Crowcon Detection Instruments
Gasmaster III Installation, Operation and Maintenance Manual Issue 2 Oct 2014
Operation and Maintenance Manual
48 Pages

Preview
Page 1
Crowcon Gasmaster 1 to 4 channel gas detection control panel
Installation, Operation and Maintenance Manual
M070010 Issue 2 October 2014
The equipment described in this manual may have mains voltages applied to it. Ensure correct safety procedures are adopted before working on the equipment. The equipment described in this manual is designed for the detection of flammable and/or toxic gases. Detectors may be sited in hazardous areas. Ensure local safety procedures are adopted before carrying out any maintenance or calibration work. The equipment described in this manual may be connected to remote alarms and/ or shutdown systems. Ensure that local operating procedures are adopted before carrying out any maintenance or calibration work.
This product has been tested and found to comply with the European Directive 2004/108/EC and the EMC requirements of EN50270. It also complies with the Council Directive 2006/95/EC relating to electrical safety and the Low Voltage Directive. It conforms to the CE Marking Directive 93/68/EEC.
Crowcon Detection Instruments Ltd 172 Brook Drive, Milton Park, Abingdon OX14 4SD UK Tel. +44 (0)1235 557700 Fax. +44 (0)1235 557749 www.crowcon.com Email: [email protected]
172 Brook Drive, Milton Park, Abingdon, Oxon, OX14 4SD, England
© Copyright Crowcon Detection Instruments Ltd 2014 All rights are reserved. No part of the document may be photocopied, reproduced, or translated to another language without the prior written consent of Crowcon Detection Instruments Ltd. Publication number: M070010 second edition: October 2014
Crowcon Gasmaster
Contents
Contents 1. Introduction... 1
4.2 System Inhibit... 35
1.1 About Gasmaster... 1
4.3 Detector Calibration... 36
1.2 About this manual... 1
4.4 Changing Batteries... 36
1.3 Instructions for use as part of an ATEX approved system... 2
4.5 Module Replacement... 36
2. Installation... 3
4.7 Service card ... 36
4.6 Event logging... 36
Please read this first ... 3
4.8 Cleaning... 36
2.1 Before installation... 4
5. Adding an input module... 37
2.1 General ... 4 2.3 Mounting... 5 2.4 Cabling requirements... 5 2.5 Installing gas and fire detectors . . 6 2.6 Installing output devices... 6 2.7 Connecting mains power... 6 2.8 Connecting input devices... 7 2.9 Connecting output devices... 11
Appendix A: Specifications... 38 Appendix B: Spare Parts and Accessories . . 39 Appendix C: Display characters... 40 Warranty Statement... 41 Regional addresses... 42
2.10 Applying power... 13 2.11 Battery back-up times... 13 2.12 Commissioning... 14 3. Operation... 17 3.1 Gasmaster Operator Panel... 17 3.2 Gasmaster start up sequence . . . 19 3.3 How to adjust display contrast . . 19 3.4 How to display Instrument serial number and system identity... 19 3.5 Using the menu system ... 20 3.6 Inhibiting channels... 20 3.7 Using the Control Panel in Supervisor Mode ... 21 3.8 In the event of an alarm... 22 3.9 mV channels: Pellistor saver mode22 3.10 In the event of a fault ... 23 3.11 System Configuration... 23 4. Maintenance... 35 4.1 Functional Testing... 35
i
Crowcon Gasmaster
Introduction
1. Introduction 1.1 About Gasmaster Gasmaster is a gas and fire control panel, designed to monitor remote gas and fire detectors. Gasmaster can also monitor flame detectors as well as Crowcon's ESU product. The status of each input is displayed on a large, clear LCD display, and alarms or faults are indicated by clear LEDs and an integral sounder. Relay outputs are provided for alarms and faults, as well as dedicated outputs for audible visual alarms. An RS-485 Modbus output is provided for two-wire transfer of all data to industry-standard control systems. Gasmaster logs all alarm and fault events so that they can be investigated at a later stage using Gasmaster PC software.
3 provides instructions for day-to-day operation of Gasmaster as well as detailed information on system configuration. Warning Regular maintenance of any safety system is essential, and failure to maintain the system according to these instructions could result in failures which could lead to harm to plant and/or personnel or even death. Details of the requirements for Gasmaster systems are provided in section 4. There are separate appendices for systems specification and spare parts identification.
There are two versions of Gasmaster:
Gasmaster 1 - single channel unit for one gas detector, fire zone or ESU sampling device.
Gasmaster 4 - four channel unit for one to four gas detectors, fire zones or ESU sampling devices.
Gasmaster 1 is identifiable from Gasmaster 4 by having only a single channel display (see figure 3.2, page 18) and a de-populated terminal PCB. All operating functions are identical to Gasmater 4. Gasmaster is designed for simple operation, and all day-to-day functions can be performed from the front panel. Please refer to section 3 for details on display operation.
1.2 About this manual The manual is divided into sections which detail procedures for installing, operating and maintaining Gasmaster. Gasmaster is a safety system and it is essential that all instructions are correctly followed. Details of the types of device that can be connected to Gasmaster are shown in section 2, along with typical connection diagrams. Section 1
Introduction
CERTIFIED PRODUCT ODIFICATIONS PERMITTED THOUT APPROVAL OF AUTHORISED PERSON CERTIFIED PRODUCT ODIFICATIONS PERMITTED HAZARDOUS AREA THOUT APPROVAL OF AUTHORISED PERSON
Crowcon Gasmaster EXAMPLES OF SAFE AREA APPARATUS
1.3 Instructions for use as part SAFE AREA of an ATEX approved system HAZARDOUS AREA SAFE AREA
CROWCON GASMONITOR SYSTEM CROWCON GASMASTER SYSTEMS CROWCON VORTEX SYSTEMS CROWCON GASMONITOR SYSTEM CROWCON GASMASTER SYSTEMS IT IS THE RESPONSIBILITY OF THE INSTALLER CROWCON VORTEX SYSTEMS TO ENSURE THAT THE EQUIPMENT ABOVE COMPLIES WITH NOTE 7. IT IS THE RESPONSIBILITY OF THE INSTALLER TO ENSURE THAT THE EQUIPMENT ABOVE COMPLIES WITH NOTE 7. EXAMPLES OF SAFE AREA APPARATUS
