Sensepoint XCD_IOM.pdf

Technical Manual

Sensepoint XCD Gas Detector

Sensepoint XCD Technical Manual SPXCDHMANEN Issue 8

1 Safety Ensure that this Operating Manual is read and understood BEFORE installing / operating / maintaining the equipment. Pay particular attention to Warnings and Cautions. All document Warnings are listed here and repeated where appropriate at the start of the relevant chapter(s) of this Operating Manual. Cautions appear in the sections/sub-sections of the document where they apply.

WARNINGS

Sensepoint XCD is designed for installation and use in Zone 1 or 2 hazardous areas in many countries including Europe and for Class 1 Division 1 or 2 area applications in North America.

Installation must be in accordance with the recognized standards of the appropriate authority in the country concerned.

Access to the interior of the detector, when carrying out any work, must only be conducted by trained personnel.

Before carrying out any work ensure local regulations and site procedures are followed. Appropriate standards must be followed to maintain the overall certification of the detector.

For installations where conduit is used, and the sensor is mounted directly to the Sensepoint XCD, there must be a “Seal Fitting” installed for each of the cable gland entries within 18 inches of the Sensepoint XCD. The total distance of the location of these Seal Fittings is 18 inches. (e.g. If all 3 gland entries are to be used, 3 Seal Fittings should be located, each within 6 inches of the wiring entrance).

In order to maintain electrical safety, the product must not be operated in atmospheres with more than 21% oxygen. Oxygen deficient atmospheres (Combustible: less than 10%V/V, Toxic: less than 6%V/V) may suppress the sensor output.

If using an anti-seize compound, the threads should be thinly coated with an approved silicone free compound e.g. petroleum jelly

To reduce the risk of ignition of hazardous atmosphere, de-classify the area or disconnect the equipment from the supply circuit before opening the detector enclosure. Keep assembly tightly closed during operation.

Never attempt to open a junction box/enclosure or replace/refit the sensor in potentially hazardous atmospheres while power is still applied to the transmitter.

The detector must be earthed/grounded for electrical safety and to limit the effects of radio frequency interference. Earth/ground points are provided inside and outside the unit. The internal grounding shall be used as the primary equipment ground. The external terminal is only a supplemental bonding connection where local authorities permit or require such a connection.

Ensure that all screens/instrument earth/clean earth wiring is earthed/grounded at a single point (either at the controller or detector - BUT NOT BOTH) to prevent false readings or alarms that may occur due to potential earth/ground loops.

Take care when handling sensors as they may contain corrosive solutions.

Do not tamper with or in any way disassemble the sensor.

Do not expose to temperatures outside the recommended ranges.

Do not expose sensors under storage conditions to organic solvents or flammable liquids.

At the end of their working life, replacement electrochemical sensors for oxygen and toxic gas must be disposed of in an environmentally safe manner. Disposal should be according to local waste management requirements and environmental legislation.

Alternatively, old replaceable sensors may be securely packaged and returned to Honeywell Analytics clearly marked for environmental disposal.

Electrochemical sensors should NOT be incinerated as this action may cause the cell to emit toxic fumes.

Refer to the local or national regulations relative to the installation at the site. For Europe see EN60079-29-2, EN60079-14, EN45544-4 and EN61241-14.

This equipment is designed and constructed as to prevent ignition sources arising, even in the event of frequent disturbances or equipment operating faults.

The sensor head must be fitted with the supplied weather protection, and mounted so that the sinter is pointing downward to provide ingress protection IPX6.

The weather protection is a potential electrostatic charging hazard. The manufacturer’s instructions should be observed.

NOTE: The control card must have a suitably rated fuse.

Special conditions for safe use – Sensepoint XCD with Flammable Sensor:

1. Compliance with the Technical Manual is required for safe use of Sensepoint XCD.

2. The following environmental conditions of operation apply for the use of the Sensepoint XCD:

Temperature: -25 °C to +55 °C Relative humidity: 0 % to 90 % Pressure: 80 kPa to 120 kPa (extended range for temperature and humidity according to EN 60079-29-1)

3. In order to minimise measurement errors, the ambient conditions (temperature, pressure, humidity) during the calibration of the measuring channels should be as close as possible to those to be encountered during normal operation.

4. Measuring values from -4 %LEL to +2 %LEL are indicated as "0 %LEL" (4 mA analogue output) in the measuring mode. Below -4 %LEL is indicated as “-0” (3.5 mA) and below -5 %LEL (1 mA) a fault “F03” message is given additionally.

5. Measuring values beyond the end of the measuring range are indicated as 100 %LEL and alternately blinking “W04” and “W05”. The analogue output is set to 22 mA.

6. Special states for Analogue output:

• ≤ 1 mA: System and other faults

• 2 mA: Start up, Inhibit

• 3.5 mA Under range

• 22 mA: Over range

7. If the Sensepoint XCD is operating in conjunction with a control unit to analyse the measuring signal, the control unit must operate correctly when the XCD transmits a value outside of the measuring range.

8. If substances (e. g. sensor poisons) that could interfere with and affect the sensitivity of the sensing device are to be expected in the atmosphere to be monitored which may cause a rapid change of sensitivity, the calibration interval shall be reduced.

9. Before use, ensure that any alarm delay set is suitable for the intended application.

10. Some types and concentrations of dust in the measured atmosphere may impair the measuring function of the gas detector.

11. Use only with the Weather Protection Cup accessory (P/N SPXCDWP).

12. The EC-Type examination certificate only applies to the measuring of Methane, Ethane and Propane in air and up to the Lower Explosive Limit (LEL). Additional

Special conditions for Sensepoint XCD with Oxygen Sensor:

1. Compliance with the Technical Manual is required for safe use of Sensepoint XCD.

2. The following environmental conditions of operation apply for the use of Sensepoint XCD with oxygen sensor:

Temperature: -20 °C to +55 °C Relative humidity: 20 % to 90 % Pressure: 80 kPa to 120 kPa (extended range for temperature according to EN 50104)

3. In order to minimise measurement errors, the ambient conditions (temperature, pressure, humidity) during the calibration of the measuring channels should be as close as possible to those to be encountered during normal operation.

