF2NH3 02/2005 REVH
11511 West 83rd Terrace
Lenexa, Kansas 66214
1.800.444.9935 or 913.894.1185
fax 913.894.1296
Copyright © 2005 Manning Systems, Inc. All Rights Reserved
email [email protected]
www.gasalarm.com
18341 ECF2NH3 02/2005 REVH
1
Contents
Serial number:
Section
Title
Page
1
System Description
3
2
Installation
4
3
Operation
7
4
Limited Warranty
9
Introduction
This manual has been prepared to help in the use and installation of the Manning Systems
EC-F2-NH3 (Electrochemical-Ammonia) Sensor. This manual will convey the operating
principles of the sensor, ensure proper installation, and demonstrate start-up and routine
maintenance procedures for the sensor.
This manual must be carefully followed by all individuals who have or will have the
responsibility for using or servicing the sensor. Warranties made by Manning Systems, Inc.
with respect to this equipment will be voided if the equipment is not used and serviced in
accordance with the instructions in this manual. If in doubt about a procedure, please contact
Manning Systems, Inc. before proceeding.
Manning EC-F2-NH3 Sensor 18341 ECF2NH3 02/2005 REVH Copyright © 2005 Manning Systems, Inc. All Rights Reserved
2
1
System Description
The Manning Systems EC-F2-NH3 Sensor is a three-wire,
4/20 mA sensor for ammonia available in ranges of
0-100 ppm, 0-250 ppm, 0-500 ppm, and 0-1,000 ppm.
The unit exhibits excellent accuracy and precision,
with negligible response to common interference gases
and dramatic changes in relative humidity. Reliable
trip levels as low as 25 ppm can be expected with the
0-100 ppm sensor. The unit exhibits extremely high
reliability with no moving parts.
Monitoring equipment must be configured to indicate a
fault if the signal is less than 1.5 mA. All signals over
20 mA must be considered a high gas concentration.
Specifications
Method: Electrochemical (diffusion)
Ranges: 0-100 ppm (standard)
0-250 ppm
0-500 ppm
0-1,000 ppm
Output: Isolated 4/20 mA, 700 ohms max at 24 VDC
Accuracy: ± 5% generally, but limited by available
calibration gas accuracy
Repeatability: ± 2% full scale
Operating Humidity: 5-100% RH (condensing). ATMOS
equipped® enviro-adaptive technology option required
for condensing conditions or refrigerated areas, and all
outdoor applications.
Operating Temperatures: –50o F to +120o F. ATMOS
equipped® enviro-adaptive technology option required
for refrigerated areas or outdoors.
Sensor Pressure Limits: 0-10 PSIG
Power Source: 24 VDC, 0.5 amp max
Gas Sampling: Diffusion method is standard
Weight: 3 lbs.
Dimensions: 6" high x 4" wide x 3.5" deep
Cable Recommendations: #18/3 shielded cable
(Belden #8770 or equal), cable runs <1,500 feet
Enclosure: NEMA 1, gasketed, #16-gauge steel
(standard). Stainless steel or explosion-proof designs,
including modified enclosures for low temperatures,
ventilation ducts, etc., are available (contact Manning
Systems). Note: The standard EC is for use in nonclassified areas only.
Manning EC-F2-NH3 Sensor 18341 ECF2NH3 02/2005 REVH Copyright © 2005 Manning Systems, Inc. All Rights Reserved
3
2
A
Installation continued
Locating the EC-F2-NH3
Sensor
Because each sensor is a point measurement, it is very
important that the sensor be located properly.
One of the most important considerations when installing
EC-F2-NH3 sensors is that they must be easily accessible for
calibration and maintenance. As a general rule, locate
sensors no closer than 1 foot from the ceiling.
If the primary application is personnel protection (representative concentration reading that an employee would be
exposed to), mount the sensor at a height in the breathing
zone of the employees. It would typically be about five feet
off the ground, which also allows easy access.
