tgaes open path combustible gas detector operating manual manual... · 2015-07-10 · tgaes open...

TGAES Open Path Combustible Gas Detector 820-0007 R01 Operating Manual

TGAES Open Path Combustible Gas Detector Operating Manual

820-0007 R01


Page ii Revised 03/19/2014

TGAES Open Path Combustible Gas Detector Operating Manual

820-0007 R01

ESP Safety, Inc. 555 North First Street San Jose, CA 95112

408-‐886-‐9746

June 2013

Revision History: 820-‐0007

Date Revision Description Approved

6/12/13 01 Initial Draft A. Burgos


Page iii Revised 03/19/2014

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of 50 Revised 03/19/2014

Introduction The TGAES is an open path (line-‐of-‐sight) gas monitoring apparatus that senses the presence of combustible gas or vapor concentrations in air in the range of 0-‐5.0 LEL•meters over a distance of 5 to 200 meters.

The function of the TGAES is to provide an alarm, the purpose of which is to give warning of the possible presence of potentially flammable concentrations of gas or vapor. The device is NOT intended for use as 1) a laboratory or scientific instrument for analysis or precise measurement, 2) an apparatus for process control and monitoring, or 3) an apparatus for residential use.

The TGAES consists of a transmitter module (TGAES TX) and a receiver module (TGAES RX). The explosion proof, stainless steel housing of the TGAES detectors allows for the devices to be used in Type 1 and Type 2 classified areas. The TGAES can be used as a stand-‐alone detection system or as a component of a Fire & Gas System, Emergency Shutdown System, or other integrated process controls.

The TGAES is capable of detecting most hydrocarbon gases and vapors including methane, propane, butane, propylene and others. No direct electrical connection between the two modules is required. In some applications, one TGAES detection system can provide protection equivalent to as many as eight to twelve point detectors.

Features and Benefits

• Standard system outputs include 4-‐20mA and RS-‐485 MODBUS RTU serialcommunication and dry contact relays for Alarm & Fault signals

• Detects methane and most common hydrocarbon gases including ethane, propane,butane and propylene with equal sensitivity

• Detection range of up to 200m

• T90 less than 10 seconds

• Corrosion-‐resistant 316 stainless steel enclosure

• Operating temperature range: -‐40o F to 140o F (-‐40oC to 60oC)

• Heated optics protect against condensation and icing

• Tri-‐color status LED or full graphical indication w/ ESP Field Control Unit (Vector or SSS-‐903)

• Primary heater protects the optics from ice and the secondary heater protects theinternal electronics

• Able to operate even when obscured by fog, rain, dust, snow, or blowing sand

• On site zero calibration with magnetic wand and TGAES configuration software

• Onboard memory provides recording of operational data and device functionsincluding factory settings and gas readings


of 50 Revised 03/19/2014

Applications The TGAES system is designed for installation in hazardous areas where combustibles and flammables are both present and require immediate and accurate detection. Typical applications include:

• Drilling and production platforms• Fuel loading facilities• Refineries, bulk terminals, and tank farms• LNG/LPG processing and storage facilities• Compressor stations and pipeline facilities• Petrochemical, paint, and fertilizer plants• Power plants and gas turbine facilities• Aircraft hangars

Our Mission ESP Safety, Inc.’s mission is to provide complete turn-‐key protection solutions beginning with the design stage, through system installation and commissioning, and on-‐going field service in hazardous environments. Our line of industry-‐leading products, services, and systems benefits society, saves lives, and preserves capital resources.