ANY SINGLE CHANNEL SHUNT ZENER DIODE SAFETY BARRIER WHICH IS ATEX CERTIFIED BY BASEEFA OR ANY EC APPROVED CERTIFICATION BODY TO [Ex ia Ga] IIC HAVING THE FOLLOWING OR LOWER OUTPUT PARAMETERS; SINGLE SHUNT ZENERWATTS. DIODEOINSAFETY BARRIER WHICH IS ATEX CERTIFIED UANY VOLTS,CHANNEL I =93mA OAND P =0.66 ANY SAFETY O=28 BY BASEEFA ORTHE ANYOUTPUT EC APPROVED CERTIFICATION BODYBYTOA RESISTOR BARRIER USED CURRENT MUST BE LIMITED [ExSUCH ia Ga]THAT IIC HAVING `R' I = U /RTHE O FOLLOWING O OR LOWER OUTPUT PARAMETERS; U O=28 VOLTS, I =93mA OAND P =0.66 WATTS. OIN ANY SAFETY BARRIER USED THE OUTPUT CURRENT MUST BE LIMITED BY A RESISTOR `R' SUCH THAT I = U /R O O
Gasmaster is approved according to the 94/9/EC SAFE AREA APPARATUS NOTE 7 ATEX Directive when used as part of a system with SAFE AREA APPARATUS UNSPECIFIED EXCEPT THAT intrinsically safe gas detectors and I.S. barriers. NOTE IT MUST 7 NOT BE SUPPLIED
FROM, NOR CONTAIN UNDER UNSPECIFIED EXCEPT THAT
NORMAL OR ABNORMAL IT MUST NOT BE SUPPLIED Gasmaster has been certified according to EN60079CONDITIONS A SOURCE 0F FROM, NOR CONTAIN UNDER POTENTIAL RESPECT 25:2010 Explosive atmospheres - Intrinsically safe NORMAL ORWITH ABNORMAL TO EARTH IN EXCESS OF 0F CONDITIONS A SOURCE OPTIONAL SCREEN electrical systems. 250 VOLTS R.M.S. POTENTIAL WITH OR RESPECT
TABLE 1: CABLE PARAMETERS
OPTIONAL SCREEN
Certificate reference: Baseefa05Y0090/1
NY ONE OF THE FOLLOWING HAZARDOUS AREA GAS DETECTORS (ONLY 1 DETECTOR PER ZENER BARRIER) YPE TXGARD IS+, CERTIFICATION No: BASEEFA 08ATEX0069X, EITHER AN OXYGEN OR A TOXIC SENSOR YPE XGARD, CERTIFICATION BASEEFA 04ATEX0115, EITHER AN (ONLY OXYGEN OR A TOXICPER SENSOR NY ONE OF THE FOLLOWINGNo. HAZARDOUS AREA GAS DETECTORS 1 DETECTOR ZENER BARRIER) YPE TXGARD IS, IS+,CERTIFICATION CERTIFICATIONNo. No:BASEEFA BASEEFA03ATEX0063X 08ATEX0069X, EITHER AN OXYGEN OR A TOXIC SENSOR TXGARDCERTIFICATION IS OXYGEN, CERTIFICATION BASEEFA 03ATEX0062X YPE XGARD, No. BASEEFANo. 04ATEX0115, EITHER AN OXYGEN OR A TOXIC SENSOR YPE TXGARD IS, CERTIFICATION No. BASEEFA 03ATEX0063X OTES:YPE TXGARD IS OXYGEN, CERTIFICATION No. BASEEFA 03ATEX0062X
GROUP CAPACITANCE INDUCTANCE TABLE 1: CABLE PARAMETERS uF mH GROUP CAPACITANCE INDUCTANCE TXGARD IS+ TOXIC OR OXYGEN GAS DETECTOR - BASEEFA 08ATEX0069X
250 VOLTSIND.C. TO EARTH EXCESS OF 250 VOLTS R.M.S. OR 250 VOLTS D.C.
IIC
HAZARDOUS AREA
mH 3.11
TXGARD IS+ TOXIC OR OXYGEN GAS DETECTOR - BASEEFA 08ATEX0069X
IIB 0.186 9.35 IIC 0.062 3.11 IIA 0.496 24.95 IIB 0.186 9.35 XGARD TOXIC OR OXYGEN GAS DETECTOR - BASEEFA 04ATEX0115
Gasmaster must be installed in the safe area only, but is certified for connection to Intrinsically Safe gas detectors installed in Zone 0, 1 or 2 hazardous areas barrier. THE ELECTRICAL CIRCUITwhen IN THE HAZARDOUSconnected by a safety 5. THE HAZARDOUS AREA CABLE Installation MAY BE; AREA MUST BE CAPABLE OF WITHSTANDING 1) A SEPARATE CABLE, OTES:AN A.C. TEST VOLTAGEmust OF 500 VOLTS R.M.S. 2) INSTALLED AS A SEPERATELY SCREENEDshown CIRCUIT IN A TYPE A be in accordance with the instructions THE CIRCUITOFINTHE THEAPPARATUS HAZARDOUS 5. THE HAZARDOUS AREA CABLE MAY BE; TOELECTRICAL EARTH OR FRAME MULTICORE CABLE, AREAONE MUST BE CAPABLE OF WITHSTANDING CABLE, A TYPE B MULTICORE CABLE, FIXED AND FOR MINUTE. OR1)3)A ASEPARATE CIRCUIT WITHIN below. AN A.C. TEST VOLTAGE 500 VOLTS R.M.S. 2)EFFECTIVELY INSTALLED AS A SEPERATELY SCREENED CIRCUIT IN A TYPE THE CAPACITANCE ANDOF INDUCTANCE OR INDUCTANCE/ PROTECTED AGAINST DAMAGE, PROVIDED THATA THE
TO EARTH ORL/R FRAME RESISTANCE RATIOOFOFTHE THEAPPARATUS HAZARDOUS AREA FOR ONEMUST MINUTE. CABLES NOT EXCEED THE VALUES SHOWN IN THE CAPACITANCE AND INDUCTANCE OR INDUCTANCE/ TABLE 1 RESISTANCE L/R RATIO THE HAZARDOUS AREA PRODUCT THE INSTALLATION MUSTOF COMPLY WITH NATIONAL CERTIFIED CABLES MUST NOT THE VALUES EN60079-14:2008) SHOWN IN REQUIREMENTS (EG.EXCEED CODE PRACTICE NOOF MODIFICATIONS PERMITTED TABLE 1 . THE SYSTEM MUST BE MARKED WITH A DURABLEAPPROVAL LABEL, NORMALLY WITHOUT OF THE INSTALLATION MUST COMPLY WITH NATIONAL AFFIXED ON OR ADJACENT TO THE PRINCIPAL ITEM OF ELECTRICAL AUTHORISED PERSON REQUIREMENTS (EG. CODE OF PRACTICE EN60079-14:2008) APPARATUS IN THE SYSTEM, OR AT THE INTERFACE BETWEEN THE .NTRINSICALLY THE SYSTEM MUST MARKED WITH A DURABLE NORMALLY SAFEBE AND NON INTRINSICALLY SAFELABEL, CIRCUITS. THIS AFFIXED ON OR ADJACENT TO THE PRINCIPAL ITEM OF ELECTRICAL MARKING SHALL INCLUDE "BASEEFA SYSTEM CERTIFICATE APPARATUS THE SYSTEM, OR AT THE INTERFACE BETWEEN THE NUMBER No.IN Baseefa05Y0090". NTRINSICALLY SAFE AND NON INTRINSICALLY SAFE CIRCUITS. THIS MARKING SHALL INCLUDE "BASEEFA SYSTEM CERTIFICATE NUMBER No. Baseefa05Y0090".
uF 0.062
IIA IIC
0.496 0.046
24.95 3.09
XGARD TOXIC OR OXYGEN GAS DETECTOR - BASEEFA 04ATEX0115
IIB 0.170 9.33 IIC 0.046 3.09 IIA 0.480 24.93 IIB 0.170 9.33 TXGARD IS TOXIC GAS DETECTOR - BASEEFA 03ATEX0063X IIA IIC
0.480 0.009
24.93 4.2
TXGARD IS TOXIC GAS DETECTOR - BASEEFA 03ATEX0063X
MULTICORE CABLE, PEAK VOLTAGE OF ANY CIRCUIT CONTAINED WITHIN THE TYPE B ORMULTICORE 3) A CIRCUITDOES WITHIN TYPE B MULTICORE CABLE, FIXED AND NOTA EXCEED 60 VOLTS.(THE CABLE TYPES EFFECTIVELY PROTECTED AGAINST PROVIDED THAT THE ARE AS DEFINED IN CLAUSE 12.2.2.8DAMAGE, OF EN60079-14:2008) PEAK VOLTAGE OF ANY CONTAINED TYPE B 6. THE BARRIER EARTH MUSTCIRCUIT BE CONNECTED VIAWITHIN A HIGH THE INTEGRITY MULTICORE DOES NOT EXCEED 60 VOLTS.(THE CABLE TYPES CONNECTION, USING AN INSULATED CONDUCTOR EQUIVALENT TO A 4mm ARE ASCONDUCTOR, DEFINED IN CLAUSE 12.2.2.8 EN60079-14:2008) COPPER SUCH THAT THEOF IMPEDANCE FROM THE POINT 6.OF THE BARRIER EARTH MUST BE CONNECTED VIA A HIGH INTEGRITY CONNECTION, TO THE MAIN POWER SYSTEM EARTH, IS LESS THAN CONNECTION, USING AN INSULATED CONDUCTOR EQUIVALENT TO A 4mm 1 OHM. COPPER CONDUCTOR, SUCH THAT THE IMPEDANCE FROM THE POINT OF CONNECTION, TO THE MAIN POWER SYSTEM EARTH, IS LESS THAN 1 OHM.