4. Measuring values from 20.7 % (v/v) up to 21.1 % (v/v) are indicated as "20.9" % (v/v) oxygen during operation in the measuring mode. Measuring values below 3 % (v/v) oxygen are indicated as 0 % (v/v) oxygen (analogue output 4 mA).

5. Measuring values above the end of the measuring range are indicated as 25 % (v/v) O2 and blinking “W04”. The analogue output is set to 22 mA.

Fault messages are shown on the display as “F-XX” and the analogue output is set to 1 mA.

6. Special states for Analogue output:

• ≤ 1 mA: System and other faults

• 2 mA: Start up, Inhibit

• 22 mA: Over ranging

7. If the Sensepoint XCD is operating in conjunction with a control unit to analyse the measuring signal, the control unit must operate correctly when the XCD transmits a value outside of the measuring range.

8. Use without Weather Protection Cup accessory (P/N SPXCDWP), only.

9. If substances (e. g. sensor poisons) that could interfere with and affect the sensitivity of the sensing device are to be expected in the atmosphere to be monitored which may cause a rapid change of sensitivity, the calibration interval shall be reduced.

10. Before use, ensure that any alarm delay set is suitable for the intended application.

11. Before use, consideration must be given to cross sensitivity to other gases. Refer to the Sensepoint XCD Technical Manual and the Sensor Datasheet for cross interference data.

12. Some types and concentration of dust in the measured atmosphere may impair the measuring function of the gas detector.

13. The Type Examination Certificate applies to the measurement of oxygen up to 25 % (v/v).

2 Information

This manual is for use with the Sensepoint XCD range transmitters only.

The Start-up/Surge/In rush current is dependant on the type of power supply used. The typical start-up current for Sensepoint XCD is less than 800mA. Measure the start-up current using the specific power supply before installation to ensure suitability for your application.

Honeywell Analytics can take no responsibility for installation and/or use of its equipment if not done so in accordance with the appropriate issue and/or amendment of the Operating Manual.

The reader of this Operating Manual should ensure that it is appropriate in all details for the exact equipment to be installed and/or operated. If in doubt, contact Honeywell Analytics for advice.

The following types of notices are used throughout this Operating Manual:

WARNING

Identifies a hazardous or unsafe practice which could result in severe injury or death to personnel.

Caution: Identifies a hazardous or unsafe practice which could result in minor injury to personnel, or product or property damage.

Note: Identifies useful/additional information.

Every effort has been made to ensure the accuracy of this document, however, Honeywell Analytics can assume no responsibility for any errors or omissions in this document or their consequences.

Honeywell Analytics would greatly appreciate being informed of any errors or omissions that may be found in the content of this document.

For information not covered in this document, or if there is a requirement to send comments/corrections about this document, please contact Honeywell Analytics using the contact details given on the back page.

Honeywell Analytics reserve the right to change or revise the information supplied in this document without notice and without obligation to notify any person or organization of such revision or change. If information is required that does not appear in this document, contact the local distributor/agent or Honeywell Analytics.

3 Table of contents

1 Safety 2 2 Information 5 3 Table of contents 6 4 Introduction 8

4.1 Transmitter 9

4.2 Flammable, Toxic Oxygen Gas sensors 9

4.3 Accessories 10

4.4 Options 12

4.4.1 Modbus® 12

5 Installation 14

5.1 Mounting and location 15

5.2 Mounting the transmitter 15

5.3 Installing the sensor 17

6 Electrical connections 18

6.1 Transmitter Wiring 19

6.2 Terminal connections 20

6.3 Power 21

6.3.1 For ATEX/IECEx/AP Versions 21

6.3.2 For UL/CSA Versions 22

6.4 Cabling 23

6.5 Cable and Earth/Ground regimes 23

6.6 Ground Terminal Wiring 24

7 Default configuration 25 8 Normal Operation 26

8.1 Display Screen 26

8.2 System Status 27

8.3 Magnetic Wand Activation 28

8.4 Operation Mode Structure 28

9 First time switch on (Commissioning) 29 10 Response Check and Calibration 31

10.1 Zeroing and span calibration 31

10.2 Zeroing and span calibration of Hydrogen Sulfide sensors 34 11 General Maintenance 35

11.1 Operational Life 35

12 Servicing 36

12.1 Sensor replacement 36

12.2 Replacing Modules within the Transmitter 38

12.3 Faults and Warnings 39

13 Menu’s and Advanced Configuration 40

13.1 Abort Function 40

13.3 Sensor / Gas Selection 45

13.3.1 Sensor Selection 45

13.3.2 Gas Selection 45

13.4 Review Mode 47

14 General specification 50 15 Ordering information 52 16 Warranty statement 54 17 Installation Drawing 55

17.1 Mechanical Installation Drawing 55

17.2 Electronic Connection Drawing 56

17.3 Duct Mounting Drawing 57

17.4 Collecting Cone Drawing 58

17.5 Mounting Bolt Assy Drawing 59

17.6 Mounting Bracket Drawing 60

18 Certification 61

18.1 China GB Ex and PA 61

18.2 Korea KTL 64

18.3 European ATEX 65

18.4 International IEC 68

18.5 ATEX Name Plate 70

18.6 UL Name Plate 71

18.7 Sensepoint XCD Warning Tag 72

18.8 Sensor Cartridges Label 73

18.9 EC Declaration of Conformity 74

19 Cross Interference and Cross Calibration 75

19.1 Cross Interference Table for Toxic and Oxygen 75

19.2 Cross Calibration Flammable Gas Detector 76

19.3 Meter Multiplication Factors for Sensepoint XCD-IR Propane 79 Appendix A - Modbus® Protocol A-2 80 Appendix A - A.2 Modbus Registers 81

Locking Grub screw

Sensor Retainer

Internal Earth Point

Enclosure

External Earth Point (x2)

Field Cable/Conduit Entries (x2)

Locking Grub screw

Cover

Seal

Display Module

Terminal Module

Sensor Socket

Plug-In Sensor Cartridge

Ex d Plug

Integral mounting plate

Certification Label

4 Introduction The Sensepoint XCD (“Exceed”) comprises a gas detector transmitter and a choice of sensors for detecting flammable gas, toxic gas and oxygen. The construction of Sensepoint XCD allows it to be used in hazardous area locations; it may also be used in other areas not classified as hazardous.