ESP Safety, Inc. Contact Information

Telephone: 408-‐886-‐9746 FAX: 408-‐886-‐9757 Address: 555 North First Street, San Jose, CA 95112

2.0 Description

Principle of Operation The TGAES monitors levels of combustible gases or vapors, in ambient air, by measuring the spectral absorption by the gases or vapors between the transmitter and receiver modules. Measurement of the combustible gas absorption is performed in the infrared (IR) regions of the electromagnetic spectrum. The transmitter module illuminates a direct linear path ending at the receiver module. As flammable hydrocarbon gases intersect the light beam between the two modules, certain IR wavelengths are absorbed by the gas while other IR wavelengths are not. A pair of optical detectors and associated electronics located in the receiver module measures the absorption for both the active wavelength and the reference wavelength. The ratio of absorption between the active and reference wavelengths determines the amount of gas intersecting the beam along its entire length. A microprocessor computes the gas concentration and converts the value into a 4-‐20mA signal and MODBUS RTU register value.

Transmitter TGAES -‐ TX The flash source of the TGAES transmitter is a highly reliable pulsed xenon lamp. The service life of the lamp is 950,000,000 flashes or 15 years of continuous operation at a flash rate of 2 Hz.

The beam angle over a distance of 200 m results in a beam diameter of 1.5-‐2 meters at the TGAES receiver (Fig 2.1). The high efficiency and the wide beam allow for ease of adjustment of the system and immunity to minor misalignment

TGAES Open Path Combustible Gas Detector820-0007 R01 Operating Manual

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Figure 2-2: LEL•meter

200m

1.5 to 2m


of 50 Revised 03/19/2014

The standard calibration gases for the TGAES system are methane and propane.

The default sensitivity range of the TGAES system is 0-‐5 LEL•m. The sensitivity of the TGAES system can also be adjusted for 0-‐1.0 LEL•m and 0-‐2.5 LEL•m.

When switching between the selectable gases that have been factory-‐programmed into the gas detector, no additional calibration is required. Conversion factors will adjust for the selected gas.

3.0 Specifications

Operational Characteristics

Detected Gases Methane, Propane, Ethane, Butane, Isobutane, Pentane, Cyclopentane, Propylene, Hexane, Methanol, Ethanol, other combustible gases including complex hydrocarbons. (The target gas is factory-‐configured according to customer request.)

Gas Detection Range Settings

0 to 1 LEL•m 0 to 2.5 LEL•m 0 to 5 LEL•m (factory default setting)

Accuracy ±.25 LEL•m or 10% of the applied gas concentration, whichever is greater

Response Time T90 < 10.0 seconds

Humidity Range up to 100%, non-‐condensing

Measuring Distance 15 ft to 650 ft (5m to 200m) * A set of apertures, mounted on the transmitter, is provided for operation at distancesless than 60m

Temperature Range Operating temperature: -‐40o F to 140o F (-‐40oC to 60oC)

Ingress Protection IP66

Warm Up Time Time from power-‐up to operational state:

Transmitter: 5 Seconds Receiver: 15 Seconds

Self-‐testing Transmitter self-‐testing: 2x/sec, Receiver self-‐testing: 2x/sec.

Real-‐Time Clock & Non-‐Volatile Memory

The TGAES receiver and transmitter have real time clock (RTC) and nonvolatile memory for up to 16,000 pages. Each page saves a single screenshot containing all the current system operational conditions data complete with time/date stamp for the following events:

- Power on- alarm- failure- beam blocking- disrupted temperature conditions- power disruption

History can be accessed with ESP Safety’s PC-‐based TGAES programs.

820-0007 R01TGAES Open Path Combustible Gas Detector

Operating Manual

of 50 Revised 03/19/2014

Calibration

Manufacturing calibration – methane and propane up to 5 LEL.m. Calibration of the range is not required in the field. Zeroing can be performed in the field by using one of the following ways:

- via a magnetic wand- via PC and TGAES Software using MODBUS RTU protocol

Optics Heating The optics heater maintains a temperature 25°C higher than the ambient temperature.

