Transcript
Critical Environment Technologies “MAC” Second Generation MINI ANALOG GAS DETECTION CONTROLLER or
SELF-CONTAINED SYSTEM
INSTALLATION / OPERATION MANUAL REV: C NOV-25-2004
Unit 145, 7391 Vantage Way Delta, BC V4G 1M3 Canada Phone: 604-940-8741 Fax: 604-940-8745 Toll: 1-877-940-8741 www.critical-environment.com 1
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IMPORTANT NOTICE READ AND UNDERSTAND THIS OPERATION MANUAL PRIOR TO USING THIS INSTRUMENT. THIS INSTRUMENT SHOULD BE INSPECTED AND PROGRAMMED BY QUALIFIED AND TRAINED TECHNICIANS. THIS INSTRUMENT HAS NOT BEEN DESIGNED TO BE INTRINSICALLY SAFE. FOR YOUR SAFETY, DO NOT INSTALL IT IN CLASSIFIED HAZARDOUS AREAS (EXPLOSION-RATED ENVIRONMENTS).
DISCLAIMER UNDER NO CIRCUMSTANCES WILL CRITICAL ENVIRONMENT TECHNOLOGIES CANADA INC. BE LIABLE FOR ANY CLAIMS, LOSSES OR DAMAGES RESULTING FROM OR ARISING OUT OF THE REPAIR OR MODIFICATION OF THIS EQUIPMENT BY A PARTY OTHER THAN CRITICAL ENVIRONMENT TECHNOLOGIES OR IT’S AUTHORISED SERVICE REPRESENTATIVES, OR BY OPERATION OR USE OF THE EQUIPMENT OTHER THAN IN ACCORDANCE WITH THE PRINTED INSTRUCTIONS CONTAINED WITHIN THIS MANUAL OR IF THE EQUIPMENT HAS BEEN IMPROPERLY MAINTAINED OR SUBJECTED TO NEGLECT OR ACCIDENT. ANY OF THE FORGOING WILL VOID THE WARRANTY.
WARRANTY POLICY CRITICAL ENVIRONMENT TECHNOLOGIES CANADA INC. WARRANTS THIS INSTRUMENT TO BE FREE FROM DEFECTS IN MATERIALS AND WORKMANSHIP FOR A PERIOD OF TWO YEARS FROM THE DATE OF PURCHASE. THE WARRANTY STATUS MAY BE AFFECTED IF THE INSTRUMENT HAS NOT BEEN INSTALLED AND MAINTAINED AS PER THE INSTRUCTIONS INDICATED IN THIS MANUAL OR HAS BEEN ABUSED, DAMAGED OR MODIFIED IN ANY WAY. THIS INSTRUMENT IS ONLY TO BE USED FOR PURPOSES STATED HEREIN. THE MANUFACTURER IS NOT LIABLE FOR AUXILIARY INTERFACED EQUIPMENT OR CONSEQUENTIAL DAMAGE. THE WARRANTY STATUS WILL BE AFFECTED (VOIDED) IF THE INSTRUMENT HAS NOT BEEN INSTALLED AND MAINTAINED AS PER THE INSTRUCTIONS INDICATED IN THIS MANUAL OR HAS BEEN ABUSED OR DAMAGED (ROUGH HANDLING, MECHANICAL DAMAGE, ELECTRICAL SHOCK DAMAGE, ETC.) IN ANY WAY. THIS INSTRUMENT IS ONLY TO BE USED FOR THE PURPOSES STATED HEREIN. THIS WARRANTY INDICATES THE FULL EXTENT OF OUR LIABILITY AND WE ARE NOT RESPONSIBLE FOR REMOVAL OR REPLACEMENT COSTS, LOCAL REPAIR COSTS, TRANSPORTATION COSTS OR CONTINGENT EXPENSES INCURRED WITHOUT PRIOR APPROVAL. CRITICAL ENVIRONMENT TECHNOLOGIES CANADA INC. WILL NOT BE HELD LIABLE FOR INDIRECT, INCIDENTAL OR CONSEQUENTIAL LOSS OR DAMAGE OF ANY KIND TO EQUIPMENT CONNECTED, IN ANY WAY, TO THE EQUIPMENT MANUFACTURED BY US. THIS WARRANTY COVERS EQUIPMENT AND PARTS SOLD TO USERS ONLY BY AUTHORISED DISTRIBUTORS, DEALERS, AGENTS OR REPRESENTATIVES,AS AUTHORISED AND APPOINTED BY CRITICAL ENVIRONMENT TECHNOLOGIES CANADA INC. DUE TO ONGOING RESEARCH, DEVELOPMENT AND PRODUCT TESTING, THE MANUFACTURER RESERVES THE RIGHT TO CHANGE SPECIFICATIONS WITHOUT NOTICE. THE INFORMATION CONTAINED HEREIN IS BASED ON DATA CONSIDERED ACCURATE. HOWEVER, NO WARRANTY IS EXPRESSED OR IMPLIED REGARDING THE ACCURACY OF THIS DATA. ALL GOODS MUST BE SHIPPED TO THE MANUFACTURER BY PREPAID FREIGHT. ALL RETURNED GOODS MUST BE ACCOMPANIED BY AN RMA NUMBER.
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SERVICE POLICY CRITICAL ENVIRONMENT TECHNOLOGIES MAINTAINS AN INSTRUMENT SERVICE FACILITY AT THE FACTORY. SOME CRITICAL ENVIRONMENT TECHNOLOGIES DISTRIBUTORS / AGENTS ALSO HAVE REPAIR FACILITIES, HOWEVER, CRITICAL ENVIRONMENT TECHNOLOGIES ASSUMES NO LIABILITY FOR SERVICE PERFORMED BY ANYONE OTHER THAN CRITICAL ENVIRONMENT TECHNOLOGIES’ PERSONNEL. REPAIRS ARE WARRANTED FOR 90 DAYS AFTER DATE OF SHIPMENT (SENSORS, PUMPS AND BATTERIES HAVE INDIVIDUAL WARRANTIES). SHOULD YOUR INSTRUMENT REQUIRE NON-WARRANTY REPAIR, YOU MAY CONTACT THE DISTRIBUTOR FROM WHOM IT WAS PURCHASED OR YOU MAY CONTACT CRITICAL ENVIRONMENT TECHNOLOGIES DIRECTLY. IF CRITICAL ENVIRONMENT TECHNOLOGIES IS TO DO THE REPAIR WORK, YOU MAY SEND THE INSTRUMENT, PREPAID, TO CRITICAL ENVIRONMENT TECHNOLOGIES , UNIT 145, 7391 VANTAGE WAY, DELTA, B.C. V4G 1M3, ATTN: SERVICE DEPARTMENT. ALWAYS INCLUDE YOUR ADDRESS, TELEPHONE NUMBER, CONTACT NAME, SHIPPING / BILLING INFORMATION AND A DESCRIPTION OF THE DEFECT AS YOU PERCEIVE IT. YOU WILL BE CONTACTED WITH A COST ESTIMATE FOR EXPECTED REPAIRS, PRIOR TO THE PERFORMANCE OF SERVICE WORK. FOR LIABILITY REASONS, CRITICAL ENVIRONMENT TECHNOLOGIES HAS A POLICY OF PERFORMING ALL NEEDED REPAIRS TO RESTORE THE INSTRUMENT TO FULL OPERATING CONDITION. PRIOR TO SHIPPING EQUIPMENT TO CRITICAL ENVIRONMENT TECHNOLOGIES CONTACT OUR OFFICE FOR AN RMA # (RETURNED MERCHANDISE AUTHORIZATION). ALL RETURNED GOODS MUST BE ACCOMPANIED WITH AN RMA NUMBER. PACK THE EQUIPMENT WELL (IN IT’S ORIGINAL PACKING IF POSSIBLE), AS WE CANNOT BE HELD RESPONSIBLE FOR ANY DAMAGE INCURRED DURING SHIPPING TO OUR FACILITY.