As well as a comprehensive range of Sensepoint XCD sensors, a wide range of existing Honeywell Analytics sensors may be used with the Sensepoint XCD transmitter to detect a broader range of target gases (please contact Honeywell Analytics for further details).

The transmitter features a display and three programmable relays for controlling external equipment e.g. alarms, sirens, valves or switches. The transmitter provides an industry standard 3-wire, 4-20mA source or sink output for connection to a dedicated gas detection control system or PLC.

Calibration and maintenance is carried out using a Magnetic Wand, this allows a single user to undertake routine maintenance without needing to access internal components.

Sensepoint XCD is suitable for use in Zone 1 or 2 hazardous areas (International) or Class I Division 1 or 2 area applications (North America).

Sensepoint XCD comprises of the main parts as shown below.

Diagram 1. – Exploded View

4.1 Transmitter

The transmitter enclosure has three threaded entries. The two cable/conduit entries either side of the upper part of the transmitter housing are for connecting the power source, signal output and relay contacts to associated signalling equipment. The bottom entry allows direct connection of the sensor socket. There is a mounting plate incorporated into the transmitter housing allowing for various mounting configuration options.

A local LCD provides gas type, concentration, alarm and operating status. The display provides numerical, bar graph and icon information.

Diagnostic information may also be displayed when the transmitter is interrogated using a magnet. The transmitter cover has a glass window which allows use of the Magnetic Wand to activate the three user interface magnetic switches that are located on the front of the display module. The magnet also enables a non intrusive, one-man calibration and configuration facility for the Sensepoint XCD.

4.2 Flammable, Toxic and Oxygen Gas sensors

The Sensepoint XCD transmitter is designed to work with a variety of gas sensors for detecting flammable gases. Sensepoint XCD sensors use NDIR infrared and electro-catalytic technologies.

In addition, the Sensepoint XCD transmitter is designed to work with a wide range of toxic gas sensors. Sensepoint XCD sensors for monitoring toxic gas or oxygen use electro-chemical cell (ECC) technology. Oxygen sensors measure Oxygen deficiency and enrichment in the range 0 - 25 %V/V. They do not measure inertization.

Diagram 2: Sensepoint XCD Display and Magnetic Switches

Measuring Units

Inhibit Icon

Test Pass Icon

Warning/ Fault Icon

Magnetic Wand activation Icon

Gas Type

Magnetic

MENU/ENTER

Switch

Magnetic UP Switch

Magnetic

DOWN

Switch

Gas Reading

Bar Graph

Alarm Icon

Full Scale

Calibration Icon

4.3 Accessories

A range of accessories are available to allow use of Sensepoint XCD in a wide variety of applications. These including mounting brackets, maintenance tools, weather housings, flow housing, collecting cone, duct mounting kit and sensor junction boxes.

Diagram 3: Sensepoint XCD Flammable, Toxic and Oxygen Sensor Cartridge

Standard Weather Protection Magnetic wand

The Standard Weather Protection (P/N:

SPXCDWP) is designed to protect the sensor from changes in environmental conditions. This is recommended to be fitted to a Sensepoint XCD sensor for outdoor exposed applications, (supplied with XCD kit).

The magnetic wand (P/N: SPXCDMAG) is used as a tool to allow the user to communicate with the Sensepoint XCD transmitter for the purpose of configuration, calibration and interrogating system status, (supplied with XCD kit).

Pipe mounting bracket Gassing Cap

The Pipe Mounting Bracket (P/N: SPXCDMTMB) is an optional accessory and may be used to allow the Sensepoint XCD to be installed onto a dedicated mounting post or existing structure at the desired location.

The Gassing Cap (P/N: S3KCAL) is an optional accessory that may be temporarily fitted to the sensor in place of the Weather Protection for Gas Response checking during commissioning and routine maintenance.

Collecting cone Duct mounting kit

The Collecting Cone (P/N: SPXCDCC) is an optional accessory that may be fitted to the Weather Protection. The collecting cone is designed for use with lighter than air.

The Duct Mounting Kit (P/N: SPXCDDMK) is an optional accessory that is designed for applications to allow the monitoring for the presence of gas inside a Heating, Ventilation or Air Conditioning (HVAC) duct is required.

Sunshade Deluge Cover Typical Mounting Arrangement

The XCD Sunshade Deluge Cover (P/N:

SPXCDSDP) is an optional accessory that may be fitted to the integral mounting plate. This accessory is designed to protect XCD from overheating in exposed hot and arid climates, particularly offering additional protection from thermal shock in Tropical Environments

4.4 Options

4.4.1 Modbus® (Modbus option not tested as part of the performance approvals)

One of the most common field buses in the industry, the optional Modbus® interface allows the XCD to connect to a bus of devices and transmit data to PLCs or controllers (see Appendix A). Connections to the XCD are made through a pluggable terminal block on the Modbus® interface circuit board. Modbus® RTU protocol uses ASCII/Hex protocols for communication. and allows all transmitter/sensor front panel functions to be transmitted using this industrial fieldbus. Modbus® protocol is a Master-Slaves protocol. Only one master (at the same time) is connected to the bus and one or up to 32 slave nodes are also connected to the same serial bus. Modbus® communication is always initiated by the master. The slave nodes will never transmit data without receiving a request from the master node. The slave nodes will never communicate with each other. The master node initiates only one Modbus® transaction at the same time.