Mean Time Between Failures, minimum

35,000 hours

Electrical Characteristics

Input Voltage +24VDC Nominal (+18 to 32VDC)

Power Consumption, Maximum (w/ Optics Heating ON)

Transmitter 15.0W @ 24V DC Receiver 15.0W @ 24V DC

Output From TGAES (receiver unit)

+4-‐20mA industry standard analogDigital RS-‐485 MODBUS RTU3 relays:

• 2 User Programmed Alarm Relays• 1 Fault Condition Relay• All Relays Contact Rating 1Amp 60VDC

Alarm Relays 2 User Programmed Alarm Relays 1 Fault Condition Relay

Mechanical Characteristics

Material of Construction: TGAES transmitter & receiver housings and associated mounting brackets

Stainless Steel Type 316

Cable Entry 2 Cable Entries ¾” NPT

Weight With Bracket 16.5lb (7.5kg), each module

Physical Dimensions 10.43” x 6.96” x 7.17” (262mm x 176mm x 182mm)

Optics Protection The lenses are protected from rain and wind by a weather hood (supplied).


of 50 Revised 03/19/2014

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Explosion Protection Means

The table below describes design features that protect the TGAES against explosions. Additional details are shown in Appendix C:

Feature Protection Means

Enclosure of Current Carrying Parts

The casing includes spigot joints with controlled gaps to meet explosion-‐proof requirements for installation in Class I, Division I, Group B, C and D, and T4 locations.

Case Mechanical Strength The high mechanical strength of the case is able to withstand high explosive pressures without rupture or failures of mechanical parts. The case design is in accordance with FM 3600 and FM 3615.

Manufacturing Control Of Casing

Refer to Appendix A1 for manufacturing details. Important parameters include:

• Maximum width and minimum length of spigot joints

• Surface roughness of the joined parts

• The number of complete intact threads at the conduit entry point

Ignition Temperature The ignition temperature of the surrounding environment is limited by the outside surface temperature of the housing, which does not exceed 275°F (135°C).

Securing of Bolts, Joints and Grounding

Spring washers, lock washers, and lock nuts maintain the integrity of the bolted connections by preventing loosening of the bolts.

Joined Parts Protection Anti-‐seize lubricant is applied on the critical joints as described on Appendix A1.

Casing Ingress Protection The design of the casing is protection class IP 66 in accordance with IEC 60529-‐004.

Sealing Cables at Conduit Entry

Use approved hazardous location sealed conduit fittings. For outdoor installations, ensure sealing meets IP66 requirements.

5.0 Installation

Important Safety Information

Be sure to read and understand the entire instruction manual before installing or operating the gas detector.

The products described in this document can be used with a variety of ESP-‐Safety gas detector models to provide early warning of the presence of a toxic or explosive gas mixture. Proper device installation, operation, and maintenance is required to ensure safe and effective operation. If this equipment is used in a manner not specified in this manual, safety protection may be impaired.


of 50 Revised 03/19/2014

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C,(5F$(3'$65I,%F$F'R'F$&%FF6$['(X'',$A>g$@$B>g.

A. 9($S56(%,-'6$1&$'T-''S5,I$A>$L'('26$%,$%M'2(C2'$56$,1($2'YC52'S.$9($(3'6'$S56(%,-'6*$%SfC6(L',(6$(1$(3'$65I,%F$6(2',I(3$%2'$M'2&12L'S$[)$%SfC6(5,I$(3'$(2%,6L5(('2$M1X'2$X5(3$(3'$NO9!"$-1,&5IC2%(51,$61&(X%2'.