If the primary application is the fastest possible leak
detection, mount the sensor near the potential leak sources.
In the case of ammonia, this is usually near the ceiling as
ammonia vapor is lighter than air. In doing this, be aware
that the indicated concentration will not be representative
of personnel exposure and easy access for the required
calibration and maintenance could be compromised.
•
•
•
If mounting sensor outdoors, consider prevailing
wind direction and proximity to the most likely
source of leaks. Protect the sensor from sun and
rain as much as possible.
Never mount the sensor in CA (controlled
atmosphere) rooms because normal atmospheric
levels of oxygen are required for operation.
For highly critical locations, more than one sensor
should be installed in each room.
Very Important:
•
•
•
•
Sensor must be mounted vertically.
Never mount flat on a ceiling.
Enter enclosure only through existing hole in bottom.
Always make a drip loop in the conduit..
Figure 1: Mounting Dimensions for the EC-F2-NH3 Sensor
2"
5/16" diameter
No matter where the sensor is mounted, it must be easily
accessible.
General Mounting Considerations:
•
•
•
•
•
•
•
•
Must be easily accessible for calibration and
maintenance.
Mount the sensor close to the potential leak source.
If personnel protection is the primary application,
mount in the “breathing zone”.
Protect sensor from water, excessive humidity, and
wash-down.
Take air movement and ventilation patterns
into account.
To prevent electrical interference, keep sensor and
wire runs away from mercury vapor lights, variable
speed drives, and radio repeaters.
Protect sensor from physical damage (fork lifts, etc.)
Do not mount the sensor over a door in a
refrigerated area.
Manning EC-F2-NH3 Sensor 18341 ECF2NH3 02/2005 REVH Copyright © 2005 Manning Systems, Inc. All Rights Reserved
MOUNT ENCLOSURE THIS END UP.
DO NOT BLOCK PERFORATED VENT HOLES.
®
6 3/4"
SENSOR
®
4
2
Installation continued
Blast freezers: Never mount sensor above the coil. The
ideal location, when possible, is below the bottom of
the coil. Try to put in return air and protect the unit
from being damaged by product loading and unloading.
Keep it away from warm, moist air during defrost.
Usually four or five feet off the ground is the best
location.
Penthouses:
Multi-Coil (defrost one coil at a time): In this case the
best location is usually in the center of the penthouse
four or five feet above the grate.
Ceiling Hung Evaporators: When mounting EC-F2-NH3
sensors near evaporators, mount the sensor no higher
than two feet below the top of the evaporator coil.
DO NOT mount in high air flow (1,200 feet/minute
maximum). NEVER mount the sensor on evaporators as
vibration can damage the sensor.
Other Locations: When mounting EC-F2-NH3 sensors in
locations such as roof top air units, duct-work, attic
spaces, makeup air intakes, etc., contact Manning
Systems for application assistance and
recommendations.
Single Coil (or when all coils defrost at the same time):
In this case high moisture conditions can occur and the
sensor should be mounted one foot above the grate.
Engine Rooms: The EC-F2-NH3 sensor should be
mounted in a cool part of the room, if possible. Keep
the sensor away from hot air exhausting from electric
motors or other machinery. Usually the best location is
four or five feet above the floor in a location where the
room exhaust fan will move air across the sensor from
the potential leak source.
Manning EC-F2-NH3 Sensor 18341 ECF2NH3 02/2005 REVH Copyright © 2005 Manning Systems, Inc. All Rights Reserved
5
2
B
Installation continued
Wiring
Figure 2 presents wiring information for the EC-F2-NH3
sensor.
Electrical wiring must comply with all applicable codes.
Plant equipment that may be involved and operating
conditions should be discussed with local operating
personnel to determine if any special needs should be
taken into account.
Almost all start-up problems are due to improper wiring
or monitor configuration. Please follow these guidelines
carefully.