Modbus® option is available only for selected gases. Please refer to chapter 15 Ordering information.

Note: MODBUS® is a registered trademark of Schneider Automation Inc.

(MODBUS ID SETTING)

Set id>>Set ModBus slave ID>>Set Baud rate>>Set Parity

1) Slave ID shall be set 1~247

2) Baud rate setting 9600 or 19200

3) Parity setting (No, Even, Odd) From the Configuration Mode screen, select ‘✓’. To set the ModBus Slave ID, use the updown ‘▲▼’switches to move to the desired position and use ‘✓’ to select it. Again, using the‘▲▼’switches, increment or decrement the value until the desired value appears, selects the value and moves to the next setting.

The communications baud rate and Parity Setting can also be set from this screen by using the‘▲▼’ switches to navigate to the baud rate display then selecting ‘✓’. Using the ‘▲▼’switches, highlight the proper baud rate or parity setting and select‘✓’. Default is Slave ID 1, 19200bps and even parity.

Note: Set ID menu is available only for XCD equipped with Modbus option.

5 Installation

WARNINGS

Sensepoint XCD is designed for installation and use in Zone 1 or 2 hazardous areas in many countries including Europe and for Class 1 Division 1 or 2 area applications in North America.

Installation must be in accordance with the recognized standards of the appropriate authority in the country concerned.

Access to the interior of the detector, when carrying out any work, must only be conducted by trained personnel.

Before carrying out any work ensure local regulations and site procedures are followed.

Appropriate standards must be followed to maintain the overall certification of the detector.

Care should be taken when removing and refitting the Sensepoint XCD plug-in Sensor to the Sensor Socket so that damage to the connection pins can be avoided.

For installations where conduit is used, and the sensor is mounted directly to the Sensepoint XCD, there must be a “Seal Fitting” installed for each of the cable gland entries within 18 inches of the Sensepoint XCD. For installations where the sensor will be mounted remotely from Sensepoint XCD, an additional “Seal Fittings” will be required: One at each of the conduit entries for the power/signal/relay contact outputs and one at the sensor wiring entrance. The total distance of the location of these Seal Fittings is 18 inches. (e.g. If all 3 gland entries are to be used, 3 Seal Fittings should be located, each within 6 inches of the wiring entrance).

If using an anti-seize compound, the threads should be thinly coated with an approved silicone free compound e.g. petroleum jelly

To reduce the risk of ignition of hazardous atmosphere, de-classify the area or disconnect the equipment from the supply circuit before opening the detector enclosure. Keep assembly tightly closed during operation.

Never attempt to open a junction box/enclosure or replace/refit the sensor in potentially hazardous atmospheres while power is still applied to the transmitter.

The detector must be earthed/grounded for electrical safety and to limit the effects of radio frequency interference. Earth/ground points are provided inside and outside the unit.

Ensure that all screens/instrument earth/clean earth wiring is earthed/grounded at a single point (either at the controller or detector - BUT NOT BOTH) to prevent false alarms due to earth/ground loops.

Take care when handling sensors as they may contain corrosive solutions.

Do not tamper with or in any way disassemble the sensor.

Do not expose to temperatures outside the recommended ranges.

Do not expose sensors under storage conditions to organic solvents or flammable liquids.

At the end of their working life, replacement electrochemical sensors for oxygen and toxic gas must be disposed of in an environmentally safe manner. Disposal should be according to local waste management requirements and environmental legislation.

Alternatively, old replaceable sensors may be securely packaged and returned to Honeywell

Analytics clearly marked for environmental disposal.

Electrochemical sensors should NOT be incinerated as this action may cause the cell to emit toxic fumes.

Refer to the local or national regulations relative to the installation at the site. For Europe see EN60079-29-2, EN60079-14, EN45544-4 and EN61241-14.

This equipment is designed and constructed as to prevent ignition sources arising, even in the event of frequent disturbances or equipment operating faults.

The sensor head must be fitted with the supplied weather protection, and mounted so that the sinter is pointing downward to provide ingress protection IPX6.

The weather protection is a potential electrostatic charging hazard. The manufacturer’s instructions should be observed.

NOTE: The control card must have a suitably rated fuse.

5.1 Mounting and location

Gas detectors should be mounted where a potential hazard of gas is most likely to be present. The following points should be noted when locating gas sensors.

• When locating detectors consider the possible damage caused by natural events e.g.

rain or flooding.

• Consider ease of access to the gas detector for functional testing and servicing.

• Consider how escaping gas may behave due to natural or forced air currents.

Note: The placement of gas detectors should be determined following the advice of experts having specialist knowledge of gas dispersion, experts having knowledge of the process plant system and equipment involved, safety and engineering personnel. The agreement reached on the location of detectors should be recorded.

5.2 Mounting the transmitter

The Sensepoint XCD transmitter has an integral mounting plate consisting of four mounting holes on the transmitter body. The transmitter may be fixed directly to a surface mounting, or to a horizontal or vertical pipe/structure, 40.0-80.0mm (1.6 to 3.1 inches) in diameter/cross section. The Pipe Mounting Bracket accessory (optional accessory) may be used for this purpose.

Caution: The location of gas detectors should be made in accordance with any relevant local and national legislation, standards or codes of practice. Always replace sensors with a sensor of the same type.

Diagram 4: Outline and mounting dimensions

All dimensions are shown in mm.

M20 entries for ATEX/IECEx/AP Versions and 3/4"NPT cable/conduit entries on UL/CSA versions

To mount the Sensepoint XCD transmitter to a Vertical or Horizontal pipe/structure, use the optional XCD Mounting Kit and following procedure:

1. Fit the four spring washers, then the plain washers to the M8 x 80mm SS316 bolts.

2. Pass the four bolts through the four mounting holes of the transmitter housing.

3. Note: If the XCD sunshade is to be used then fit the sunshade and the two locking bolts and washers to the M8 x 80 bolts.