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of 50 Revised 03/19/2014

L"4I(A$E'4;(A*+"'E*N(

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of 50 Revised 03/19/2014

7.0 Functional Testing & Zero Calibration

L.+<"$(+*/#4-%"$+1# 8%F5[2%(51,$M%2%L'('26$%2'$X25((',$%,S$6(12'S$1,(1$(3'$1,[1%2S$L'L12)$1&$(3'$NO9!"$6)6('L$%($(3'$&%-(12)$SC25,I$-1,&5IC2%(51,$%,S$-%F5[2%(51,.$N3'2'&12'*$5,S5R5SC%F$-%F5[2%(51,$1&$I%6$S'('-(126$X5(3$(3'$%5S$1&$2'%F$I%6$L5T(C2'6$SC25,I$(3'$5,6(%FF%(51,$%,S$1M'2%(51,$56$,1($2'YC52'S.$$

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L.+<"$(+*/#4-%"$+1#E)(<-3.)-#

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of 50Revised 03/19/2014

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of 50 Revised 03/19/2014

8.0 Troubleshooting

The TGAES gas detector troubleshooting procedure may require the following tools and materials:

• Set of screwdrivers• Set of HEX keys/Allen wrenches• Multimeter• A small bottle of isopropyl alcohol• Clean cotton cloth• Regular Windows XP based PC or laptop• RS485 to USB or RS232 converter.

TRANSMITTER UNIT: If the lamp does not flash every ½ second

RECEIVER UNIT: If the LED does not light up

Check the power supply.

If power supply is not working, replace it.

If power supply is working, unscrew the removable protective back cover and connect the minus probe of the voltmeter (black wire) to the GND terminal and connect the plus probe (red wire) to the +24 Terminal -‐ Measure the voltage.

If the reading is 18-‐30 volts DC:

Check the voltage on the Terminal Blocks. Check the voltage between GND & RS485B, between GND & RS485A. If voltmeter reads over 5 volts, remove the wire from that terminal & determine the source of the voltage. Check voltage between GND 4-‐20. If over .5 volts, determine the source of the voltage. If the normal working state is not restored, the device may need to be replaced.

If the reading is not 18-‐30 volts DC:

Confirm the correct power supply is in use and is working properly. If the normal working state is not restored, the device may need to be replaced.

If the reading is negative change the polarity.

Check the power supply.

If power supply is not working, replace it.

If power supply is working, unscrew the removable protective back cover and connect the minus probe of the voltmeter (black wire) to the GND terminal and connect the plus probe (red wire) to the +24 Terminal -‐ Measure the voltage.

If the reading is 18-‐30 volts DC:

Check the voltage on the Terminal Blocks. Check the voltage between GND & RS485B, between GND & RS485A. If voltmeter reads over 5 volts, remove the wire from that terminal & determine the source of the voltage. Check voltage between GND 4-‐20. If over .5 volts, determine the source of the voltage. If the normal working state is not restored, the device may need to be replaced.

If the reading is not 18-‐30 volts DC:

Confirm the correct power supply is in use and is working properly. If the normal working state is not restored, the device may need to be replaced.

If the reading is negative change the polarity.


of 50 Revised 03/19/2014

RECEIVER UNIT FAULT CONDITION

Fault Conditions Actions

Low 24 Volts

24 VDC operating voltage is out of range. Verify proper wiring to the detector and correct voltage output from the power source. Power supply faults are self-‐clearing when the condition is corrected.

Low or No Signal

Check the power on the transmitter module.

Check the optical clearance of the beam path. Clear the optical beam path if required.

Dirty Optics. Perform cleaning procedure, then recalibrate as required. (Refer to “Maintenance” section for details)

Check the alignment. Perform the alignment procedure if required. (Refer to “Alignment” section for details)

Temperature Fault Check the temperature of the device and lens. Enable the heater (Refer to “Software Overview” for details)

TRANSMITTER UNIT FAULT CONDITION

Fault Conditions Actions

Low 24 Volts

24 VDC operating voltage is out of range. Verify proper wiring to the detector and correct voltage output from the power source. Power supply faults are self-‐clearing when the condition is corrected.

No Flash

Check the power supply. If power supply is not working, replace it.

Check the power on the transmitter module. If power is not working check the wiring and cable isolation.