IIB 0.133 12.6 IIC 0.009 4.2 IIA 0.443 33.6 IIB 0.133 12.6 TXGARD IS OXYGEN GAS DETECTOR - BASEEFA 03ATEX0062X 2
IIA IIC
0.443 0.024
33.6 4.2
TXGARD IS OXYGEN GAS DETECTOR - BASEEFA 03ATEX0062X 2
SAFE AREA
ANY SINGLE CHANNEL SHUNT ZENER DIODE SAFETY BARRIER WHICH IS ATEX CERTIFIED BY BASEEFA OR ANY EC APPROVED CERTIFICATION BODY TO [Ex ia Ga] IIC HAVING THE FOLLOWING OR LOWER OUTPUT PARAMETERS; U O=28 VOLTS, I =93mA OAND P =0.66 WATTS. OIN ANY SAFETY BARRIER USED THE OUTPUT CURRENT MUST BE LIMITED BY A RESISTOR `R' SUCH THAT I = U /R O O
OPTIONAL SCREEN
4. THE SYSTEM MUST BE MARKED WITH A DURABLE LABEL, NORMALLY AFFIXED ON OR ADJACENT TO THE PRINCIPAL ITEM OF ELECTRICAL APPARATUS IN THE SYSTEM, OR AT THE INTERFACE BETWEEN THE INTRINSICALLY SAFE AND NON INTRINSICALLY SAFE CIRCUITS. THIS MARKING SHALL INCLUDE "BASEEFA SYSTEM CERTIFICATE NUMBER No. Baseefa05Y0090".
2
uH/OHM L/R RATIO uH/OHM 53 200 53 422 200 422 53 200 53 422 200 422 53 200 53 422 200 422 53
IIB IIC IIA IIB
0.148 0.024 0.458 0.148
12.6 4.2 33.6 12.6
200 53 422 200
IIA
0.458
33.6
422
SAFE AREA APPARATUS NOTE 7 UNSPECIFIED EXCEPT THAT IT MUST NOT BE SUPPLIED FROM, NOR CONTAIN UNDER NORMAL OR ABNORMAL CONDITIONS A SOURCE 0F POTENTIAL WITH RESPECT TO EARTH IN EXCESS OF 250 VOLTS R.M.S. OR 250 VOLTS D.C.
ANY ONE OF THE FOLLOWING HAZARDOUS AREA GAS DETECTORS (ONLY 1 DETECTOR PER ZENER BARRIER) TYPE TXGARD IS+, CERTIFICATION No: BASEEFA 08ATEX0069X, EITHER AN OXYGEN OR A TOXIC SENSOR TYPE XGARD, CERTIFICATION No. BASEEFA 04ATEX0115, EITHER AN OXYGEN OR A TOXIC SENSOR TYPE TXGARD IS, CERTIFICATION No. BASEEFA 03ATEX0063X TYPE TXGARD IS OXYGEN, CERTIFICATION No. BASEEFA 03ATEX0062X NOTES:1. THE ELECTRICAL CIRCUIT IN THE HAZARDOUS AREA MUST BE CAPABLE OF WITHSTANDING AN A.C. TEST VOLTAGE OF 500 VOLTS R.M.S. TO EARTH OR FRAME OF THE APPARATUS FOR ONE MINUTE. 2. THE CAPACITANCE AND INDUCTANCE OR INDUCTANCE/ RESISTANCE L/R RATIO OF THE HAZARDOUS AREA CABLES MUST NOT EXCEED THE VALUES SHOWN IN TABLE 1 3. THE INSTALLATION MUST COMPLY WITH NATIONAL REQUIREMENTS (EG. CODE OF PRACTICE EN60079-14:2008)
L/R RATIO
5. THE HAZARDOUS AREA CABLE MAY BE; 1) A SEPARATE CABLE, 2) INSTALLED AS A SEPERATELY SCREENED CIRCUIT IN A TYPE A MULTICORE CABLE, OR 3) A CIRCUIT WITHIN A TYPE B MULTICORE CABLE, FIXED AND EFFECTIVELY PROTECTED AGAINST DAMAGE, PROVIDED THAT THE PEAK VOLTAGE OF ANY CIRCUIT CONTAINED WITHIN THE TYPE B MULTICORE DOES NOT EXCEED 60 VOLTS.(THE CABLE TYPES ARE AS DEFINED IN CLAUSE 12.2.2.8 OF EN60079-14:2008) 6. THE BARRIER EARTH MUST BE CONNECTED VIA A HIGH INTEGRITY CONNECTION, USING AN INSULATED CONDUCTOR EQUIVALENT TO A 4mm COPPER CONDUCTOR, SUCH THAT THE IMPEDANCE FROM THE POINT OF CONNECTION, TO THE MAIN POWER SYSTEM EARTH, IS LESS THAN 1 OHM.
EXA
C C
IT IS THE TO EN
GROUP
TXGARD IS+ T
IIC IIB IIA
XGARD TOXIC
IIC IIB IIA
TXGARD IS TO
IIC IIB IIA
TXGARD IS OX
IIC IIB IIA
Crowcon Gasmaster
Installation
2. Installation Please read this first Before commencing the installation and commisioning of your Gasmaster system, please read through the following information which will guide you through the whole process. The installation instructions contained in this section are for a pre-configured Gasmaster. For instructions on installing and commissioning gas and fire detectors, please follow the user manual instructions supplied with the detectors. Alternatively contact Crowcon for advice. To complete the installation of your Gasmaster system you will need to use the Operator panel and Menu. Full instructions can be found in section III. Operation, you are advised to familiarise yourself with the operator buttons on the front panel and the menu structure, see page 25. Some configuration steps may require you to enter Supervisor mode. Crowcon advises that personnel familiar with installing and commisioning gas and fire detection systems carry out this part. If you have purchased a Gasmaster 1 Please follow the instructions in this section but ignore the reference to additional channels. If you have purchased a non-configured Gasmaster 4 Please follow the installation instructions for a pre-configured Gasmaster 4. Additional information on setting-up your Gasmaster system can be found in section III. Operation. Step-by-step instructions The installation and commissioning of your Gasmaster system is presented in easy to follow instructions. A summary table of contents detailing a typical sequence of installation steps is shown below. Depending on your configuration some or part of each step may be omitted. Note: two batteries are shipped separately from the main unit to prevent potential damage during transit. These should be installed as shown in section 2.2.