4. Place the transmitter housing against the mounting position and fit the two “U” channel mounting bars the other side of the Pipe/Structure.

5. Secure bolts to the threaded holes of the “U” channel mounting bars.

6. Tighten the four bolts securely, (but do not over-tighten) until the transmitter housing cannot be moved by hand on its mounting position.

Note: For further details of installation please see section 17.

Diagram 5: Mounting arrangements

5.3 Installing the sensor

The XCD gas sensor cartridge plugs into the XCD Sensor Socket.

WARNINGS

Care should be taken when removing and refitting the Sensepoint XCD plug-in Sensor to the Sensor Socket so that damage to the connection pins can be avoided.

If using an anti-seize compound, the threads should be thinly coated with an approved silicone free compound e.g. petroleum jelly

Take care when handling old sensors as they may contain corrosive solutions.

Take care when removing or replacing the Sensor Retainer as there may be sharp edges present on the adjoining threads.

The equipment is designed and constructed as to prevent ignition sources arising, even in the event of frequent disturbances or equipment operating faults.

The sensor head must be fitted with the supplied weather protection, and mounted so that the sinter is pointing downward to provide ingress protection IPX6.

The weather protection is a potential electrostatic charging hazard. The manufacturer’s instructions should be observed.

To install the XCD Sensor Cartridge to the XCD Sensor Socket:

1. Remove the weather protection (if fitted) from the sensor.

2. Use a 1.5mm Allen key (hexagonal wrench-included) to loosen the Locking Grub Screw on the Sensor Retainer.

3. Unscrew and remove the Sensor Retainer.

4. Remove the XCD Sensor Cartridge from its packaging and plug it into the XCD Sensor Socket, taking care to align the sensor pins with the connector.

5. Refit the Sensor Retainer and tighten the Locking Grub Screw.

6. Refit the weather protection (as required) to the XCD sensor.

Sensor Socket

Weather Protection

Plug-In Sensor Cartridge

Sensor Retainer Locking Grub Screw

Diagram 6: Installing the Sensor

6 Electrical connections

WARNINGS

Sensepoint XCD is designed for installation and use in Zone 1 or 2 hazardous areas in many countries including Europe and Class 1 Division 1 or 2 area applications in North America.

Installation must be in accordance with the recognized standards of the appropriate authority in the country concerned.

Access to the interior of the detector, when carrying out any work, must only be conducted by trained personnel.

Before carrying out any work ensure local regulations and site procedures are followed.

Appropriate standards must be followed to maintain the overall certification of the detector.

Care should be taken when removing and refitting the Sensepoint XCD Sensor Cartridge to the Sensor Socket so that damage to the connection pins can be avoided.

For installations where conduit is used, and the sensor is mounted directly to the Sensepoint XCD, there must be a “Seal Fitting” installed for each of the cable gland entries within 18 inches of the Sensepoint XCD. The total distance of the location of these Seal Fittings is 18 inches. (e.g. If all 3 gland entries are to be used, 3 Seal Fittings should be located, each within 6 inches of the wiring entrance).

If using an anti-seize compound, the threads should be thinly coated with an approved silicone free compound e.g. petroleum jelly

To reduce the risk of ignition of hazardous atmosphere, de-classify the area or disconnect the equipment from the supply circuit before opening the detector enclosure. Keep assembly tightly closed during operation.

Never attempt to open a junction box/enclosure or replace/refit the sensor in potentially hazardous atmospheres while power is still applied to the transmitter.

The detector must be earthed/grounded for electrical safety and to limit the effects of radio frequency interference. Earth/ground points are provided inside and outside the unit.

Ensure that all screens/instrument earth/clean earth wiring is earthed/grounded at a single point (either at the controller or detector - BUT NOT BOTH) to prevent false alarms due to earth/ground loops.

Take care when handling sensors as they may contain corrosive solutions.

Do not tamper with or in any way disassemble the sensor.

Do not expose to temperatures outside the recommended ranges.

Do not expose sensors under storage conditions to organic solvents or flammable liquids.

At the end of their working life, replacement electrochemical sensors for oxygen and toxic gas must be disposed of in an environmentally safe manner. Disposal should be according to local waste management requirements and environmental legislation.

Alternatively, old replaceable sensors may be securely packaged and returned to Honeywell

Analytics clearly marked for environmental disposal.

Electrochemical sensors should NOT be incinerated as this action may cause the cell to emit toxic fumes.

Refer to the local or national regulations relative to the installation at the site. For Europe see EN60079-29-2, EN60079-14, EN45544-4 and EN61241-14.

6.1 Transmitter Wiring

The Sensepoint XCD transmitter may be wired in either Current SOURCE or Current SINK configuration. These two options are offered to allow greater flexibility in the type of control system that it can be used with. SOURCE/SINK is selectable via the switch located on the back side of the display module; accessible by removing the display module during installation / commissioning (see section 9).

Caution: All electrical connections should be made in accordance with any relevant local or national legislation, standards or codes of practice.

Note: Terminate cable screen at detector or controller, not both.

250ohm load resistor (RL) is installed in the factory, In case of connection with controller, this resistor should be removed because controller has load resistor internally.

Controller

+VE

Signal

Detector

+VE

Signal

-VE

RL

-VE

Controller

+VE

Signal

Detector

+VE

Signal

-VE

RL

-VE

XCD Source 3 Wire 4-20mA (Source)

XCD Sink 3 Wire 4-20mA (Sink)

RL

Controller

+VE

Signal

Detector

+VE

Signal

-VE -VE

RL

Controller

+VE

Signal

Detector

+VE

Signal

-VE -VE

6.2 Terminal connections

Note: Ensure that none of the wires in the terminal area cause an obstruction when refitting the Display Module. Ensure that the socket on the Display Module is fully engaged in the Display Module Connector on the Terminal Module.