MANUAL REVISIONS ALL INFORMATION CONTAINED IN THIS MANUAL IS BELIEVED TO BE TRUE AND CORRECT AT THE TIME OF PRINTING. HOWEVER, AS PART OF IT’S CONTINUING EFFORTS TO IMPROVE IT’S PRODUCTS AND THEIR DOCUMENTATION, CRITICAL ENVIRONMENT TECHNOLOGIES RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE. REVISED COPIES OF THIS MANUAL CAN BE OBTAINED BY CONTACTING CRITICAL ENVIRONMENT TECHNOLOGIES CANADA INC.
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INDEX
SECTION
DESCRIPTION
PAGE
Notice and warranty policy
3-4
1.0
Introduction
7
2.0
General specifications
7-9
2.1
Configurations available
9
2.2
Warm Up Periods
10
2.3
Integral sensor specifications -Table-1
11
3.0
One sensor general purpose enclosure exterior drawing
12
3.1
One sensor general purpose enclosure interior layout drawing
13
3.2
Two sensor general purpose enclosure exterior drawing
14
3.3
Two sensor general purpose enclosure interior layout drawing
15
3.4
Controller general purpose enclosure interior layout drawing
16
4.0
Installation
17
4.1
Mounting heights
17-18
4.2
Power for MAC
18
4.3
Wiring a MAC
19-21
5.0
System operation
22-23
5.1
Test Functions
24
5.2
Relays
24
5.3
Time delay functions -Table-2
24-25
5.4
Adjusting alarm set points
25-28
5.41
Low gas alarm ascending set point adjustment
26
5.42
High gas alarm ascending set point adjustment
26
5.43
Low gas alarm descending set point adjustment
26-27
5.44
High gas alarm descending set point adjustment
27
5.5
Sensor ranges & alarm set point references -Table-3
28
6.0
Calibrating analog output
29-30
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INDEX, CONT’D…..
SECTION
DESCRIPTION
PAGE
6.1
Calibrating 4-20 mA portion of analog output module
29
6.11
Calibrating low range output (4.00 mA)
29
6.12
Calibrating high range output (20.0 mA)
29
6.2
Calibrating 0-10 VDC portion of analog output module
30
6.21
Calibrating high range output (10.0 VDC)
30
7.0
Calibrating sensors
30-33
7.1
Calibration specifications
31
7.2
Calibration procedure
31
7.21
Setting span gas value
31-32
7.22
Calibrating null (zero) value
32
7.23
Calibrating span gas value
32-33
7.24
Calibration Set-Up Photo
33
8.0
Options / Accessories for MAC controller
34-35
8.1
Water/dust tight controller enclosure
34
8.2
Splash guard
35
8.3
Strobe / siren combo alarm device
35
8.4
Strobe light
36
8.5
Analog output module
36
9.0
Accessories
37-38
9.1
Calibration kit
37
9.2
Metal protective guards
38
10.0
Trouble Shooting
38-39
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1.0 INTRODUCTION
The MAC-ll series systems are rugged, user-friendly, configurable controllers or self-contained gas detectors for use in non-hazardous (non-explosion rated) environments for commercial HVAC and light industrial use. They can be configured for use with one or two sensors, integral or remote. A standard system provides a tri-colour LED indicating light for power, fault, low alarm and high alarm, audible alarm with silence push-button, two dry contact relays, optional analog output signal, optional LED digital display and other enclosure options. A large selection of electrochemical sensors, MOS (Metal Oxide Semiconductor) sensors, catalytic combustible sensors or infrared sensors are available for use with this gas detector. The sensors utilized in the MAC are more than accurate enough to measure to Occupational Health & Safety exposure levels for toxic and combustible gases and Oxygen deficiency and excess. Note: The MAC-II gas detectors operate by diffusion. If a sample draw system is desired, consult a CETCI authorized distributor or the factory for details.
2.0 GENERAL SPECIFICATIONS
Physical:
Standard pvc enclosure: a) Dimensions: 7.52” (191 mm) wide X 8.24” (209 mm) high X 3.36” (85 mm) deep b) Weight: pounds ( kg) Optional water / dust tight enclosure: a) Dimensions: 6.90” (175 mm) wide X 8.50” (216 mm) high X 4.30” (109 mm) deep b) Weight:
Construction:
Standard enclosure: Rugged PVC with hinged, secured door and Lexan door label. Door has 1/2” overlap making it drip-proof Water/Dust tight enclosure: Rugged fiberglass reinforced polyester with hinged, secured door and Lexan door label
Strobe Output:
Maximum 12VDC @ 200 mA (3” diameter strobe light with red lens) Maximum 24VDC @ 300 mA (4” diamter strobe light with red lens) Note-1: The current ratings indicated here are the maximum that can be utilized by the strobe voltage supply output of the MAC controller Note-2 Ratings indicated are for strobe lights supplied by CETCI
Power:
Scenario-1: No strobe light connected to system: 12VAC to 30VAC or 16VDC to 30VDC Scenario-2: One strobe light connected to system: 16VAC to 30VAC or 18VDC to 30 VDC 7
2.0 GENERAL SPECIFICATIONS, CONT’D…..
Current draw:
Scenario-1: 18VDC power supply utilized to power system and current is measured at the 18VDC power supply line. a) System with relays normally energized: 130 mA b) System with relays normally energized and LED digital display and installed: 140 mA c) System with relays normally energized and LED digital display and analog output board installed: 170 mA d) System with relays normally energized, LED digital display and analog output board installed plus one 12VDC strobe light attached: 250 mA e) System with relays normally energized, LED digital display and analog output board installed, one 12VDC strobe light attached and one remote mount analog transmitter with solid-state sensor attached: 430 mA Scenario-2: 16VAC power supplied from transformer and current measured at the 16VAC power supply line. a) System with relays normally energized: 170 mA b) System with relays normally energized and LED digital display and installed: 190 mA c) System with relays normally energized and LED digital display and analog output board installed: 210 mA d) System with relays normally energized, LED digital display and analog output board installed plus one 12VDC strobe light attached: 320 mA e) System with relays normally energized, LED digital display and analog output board installed, one 12VDC strobe light attached and one remote mount analog transmitter with solid-state sensor attached: 520 mA
Relays:
Standard: Two only S.P.D.T. dry contact relays rated 5 amps @ 240 VAC each
Indicators:
a) One tri-colour LED: Green = power, Amber = Low alarm, Red = High alarm, Flashing Red = Fail b) Amber colored, LED light, relay coil status indicators (internal) c) 4-20 mA “open loop” indicator (red LED) for remote transmitter d) Audible alarm 80 dB @ 10’ (optional 90 dB @ 10’)
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2.0 GENERAL SPECIFICATIONS, CON’T…..
Options
a) LED digital display (3.5 digits) b) Analog output signal: 4-20 mA or 0-10VDC field selected with jumper c) Water/dust tight enclosure (see specifications above) d) Splash guard (water tight controller and transmitter enclosure only) e) Top mounted strobe, siren or combination strobe/siren alarm f) data logger g) transformer (totally enclosed step down) h) Sample draw system
Sensors (Remote): “AST” Analog Transmitters All of the gas sensors indicated on page 11 plus any sensor available in the AST series remote analog transmitters.
2.1 CONFIGURATIONS AVAILABLE
1) MAC Type-A: Self-contained system with one integral electrochemical sensor:
2) MAC Type-B: One integral circuit board acting as a controller to accommodate one remote AST series analog sensor / transmitter 3) MAC Type-C: Two integral circuit boards acting as controllers to accommodate two remote AST series sensor / transmitters 4) MAC Type-D: Self-contained system with one integral electrochemical sensor and one integral circuit board acting as a controller to accommodate one remote AST series analog transmitter 5) MAC Type-E: Self-contained system with two integral electrochemical sensors Note-1: If solid-state or catalytic sensors are required, they can be accommodated by the MAC as remote mount analog transmitters. The MAC accepts only electrochemical sensors integrally.
