Model 1000 CO2 Process Analyzer PART NO. MODEL NO. SERIAL NO. INPUT VOLTAGE FREQUENCY CURRENT LOAD AREA CLASSIFICATION detcon inc. AIR INLET SAMPLE FLOW 3200 A-1 Research Forest Dr. The Woodlands, TX 77381 www.detcon.com AIR AIR FLOW SAMPLE PRESSURE 10 PSIG (CONSTANT) SAMPLE INLET Operator’s Installation and Instruction Manual Detcon Model 1000 CO2 Analyzer consists of two major assemblies: 1. The Model 1000 Series gas sample conditioning assembly. 2. The Model IR-640/IR642 CO2 gas sensors.
Model 1000 CO2 This page left intentionally blank Model 1000 CO2 Instruction Manual ii
Model 1000 CO2 Table of Contents 1.0 Introduction.............................................................................................................................................. 1 1.1 IR-640/IR-642 Description................................................................................................................... 1 1.1.1 Non-dispersive infrared (NDIR) optical sensor ........................................................................... 2 1.1.2 Microprocessor Control Circuit..
Model 1000 CO2 Table of Figures Figure 1 IR Sensor Assembly............................................................................................................................ 1 Figure 2 IR Cell Construction ........................................................................................................................... 2 Figure 3 Control Faceplate ................................................................................................................................
Model 1000 CO2 1.0 Introduction The Detcon Model 1000 Series CO2 Process Analyzer is a 110/220VAC or 24VDC powered analyzer that provides a select gas sample mixture to an IR-640/IR-642 CO2 gas sensor assembly. The ranges of analysis are determined at time of order. The NEMA 7X rating is achieved by housing all electronic components in suitable NEMA 7X enclosures. When located outdoors, the CO2 Process Analyzer package should be appropriately covered from direct weather exposure.
Model 1000 CO2 sensors feature field adjustable, fully programmable alarms and provide relays for two alarms plus fault as standard. The sensor comes with two different outputs: analog 4-20mA, and serial RS-485. These outputs allow for greater flexibility in system integration and installation. The microprocessor-supervised electronics are packaged as a plug-in module that mates to a standard connector board.
Model 1000 CO2 The control circuit is microprocessor based and packaged as a plug-in field replaceable module, facilitating easy replacement and minimum down time. Circuit functions include a basic sensor pre-amplifier, sensor temperature measurement, on-board power supplies, microprocessor, back lit alpha numeric display, alarm status LED indicators, magnetic programming switches, an RS-485 communication port, and a linear 4-20mA DC output. 1.1.
Model 1000 CO2 Figure 5 IR Block Diagram 1.1.5 Characteristics The NDIR optical sensor element maintains strong sensitivity to CO2. Typical zero calibration intervals would be quarterly and typical span calibration intervals would be quarterly to bi-annual. However, actual field experience is always the best determination of appropriate calibration intervals.
Model 1000 CO2 Flow Fault (optional) Pump/Scrubber Power Supply/ Terminal PCB + 24VDC OUT 2.1A Left Sensor (side view) Sensor + 18-36 VDC IN Right Figure 8 Explosion proof enclosures A 24 VDC power supply and termination PCB for the power, relay contacts, 4-20mA output, and or RS485 signal, are located in the explosion proof enclosure located in the upper right of the unit.
Model 1000 CO2 Explosion Proof; Class I, Division 1, Groups C, D Analyzer Weight 75 lbs. Dimensions 29”H X 29”W X 8”D 3.0 Installation 3.1 Mounting Securely mount the Model 1000 analyzer panel or (optional) NEMA 4 enclosure in accordance with Figure 9. Figure 9 Unit Dimensions 3.2 Gas Connections and Sampling System Notes 1. Install a length of tubing from the desired sample point to the sample Inlet Port (Figure 10). Sample draw tubing should be 316 stainless steel of 1/4" O.D.