Always use three conductor, insulated, stranded,
shielded copper cable. Use only three conductor cable,
not two cables of two conductor wire.
Do not pull sensor wiring with AC power cables. This
will cause electrical interference. Be sure there are no
breaks or splices in sensor wiring runs. If cable runs
cannot be made without a splice, all connections must
be soldered. Soldering should be done using a rosin flux
to tie the connecting ends of sensor wires to ensure a
positive and long-lasting contact.
Output: Circuit board mounted sensor provides a linear
4/20 mA output. Monitoring equipment may have a
maximum input impedance of 250 ohms.
Cable Recommendation: #18/3 shielded cable (Belden
#8770 or equivalent). Length of cable to sensor should be
no greater than 1,500 feet. Use only the existing punched
holes for connections to the sensor.
Monitoring: The EC-F2-NH3 Ammonia Sensor may be
monitored by the Manning Systems GM-10, GM-4, GM-1,
GM-JR or other appropriately configured system.
Monitoring equipment must be configured to indicate a
fault if the signal is below 1.5 mA. All signals over 20 mA
must be considered a high gas concentration.
Figure 2: Wiring Diagram for the EC-F2 Sensor
SPAN
SENSOR
®
Ground the shield at the main control panel. Connect
the shield wire in the sensor terminal block labeled
SHLD.
TEST(+)
Tape all exposed shield wire at the sensor to insulate it
from the enclosure.
Mount sensor enclosures through the flange holes as
shown in Figure 1, and always mount vertically.
Electrical Power: 24 VDC regulated, 30 mA. With an
ATMOS equipped® enclosure the current draw is
500 mA max.
Manning EC-F2-NH3 Sensor 18341 ECF2NH3 02/2005 REVH Copyright © 2005 Manning Systems, Inc. All Rights Reserved
+24
SIG
SIG
GND
+ 24
SHLD
GND
Make drip loops for cables going into sensor housings.
When heated enclosures are used, follow the special
mounting instructions on the enclosure (...This End Up).
TEST(-)
SHLD
All penetrations into a refrigerated room should be
sealed to prevent condensate from forming in the
conduit and dripping into the sensor enclosure. Silicone
should not be used near the sensor, because silicone
can damage the sensor.
40 to
200 MVDC
E/C-F2
White— Connects to signal input
of monitoring equipment
Red— Connects to 24 VDC power
supply positive side (40-500 mA
depending on environment)
Black—Connects to 24 VDC
ground side
Outside bare wrap—Connects to
case ground of monitoring equipment
(earth ground)
6
3
A
Operation
Start-Up Procedures
Before applying power, make a final check of all wiring
for continuity, shorts, grounds, etc. (see Figure 3,
Note 5). It is usually best to disconnect external alarms
and other equipment from the sensor until the initial
start-up procedures are completed.
After power-up, allow 24 hours for the system to
stabilize before testing the sensors. Because sensors are
normally located at a distance from the main unit, the
test time required and accuracy of the response checks
will be improved if two people perform the start-up
procedures and use radio contact.
Start-Up Test:
1)
2)
B
One person exposes each sensor to a small
amount of the gas that is being monitored.
The second person stays at the control unit to
determine that each sensor, when exposed to the
gas fumes, is connected to the proper input and
responds, causing appropriate alarm functions.
•
•
Apply span gas at 0.8 L/min (span gas must be in
air, not nitrogen or other carrier).
After span gas has been on sensor for two
minutes, adjust the span pot until the correct
output is achieved (see Figure 3, Note 1).
Figure 3: Checking sensor output, power supply voltage,
and zero and span adjustments to the EC-F2 Sensor
Note 1: Span adjustment
Note 5: Sensor cable plugs
in here. Verify that sensor
is plugged in properly and
cable is secured.
Note 2: Zero adjustment
NH3
PPM
MODEL: EC-F2-NH3
S/N: 0000
ZERO
SPAN
Calibration
SENSOR
The EC-F2-NH3 Sensor comes factory calibrated and should
require minimal adjustments after installation. There are
two pots on the preamp that are used for calibrations.