Warning: Gasmaster is not certified for use in hazardous areas, but may be connected to detectors and/or alarm devices which are installed in a hazardous area. Instructions for field devices must be closely observed when installing a Gasmaster system. 2.1 Before installation 2.2 General 2.3 Mounting 2.4 Cabling requirements 2.5 Installing gas and fire detectors 2.6 Installing output devices 2.7 Connecting mains power 2.8 Connecting input devices 2.8.1 Two wire 4-20mA devices 2.8.2 Three wire 4-20mA devices 2.8.3 mV bridge pellistor detectors. 2.8.4 Heat/smoke detectors 2.8.5 Environmental Sampling Unit (ESU) 2.8.6 Flame detectors 2.8.7 Remote inhibit and accept/ reset inputs 2.9 Connecting output devices 2.9.1 Audible visual alarms 2.9.2 Common relay connections 2.9.3 Channel relay connections 2.9.4 Analogue outputs 2.9.5 RS485 communications 2.10 Applying power 2.11 Battery back-up time/ power calculations 2.12 Commissioning 2.12.1 Commissioning mV pellistor detectors 2.12.2 Zero adjustment and calibration 2.12.3 Testing fire channels 2.12.4 Testing ESU channels
3
Installation
Crowcon Gasmaster
2.1 Before installation
Front cover
Before carrying out any installation work, ensure that local regulations and site procedures are followed. Further advice is available from Crowcon if required. Gasmaster is intended for use in non hazardous areas. Gas and fire detectors may be mounted in potentially flammable atmospheres using appropriate barrier devices where necessary. Check the equipment to be installed is suitable for the area classification. Please refer to instrument installation manuals for information on location. Crowcon recommends the installation of Gasmaster be carried out by people with experience of installing electrical equipment in potentially hazardous areas.
2.2 General
Display Display chassis
Figure 2.1 shows the internal arrangement of a Gasmaster system. The front cover is removed by unscrewing the four screws and carefully disconnecting the two-pole sounder connector from the display PCB . The front cover can either be supported by the case using one of the retaining screws, or removed completely and placed in a safe location. Two separate chassis support the display PCB and batteries which supports the display PCB and batteries . The terminal PCB contains the input modules, and all of the input and output terminals. The display PCB is connected to the terminal PCB via a 50-way ribbon connector, and is hinged on the left side so that it can be moved to provide access to the detector input terminals. Most terminals are accessible once the display PCB is moved and the batteries are removed. If necessary the two chassis can be removed for easier terminal access. In order to remove the display chassis, the display PCB ribbon connector must first be carefully un-plugged. Care should be taken when re-fitting the display 4
Chassis plate
Input modules plug in to terminal PCB
This section describes how to get started with a Gasmaster 4 or Gasmaster 1 system that has been pre-configured for the detectors supplied. Figures 2.1, 2.2 and 2.5 show the internal structure of Gasmaster. See the Specification and Inspection Certificate provided with your system for full details of its configuration.
Batteries
PCB
Terminal PCB
Gland
knock outs
Optional
comms port
Figure 2.1 Exploded view of Gasmaster
PCB so as not to damage the connector or ribbon cable. Six punched cable gland knock-outs are provided on the top and bottom of the enclosure. The knock-outs are suitable for M20, 1/2"NPT or PG13.5 cable glands. To remove Knock-outs, tap around the edge of the recessed flange using a small hammer and a screwdriver. The knocks outs should then come away from the enclosure. Knock-outs should be removed prior to mounting Gasmaster and great care must be taken to avoid damaging internal components. Power supply Gasmaster comes fitted with an auto-ranging power supply suitable for 100-240 V ac 50-60 Hz operation. This provides a nominal 24 V dc supply with a maximum power of 60 W. Alternatively Gasmaster can be powered from an external 24 V dc supply, a maximum 60 W supply is required. Gasmaster must never be connected to ac and dc supplies at the same time.
Crowcon Gasmaster
Installation
Each detector input is short-circuit protected. Self-resetting ‘polyfuses’ are fitted to the 24 V power supply which will cut power in the event of a cabling fault, and automatically reset when the fault is corrected. Detectors with a maximum consumption of 500 mA may be connected. Circuit breaker If the equipment is permanently connected to a mains supply then a dedicated circuit breaker must be included in the installation, to comply with EN 61010-1. The circuit breaker must be close to Gasmaster, in easy reach of the operator. It must be marked as the disconnecting device for the Gasmaster system, and the ON and OFF positions must be clearly marked. The circuit breaker must comply with the relevant requirements of IEC60947-1 and IEC60947-3. The protective earth must not be disconnected even when the breaker is activated.
Gasmaster should be removed before drilling the mounting holes. Nylon bushes suitable for up to 5mm screws are fitted within the Gasmaster mounting points. Ensure these bushes are present when mounting as they are essential to maintain the ingress protection of the enclosure. 278 110
120
77 5
214
Short circuit protection
sounder connector from the display PCB. The cover should be placed in a secure location. It is recommended that Gasmaster is positioned by hand in the desired location, and a pencil used to mark the mounting hole positions.
288
The Gasmaster power supply contains no user replaceable fuses.
Mounting holes
Batteries
Figure 2.3 Dimensional mounting holes shown
view
of
Gasmaster
with
2.4 Cabling requirements Battery connection diagram
Cabling to Gasmaster and detectors must be in accordance with the recognised standards of the appropriate authority in the country concerned, and must meet the electrical requirements of the detector. Explosion-proof (Exd) devices
Figure 2.2 Gasmaster chassis plate with display PCB board and batteries.
2.3 Mounting All Gasmaster systems should be installed in a safe area. Consider location, cabling and earthing requirements. Figure 2.3 provides a dimensional view of Gasmaster. To access the mounting points, first remove the front cover by unscrewing the fixings labelled in figure 2.1. Carefully remove the
Crowcon recommends the use of steel wire armoured (SWA) cable. Suitable explosionproof glands must be used. Intrinsically Safe (I.S.) devices
Crowcon recommends the use of twisted pair cable with overall screen and sheath. Suitable weatherproof glands must be used. I.S. devices must be used with a suitable Zener Barrier or Galvanic Isolator when used in a hazardous area.
5
Installation
Crowcon Gasmaster
Fire detectors,
Crowcon recommends the use of twisted-pair cable, screened with an overall protective sheath that is fireproof, for example, Pirelli FP200 or similar. A 1K8 end-of-line resistor must be fitted to the last detector on each conventional smoke or heat detector loop. Alternative cabling techniques, such as steel conduit, may be acceptable provided that appropriate standards are met. The minimum acceptable supply voltage measured at the detector and the maximum current drawn by that detector is different for each device. Please refer to the relevant Installation, Operating and Maintenance Instructions provided with each detector to calculate the maximum cable distances allowed for different cable types. The maximum cable distance allowed is dependent upon the installation, for example, whether Zener Barriers or Galvanic Isolators are required (for I.S. devices) or not. When calculating maximum cable distances for detectors, assume a minimum supply of 19 V and a sense resistance of 98 Ω (39 Ω for convential fire channels). Table 1: Typical cable characteristics c.s.a (mm2)*
Resistance (Ω per km)
– Screened cable with the screen terminated inside the enclosure via a metal tag attached to the gland. – Screened cable using an EMC gland where the screen is terminated to the enclosure via the gland. – For detectors, 4-20 mA outputs and RS-485 terminations: screened cable where the screen is connected to the SCR terminal on the appropriate terminal strip.
2.5 Installing gas and fire detectors Install gas and fire detectors as per instrument installation manuals, paying attention to location and cabling requirements. For ESU devices please refer to installation manual provided.
2.6 Installing output devices Gasmaster can drive 12 V dc or 24 V dc audible visual alarms directly via the Audible Visual drive terminals on the terminal PCB. Relays are provided for switching additional outputs, and 12 V dc or 24 V dc 200 mA auxiliary supplies are available adjacent to each block of relay terminals for switching low power devices. Section 2.9 provides detailed information on connections to output devices.