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2.1 CONFIGURATIONS AVAILABLE, CONT’D…..
MAC-A-MCO (SINGLE INTEGRAL SENSOR STAND-ALONE)
MAC-C-N (TWO CHANNEL CONTROLLER WITH OPTIONAL DIGITAL DISPLAY
MAC-B-N (SINGLE CHANNEL CONTROLLER WITH OPTIONAL DIGITAL DISPLAY
MAC-EMCO-END (DUAL INTEGRAL SENSORS STAND-ALONE) CO AND NO2 COMBINATION SHOWN
2.2 WARM UP PERIODS Typically the MAC controller will flash the front door LED green for two-minutes for most applications. This indicates the system has been recently powered up and is in a warm-up period. For systems utilizing Ammonia, Chlorine or Ozone sensors (integral or remote), the warm up period is five-minutes.
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2.3 INTEGRAL SENSOR SPECIFICATIONS
SENSOR TYPE
MEASUREMENT RANGE
DEFAULT LOW SET POINT
DEFAULT HIGH SET POINT
ESTIMATED LIFE SPAN
Ammonia (NH3) (see note-2 0-500 ppm below)
25 ppm
100 ppm
2-3 years
Carbon Monoxide (CO)
0-200 ppm
25 ppm
100 ppm
5-8 years
Chlorine (Cl2) (see note-1 below)
0-5.0 ppm
0.5 ppm
1.0 ppm
2-3 years
Ethylene Oxide (ETO)
0-10.0 ppm
1.0 ppm
2.0 ppm
2 years
Hydrogen (H2)
0-2000 ppm
500 ppm
1000 ppm
2-3 years
Hydrogen Chloride (HCl)
0-10 ppm
2 ppm
5 ppm
2-3 years
Hydrogen Cyanide (HCN)
0-10 ppm
2 ppm
5 ppm
2-3 years
Hydrogen Sulphide (H2S) (see note-1 below)
0-50 ppm
10 ppm
15 ppm
2-4 years
Nitric oxide (NO)
0-100 ppm
50 ppm
100 ppm
2-3 years
Nitrogen Dioxide (NO2)
0-5.0 ppm
0.7 ppm
1.5 ppm
3-4 years
Oxygen (O2)
0-25.0% Volume
19.5% Vol.
18.0% Vol.
2 years
Ozone O3 (see note-1 below)
0-2.0 ppm
0.10 ppm
0.30 ppm
2 years
Sulphur Dioxide SO2 (see note-1 below)
0-20 ppm
2 ppm
5 ppm
2-4 years
Table-1
Note-1: Chlorine, Ethylene Oxide, Hydrogen Cyanide, Hydrogen Sulphide, Ozone and Sulphur Dioxide are corrosive/reactive gases and if the user desires an integral sensor, the water tight enclosure option is recommended. It is recommended that these sensors be utilized in a remote analog transmitter enclosure. The transmitter enclosure supplied with these sensors are water tight as a standard (no extra cost). If the user selects the general purpose pvc enclosure with one of these three sensors installed integrally, the warranty may be voided if corrosion damage occurs. Note-2: Other ranges are available for the above sensors upon request. However, it should be noted that selecting a small range for a sensor that has a much larger measuring range can result in some signal instability at the low end measurements. The “0” readings may drift a little.
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3.0 ONE-SENSOR GENERAL PURPOSE ENCLOSURE EXTERIOR DRAWING
12
3.1 ONE-SENSOR GENERAL PURPOSE ENCLOSURE INTERIOR LAYOUT DRAWING
13
3.2 TWO-SENSOR GENERAL PURPOSE ENCLOSURE EXTERIOR DRAWING
14
3.3 TWO-SENSOR GENERAL PURPOSE ENCLOSURE INTERIOR LAYOUT DRAWING
15
3.4 CONTROLLER GENERAL PURPOSE ENCLOSURE INTERIOR LAYOUT DRAWING
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4.0 INSTALLATION
The MAC-II should be installed on a flat vertical surface with the sensor pointing outwards in a clean, dry environment. If the MAC-II is to be installed in a potentially wet environment, the optional water tight enclosure should have been selected. This reference refers to the standard, general purpose pvc enclosure. Four 3/8” diameter mounting holes are provided in the enclosure base for securing the MAC to the wall. Do not block the front of the enclosure as this is where the MAC sensor is situated and where it monitors the air for the target gas. Note-1: Provide enough room to allow the end user to open the door fully to access the internal adjustments. Two conduit entry points are provided. One through the bottom of the enclosure base and one through the back of the enclosure base. Reference drawings on preceding pages. Note-2: DO NOT USE SOLID-CORE WIRE AT THE WIRING TERMINAL STRIP. The memory in solid-core wire can pull a soldered terminal strip off a circuit board. The door of a MAC-II controller can be easily removed to facilitate installation of the base. Simply grasp the lid with one hand, being careful not to make contact with any of the internal components, grasp the base with your other hand. Tug on the base, pulling it towards you. The section of the hinges located on the base should “snap” apart from the part of the hinges located on the door. After installation, simply locate the lid hinges over the installed base hinges and pull toward you The hinges should easily “snap” back into place. The MAC-II enclosure has one screw securing the door to the base for electrical safety and provides an opening to allow the user to apply a padlock if they desire the controller to be locked. See drawing reference on preceding pages. The MAC-II enclosure, by design of the substantially overlapping door, is drip-proof. It is not water tight or dust tight. An optional water / dust tight enclosure is available. Note-3: The MAC-II gas detector is a low voltage powered device. If the installer wishes to use line voltage to power the MAC-II, a totally enclosed transformer can be ordered as an option from CETCI. This allows the installer to mount the transformer just below the MAC-II enclosure. The transformer enclosure has conduit “knock outs” for ease of installation. This transformer steps 120VAC line voltage down to approximately 20VAC to power the MAC-II. For 200 to 240 VAC line voltage application, contact the CETCI factory. Reference drawings at sections 3.1 and 3.2
4.1 MOUNTING HEIGHTS
Carbon Monoxide, Nitrogen Dioxide (see note-1), Carbon Dioxide (see note-2), Nitric Oxide, Oxygen (about the same weight as air): 4’ to 6’ from the floor (breathing zone) Ammonia, Methane, Hydrogen (lighter than air): On or near the ceiling H2S, Chlorine, Ozone, Propane, Sulphur Dioxide, Refrigerants (see note-3) (heavier than air): 6” from the floor Note-1: Although NO2 is heavier than air, we recommend mounting NO2 sensors for vehicle exhaust applications, in the “breathing zone” so the detectors are monitoring the air “we” breath.
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4.1 MOUNTING HEIGHTS, CON’T…..
Note-2: Although CO2 is heavier than air, we recommend mounting CO2 sensors in the “breathing zone” for some applications. Note-3: Although most refrigerants (Freons) are heavier than air some applications may be better suited to a slightly higher mounting height for refrigerant sensors.
4.2 POWER FOR MAC CONTROLLER
All MAC detectors are low voltage powered devices. If the installer wishes to utilize line voltage to power the MAC, a step down transformer must be utilized. For ease of installation, CETCI can provide an optional totally enclosed transformer that can be installed directly underneath the MAC controller enclosure. This transformer steps the power down from 120VAC to 22VAC. The metal enclosure for the transformer has knock outs to accommodate easy installation of conduit. Reference the following drawing and photo. Optionally, the installer can provide his own step down transformer.