®
TEST(+)
Calibration kits are available from Manning Systems. Each
kit contains certified calibration gas and complete, detailed
instructions for calibration of all Manning Systems sensors.
40 to
200 MVDC
Zero Calibration: After the unit is installed and has
been powered up for a minimum of 24 hours, the unit
should be zero calibrated by the following:
•
Be sure the unit is in clean air.
• Adjust the zero pot until the sensor outputs 40 mV
from Test (–) to Test (+) (see Figure 3, Notes 2 and 4).
Span Calibration: The unit is factory calibrated and
normally does not need to be spanned upon initial
installation. Do not adjust the span pot without certified
calibration gas! If span adjustment is required, the
following procedure will span the unit:
•
Perform zero adjustment before spanning.
GND
+24
SIG
SIG
GND
+ 24
SHLD
SHLD
TEST(-)
24.0
40-200 mV
VDC
mVDC
Black
-
Red
+
Note 3: Power supply voltage
Manning EC-F2-NH3 Sensor 18341 ECF2NH3 02/2005 REVH Copyright © 2005 Manning Systems, Inc. All Rights Reserved
E/C-F2
Black
-
Red
+
Note 4: Sensor output
7
3
C
Operation continued
Troubleshooting
If the sensor output is 0 mA: First, verify +24 VDC at
the sensor terminal block (see Figure 3, Note 3).
Second, check voltage between Test (–) and Test (+)
(see Figure 3, Note 4). Voltage should be in the range of
40 mV to 200 mV corresponding to an actual current
flow of 4 mA to 20 mA. If this voltage is 0 mV, the signal
has no path to ground. Check monitoring equipment
connections and configuration. Input impedance must
be 250 ohms or less.
Electrical Interference: This sensor has been designed
to be highly resistant to EMI/RFI using multiple stages
of filtering and protection. However, in extreme
environments, some noise pickup can occur directly
through the sensor. Ensure that the bare shield wire of
the instrument cable is connected to the terminal block
marked SHLD at the sensor (not touching the metal
enclosure) and properly grounded at the readout unit.
Interference Gases: The EC-F2-NH3 is designed to be
quite specific to ammonia. However, some other gases
can affect the reading. Phosphene, methyl mercaptan,
and hydrogen can give a slight upscale indication.
Bromine, ozone, fluorine, chlorine, and nitrogen dioxide
can give a slight down-scale indication. Contact Manning
Systems if any of these gases are present in your
application.
D
Maintenance
For proper operation it is essential that the test and
calibration schedule be followed. Manning Systems
recommends the following maintenance schedule:
•
Calibration should be performed with certified
calibration gas every six months or after major
exposure to a leak. Calibration kits are available
from Manning Systems.
•
Response test once between calibrations, i.e. at
three month intervals. Expose sensor to
ammonia/water solution to verify proper sensor
•
response and alarm functions. Test more
frequently in highly critical applications. The
response test is not required if multiple electrochemical sensors are installed in the same room.
All tests and calibrations must be logged.
Sensor Life: These electrochemical cells are extremely
reliable, but several things can cause the cell chemicals
to become depleted including:
•
a period of time,
•
exposure to high temperatures,
•
exposure to varying concentrations of the
target gas,
•
exposure to high moisture for extended periods
without proper sensor enclosure.
When the cell becomes depleted, the unit will give no
indication of failure other than that the sensor will not
respond. For this reason it is absolutely essential that
these units be exercised with a gas sample on a
regular and timely basis.
Typical sensor life in a refrigerated area will be three to
four years. Typical life in a non-refrigerated area will be
one and a half to two years. Exposure to high levels of
ammonia will shorten these times. In addition to timely
response checks, a preventative maintenance program
of periodic cell replacement should be implemented.