Cable
Loop
2.7 Connecting mains power
0.5 (20)
39.0
78.0
Connect the external power supply using the two part screw terminals, refer to Figures 2.4 and 2.5. Gasmaster must be earthed either at the power connector earth terminal (see Figure 2.4) or using the stud on top of the enclosure.
1.0 (17)
18.1
36.2
1.5 (15)
12.1
24.2
2.5 (13)
8.0
16.0
*Approximate c.s.a. in awg given in brackets.
Cable lengths should be calculated according to the equations defined in the detector instructions sheet and the cable and Gasmaster characteristics specified above. There are a number of suitable ways of terminating cables and glands to Gasmaster dependant on the cable and gland type:
Figure 2.4 Mains connection terminals on terminal PCB
Pb
6
CROWCON
– Steel wire-armoured (SWA) cable and glands with electrical termination of the armour to the enclosure via the gland.
Crowcon Gasmaster
Installation
Mains supply
Input modules
Detector input terminals
Common relay terminals
Pb
CROWCON
Channel relay terminals
+
Display PCB connector
24 V dc supply.
Analogue outputs
+
+
+
+
Link to chassis on I.S. systems only.
+
Link to chassis on non-I.S. systems only.
RS-485 Modbus terminals
Audible/Visual Alarm terminals
Remote inhibit and accept/reset inputs
Figure 2.5 Terminal PCB layout
2.8 Connecting input devices
4-20 mA Inputs
Gasmaster may be fitted with between one and four input modules (one only for Gasmaster 1) of the following types:
Gasmaster provides analogue 4-20 mA inputs with a sensor supply voltage of 19 to 28 V dc and measures the signal across a 98 Ω sense resistor. Inputs can be gas detectors or flame detectors in 4-20 mA 2-wire sink, or 3-wire sink or source configurations. Gasmaster will track inputs from 3 to 21.5 mA at which point an 'over-range' fault will be indicated. Connection details are shown in section 2.8.1 and 2.8.2.
•
4-20mA/Fire module for 4-20mA type detectors, conventional smoke/heat detectors or ESU.
•
mV Pellistor module for mV bridge type flammable gas detectors.
Details of hardware configurations and link settings can be found in section 2.8.1 to 2.8.6.
Conventional fire detectors A loop of up to 20 conventional smoke/heat detectors (for example Apollo Series 65 or Orbis 7
Installation
Environmental Sampling Unit (ESU) Each Gasmaster input can monitor a Crowcon Environmental Sampling Unit (ESU), which enables detection of flammable or toxic gases over a wide area using a sample draw technique. It is essential that the sampling device on the ESU is operating correctly, and Gasmaster provides this monitoring function to ensure a sample is being drawn. Gasmaster provides a 2-wire 24 V dc supply to the sampling device. Separate Gasmaster input channels are required to monitor the gas detector or detectors fitted to the ESU. Connection details are shown in section 2.8.5.
I.S. Link Settings
Figure 2.6 Connections for 2 wire detector 4-20mA/Fire input module
Figures 2.7 and 2.8 show typical wiring configurations for a 2 wire sink I.S.detector with Zener barrier or Galvanic Isolator. Set the link for the appropriate channel as shown in each diagram.
2.8.2. Three wire 4-20mA devices Figure 2.9 shows a typical wiring configuration for a 3-wire detector. Set the link on the 4-20 mA/ Fire input module to SOURCE for a current source detector, and SINK for a detector configured as current sink.
Figure 2.6 shows a typical wiring configuration for a 2-wire current sink detector for safe area use only. Figures 2.7 and 2.8 show typical wiring configurations for I.S. detectors installed in hazardous areas using Zener Barriers or Galvanic isolators. Refer also to section 1.3. Set the link on the 4-20 mA/Fire input module to SINK in all cases.
8
I.S. Link Settings
DETECTOR
S
-
2.8.1. Two wire 4-20mA devices
PWR SIG 0V SCR
Gasmaster Detector Input Terminals
+
Please contact Crowcon for specific wiring details for Crowcon detectors
SOURCE SINK FIRE
DETECTOR
mV bridge pellistor detectors Some flammable gas detectors provide a mV bridge type signal rather than a 4-20mA signal. Example Crowcon products are Xgard Type 3 and Xgard Type 4. The procedure for setting-up these detectors is different from 4-20mA devices: refer to section 2.12.1 for detailed instructions on commissioning mV bridge type detectors
Channel Link Settings
+
devices’) can be connected to each Gasmaster input channel. A fire loop can also comprise switched devices such as manual alarm call points or flame detectors, and devices can be mixed on the same loop provided electrical characteristics are compatible and fire regulations allow. Switched devices require a 470 Ω series resistor. Each fire loop must be terminated with a 1K8 end-of-line resistor, which is monitored to provide indication of open circuit or short circuit faults. Connection details are shown in section 2.8.3.
Crowcon Gasmaster
Channel Link Settings
SOURCE SINK FIRE
1K PWR SIG 0V SCR
Gasmaster Detector Input Terminals
Figure 2.9 Connections for 3 wire detector 4-20mA/Fire input module
2.8.3. mV bridge pellistor detectors. Detectors such as Crowcon’s Xgard Type 3 or 4 should be connected as shown. Refer to section 2.12.1 for instructions on detector set-up. Refer to Figure 5.1 on page 37 for wiring details. Warning: Ensure the ‘Head Voltage’ potentiometer is set fully anti-clockwise before connecting and powering mV pellistor type detectors for the first time (or when fitting a new/replacement mV module). This will ensure the voltage supplied to
O
Installation
I.S. Link Settings Hazardous Area
Channel Link Settings
SOURCE SINK FIRE
Safe Area
Gas Detector
4-20mA Current Sink
Z728
PWR SIG 0V SCR
8 7
+ -
2 1
I.S. Earth P&F Z728 Zener Barrier Crowcon Part Number: C03317
Figure 2.7 Typical connections for 2 wire I.S. detector with Zener barrier, 4-20mA/Fire input module Set channel link to SINK (see figure 2.5) and configuration to DET4-20 SINK (see Menu System Overview section, page 25 and 33. Refer to earth connection requirements on Figure 2.5, page 7 I.S. Link Settings Channel Link Settings
HAZARDOUS AREA +
+
OUT IN COM -
Detector + + OUT IN COM – -
+
I.S. Link Settings
Safe Area
SAFE AREA
1 2
ORBIS Smoke or Heat Detectors
Z728
11 12
13 14
Channel Link Settings SOURCE SINK SOURCE SINK FIRE
FIRE
8 7
Hazardous Area
2 1
K8
Crowcon Gasmaster
PWR SIG 0V SCR PWR SIG
– 20-35Vdc + supply
0V SCR
I.S. Earth MTL 5541 P&F Z728 Zener Barrier
Detector
– +
Crowcon Part Number: C03317 3 1
PWR SIG
7 8 15 14
Pepperl& Fuchs KFD2-STC4-Ex1.H
– 20-35Vdc + supply
0V SCR
Figure 2.8 Typical connections for 2 wire I.S. detector with Galvanic Isolator, 4-20mA/Fire input module. Set channel link to SRCE (see figure 2.5) and configuration to DET4-20 SRCE (see Menu System Overview section, page 25 and 33.
9
Installation
Crowcon Gasmaster
the sensor is set to minimum and avoid potentially burning-out the pellistor by applying excessive voltage.