DIGITAL PHOTO # 1: TOTALLY ENCLOSED TRANSFORMER
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4.3 WIRING A MAC
System power: The main wiring terminal strip on the MAC circuit board can be unplugged for easier wiring installation. Grasp the two sides of the terminal strip and lift upward with a slight rocking motion. Reference digital photos on the following pages. Attach two power wires for 24V nominal supply voltage (see specifications for input power range) to the two bottom wiring terminals. These terminals are not polarity sensitive. Alternatively, if the totally enclosed transformer option has been supplied, install the transformer underneath the MAC enclosure and join the two devices with a short piece of conduit (reference drawings in section 3.1 and 3.3). Relays: Attach relay control wiring to the alarm relays wiring terminals, if they are to be utilized. Note the rating on the relays from the specifications section. DO NOT EXCEED THIS CONTACT LOAD. Damage as a result of overloading the system relays is not covered by the system warranty. DO NOT USE HEAVY GUAGE, SOLID-CORE WIRE AT THE SYSTEM WIRING TERMINALS. IT MAY DAMAGE THE MAIN BOARD. Damage resulting from the use of heavy gauge, solid-core wire is not covered under warranty. For normal, fail-safe operation, attach relay control wiring to “N/C” (normally closed) and “COM” (common) wiring terminals. Typically exhaust fans and make up air fans are activated from low alarm status. Note-1: The relays utilized in the MAC controller are standard Form-C, dry contact relays. Relays act like a switch to turn things on and off. They do not provide voltage or current to power a remote device. Note-2: If the application is a car park and the exhaust fans run continuously after power up warm up, the most likely scenario is that the installer has wired the fan control to the “N/O” and “COM” terminals. This is easily rectified by moving the wire from the “N/O” wiring terminal to the “N/C” wiring terminal. Note-3: Reference the wiring connections drawing in section 3.1 and section 3.3 Note-4: If a MAC-II “E” type system has been supplied and the user wants either integral sensor to activate all four system relays in the event of an alarm condition, the installer must jumper the relays in the top circuit board to the relays on the lower circuit board. MAC systems supplied with an electrochemical toxic gas or Oxygen sensor come with the sensor installed internally. It cannot be mounted remotely. If a remote sensor is required, attach any AST series analog transmitter. using 3-wire, shielded cable. If a MAC-II has been purchased with a remote analog sensor / transmitter, it can be installed up to 2000’ away from the controller with a minimum 18 gauge wire. If the strobe or alarm output voltage terminal is to be utilized to provide power and activation for a strobe light or other such alarm device, attach two 18 gauge wires to the terminal strip labeled “STROBE”. Note-5: Make sure the jumper just to left of this terminal strip has been set in the correct position for the required output voltage (12VDC or 24 VDC). Check the specifications section to make sure the device you are providing voltage to does not exceed the maximum current draw of the board.
DIGITAL PHOTOS #2 SETTING VOLTAGE OUTPUT FOR REMOTE ALARM
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4.3 WIRING A MAC, CONT’D…..
RELAY COIL LED INDICATORS
MAIN WIRING TERMINAL STRIP PLUGGED
WIRING TERMINAL FOR ALARM OUTPUT 12/24 VDC
JUMPERS FOR PERFORMING VARIOUS FUNCTIONS
DIGITAL PHOTO #3 MAIN CIRCUIT BOARD WITH LOCATORS
TP-5 AND TP-6 TEST POINTS
MAIN WIRING TERMINAL STRIP UNPLUGGED
TIME DELAY DIP SWITCHES OPEN LOOP LED INDICATOR FOR ANALOG INPUT (TRANSMITTER)
JUMPER SELECT 12/24 VDC ALARM OUTPUT
RIBBON CABLE HEADER FOR ANALOG OUTPUT BOARD
DIGITAL PHOTO #4 MAIN CIRCUIT BOARD WITH LOCATORS 20
4.3 WIRING A MAC, CONT’D…..
N/C - LOW RELAY (DRY CONTACT) COM - LOW RELAY (DRY CONTACT) N/O - LOW RELAY (DRY CONTACT) N/C - HIGH RELAY (DRY CONTACT) COM - HIGH RELAY (DRY CONTACT) N/O - HIGH RELAY (DRY CONTACT) POSITIVE (4-20 mA ANALOG TRANSMITTER INPUT)
DIGITAL PHOTO #5 WIRING CONNECTIONS FOR MAC
NEGATIVE (4-20 mA ANALOG TRANSMITTER INPUT) SIGNAL (4-20 mA ANALOG TRANSMITTER INPUT) 24V INCOMING POWER 24V INCOMING POWER
If an analog output signal option has been supplied, attach a 2-wire, 18 to 20 gauge, shielded cable to the wiring terminal. The analog output signal is supplied by a small additional circuit board mounted inside the base of the enclosure. This circuit has an “open loop” indicator to provide a minimum amount of trouble-shooting for the end user. The red “LOOP” indicating LED illuminates if the 4-20 mA loop has not been installed properly. This loop indicator is illuminated all the time if the 0-10VDC output signal has been selected. Reference digital photo # 6 below. Note-6: Make sure the jumper just below this terminal strip has been set in the correct position for the required output signal (4-20 mA or 0-10VDC). Reference digital photo #6 below.
SIG+ COM
RIBBON CABLE HEADER TO CONNECT TO MAIN BOARD
“OPEN LOOP” LED
4-20 mA OUT 0-10VDC OUT
DIGITAL PHOTO # 6: ANALOG OUTPUT BOARD OPTION
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5.0 SYSTEM OPERATION
After installation, double check wiring prior to applying power to the MAC-II controller. Remember, these are low voltage operating systems. After power up, the tri-colour LED will flash green indicating the system is in a warm-up period (see page-10 for details). During the warm-up period, the visual and audible alarms and the system relays are disabled. If a digital display option has been selected, the LED display will indicate a scrolling decimal “…..”. In a non-alarm state, the tri-colour LED will be illuminated green and the two amber relay coil LEDs internally will also be illuminated. The relay coil LEDs indicate to the user that the relay coils are energized. The MAC controllers have been designed to operate in a fail-safe manner, meaning that the relay coils are energized in non-gas-alarm state and de-energize when a gas alarm is indicated. As noted in section 4.4, this achieved by wiring the device to be controlled to the “N/C” (normally closed) and “COM”” (common) terminals. In the event of a sensor failure, the system fail condition is activated and anything controlled by the system relays is activated continuously until the fail condition has been corrected. Note: The installer has the option of wiring to “N/O” (normally open) and “COM” (common) terminals, however it must be noted that the system will no longer be operating in a fail-safe state. A sensor failure will then simply activate the front LED to change to flashing red and activate the audible alarm.
GAS ALARMS Upon detection of a concentration of target gas above the preset low alarm threshold, the tri-colour LED on the front door changes to amber colour and the low alarm relay de-energizes unless an “ON” time delay has been selected from the on board DIP switches. Upon detection of a concentration of target gas above the preset high alarm threshold, the tri-colour LED on the front door changes to red colour, the audible alarm sounds (unless it has been switched off at the on board DIP switches) and the high alarm relay de-energizes unless an “ON” time delay has been selected from the on board DIP switches. At this time, power is also activated to the alarm output terminal strip to activate a remote alarm. This output can supply 12VDC power or 24VDC power depending upon which position the user has selected with the jumper. Factory default setting is at 12VDC jumper position. During a high gas alarm condition, the low gas alarm condition, which has already been activated, stays activated until the alarm state resets. Both alarm levels will automatically reset themselves and the relays will re-energize unless a time delay “OFF” (minimum run time) has been selected from the on board DIP switches or the “latching” function has been set. If the latching function has been set, use the acknowledge button on the enclosure door to reset the relays after the alarm condition has subsided The two gas alarm levels are field adjustable. More details are provided further on in this manual. Audible Time Delay: The MAC also provides the end user with a time delay for the audible alarm. If a time delay has been programmed and the system goes into high level gas alarm, the audible alarm will not be activated until the delay times out. Note: The audible time delay can only be set with the use of the “Device Master” terminal software program. This function should be noted at the time of placing an order for a MAC product.