Diagram 7: Terminal module

Terminal Block Power & Signal

Display Module Connector

Display Module Alignment Pin

Locator

Ground/Earth Point

Terminal Block for Relays

Sensor Connector

Note: Terminal Blocks are plug/socket type and may be removed to ease wiring.

Terminal Module Connections Terminal Number Marking Connection Description

1 24V +VE Supply

Controller Connections2 0V -VE Supply(0VDC) 3 4~20mA Current Output Signal 4 COM Drain

MODBUS RTU.

RS485 (Optional)5 TxD MODBUS B (+)

6 RxD MODBUS A (-) 7 RLY1/NC Normally Closed

Programmable Relay 1 (Default A1)8 RLY1/COM Common

9 RLY1/NO Normally Open 10 RLY2/NC Normally Closed

Programmable Relay 2 (Default A2)11 RLY2/COM Common

12 RLY2/NO Normally Open 13 RLY3/NC Normally Closed

Programmable Relay 3 (Default Fault)14 RLY3/COM Common

15 RLY3/NO Normally Open

Table 1: Transmitter terminal connections

6.3 Power

6.3.1. For ATEX/IECEx/AP Versions

The Sensepoint XCD transmitter (ATEX/IECEx/AP Versions) requires a power supply from the controller of between 16Vdc and 32Vdc. Ensure that a minimum supply of 16Vdc is measured at the sensor, taking into account the voltage drop due to cable resistance.

The maximum loop resistance in the field cable is calculated as follows:

R loop = (V controller – V detector min) / I detector

Example;

The controller is supplying a nominal 24Vdc (V controller), the detector minimum allowable voltage is 16Vdc (V detector min), therefore the maximum allowable voltage drop between the controller and detector is 8Vdc; this means a voltage drop of 4V in each core (+ve core and -ve core).

Power consumption of the detector is 5.0W. The current required to drive the detector at the minimum voltage is (I = P / V), 5.0 / 16 = 312.5mA (I detector).

So, the maximum field cable loop resistance (R loop) = 8 / 0.31 = 26 Ohms, or 13 Ohms per core, (allowing for component variations, losses, etc.).

The following tables show the maximum cable distances between the controller and transmitter assuming a voltage drop of 4V in each core and for different cable parameters.

The tables are examples only and actual cable parameters and source power supply voltage for the application should be used to calculate the maximum cable distance allowed at the installation site.

Typical cable data Maximum Cable length (L)** Cable size

(cross sectional area) Cable resistance Ω/km (Ω/mi)

Meters Feet

0.5mm2 (20AWG*) 36.8 (59.2) 353 1158 1.0mm2 (17AWG*) 19.5 (31.4) 666 2185 1.5mm2 (16AWG*) 12.7 (20.4) 1023 3356 2.0mm2 (14AWG*) 10.1 (16.3) 1287 4222 2.5mm2 (13AWG*) 8.0 (12.9) 1621 5318

*nearest equivalent **example for 24Vdc supply voltage Table 2: Maximum cable distances

+24V +20V

(wrt Controller 0V)

+4V (wrt Controller 0V)

0V

4-20mA

Field Cable (L)

Signal

Diagram 8: Power Connection

16V (min) ControllerXCD

6.3.2. For UL/CSA Versions

The Sensepoint XCD transmitter (UL/CSA Versions) requires a power supply from the controller of between 12Vdc and 32Vdc. Ensure that a minimum supply of 12Vdc is measured at the sensor, taking into account the voltage drop due to cable resistance.

The maximum loop resistance in the field cable is calculated as follows:

R loop = (V controller – V detector min) / I detector

Example;

The controller is supplying a nominal 24Vdc (V controller), the detector minimum allowable voltage is 12Vdc (V detector min), therefore the maximum allowable voltage drop between the controller and detector is 12Vdc; this means a voltage drop of 6V in each core (+ve core and -ve core).

+24V +18V

(wrt Controller 0V)

+6V (wrt Controller 0V)

0V

4-20mA

Field Cable (L)

Signal

Diagram 8: Power Connection

12V (min) ControllerXCD

Power consumption of the detector is 5.0W. The current required to drive the detector at the minimum voltage is (I = P / V), 5.0 / 12 = 416.7mA (I detector).

So, the maximum field cable loop resistance (R loop) = 12/0.42 = 28.8 Ohms, or 14.4 Ohms per core, (allowing for component variations, losses, etc.).

The following tables show the maximum cable distances between the controller and transmitter assuming a voltage drop of 4V in each core and for different cable parameters.

The tables are examples only and actual cable parameters and source power supply voltage for the application should be used to calculate the maximum cable distance allowed at the installation site.

Typical cable data Maximum Cable length (L)** Cable size

(cross sectional area) Cable resistance Ω/km (Ω/mi)

Meters Feet

0.5mm2 (20AWG*) 36.8 (59.2) 391 1284 1.0mm2 (17AWG*) 19.5 (31.4) 738 2421 1.5mm2 (16AWG*) 12.7 (20.4) 1134 3727 2.0mm2 (14AWG*) 10.1 (16.3) 1426 4665 2.5mm2 (13AWG*) 8.0 (12.9) 1800 5894

*nearest equivalent **example for 24Vdc supply voltage

6.4 Cabling

Caution: All unused and used cable/conduit entries must be sealed with a suitable certified sealing plug and cable gland.

The use of industrial grade, suitably armoured field cable is recommended.

For example, screened 3 cores (plus screen 90% coverage), suitably mechanically protected copper cable with a suitable M20 explosion-proof gland, or ¾” NPT steel conduit, with 0.5 to 2.5 mm2 (20 to 13 AWG) conductors. Ensure the cable gland is installed correctly and fully tightened. All unused cable/conduit entries must be sealed with a suitable certified sealing plug (one plug is supplied).