2.8.4. Heat/smoke detectors
tions, details are shown on the instructions provided with the ESU. Channel Link Settings
Conventional fire detectors for safe area use should be setup according to Figures 2.10 and 2.11. Conventional fire detectors for hazardous area use should be setup according to Figure 2.12. Figure 2.11 shows connections for manual alarm call points. I.S. Link Settings
COM-
COM-
IN+
L2
Figure 2.10 Connections for 4-20mA/Fire input module
smoke/heat
FAN+ FAN-
I.S. Link Settings
detector,
-
Hazardous Area
PWR SIG 0V SCR
S
PWR SIG 0V SCR
470R
I.S. Link Settings
Safe Area
Figure 2.11 Connections for manual alarm call points, 4-20mA/Fire input module
Channel Link Settings
SOURCE SINK FIRE
DETECTOR
Manual alarm call points
470R
Gasmaster
Figure 2.13 Connections for ESU sampling device, 4-20mA/Fire input module
I.S. Link Settings
1K8
Input 1,2,3 or 4
To Fan
+
L2
PWR SIG 0V SCR
+ SIG -
Figure 2.14 shows a typical wiring configuration for a 4-20 mA 3 wire Flame detector. Set the detector type link appropriate for the type of flame detector, refer to Figure 2.5. Do not set link to FIRE.
PWR SIG 0V SCR
1K8
IN+
SOURCE SINK FIRE
2.8.6. Flame detectors
Channel Link Settings
SOURCE SINK FIRE
Smoke/Heatdetector
I.S. Link Settings
ESU SAMPLING DEVICE TERMINAL BOX
Channel Link Settings
Gasmaster Detector Input Terminals
Figure 2.14SOURCE Connections for 4-20 mA 3 wire Flame SINK FIRE detector, 4-20mA/Fire input module
Gas Detector
+ -
2 1
8 7
PWR
2.8.5. Environmental Sampling Unit Z728 (ESU)
SIG 2.8.7. Remote 0V inhibit and accept/ reset inputs SCR
Gasmaster has inputs for the connection of Currentthe Sink wiring configuration for Figure 2.134-20mA shows I.S. Earth remote switches to inhibit alarm outputs or monitoring the ESU sampling device. Gas detecP&F Z728 Zener Barrier accept and reset alarms. Inputs are activated tors fitted to the ESU should be cabled separately Crowcon Part Number: C03317 when pulled down to 0 V, the open circuit voltto the appropriate input channels on the age is 5 V dc. Gasmaster or other control panel. For connecI.S. Link Settings Hazardous Area
+
-
+
+
OUT IN COM -
2 1
OUT IN COM
Z728
8 7
+
1K8
ORBIS Smoke or Heat Detectors I.S. Earth P&F Z728 Zener Barrier Crowcon Part Number: C03317
10
Channel Link Settings
SOURCE SINK FIRE
Safe Area
PWR SIG 0V SCR
Figure 2.12 Connections for conventional fire detectors for hazardous area, 4-20mA/Fire input module Refer to earth connection requirements on Figure 2.5, page 7
Crowcon Gasmaster
Installation
Warning Crowcon strongly recommends that remote inhibit switches be key operated only, and that access to the key should be restricted to authorised personnel. A Gasmaster system that has been inhibited without other safety precautions being in place may not provide the protection for which it was designed. Steps should be taken to ensure that all appropriate personnel are aware when a Gasmaster system is inhibited. Remote ACCEPT/RESET Close the contact momentarily to accept alarms and cancel audible alarms. Close the contact again when the hazard is cleared to reset alarms. Remote INHIBIT Closing the contact will inhibit alarms on all input channels. Channels will remain inhibited until the contact is opened; the Gasmaster will then return to its original state (any channels that have been set to inhibit using the Supervisor menu will remain inhibited). Figure 2.15 shows wiring configurations for remote inputs. Crowcon recommends screened cables for connecting remote switches. The screen should be terminated at the appropriate ‘SCR’ terminal.
0V INHIBIT ACCEPT/ RESET 0V
Gasmaster is compatible with A/V alarms which require a common 0V supply (+VE switched), or a common +VE DC supply (0V or ‘-VE’ switched). Connect the A/V device to the ‘AV +VE SWITCHING’ or ‘AV -VE SWITCHING’ terminals as appropriate. Two separate sounder outputs are provided to activate on level 1 and level 2 alarms respectively (terminal AV2 becomes active on alarm level 1; AV3 becomes active on alarm level 2). If a single tone sounder is used, connections should be to terminal AV2 (and the common terminal) only. The sounder will activate on alarm level 1. Terminal AV1 is intended to drive a visual alarm and activates on a level 1 alarm. CONNECTIONS FOR A 0V (-VE) SWITCHED A/V DEVICE
AUDIBLE VISUAL ALARM 1 BEACON +
Link Settings for 24V Alarm Devices
Figure 2.15 Connections for remote inhibit/accept/reset inputs
2.9 Connecting output devices WARNING: After accounting for internal power consumption, the maximum power available for input and output devices is 48 W
2.9.1. Audible visual alarms Figure 2.16 shows a typical wiring diagram for audible & visual (A/V) alarms, in this example a two-tone sounder is depicted. The A/V drive from Gasmaster is capable of providing up to 650mA, which equates to two general purpose A/V alarm
SOUNDER
V S1 S2
Link Settings for 12V Alarm Devices
24V VAV 12V
AV -ve
INHIBIT ACCEPT/ RESET 0V
REMOTE I/P
0V
Gasmaster is compatible with 12 V dc or 24 V dc A/V alarms (Gasmaster can be set for 12v or 24V output; not both): refer to Figure 2.16 for link settings.
24V VAV 12V
Global Inhibit
REMOTE I/P
Remote Accept/Reset
devices using xenon type beacons. A greater number of LED-based beacons may be powered; contact Crowcon for advice.
VAV AV3 AV2 AV1
Loop all connections to a second audible visual alarm if required.
Figure 2.16 Connections for AV drive
2.9.2. Common relay connections Double-Pole-Change-Over (DPCO) relays with contact rating of 250 V ac 8 A (non-inductive), 5 A (inductive) are provided for Alarm 1, Alarm 2 and Fault. Each relay can be set in its non-active state as energised (Fail safe) or de-energised. It is common practice to set the Fault relay as Fail Safe so in the event of power loss, the fault relay will change state. See Figure 2.5 for Common Relay terminal location and Figure 2.17 for contact definitions. Terminals are fitted adjacent to all relay blocks to provide 12 V or 24 V dc supplies for switching low power devices. The dc auxiliary
11
Installation
Crowcon Gasmaster
output terminals may be set to either 12 V dc or 24 V dc by moving the ‘V AV’ link. Refer to Figure 2.5 on page 7 for details Common Alarm and Fault relay configurations can be set using the User Control Panel and Menu System. See Section 3 "Operation" on page 17 for details.
POLE 1
C
Contacts shown de-energised (non-inverted)
POLE 2
NO
Contacts shown energised (inverted)
NC
NC
C
NO
Figure 2.17 Gasmaster contacts for all relays are identified on the terminal PCB.