FAIL CONDITION In the event of a failure, the tri-colour LED on the front door will flash red, both alarm relays will de-energize and the audible alarm will sound. A failure can consist of a burned out sensor element (solid-state or catalytic only and available in analog transmitters only), any sensor drifting into the negative or a failed sensor or component on the circuit board. 22
5.0 SYSTEM OPERATION, CONT’D….. FAIL CONDITION, CONT’D….. Note: The built-in audible alarm can be silenced by depressing the silence push-button on the outer door or switched off from one of the on board DIP switches. To silence the audible, depress the silence button momentarily. This will not eliminate the alarm status but simply silences the audible alarm. The silence push-button is located on the centre of the top edge of the standard pvc enclosure or on the centre of the front door of the water tight enclosure. Important: It should be noted that switching the audible alarm off from the internal DIP switch prevents any audible notification of high gas or fail conditions to the end user. This may be deemed an unsafe operating condition in some applications. OTHER WARNINGS Notification of calibration: All sensors require calibration to maintain accuracy and best performance. This is an audible / visual warning and has been factory set at either 6 or 12 months. At 6 or 12 months, the audible alarm will beep five times every hour to remind the user that the system is due for calibration. The end user can disable this feature for 1 month by depressing both the “up” and “down” push buttons simultaneously. After 1 month, the audible/visual reminder will reactivate and once again, the user has the option of disabling this function again for 1 month or having the instrument calibrated. If the system is recalibrated, the system timer is automatically reset for another 6 or 12 months (or whatever the factory default setting was at the time of ordering). Note-1: For sensors detecting gases with lower ranges (Chlorine, Ozone, Ammonia) and lower alarm set points or reactive gases, the calibration timer is factory set at 6 months. Note-2: During the calibration warning state, other normal functions are temporarily disabled until the detector is calibrated or the notification function has been temporarily disabled.
POWER The MAC systems work well with either 24 VAC or 24 VDC (nominal) and the two wiring input terminals are not polarity sensitive. The circuit has a built-in thermal fuse to protect it. If this fuse “blows”, simply disconnect at least one incoming power wire and allow the fuse to cool down for about five minutes. It will then reset itself unless there has been more serious damage to the input circuit.
BACK-UP POWER The most economical way to provide back-up power to this gas detector when power is “down”, is to purchase a low cost UPS (Uninterrupted Power Supply) similar to what is typically used with a PC. They are readily available and low cost. Consult specifications for power consumption details.
ANALOG SIGNAL OUTPUT If the analog output option has been purchased, the MAC provides a linear 4-20 mA or 0-10VDC (jumper selectable) analog output signal which can be “fed” into a DDC, BAS, PLC, data logger, etc. Reference digital photo # 6 on page 21.
23
5.1 TEST FUNCTIONS
1) Circuit Test: Hold the silence push-button in for 5 to 7 seconds then release. The system performs a circuit test. The low alarm relay is de-energized for 10 seconds then re-energized. Next, the high relay is de-energized for 10 seconds and the audible alarm is activated for 10 seconds then both are reset. If the MAC-II model being tested has been fitted with a digital display, the display indicates “tESt” during this test function. Note: During this test period, any devices controlled by the system relays will be activated for 10 seconds. 2) Sensor Bypass: Hold silence push-button in for 10 to 13 seconds then release. Both relays are de-energized for 15 minutes. After the 15 minute time period, they return to normal operation (activated by sensor responses). This function allows the user to bypass sensor control and run any exhaust fans that are controlled by the system relays to evacuate the air in one or more areas of the car park. During this bypass sequence of operation, the system functions normally, activating visual and audible alarms as they are initiated by the sensor. 3) Sensor Test: The circuit automatically performs a response test on any integral sensor, once per month. If the expected response is not received, the fail alarm is activated to notify the end user that the sensor needs to be checked and may need to be replaced. Important Note: During this self test function, the sensor outputs a large current to the circuit and thus to avoid annoying alarm conditions, all system functions are halted for the period of the test (3 to 5 minutes).
5.2 RELAYS
The system relays are Form-C, S.P.D.T. (Single pole, double throw) meaning that the MAC controller provides both normally open and normally closed contacts for the end user to access. Each relay is rated 5 amps @ 240VAC (dry contact load rating). In normal operating, non gas alarm condition, the relay coils are energized for fail-safe operation. In an alarm condition, the relay coils de-energize. The installer should wire normal controlled devices to the normally closed and common terminals. The system relays can also be utilized as ‘latching” meaning they stay de-energized after activation until they are manually reset. They can be reset by pushing the silence push-button once. If the system is indicating a high gas alarm, and both relays are in a de-energized state and the audible alarm is activated, the user can silence the audible alarm by pushing the silence button. The system will not allow the user to re-energize the relay coils again until after the gas alarm has gone, meaning that the end user must push the silence button again to reset the relays. To set the system relays to “latching” follow this procedure: 1) Move the jumper to J9 position. The audible alarm “beeps” for confirmation. The system is now waiting for the user to set the desired value. Reference digital photo #8 on page 27. 2) To set the relays into the latching mode, push the “UP” push-button once. To take the relays out of the latching mode, press “DOWN” push-button once. 3) Move the jumper back to position “1” (resting position).
5.3 TIME DELAY FUNCTIONS
The MAC is supplied with one bank of on board DIP switches. This bank has eight positive “on/off” switches. These switches provide a selection of time delays as well as audible alarm control. Reference photo and details on the following page.
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5.3 TIME DELAYS FUNCTIONS, CONT’D…..
DIGITAL PHOTO # 7: DIP SWITCH PACKAGE IS LOCATED AT FAR LEFT CORNER OF CIRCUIT BOARD
5.3 TIME DELAY FUNCTIONS
The DIP switches are identified as follows: Assume viewing the board with the wiring terminal strip on the right side:
DIP-1
DIP-2
DIP-3
DIP-4
2-MINUTE DELAY “ON” LOW RELAY
ON
OFF
5-MINUTE DELAY “ON” LOW RELAY
OFF
ON
10-MINUTE DELAY “ON” LOW RELAY
ON
ON
2-MINUTE DELAY “ON” HIGH RELAY
ON
OFF
5-MINUTE DELAY “ON” HIGH RELAY
OFF
ON
10-MINUTE DELAY “ON” HIGH RELAY
ON
ON
FUNCTION
10-MINUTE “OFF DELAY LOW RELAY
DIP-5
DIP-6
DIP-7
DIP-8
ON
10-MINUTE “OFF” DELAY HIGH RELAY
ON
AUDIBLE ALARM “OFF”
OFF
NOT USED FOR ANY FUNCTION
OFF Table-2
5.4 ADJUSTING ALARM SET POINTS
Alarm settings on the second generation MAC controller are voltage settings. The range of 04.0 VDC is equal to the full measurement range of the sensor. Eg. HVAC CO sensor has a standard measurement range of 0-200 ppm. Therefore 4.0 VDC = 200 ppm. Prior to adjusting the alarm set points, determine or calculate the voltage value required. Consult table number 3.0 on page 28 for standard pre-calculated voltages. If the value desired is not indicted, use the following formula to calculate the voltage required.
25
5.4 ADJUSTING ALARM SET POINTS, CONT’D…..
DESIRED SET POINT = % OF RANGE SENSOR RANGE
EG. 100 ppm = 50% OF RANGE 200 ppm
50% OF 4.0 VDC = 2.0 VDC Therefore the required voltage setting to achieve an alarm set point of 100 ppm is 2.0 VDC. The MAC detectors are shipped from the factory with default alarm set points. These set points can easily be changed in the field. Along with changing the alarm set points, the user also has the option of making the alarms “ascending” or “descending”. Ascending alarms are typically used for toxic and combustible gas monitoring applications because the user needs to be notified when gas levels are ascending to potentially dangerous levels. Descending alarms are typically used for Oxygen monitoring applications because the user needs to be notified when Oxygen levels are descending to levels that are unsafe for human survival. Note-1: Ascending Alarms: The low alarm threshold cannot be set higher than the high alarm threshold. If you have to increase the low alarm threshold higher than what the high is currently set for, increase the high threshold first. Note-2: Descending Alarms: The low alarm threshold cannot be set lower than the high alarm threshold. If you have to decrease the low alarm threshold lower than what the high is currently set for, decrease the high threshold first.