Temperature Fault Check the temperature of the device and lens. Enable the heater


of 50 Revised 03/19/2014

9.0 Maintenance

T6I=!=5V#E)$()#"(#;.+<"$(+*/#"-%"$+1#(;#",-#45678#82%"-&A#-+%.)-#",*"#",-#45678#3-"-<"()#$%#(;;/$+-#;)(&#*+2#*/*)&$+1#3-:$<-%#<(++-<"-3#"(#",-#3-"-<"()#%$1+*/#(."'."%9(

D*$+"-+*+<-#6<"$:$"$-%# N3'$NO9!"$,''S6$R'2)$F5((F'$21C(5,'$L%5,(',%,-'q$[C($M'251S5-$-3'-V6$&12$M21M'2$6)6('L$&C,-(51,$%2'$6(21,IF)$%SR56'S.$N3'$&2'YC',-)$1&$(3'6'$-3'-V6$631CFS$['$S'('2L5,'S$[)$(3'$6M'-5&5-$5,6(%FF%(51,.$

9F(31CI3$(3'$&%CF(@S'('-(51,$-52-C5(2)$-1,(5,C1C6F)$L1,5(126$&12$R%251C6$M21[F'L6*$5($S1'6$,1($L1,5(12$'T('2,%F$2'6M1,6'$'YC5ML',($12$X525,I.$N3'6'$S'R5-'6$LC6($['$-3'-V'S$M'251S5-%FF)$5,$(3'$012L%F$L1S'$(1$',6C2'$M21M'2$&C,-(51,5,I.$

E-)$(3$<#D*$+"-+*+<-# N)M5-%F$L%5,(',%,-'$%-(5R5(5'6$(1$['$M'2&12L'S$$1,$(3'$NO9!"$

• d56C%F$'T%L5,%(51,

• 8F'%,5,I$1&$1M(5-%F$'F'L',(6*$5&$,''S'S

• #'2&12L%,-'$('6(.

10.0 Transportation and Storage

4)*+%'()"*"$(+# W3',$635MM'S$5,$(3'$&%-(12)@6CMMF5'S$-%2(1,*$(3'$L1S'F$NO9!"$JM',$#%(3$81L[C6(5[F'$O%6$G'('-(12$-%,$['$635MM'S$R5%$%,)$L'(31S$1&$(2%,6M12(%(51,$&21L$(3'$L%,C&%-(C2'2e6$65('$(1$%,)$S'6(5,%(51,$2'I%2SF'66$1&$S56(%,-'.$

8"()*1-# U,(5F$C6'*$6(12'$(3'$S'('-(12$5,$(3'$L%,C&%-(C2'2e6$125I5,%F$-%2(1,.$N3'$6(12%I'$&%-5F5()$631CFS$['$&2''$1&$SC6(*$%-5S$%,S$%FV%F5,'$R%M126*$-122165R'$I%6'6$%,S$1(3'2$3%2L&CF$6C[6(%,-'6.$

11.0 Repair and Return

L$-/3#I-'*$)# N3'$NO9!"$56$,1($5,(',S'S$(1$['$2'M%52'S$5,$(3'$&5'FS.$$+&$%$M21[F'L$631CFS$S'R'F1M*$2'&'2$(1$"'-(51,$?.>$N21C[F'6311(5,I$1&$(356$L%,C%F.$$#F'%6'$2'(C2,$(3'$S'R5-'$(1$(3'$&%-(12)$&12$2'M%52$12$2'MF%-'L',(.$


of 50 Revised 03/19/2014

I-".)+#D*"-)$*/#6.",()$N*"$(+#aID6@#=.&0-)#

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12.0 Parts Ordering Information