2.9.3. Channel relay connections Gasmaster 4 provides Double-Pole-Change-Over (DPCO) relays for each channel. The relays provide a contact rating of 250 V ac 8 A (non-inductive), 5 A (inductive) for Alarm 1 and Alarm 2. Each relay can be set in its non-active state as energised (Fail safe) or de-energised. Refer to Figure 2.5 for location of Channel Relay terminals and Figure 2.17 for contact definitions. Terminals are fitted adjacent to all relay blocks to provide 12 V or 24 V dc supplies for switching low power devices. The dc auxiliary output terminals may be set to either 12 V dc or 24 V dc by moving the ‘V AV’ link. Refer to Figure 2.5 on page 7 for details Channel Alarm thresholds and configurations can be set using the User Control Panel and Menu System. See Section "3. Operation" on page 17 for details. Fire Channels Conventional fire channels will activate both Alarm 1 and Alarm 2 relays on the affected channel in the event of an alarm. The Common Alarm 2 relay will also activate (the Common Alarm 1 relay will
12
not activate). 4-20 mA flame detectors will activate two levels of alarm as per a gas detector. The Channel Alarm 1 relay will operate as ‘nonlatching’; this is not configurable. The Channel Alarm 2 and Common Alarm 2 relays can be configured as ‘latching’, ‘non-latching’ or ‘latching acceptable’. ESU Channels If the ESU sampling device slows significantly causing reduced sample flow the Alarm 1 relay for that channel will activate. If the sampling device stops the Alarm 2 relay will activate. The Common Alarm relays will not activate if the sampling device slows or stops. If the cable to the sampling device is open or short-circuited the Common Fault relay will activate.
2.9.4. Analogue outputs Gasmaster provides an analogue output for each channel which can be set as either 4-20 mA or 1-5 V dc by fitting a link (see Figure 2.18). These signals can be used to drive PLC/DCS/SCADA systems or remote displays. 4-20 mA outputs are current source (resolution 0.1 mA) and can drive a maximum load of 700 Ω, 1-5 V outputs require a minimum load of 50 KΩ. Analogue outputs will function in the following way: 4-20 mA gas detectors: the output will track the input from 3 to 21.5 mA, the signal will drop to 0 mA if the input rises above 21.5 mA to signal a fault. A sensor signal that is greater than 110% of range is designated by Gasmaster as a fault condition. The signal will be set to 2 mA to indicate when a channel is inhibited, and 0 mA when a channel is in fault. Fire channels: a signal of between 4 and 12 mA indicates a 'no-fire' condition, 12-20 mA indicates a fire, 0mA indicates a fault (open or short circuit). A 2 mA signal indicates that a channel is inhibited. ESU channels: a signal of between 4 and 12 mA indicates the sampling device is operating correctly, 12-20 mA indicates a sampling device failure, 0 mA indicates a fault (open or short circuit). A 2 mA signal indicates that a channel is inhibited. mV Pellistor channels: the output will rise between 4mA and 19.2mA according to the 0-95%LEL
input signal. If the ‘pellistor saver’ function is enabled, at 95%LEL (this value is adjustable) gas concentration the channel will enter ‘pellistor saver’ mode (refer to section 3.9); the channel will go into fault and the analogue output signal will be set to 0mA.
OUTPUT 4
OUTPUT 3
OUTPUT 2
OUTPUT 1
If the ‘pellistor saver’ function is disabled the analogue output will rise to a maximum of 25.8mA; the %LEL indication will depend on the gain levels set for the sensor. SCR 0V SIG
Link: 1-5V No Link: 4-20mA
SCR 0V SIG
Link: 1-5V No Link: 4-20mA
SCR 0V SIG
Link: 1-5V No Link: 4-20mA
SCR 0V SIG
Link: 1-5V No Link: 4-20mA
Figure 2.18 Gasmaster analogue output connection terminals
2.9.5. RS-485 communications
Installation
485A 485B SCR
J14
Crowcon Gasmaster
LK2
RS485 TERM
Figure 2.19 Gasmaster RS-485 terminals
2.10
Applying power
Before applying power ensure that any control or shutdown systems to which the Gasmaster is connected are inhibited. Once all field cables have been installed, the batteries can be connected as per the diagram attached to the chassis plate. (Refer to section 4.4.) Gasmaster will not power up until an external power supply is applied. Apply power to Gasmaster from either the AC or 24 V dc external supplies. Outputs are inhibited for a preset time after power-up, and the system will perform a start up sequence testing alarm indicators and the internal sounder. If after a settling period faults are reported, check the sensor connections again or refer to "Faults menu (lists faults present on the system)" on page 24. When power is applied the green Power LED will illuminate and flash every 5 seconds to indicate that the system is operational.
Gasmaster can provide alarm and system information to PLC/DCS/SCADA systems via a two-wire link using the Modbus RTU protocol (9600 baud, 8 data bits, no parity, 1 or 2 stop bits). Up to 16 Gasmaster systems can be 'multi-dropped' on a single two-wire link with a maximum cable length of 1 Km, two-core twisted pair cable is recommended. Single Gasmaster systems that are to communicate via the RS-485 link should have the RS485 TERM link made, which connects a terminating resistor. For multi-dropped systems the RS485 TERM link should be removed from all Gasmasters except the last unit on the line.
If the external supply fails, Gasmaster will continue to operate from its internal batteries and the Power LED will flash every second. Depending on configuration, Gasmaster will display either a Warning (Warning LED lights and the sounder will beep every 5 seconds) or a fault (the Fault LED and sounder will activate, and the fault relay will change state).
A Modbus specification document is available from Crowcon on request.
Note: your Gasmaster is supplied pre-configured, refer to the Specification and Inspection Certificate provided with your system. If no channels are configured, Gasmaster will display the following screen:
The RS-485 terminals on Gasmaster systems ordered with the optional local communications connector will be used for terminating the connector leads. These leads must be removed if a remote RS-485 serial link is required.
Gasmaster should display all channels being monitored. Allow sensors to settle before commencing calibration, refer to sensor instructions supplied with detectors for recommended settling times.
13
Installation
Crowcon Gasmaster
No detectors!
Please configure To configure your system go to page 25.
2.11
Battery back-up times
Gasmaster is fitted with 1.2 Ah batteries to provide continued operation in the event of a power loss. Examples of typical back-up times are provided below for a system in a non-alarm state, relays set as de-energised and with the 4-20mA outputs unused (system current consumption without detectors is approximately 50mA): Gasmaster 1 with a toxic gas detector (2-wire): 21 hours Gasmaster 1 with an oxygen detector (2-wire): 16 hours Gasmaster 1 with a mV pellistor flammable gas detector: 12 hours Gasmaster 4 with four toxic gas detectors (2-wire): 10 hours Gasmaster 4 with four oxygen detectors (2-wire): 4 hours Gasmaster 4 with four mV pellistor flammable gas detectors: 3 hours Gasmaster incorporates protection to prevent the internal batteries being damaged by being deeply discharged. When operating from internal batteries, Gasmaster will display a "Warning battery low" fault message when the battery voltage drops to 22 V. When the voltage drops to approximately 20 V, the batteries will be automatically disconnected. The batteries will only be re-connected when the external power supply is re-instated, and will take approximately 18 hours to fully re-charge. Note: The internal batteries may not be charged efficiently when Gasmaster is powered from an external dc supply, and therefore the back-up function may not work if the external supply fails Please contact Crowcon for further advice.
14
2.12
Commissioning
Note: it is strongly recommended that persons intending to commission a Gasmaster system first read and understand the Operating instructions provided in section III. Operation. When all field devices have been connected and powered-up, commissioning can commence. Gas detectors should be calibrated according to their instructions, fire detectors should be tested using appropriate tools. Alarms should be simulated and actions noted to ensure that the system operates as intended. All warning devices should be checked, and interfaces with auxiliary equipment should also be verified. The Test and View menu's are provided for this purpose (see page 30 and on page 27).