5.41 ASCENDING LOW GAS ALARM SET POINT ADJUSTMENT 1) Move the jumper to J5 position. The audible alarm “beeps” for confirmation. The system is now waiting for the user to set the desired value. Reference digital photo #8 on page 27. 2) Attach digital multi-meter leads to test points TP-5 and TP-6 (digital photo #4 page-20). 3) Using the “UP” or “DOWN” push-buttons, achieve the calculated voltage reading on the multi-meter. Reference digital photo # 9 on page 29. 4) Move the jumper back to it’s resting position. At this time the new value is saved and the audible alarm “beeps” for confirmation.
5.42 ASCENDING HIGH GAS ALARM SET POINT ADJUSTMENT 1) Move the jumper to J6 position. The audible alarm “beeps” for confirmation. The system is now waiting for the user to set the desired value. Reference digital photo #8 on page 27. 2) Attach digital multi-meter leads to test points TP-5 and TP-6 (digital photo #4 page-20). 3) Using the “UP” or “DOWN” push-buttons, achieve the calculated voltage reading on the multi-meter. Reference digital photo # 9 on page 29. 4) Move the jumper back to it’s resting position. At this time the new value is saved and the audible alarm “beeps” for confirmation.
5.43 DESCENDING LOW GAS ALARM SET POINT ADJUSTMENT 1) Move the jumper to J7 position. The audible alarm “beeps” for confirmation. The system is now waiting for the user to set the desired value. Reference digital photo #8 on page 27. 26
5.4 ADJUSTING ALARM SET POINTS, CONT’D…..
5.43 DESCENDING LOW GAS ALARM SET POINT ADJUSTMENT, CONT’D….. 2) Attach digital multi-meter leads to test points TP-5 and TP-6 (digital photo #4 page-20). 3) Using the “UP” or “DOWN” push-buttons, achieve the calculated voltage reading on the multi-meter. Reference digital photo # 9 on page 29. 4) Move the jumper back to it’s resting position. At this time the new value is saved and the audible alarm “beeps” for confirmation.
5.44 DESCENDING HIGH GAS ALARM SET POINT ADJUSTMENT 1) Move the jumper to J8 position. The audible alarm “beeps” for confirmation. The system is now waiting for the user to set the desired value. Reference digital photo #8 on page 27. 2) Attach digital multi-meter leads to test points TP-5 and TP-6 (digital photo #4 page-20). 3) Using the “UP” or “DOWN” push-buttons, achieve the calculated voltage reading on the multi-meter. Reference digital photo # 9 on page 29. 4) Move the jumper back to it’s resting position. At this time the new value is saved and the audible alarm “beeps” for confirmation.
Jumper Positions:
J9
LATCHING RELAY FUNCTION
J8
DESCENDING HIGH ALARM SET POINT
J7
DESCENDING LOW ALARM SET POINT
J6
ASCENDING HIGH ALARM SET POINT
J5
ASCENDING LOW ALARM SET POINT
J4
CALIBRATING SPAN VALUE
J3
CAIBRATING NULL VALUE
J2
SETTING SPAN GAS VALUE
J1 (RESTING POSITION)
DIGITAL PHOTO # 8: JUMPER HEADER IS LOCATED AT UPPER LEFT SIDE OF CIRCUIT BOARD
27
5.4 ADJUSTING ALARM SET POINTS, CONT’D…..
SENSOR / GAS
MEASUREMENT RANGE
LOW ALARM SET VOLTAGE
HIGH ALARM SET VOLTAGE
CO
0-200 ppm
25 ppm / 0.50 VDC
100 ppm / 2.00 VDC
CO
0-200 ppm
35 ppm / 0.70 VDC
200 ppm / 4.00 VDC
NO2
0-5.0 ppm
0.7 ppm / 0.56 VDC
1.0 ppm / 0.80 VDC
NO2
0-5.0 ppm
2.0 ppm / 1.60 VDC
5.0 ppm / 4.00 VDC
Cl2
0-5.0 ppm
0.5 ppm / 0.40 VDC
1.0 ppm / 0.80 VDC
Cl2
0-5.0 ppm
1.0 ppm / 0.80 VDC
3.0 ppm / 2.40 VDC
NH3
0-500 ppm
25 ppm / 0.20 VDC
100 ppm / 0.80 VDC
NH3
0-500 ppm
35 ppm / 0.28 VDC
300 ppm / 2.40 VDC
NH3
0-300 ppm
35 ppm / 0.47 VDC
300 ppm / 4.00 VDC
O2
0-25.0% Volume
19.5% Vol./ 3.12 VDC 23.0% Vol. / 3.68 VDC
O2
0-25.0% Volume
17.0% Vol. / 2.72 VDC
18.5% Vol. / 2.96 VDC
O3
0-2.00 ppm
0.10 ppm / 0.20 VDC
0.30 ppm / 0.60 VDC
O3
0-2.00 ppm
0.30 ppm / 0.60 VDC
1.00 ppm / 2.00 VDC
NO
0-100 ppm
25 ppm / 1.00 VDC
50 ppm / 2.00 VDC
H2S
0-50 ppm
10 ppm / 0.80 VDC
15 ppm / 1.20 VDC
SO2
0-20 ppm
2 ppm / 0.40 VDC
5 ppm / 1.00 VDC
H2
0-4000 ppm
1000 ppm / 1.00 VDC 2000 ppm / 2.00 VDC
ETO
0-10.0 ppm
1.0 ppm / 0.40 VDC
2.0 ppm / 0.80 VDC
C3H8
0-50% LEL
10% LEL / 0.80 VDC
20% LEL / 1.60 VDC
C3H8
0-50% LEL
20% LEL / 1.60 VDC
40% LEL / 3.20 VDC
CH4
0-50% LEL
10% LEL / 0.80 VDC
20% LEL / 1.60 VDC
CH4
0-50% LEL
20% LEL / 1.60 VDC
40% LEL / 3.20 VDC
H2
0-50% LEL
10% LEL / 0.80 VDC
20% LEL / 1.60 VDC
C3H8
0-100% LEL
20% LEL / 0.80 VDC
40% LEL / 1.60 VDC
CH4
0-100% LEL
20% LEL / 0.80 VDC
40% LEL / 1.60 VDC
H2
0-100% LEL
20% LEL / 0.80 VDC
40% LEL / 1.60 VDC
Freons (R series)
0-2000 ppm
500 ppm / 1.00 VDC
1000 ppm / 2.00 VDC
TABLE 3 28
6.0 CALIBRATING ANALOG OUTPUT
If the analog output (4-20 mA / 0-10VDC) option has been supplied, it is shipped pre-calibrated from the factory. If someone has made adjustments to it without using the proper equipment or the user feels it is not accurate for some reason, a re-calibration may be required. This device should be calibrated by a qualified, trained technician. An accurate current source (4-20 mA), accurate voltage source (0-10 VDC) and an accurate digital multi-meter are required to perform the calibration procedure on this device. Note: The MAC controller must be in the un-initialized state before calibration of the analog output module can take place. The “Device Master” terminal software program is required to put the MAC controller in the un-initialized state.
6.1 CALIBRATING THE 4-20 mA PORTION OF THE ANALOG OUTPUT MODULE
6.11 CALIBRATING THE LOW RANGE OUTPUT (4.00 mA) Note-1: Before starting, ensure the jumper on the analog output board is set in the 4-20 mA position. 1) Move the jumper to J1 position. The audible alarm “beeps” once for confirmation. The system is now waiting for the user to apply 4.00 mA. Reference Digital Photo #8 on page 27. 2) Attach digital multi-meter leads to the output wiring terminal. Set the range to DC mA. 3) Using the “UP” or “DOWN” push-buttons, achieve a reading of 4.00 mA on the digital multi-meter. Reference digital photo # 9 below. 4) Move the jumper back to it’s resting position. At this time the new value is saved and the audible alarm “beeps” once for confirmation.