Type Cable Spec Max Length Modbus AWM2464 AWG26~AWG12

Shield 1000meters

6.5 Cable and Earth/Ground regimes

Effective Earth/Ground bonding is important to ensure good EMC and RFI immunity.

The following diagrams show examples of how to earth/ground bond the cable at enclosures. The same principles apply to conduit installations. These bonding techniques provide good RFI/EMC performance. Earth/ground loops must be avoided to prevent the risk of false signal variation.

Cable to Transmitter

Diagram 9: Controller Grounding

Diagram 10: System grounding

Cable outer sheath Cable inner sheath

Clean / Instrument Earth Screen

Controller

Power & Signal

Earth Screen

Controller Transmitter

The Earth Screen of the field cable should be “tied to Earth” or connected to Ground at one point only. It is common practise to adopt a STAR EARTH connection regime where all instrumentation Screens are connected at one common point.

The Screen at the other end of the cable should be “parked” or terminated into a blank terminal.

The following diagrams show how to install the wire into the ground screw of the enclosure.

6.6 Ground Terminal Wiring

Internal Ground connection: Utilize the shield of the wiring cable recommended in the wiring instructions. For connection to this terminal. Twist the shield wire to avoid stray shield wires, Loosen the screw sufficiently and wrap the wire around the screw in a “U” shape. Raise the clamp and place the wire between the clamp and ground base, lower the clamp and tighten the screw to 6.9lb-in torque.

External Ground Connection: If required by local authority, Utilize a No 14 AWG copper, (Stranded or Solid), wire. Loosen the screw sufficiently to enable ‘wrapping the wire around the screw in a “U” shape. Raise the clamp and place the wire between the clamp and ground base, lower the clamp and tighten the screw to10.4lb-in torque.

Loosen the bolt Insert cable Fasten the bolt

7 Default configuration The Sensepoint XCD transmitter is supplied with the following default configuration.

Function Value/Setting Meaning

Sensor Type Automatic according to Sensor type connected

XCD recognizes the XCD sensor cartridge according to the gas type within its own sensor family i.e. mV, EC or O2 .

Signal output

≥0.0<1.0 mA Fault (refer to table 5 section 12.3 for details)

2.0 mA or 4.0 mA (17.4mA) Inhibit (during configuration/user settings) For Oxygen, 2.0 mA or 17.4 mA

4.0 mA to 20.0 mA Normal gas measurement

22.0 mA Maximum over range

Alarm Relay 1*

Value is sensor dependant Lower alarm level De-energized Energizes on alarm Contact Normally Open (NO) Closes on alarm Non-latching

Alarm Relay 2*

Value is sensor dependant Higher alarm level De-energized Energizes on alarm Contact Normally Open (NO) Closes on alarm Non-latching

Fault Relay**

<1mA Detector Fault Energized De-energizes on alarm Contact Normally Open (NO) Closes on alarm Non-latching

Inhibit

2.0 mA (default) or 4.0 mA for Toxic and Flammable

2.0 mA (default) or 17.4 mA For Oxygen

Signal output inhibited during menu use.

If any relay is set to inhibit relay, then inhibit relay will be activated.

Timeout Disabled

No inhibit timeout. The detector waits for a button press before returning to the previous state/setting.

Timeout period can be set in ‘Configure Inhibit’ menu in Configuration Mode.

Password 0000 (Disabled) 0000 (Password disabled). If changed then password is activated.

Location (Tag Number) 0000 Optional feature to identify the location or User’s “Tag” number of the XCD Temperature oC Option to have oC or oF

ModBus ID, baud rates and Parity bit

ID : 1

Baud rates : 19,200 Parity bit : EVEN

* Alarm relays automatically reset when reading falls within alarm thresholds. If relay configured to LATCH, then relays must be reset using the Magnetic Wand.

** Fault state (fault relay and analogue output <1 mA) is always non-latching.

Table 3: Default configuration

Gas Name Default Range Lower Alarm Lower Alarm Type

Higher Alarm Higher Alarm Type

Oxygen 25.0%VOL 19.5%Vol Falling 23.5%Vol Rising Hydrogen Sulfide 50.0ppm 10.0ppm Rising 20.0ppm Rising Carbon Monoxide 300ppm 100ppm Rising 200ppm Rising Hydrogen 1,000ppm 200ppm Rising 400ppm Rising Nitrogen Dioxide 10.0ppm 5.0ppm Rising 10.0ppm Rising Flammable IR 100%LEL 20%LEL Rising 40%LEL Rising Flammable CAT 100%LEL 20%LEL Rising 40%LEL Rising Carbon Dioxide IR 2.00%Vol 0.40%Vol Rising 0.80%Vol Rising

For details of how to change the configuration of the Sensepoint XCD please refer to section 13.

8 Normal Operation Sensepoint XCD is supplied configured and ready for use according to the “Default Settings” table shown above. However these setting may be tailored to a specific application requirement using the Sensepoint XCD configuration menu system.

Access to the Sensepoint XCD transmitter’s configuration menus system is via the Magnetic Activation Tool.

8.1 Display Screen

The Sensepoint XCD display features an LCD with Numeric and bar-graph gas concentration data, alpha-numeric warning and status indication, a target for magnetic switch activation and the UP/DOWN/ESC/ENTER zones for remote configuration. The LCD is also backlit with hi-intensity multi-colour LED indicator to show NORMAL, ALARM and FAULT status.

During normal operation the instrument display shows a steady GREEN backlight.

During Low and High Gas Alarm it displays a flashing RED backlight

During Fault condition the instrument display shows a flashing YELLOW backlight.

The screen is visible through the window of the transmitter’s cover. The display shows the gas concentration (both graphically and numerically), range, units, alarm/ fault status, etc.

Note: The detector display may become sluggish in sub-zero temperatures and possibly unclear at temperatures below -40 °C, but the detector continues its gas monitoring function. The display is not damaged and recovers when the temperature increases.