When the cell becomes depleted, a replacement cell can
be obtained from Manning Systems. Simply unplug the
ribbon cable from the pins labeled Sensor, pull the old
cell from the spring clip, discard the old cell and replace
it with a new one.
The sensor should be calibrated after a 24 hour warmup period.
E
Replacement Parts
For replacement parts, contact Manning Systems. Be
sure to give serial number of unit and model number.
Manning EC-F2-NH3 Sensor 18341 ECF2NH3 02/2005 REVH Copyright © 2005 Manning Systems, Inc. All Rights Reserved
8
4
1.
Limited Warranty
Limited Warranty
Manning Systems, Inc. (“Manning”) warrants to
the original purchaser and/or ultimate customer
(“Purchaser”) of Manning’s Products (“Product”)
that if any part thereof proves to be defective in
material or workmanship within eighteen (18)
months of the date of shipment by Manning or
twelve (12) months from the date of first use by
the purchaser, whichever comes first, such
defective part will be repaired or replaced, free of
charge, at Manning’s discretion if shipped prepaid
to Manning at 11511 W. 83rd Terrace, Lenexa,
Kansas 66214, in a package equal to or in the
original container. The Product will be returned
freight prepaid and repaired or replaced if it is
determined by Manning that the part failed due to
defective materials or workmanship. The repair or
replacement of any such defective part shall be
Manning’s sole and exclusive responsibility and
liability under this limited warranty.
2.
Exclusions
A. If gas sensors are part of the Product, the gas
sensor is covered by a twelve (12) month
limited warranty of the manufacturer.
B. If gas sensors are covered by this limited
warranty, the gas sensor is subject to
inspection by Manning for extended exposure
to excessive gas concentrations if a claim by
the Purchaser is made under this limited
warranty. Should such inspection indicate that
the gas sensor has been expended rather than
failed prematurely, this limited warranty shall
not apply to the Product.
C. This limited warranty does not cover
consumable items, such as batteries, or items
subject to wear or periodic replacement,
including lamps, fuses, valves, vanes, sensor
elements, cartridges, or filter elements.
3.
Warranty Limitation and Exclusion
Manning will have no further obligation under this
limited warranty. All warranty obligations of
Manning are extinguishable if the Product has
been subject to abuse, misuse, negligence, or
accident or if the Purchaser fails to perform any
of the duties set forth in this limited warranty or
if the Product has not been operated in
accordance with instructions, or if the Product
serial number has been removed or altered.
4.
Disclaimer of Unstated Warranties
THE WARRANTY PRINTED ABOVE IS THE ONLY
WARRANTY APPLICABLE TO THIS PURCHASE.
ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING, BUT NOT LIMITED TO,
THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE ARE HEREBY
DISCLAIMED.
5.
Limitation of Liability
IT IS UNDERSTOOD AND AGREED THAT
MANNING’S LIABILITY, WHETHER IN
CONTRACT, IN TORT, UNDER ANY WARRANTY,
IN NEGLIGENCE OR OTHERWISE SHALL NOT
EXCEED THE AMOUNT OF THE PURCHASE
PRICE PAID BY THE PURCHASER FOR THE
PRODUCT AND UNDER NO CIRCUMSTANCES
SHALL MANNING BE LIABLE FOR SPECIAL,
INDIRECT, OR CONSEQUENTIAL DAMAGES.
THE PRICE STATED FOR THE PRODUCT IS A
CONSIDERATION LIMITING MANNING’S
LIABILITY. NO ACTION, REGARDLESS OF
FORM, ARISING OUT OF THE TRANSACTIONS
UNDER THIS WARRANTY MAY BE BROUGHT BY
THE PURCHASER MORE THAN ONE YEAR
AFTER THE CAUSE OF ACTIONS HAS
OCCURRED.
Manning EC-F2-NH3 Sensor 18341 ECF2NH3 02/2005 REVH Copyright © 2005 Manning Systems, Inc. All Rights Reserved
9