6.12 CALIBRATING THE HIGH RANGE OUTPUT (20.0 mA) 1) Move the jumper to J2 position. The audible alarm “beeps” once for confirmation. The system is now waiting for the user to apply 20.0 mA. Reference Digital Photo #8 on page 27. 2) Attach digital multi-meter leads to the output wiring terminal. Set the range to DC mA. 3) Using the “UP” or “DOWN” push-buttons, achieve a reading of 20.0 mA on the digital multi-meter. Reference digital photo # 9 below. 4) Move the jumper back to it’s resting position. At this time the new value is saved and the audible alarm “beeps” once for confirmation.
DIGITAL PHOTO # 9: “UP” / “DOWN” ADJUSTMENT PUSH-BUTTONS ARE LOCATED SLIGHTLY ABOVE CENTRE OF THE CIRCUIT BOARD, JUST TO THE LEFT OF THE RELAYS
29
6.0 CALIBRATING ANALOG OUTPUT, CONT’D…..
6.2 CALIBRATING 0-10VDC PORTION OF THE ANALOG OUTPUT MODULE * Before starting ensure jumper on analog output board is in the 0-10V position 6.21 CALIBRATING THE HIGH RANGE OUTPUT (10.0 VDC) 1) Move the jumper to J3 position. The audible alarm “beeps” for confirmation. The system is now waiting for the user to apply 10.0 VDC. Reference Digital Photo #8 on page 27. 2) Attach digital multi-meter leads to the output wiring terminal. Set the range to DC mV. 3) Using the “UP” or “DOWN” push-buttons, achieve a reading of 10.0 V DC on the digital multi-meter. Reference digital photo # 9 on page 29. 4) Move the jumper back to it’s resting position. At this time the new value is saved and the audible alarm “beeps” once for confirmation. Note: When the MAC is utilized as a controller (no integral sensor), jumper positions “J3” and “J4” are used to calibrate the analog input for remote analog transmitters. J3 calibrates the 4.0 mA input and J4 calibrates the 20.0 mA input. An accurate current source is required to accomplish this. All analog inputs are calibrated at the factory and do not require field calibration.
7.0 CALIBRATING SENSORS
Calibration Frequency:
a) Parking garage detectors: Once every 12 months b) OHS applications: Once every 6 months (OHS: Occupational Health & Safety) c) Sensors targeting gases with very low TLVs: Chlorine, Ozone, etc. Ethylene Oxide, etc: Once every six months
Gas Testing Frequency: For the purposes of safety in OHS applications, sensors should be gas tested once every month to confirm response. The second generation MAC provides an automated sensor test initiated by the internal system software every month but this is a test for potential expiration not response. The exception being the Carbon Monoxide sensor. This self-test performed every month actually tests for sensor response and potential expiration. A manual test using span gas is still recommended for all sensors. Note: A calibration label should be applied after every calibration to confirm work performed and the date it was confirmed. If a controller is involved, the alarm set points should be indicated on a label on the front door of the enclosure so anyone working in the environment can be aware. Calibration is achieved at the MAC controller if the sensor is integral. If the sensor is remote (AST series analog transmitter) the calibration is achieved at the transmitter using the procedure indicated in the operation manual provided with it. Required Equipment:
• • • •
Digital multi-meter Potentiometer screw driver (for AST current generation transmitters) Calibration kit Calibration gases 30
7.0 CALIBRATING SENSORS, CONT’D…..
Users can order the calibration kit, calibration accessories and/or gases from any CETCI authorized distributor or they can supply their own gas and equipment as long as the gas meets the minimum specifications indicated on the next page. 7.1 CALIBRATION SPECIFICATIONS Gas: Calibration span gases should be at least +/- 5% accuracy and have a current date stamp. Gas generators should have a current dated cell installed. Service personnel should flow zero emissions air or Oxygen to before attempting to null adjust toxic gas sensors. In some cases N2 (Nitrogen) can be substituted for zero air. Contact CETCI for clarification. Nitrogen is required to null (zero) Oxygen (O2) and Carbon Dioxide CO2 sensors. Exception: Flow Nitrogen over Oxygen sensors before attempting to null adjust them. If the service person is confident of air quality and is careful (do not exhale in the direction of the Oxygen sensor being serviced while span adjusting). Oxygen in the breathing environment can be used as a fairly accurate source of span gas (20.9% volume) “in a pinch”. It is not recommended to use this procedure for all span adjustments of Oxygen sensors. Regulators & Flow: Calibration gases that are lighter than or the same weight as air (CO, O2, etc.) should be flowed at 0.5 LPM. Gases heavier than air (NO2, Cl2 etc.) should be flowed between 0.5 and 1.0 LPM. Fixed flow regulators provide more accuracy. Gases should be flowed over the sensor for at least 2 1/2 to 4 minutes. Carbon Monoxide sensors settle out very quickly, but sensors for reactive gases (NH3, etc.) will take longer to stabilize to the calibration gas. All cylinder regulators supplied by CETCI use a fixed flow orifice. The proper calibration adapter should be utilized to allow the gas to properly diffuse around the sensor. They are available from CETCI. A humidification chamber must be utilized for all solid-state sensors except Ammonia. This is also available form CETCI.
7.2 CALIBRATION PROCEDURE The calibration procedure within the second generation MAC controller is push-button automated (there are no potentiometers to adjust). To achieve calibration the user must first tell the MAC what concentration of span he is going to flow over the sensor. Within the controller, calibration is a voltage setting. The range of 0-4.0 VDC is equal to the full measurement range of the sensor. Eg. HVAC CO sensor has a standard measurement range of 0-200 ppm. Therefore 4.0 VDC = 200 ppm. Prior to attempting to calibrate, determine or calculate the voltage value required. Consult table number 3.0 for standard voltages. If the value desired is not indicted, use the following formula to calculate the voltage required. CALIBRATION SPAN GAS VALUE = % OF RANGE OF RANGE SENSOR RANGE
EG. 100 ppm = 50% 200 ppm
50% OF 4.0 VDC = 2.0 VDC Therefore the required voltage setting to calibrate with 100 ppm is 2.0 VDC.
7.21 SETTING SPAN GAS VALUE 1) Move the jumper to J2 position. The audible alarm “beeps” once for confirmation. The system is now waiting for the user to set the desired value. 2) Attach digital multi-meter leads to test points TP-5 and TP-6 (digital photo #4 page-20). 31
7.0 CALIBRATING SENSORS, CONT’D….. 7.21 SETTING SPAN GAS VALUE, CONT’D….. 3) Using the “UP” or “DOWN” push-buttons, achieve the calculated voltage reading on the multi-meter. Reference digital photo # 9 on page 29. 4) Move the jumper back to it’s resting position. At this time the new value is saved and the audible alarm “beeps” once for confirmation. 7.22 CALIBRATING THE NULL (ZERO) VALUE
1) Attach regulator to cylinder of zero air. 2) Insert the calibration adapter into the sensor opening in the front of the enclosure door. Use a slight twisting motion as you gently push the calibration adapter into the sensor opening. If the calibration adapter is hard to insert, moisten the o’ring slightly seal then try re-inserting it. Reference the photo on the following page. 3) Open regulator valve fully and allow zero air to flow over sensor. 4) Move the jumper to J3 position. The audible alarm “beeps” once for confirmation. The system now waits 30 seconds to ensure the user is flowing zero air. Reference Digital Photo #8 on page 27. 5) The MAC then enters a 60 second count down during which time it adjusts the null value. If the user wishes to view this, attach meter leads to test points TP-5 and TP-6 (digital photo #4 page-20). The meter will show “0” VDC indicating the MAC has null adjusted the circuit. 6) When the count down is finished, the MAC “beeps” to let the user know the procedure is finished. 7) Move the jumper back to it’s resting position. At this time the new value is saved and the audible alarm “beeps” once for confirmation. Note-1: If the user attempts to null adjust the sensor without applying zero air and the sensor detects a background gas of more than +/- 1% of “0”, the audible alarm “beeps” eight times quickly and repeatedly. This alarm repeats itself to let the user know the circuit cannot be null adjusted in a background of the target gas. This is unsafe and would produce inaccurate readings. If after flowing zero air, the circuit does not settle within the 20% tolerance value, the user can continue the null procedure by performing an unlock function. To achieve this, push both the “UP” and “DOWN” buttons together. The null procedure will then continue.