Diagram 11: Example of a O2 Transmitter Display screen – Normal Operation

Test Pass Icon

Gas Type

Gas Reading

Bar Graph (Proportional to gas reading)

Full Scale

Measuring Unit

8.2 System Status

Display indications, current output and relay states for various operational conditions are shown in the following table. For further details of error messages and trouble shooting see section 12.3.

System Status

Status Display Current Output Relay Back LightA1 A2 Fault

Fault:

Circuit or sensor error

F-XX

fault number with fault icon blinking

0-1.0 mA Yellow, flashing

System Fault N/A 0-0.15mA Note: In the event of processor failure the watchdog will automatically reset the system for recovery.

Warning

W-XX

warning number with fault icon blinking

Dependent on system status

Green Steady

Normal 0.0 Gas concentration

4-20 mA Green Steady

Alarm 1

Gas concentration.

1st alarm icon blinking

4-20 mA Red, flashing

Alarm 2

Gas concentration.

2nd alarm icon blinking

4-20 mA 1 Red, flashing

Over-range Full scale icon and reading blinking

22mA 2 Red, flashing

Inhibit

Inhibit icon dependent on Menu command. If any relay is set to inhibit relay, then inhibit relay will be activated.

2 or 4mA depending on configuration.

Note:

2 or 17.4mA for Oxygen version

Green Steady

Table 4: System status

Note:

8.3 Magnetic Wand Activation

The magnetic wand is used as a tool to allow the user to communicate with the Sensepoint XCD transmitter.

Communication with the XCD is achieved by positioning the Magnetic Wand at one of three different positions on the front glass window of the Sensepoint XCD transmitter.

Activation of the switches is verified by observing the Magnetic Wand Activation Icon on the LCD display

Hold the Magnetic Wand in position for up to 2 seconds =

Hold the Magnetic Wand in position for 3 seconds or more =

8.4 Mode Structure

Sensepoint XCD has 3 operating modes.

1. Monitoring mode, is the normal operating status while XCD measures and displays gas concentration. The fault/warning status is periodically checked, relay contacts are activated according to the configuration.

be protected by a password mechanism to prevent unauthorised changes being made.

3. Review mode, allows the user to view the current configuration settings.

Diagram 12: Mode Structure

Further details of the information available and configuration options for the Sensepoint XCD can be found in Section 13. of this manual.

Start - Up

Configuration

Mode

Review

Monitoring

1. Remove the transmitter housing cover and detach the display unit by lifting the semi-circular handle and pulling the assembly directly away from the termination module (without twisting it)

2. Configure the detector's analogue output signal configuration for Current SINK or Current SOURCE operation using the selector switch located on the back of the display module. The default setting is Current SOURCE.

3. Check that all electrical connections are terminated correctly as per section 6.

4. Switch On the external power supply to the transmitter at the safe area gas detection controller (or PLC).

5. Using a Digital Multi Meter (DMM), check the Supply Voltage at the terminals 1 (24V) and 2 (0V), this should be a minimum supply voltage of 12Vdc or 16Vdc depending on the transmitter version (Maximum supply voltage is 32V DC)

6. Switch Off the external power to the detector.

7. Refit the Display Module and Cover.

Note: Ensure that none of the wires in the terminal area cause an obstruction when refitting the Display Module. Ensure that the socket on the Display Module is fully engaged in the Display Module Connector on the Terminal Module.

8. Switch On external power to the detector.

9. All the display icons/text/numbers are displayed for 3 seconds.

10. A start up sequence will then be displayed, similar to the one shown in Diagram 15.

Note: Calibration is mandatory before the detector can be used for gas monitoring. Refer to Section 10.1 Calibration for the proper procedure.

9 First time switch on (Commissioning)

WARNING

The following procedure requires the Transmitter Cover to be removed while carrying out supply voltage checks. Therefore the appropriate permits to work should be sought in preparation.

Prior to carrying out any HOT WORK ensure local and site procedures are followed.

Ensure that the associated control panel output actuation is inhibited so as to prevent false alarms.

Caution: The following procedure should be followed carefully and only performed by suitably trained personnel

Diagram 15: Normal Start up procedure (For the CO sensor version)

Note:

For a full description of each screen shown in Diagram 15., please refer to Section 13.3 “Review Mode” of this Manual.

11.The warm up countdown of 60 seconds (depending on the gas type) is then displayed.

12. Normal Monitoring Mode is then resumed.

10 Response Check and Calibration It is recommended to periodically carry out a gas response check on the Sensepoint XCD to ensure correct operation. This may be done in two ways;

1. A simple Response Check often referred to as a “BUMP TEST” is a test using calibration gas applied to the sensor via the nozzle of the Weather Protection or using the Sensepoint XCD Gassing Cap.

If a BUMP TEST is done via the Weather Protection nozzle it may be necessary in windy conditions to increase the flow rate of the test gas by a further 1 LPM, OR, to shelter the weather protection from the wind.

2. A full gas calibration of the sensor as described in the following section, using ONLY the Sensepoint XCD Gassing Cap (Part No.: S3KCAL).

10.1 Zeroing and span calibration

To calibrate the detector, use an appropriate span gas cylinder, constant flow regulator AND the Sensepoint XCD Gassing Cap (see section 4.7). The flow rates used for calibration gas are as follows:

Gas Type Flow rate (L / Min) Air or N2 for Zero 0.5 to 1.0 Flammable CAT 1 to 1.5

O2 0.5 to 1.0 H2S 0.5 to 1.0 CO 0.5 to 1.0 H2 0.5 to 1.0

NO2 0.5 to 1.0 Flammable IR 0.4 to 0.6

CO2 IR 0.4 to 0.6

A compressed air cylinder (20.9%Vol oxygen) should be used to perform the zero calibration if the area where the detector is located contains any residual amount of the target gas.