2.12.1. Commissioning mV pellistor detectors It is essential for these types of detectors that the correct ‘head voltage’ and balance is set before attempting to zero and calibrate the sensor. To set the head voltage, measure the voltage across the ‘+’ and ‘-‘ terminals at the detector and adjust the ‘HEAD VOLTAGE’ potentiometer on the appropriate Gasmaster input module. Check the detector instructions for voltage settings: 2 V dc is typical for an Xgard Type 3 or 4 detector. Allow the sensor to warm-up for 1 hour and then adjust the amplifier balance as follows: connect a meter set in the dc mV range to test-points TP12 and TP13 on the Gasmaster mV pellistor input module. Adjust the ‘BALANCE’ potentiometer until the meter reads ‘300 mV'. The sensor is now ready for zeroing (having first checked no flammable gas is present) and calibration. Note: for some gas types or pellistor types in may be necessary to change amplifier gain settings. These procedures are explained on technical note FGM3001 which can be downloaded from the Partners section of the Crowcon website. Alternatively contact [email protected].
Crowcon Gasmaster
2.12.2. Zero adjustment and calibration Calibration must be carried out separately on individual gas detectors on Gasmaster. Follow calibration instructions supplied with each detector. Ensure at all times the local legislation and codes of practice are complied with. Allow detectors to stabilise for at least one hour before commencing calibration. Refer to detector manual for more information. Gasmaster provides Zero and Calibration Wizards to enable you to carry out calibration easily. These are accessed through the Operator Display Panel and Menu System. Section III. Operation provides detailed information on the menu structure and operator buttons. Zero adjustment 1. From the normal operating display, press the Continue button to enter the menu system. 2. Use the Up and Down buttons as necessary to select Supervisor and press Continue . 3. You will be asked to enter a password, press Continue . The default password is ZZZ (uppercase), use the Up and Down buttons to enter the first character of the password. Note: Double click the Up or Down button to move to the top or bottom of the alphabet list. To enter numbers or lower case characters, continue pressing the Up or Down button. When you have selected the correct character, press Continue , the cursor will move to the next character position. Continue entering the rest of the password. When you have finished press the Continue button twice. (See 3.7 in section III. Operation for details of entering text strings). 4. The Zero Wizard offers temporary Inhibit but you may wish to Inhibit all channels during the calibration process. How to set global inhibit:
Installation
From the Supervisor menu, scroll down to Inhibit and press Continue . Select All and press Continue . Use the Up or Down button to set inhibit to INHIBIT=ON, press Continue to accept. Use the Back button to return to the Supervisor menu. The Inhibit icons will appear on the channel display. How to set channel inhibit: Channel inhibit can be selected from the Inhibit menu or within the Zero or Calibrate menu. Follow the instructions provided above, selecting the Channel #n (where n represents the channel number) in place of All. 5. From the Supervisor menu, use the Up and Down buttons to select Zero by pressing the Continue button. 6. Select the channel to apply zero. Press the Continue button to step through the Zero Wizard. when ‘…Only continue if in clean air!…’ is
7. Press Continue
displayed, ensure the detector has been correctly zeroed first (i.e. 4 mA) Press Continue
to apply Zero now.
Gasmaster will display ‘Pass’ when zero is successful or ‘Fail’ if the detector zero is out of range. 8. Use the Continue button to Zero other channels or Back button to the Supervisor menu to continue calibration.
Calibration 1. Follow points 1 to 3 above in Zero adjustment to enter Supervisor mode. 2. Before you commence calibration, ensure the channels are inhibited prior to applying gas. Channels can be inhibited globally or individually. Follow the instructions given in step 4 in Zero Adjustment. 3. From Supervisor menu, scroll down and select Calibrate. 4. Select the channel to calibrate. Press the Continue button to step through the 15
Installation
Calibrate Wizard. Ensure the channels are inhibited prior to applying gas. 5. The next wizard screen displays the default calibration gas concentration as 50% of range. If necessary this calibration figure must be adjusted to match the concentration of the calibration gas used. Adjust the value using the Up and Down buttons as necessary and press Continue . 6. When "Apply Gas" is displayed, apply gas to the detector and press Continue , allow readings to settle. when the reading on 7. Press Continue the appropriate channel is stable, and the detector has been calibrated according to its instructions. Gasmaster will display ‘Pass’ when successful or ‘Fail’ if the detector signal is out of range. 8. Calibration is complete when ‘Purge’ is displayed, remove the gas from the detector. Use the Continue button to calibrate another channel or Back button to exit Supervisor mode and return to the main display. 9. Ensure that all channel inhibits are removed after calibration is complete.
2.12.3. Testing fire channels To test smoke detectors, inhibit the relevant FIRE channel and use a smoke test aerosol to test each detector on a loop in turn. The channel display will indicate FirE when the detector activates. Each detector on a loop should be reset before testing the next to ensure that all detectors activate the alarm. Heat detectors can be tested with a heat-gun using the same method as described above. Flame detectors can either provide a signal using contacts, or a 4-20 mA signal. A contact type detector will be connected as a conventional fire loop using 470 Ω series resistors and a 1K8 end of line resistor and will only indicate FIRE or FAULT. A 4-20 mA detector will be 16
Crowcon Gasmaster
connected directly as a 4-20 input, and may have various alarm levels to indicate UV or IR activation (please refer to the instructions supplied with the device for details). Flame detectors require a UV or IR torch (depending on detector type) to simulate alarms. Inhibit the relevant channel, shine the torch at the detector and check that FirE is shown on the Gasmaster display. For 4-20 mA detectors, also check that the appropriate alarm level is displayed.
2.12.4. Testing ESU channels To test a channel monitoring an ESU sampling device, inhibit the channel and manually slow the device, check that Alarm Level 1 is activated. Manually stop the device and check that Alarm Level 2 is activated. If the alarms do not activate the thresholds may need changing, refer to section 3.10 for details on how to change alarm levels. When commissioning is complete ensure that the system is left fully functional with no faults present and no channels inhibited.
Crowcon Gasmaster
Operation
3. Operation Every Gasmaster system is pre-configured by Crowcon, please refer to the Specification and Inspection Certificate provided with the product for configuration details. This section describes the operation of pre-configured units, and includes procedures for altering settings.
3.1 Gasmaster Operator Panel The Operator Panel allows you to communicate with Gasmaster. Use it to monitor the status of all attached field devices, determine system settings and configuration of field devices. Figure 3.1 shows the Operator Panel and typical display under normal, non-alarm monitoring conditions. Fault LED
Power LED
Alarm LED
Message and channel reminder display area
Accept/ Reset Up Down
Warning LED
Back
#1=CH4 #2=H2S #3=O2 #4=Fire
Continue
1
0 0 LEL
2
Channel display area
0 0 V/V
3
PPM
Channel number
4
Figure 3.1 Operator Display Panel and buttons
Gasmaster Display The User display provides continuous readings for up to 4 field devices plus a display area for user messages and channel number summary. Gasmaster 1 provides display for one field device plus the message area. Message display area In normal, non-alarm condition, the message area displays the channel numbers and detector types, e.g. CH4 refers to methane detector, see following example.
#1=CH4
#2=O2
#3=H2S
#4=FIRE
In the event of an alarm, this message area will display the channels in alarm and their location. See section 3.8 for more information on alarm conditions.
ALARM:
#1=CH4
Boiler room If more then one channel is in alarm, the alarm message will cycle through all messages.
In the case of a fault (or warning), brief details of the fault will be displayed. See section 3.9 for more information on fault conditions. Detailed fault and warning messages can be found in section 3.10.
FAULT:
=30
Chan #3 over range.. Note: User messages longer then sixteen characters are displayed as scrolling text. If fault and alarm conditions are present at the same time, alarm messages take priority. Channel display area Gasmaster 4 has a large clear display which shows all gas levels simultaneously. Gasmaster 1 has a display for one gas level only, see figure 3.2. The image below shows details of the channel display area and icons that are used on Gasmaster.
The # symbol represents the channel number (i.e. #1 is channel 1).
17