7.23 CALIBRATING THE SPAN GAS VALUE
1) Attach regulator to cylinder of span gas. 2) Insert the calibration adapter into the sensor opening in the front of the enclosure door. Use a slight twisting motion as you gently push the calibration adapter into the sensor opening. If the calibration adapter is hard to insert, moisten the o’ring slightly seal then try re-inserting it. Reference the photo on the following page. 3) Open regulator valve fully and allow span gas to flow over sensor.
32
7.0 CALIBRATING SENSORS, CONT’D…..
7.23 CALIBRATING THE SPAN GAS VALUE, CONT’D….. 4) Move the jumper to J4 position. The audible alarm “beeps” once for confirmation. The system now waits 30 seconds to ensure the user is flowing span gas. 5) The MAC then enters a 150 second count down during which time it adjusts the circuit to the span value which was set earlier (see “setting span gas value”). If the user wishes to view this, attach meter leads to test points TP-5 and TP-6 (digital photo #4 page-20). The meter will show an increasing voltage indicating the MAC sensor is responding to the span gas and the circuit is being adjusted for accuracy. 6) When the count down is finished, the MAC “beeps” to let the user know the procedure is finished. 7) Move the jumper back to it’s resting position. At this time the new value is saved and the audible alarm “beeps” once for confirmation. Note-1: If the sensor response is more than +/- 20% of span gas value set earlier, the audible alarm “beeps” eight times quickly repeatedly. This alarm repeats itself to let the user know the circuit cannot be span adjusted because it is outside of the pre-programmed system tolerance. The sensor span may have drifted for one reason or another and so the user can continue the span procedure by performing an unlock function. To achieve this, push both the “UP” and “DOWN” buttons together. The span procedure will then continue.
7.24 CALIBRATION SET UP PHOTO
DIGITAL PHOTO# 10: CALIBRATION SET UP
33
8.0 OPTIONS FOR MAC CONTROLLER
8.1 WATER/DUST TIGHT ENCLOSURE
The water tight enclosure is made from fiberglass reinforced polyester and has two securing screws for the front, hinged door. This enclosure is from the same family of enclosures utilized for water tight options for the model PAC-44 (4-channel controller) and model PDC (multi-channel controller). If the water tight enclosure option has been selected, it comes with a slightly louder audible alarm that is installed in the front door (single-channel systems) or bottom right area of the controller enclosure base (two-channel “E” type systems). The photo shown is the MAC as a single channel controller (no integral sensor).
DIGITAL PHOTO #11: WATER/ DUST TIGHT, CORROSION RESISTANT
34
8.0 OPTIONS FOR MAC CONTROLLER, CONT’D…..
8.2 SPLASH GUARD
If the application for a water tight enclosure is for a wet environment with the potential for wash down or a pressurized hose to be directed at the sensor, a splash guard is absolutely mandatory. Electrochemical sensors are very sensitive to excessive pressure and can easily be damaged by directing pressurized air or liquid at them. The splash guard is made of molded urethane and attaches to the outside of the enclosure door directly over the sensor opening (for integral sensors). They are also fitted to water tight analog transmitter enclosures for remote sensor applications.
DIGITAL PHOTO #12: SPLASH GUARD. ATTACHES TO THE FORNT OF WATER TIGHT ENCLOSURES
8.3 VISUAL / AUDIBLE ALARMS
Strobe/siren combo alarm If the strobe / siren option has been supplied, it can be installed on top of the enclosure or installed remote from the enclosure. This must be specified at the time of order. The MAC controller outputs 12VDC to power this device so the end user does not have to use one of the system relays to control it. Operation options include: a) Both the strobe light (red) and the siren will be activated at the same time. b) Strobe and siren are activated individually (this function may require the use of one of the system relays to achieve the two types of alarms).
DIGITAL PHOTO #13: STROBE / SIREN COMBO ALARM
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8.4 STROBE LIGHT
If the strobe light option has been supplied, it can be installed on top (3” diameter) of the enclosure or installed remote from the enclosure (4” diameter). This must be specified at the time of order. The MAC controller outputs 12VDC to power the 3” diameter strobe or 24VDC to power the 4” diameter strobe so the end user does not have to use one of the system relays to control it. The strobe light is a red lens, double flash strobe. Note-1: For remote installation, a 4” diameter or 6” diameter red lens, double flash strobe light can be purchased. Consult any CETCI authorized distributor for more details. Note-2: Reference photos further on in this manual for the above options
DIGITAL PHOTO # 14: 3” DIAMETER RED STROBE LIGHT OPTION INSTALLED.
DIGITAL PHOTO # 15: 4” DIAMETER RED STROBE LIGHT OPTION FOR REMOTE MOUNTING 36
8.5 ANALOG OUTPUT MODULE
If the analog output signal option has been supplied, a separate small circuit board will be installed in the base of the enclosure and connected to the main MAC circuit board via a ribbon cable. This board provides a linear, analog signal of 4-20 mA or 0-10VDC (jumper selectable). Maximum impedance is 300 ohms. A 2-conductor, 18 gauge, shielded cable is recommended for the connection.
DIGITAL PHOTO # 16: ANALOG OUTPUT BOARD OPTION
9.0 ACCESSORIES
9.1 CALIBRATION KIT Calibration kits and gases are available from the CETCI factory. Many gases are carried in inventory but not all. Check with any CETCI authorized distributor for availability of specific gas types. Reference photo example below.
DIGITAL PHOTO # 17: CALIBRATION KIT
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9.0 ACCESSORIES, CONT’D…..
9.2 METAL PROTECTIVE GUARDS
MAC detectors are all supplied in very rugged, non-metallic enclosures. However, in some applications more protection may be desired. CETCI can provide protective guards made from 16 gauge galvanized metal with a pattern of square perforations to permit air and gas to diffuse easily to the sensor. Reference photos and drawings further on in this manual for more information.
DIGITAL PHOTO # 18 & 19: METAL PROTECTIVE GUARDS
10.0 TROUBLE SHOOTING
PROBLEM-1 Digital display indicates “- - - -” even after warm up period. POSSIBLE CAUSE-1 There is a break in communication between the main board and the digital display board. POSSIBLE SOLUTION-1 Check ribbon cable connections to ensure it is securely plugged into the cable headers on both boards. between the two board. Check ribbon cable for loose or damaged ribbon connection. PROBLEM-2 During null or span procedure, the audible alarm “beeps” rapidly several times. 38
10.0 TROUBLE SHOOTING
POSSIBLE CAUSE-2 The sensor response in clean air or span gas is more than the preset tolerance value allowed to safely null or span adjust. POSSIBLE SOLUTION-2 If you are sure the sensor is in a clean air environment while you are performing the null function, push both the “UP” and “DOWN” push-buttons together. This will unlock the safety trap in the instrument firmware and allow the null function to take place. The same solution applies to the span function. If you are confident that you have set the span gas value correctly and the sensor response to flowing the span gas is outside of the preset tolerance value, push both the “UP” and “DOWN” push-buttons together. Again, this will unlock the safety trap in the instrument firmware and allow the span function to take place.
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