N3'$&1FF1X5,I$5('L6$&12$(3'$NO9!"$L%)$['$12S'2'Sb$

755"%%&+$"%-(

8%F5[2%(51,$K%I,'($]L%I,'(5-$X%,S^*$#E0$A;;@>>>/$

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#F'%6'$,1('$(3%($635MM5,I$-3%2I'6$X5FF$['$%SS'S$(1$)1C2$12S'2.$


of 50 Revised 03/19/2014

13.0 Warranties

ESP Safety, Inc. (“ESP”) warrants the TGAES to be free from defects in material and workmanship under normal use and service for a period of three (3) years, beginning on the date of shipment to the buyer. This warranty extends only to the sale of new and unused products to the original buyer. ESP’s warranty obligation is limited, at ESP’s option, to refund of the purchase price, repair, or replacement of a defective product or a component thereof, to the extent that the product is properly returned to ESP within the warranty period.

This warranty does not include:

a) fuses, disposable batteries or the routine replacement of parts due to the normalwear and tear of the product arising from use;

b) any product or component which in ESP’s opinion, has been misused, altered,abused, tampered with, improperly maintained or used, neglected or otherwisedamaged by accident or abnormal conditions of operation, handling or use, or tohave deteriorated due to aging of any component made of rubber or any otherelastomer; or

c) any damage or defect attributable to repair of the product by any person other thanan authorized dealer, or the installation of unapproved parts on the product.

The obligations set forth in this warranty are conditional on:

a) proper storage, installation, calibration, use, maintenance and compliance with theproduct manual instructions and any other applicable recommendations of ESP;

b) the buyer promptly notifying ESP of any defect and, if required, promptly making theproduct available for correction. No goods shall be returned to ESP until receipt bybuyer of shipping instructions from ESP. A return authorization number must beobtained from ESP prior to shipment; and

c) all warranty returns being shipped directly to ESP Safety, Inc.;d) the right of ESP to require that the buyer provide proof of purchase such as the

original invoice, bill of sale or packing slip to establish that the product is within thewarranty period.

THE BUYER AGREES THAT THIS WARRANTY IS THE BUYER’S SOLE AND EXCLUSIVE REMEDY AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. ESP SHALL NOT BE LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES OR LOSSES. ESP WILL NOT BE LIABLE FOR LOSS OR DAMAGE OF ANY KIND CONNECTED TO THE USE OF ITS PRODUCTS OR FAILURE OF ITS PRODUCTS TO FUNCTION OR OPERATE PROPERLY. IN NO EVENT SHALL ESP’S LIABILITY HEREUNDER EXCEED THE PURCHASE PRICE ACTUALLY PAID BY THE BUYER FOR THE PRODUCT.

To the extent any provision of this warranty is held invalid or unenforceable by a court of competent jurisdiction, such holding will not affect the validity or enforceability of any other provision.


of 50 Revised 03/19/2014

Field Repair The TGAES is not intended to be repaired in the field. If a p rob lem should develop, refer to the troubleshooting section of this manual. If it is determined that the problem falls within this warranty, please return the product to ESP as instructed hereunder.

Expected Service Life of Unit

The average expected service life of the TGAES is not less than 10 years.


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Appendix A-2: Wiring Diagrams

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of 50Revised 03/19/2014

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PH3L\A(!9\(

!O=OC]O!(


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Revised 04/16/2013

MODBUS RTU

RECEIVER


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Revised 10/14/2013

MODBUS RTU (DAISY CHAIN)

RECEIVER RECEIVER RECEIVER


MODBUS RTU (PARALLEL DROPS)

RECEIVER

RECEIVER

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Revised 10/14/2013


MULTIPLE USE

RECEIVER

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Revised 10/14/2013


TGAES WITH VECTOR DISPLAY (SINGLE SUPPLY)

RECEIVER

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Revised 10/14/2013


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TGAES WITH VECTOR DISPLAY (SEPARATE SUPPLIES)

RECEIVER


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Revised 04/16/2013

RELAY OUTPUTs


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Revised 10/14/2013

DIGITAL OUTPUTS


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Appendix B: Wire Size Chart

TGAES WIRE SIZE CHART


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Appendix C: Explosion Protection Means


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