Model 1000 CO2 changes. An insertion probe membrane device is advisable to use for pipeline sources with high levels of condensates, mist, and contamination. 2. Whenever possible, the Sample Bypass flow control valve of the Genie membrane filter should be used to minimize the sample lag time between the sample tap and the analyzer location. It can also be used as a means to exhaust condensed liquids in the sample line away from the Genie filter and prevent a “loss of flow” condition.
Model 1000 CO2 Customer Connections INPUT + + 24VDC OUT 2.1A + 24VDC OUT 2.1A + 18-36 VDC IN 18-36 VDC IN + - +24VDC -24VDC (Ground) 117VAC / 24VDC In 4-20mA, RS485, Alarm/Fault Sensor Relays Low Flow Air/ Sample Relays (Optional) SAMPLE FLOW AIR FLOW Figure 11 Installation Wiring Connections 4. Optional Low Flow Fault alarms for Sample gas and Air are also available on the Terminal Connector Board (Figure 11).
Model 1000 CO2 If a jumper tab is installed in the latch position, the alarm relay will be in the latching mode. The latching mode will latch the alarm after alarm conditions have cleared until the alarm reset function is activated. The non-latching mode (jumper removed) will allow alarms to de-activate automatically once alarm conditions have cleared. The default Factory set-up for Alarm 1 and Alarm 2 relays is non-latching. The default factory set-up for the Fault relay is latching.
Model 1000 CO2 Table 1 Hexadecimal Table ID# 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 SW1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 SW2 0 1 2 3 4 5 6 7 8 9 A B C D E F 0 1 2 3 4 5 6 7 8 9 A B C D E F 0 1 2 3 4 5 6 7 8 9 A ID# 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 SW1 2 2 2 2 2 3 3 3 3 3 3 3 3
Model 1000 CO2 NOTE: All alarms will be disabled for 1 minute after power up. In the event of power failure, the alarm disable period will begin again once power has been restored. NOTE: Sample flow rates are actual Rotameter set-point flow rates, after accounting for Rotameter gas. 5.0 Operating Software 5.1 Programming Magnet Operating Instructions Operator interface to MicroSafe™ gas detection products is via magnetic switches located behind the transmitter faceplate.
Model 1000 CO2 5.2.1 Normal Operation In normal operation, the display tracks the current status of the sensor and gas concentration and appears as: “##.# % CO2”. The milliamp current output corresponds to the monitoring level and range of the sensor, where Full Scale is 20mA. 5.2.2 Calibration Mode Calibration mode allows for sensor zero and span adjustments. “1-ZERO 2-SPAN” Zero Adjustment Zero is set in ambient air with no CO2 gas present or with zero gas applied to the sensor.
Model 1000 CO2 ¾ Alarm relay energize state of the fault alarm. The menu item appears as: “FLT ENERGIZED” or deenergized. ¾ Calibration gas level setting. The menu item appears as: “CalLevel @ #.##%” ¾ Identification of the RS-485 ID number setting. The menu item appears as: “485 ID SET @ ##” ¾ Sensor temperature in °C appears as: “TEMPERATURE ## °C” ¾ Estimated remaining sensor life.
Model 1000 CO2 5.2.4 Software Flow Chart Figure 15 IR-640/IR-642 Software Flow Chart Model 1000 CO2 Instruction Manual Rev. 2.
Model 1000 CO2 6.0 Calibration Model 1000 Series CO2 Process Analyzer is calibrated prior to shipment. Only minimal adjustment should be required at time of commissioning. IR-640/IR-642 Initial Calibration Recommendations: A zero and span calibration should be performed at start-up to assure optimum system performance. After that, a zero and span calibration interval of every 3 months is recommended. 6.
Model 1000 CO2 1) Verify that the current calibration gas level is equal to the calibration span gas concentration. (Refer to Section 5.2.3 Program Mode, “View Sensor Status”. The item appears as “CAL LEVEL @ ### %”.) 2) If the calibration gas level setting is equal to the calibration span gas concentration, proceed to item “3)”.
Model 1000 CO2 7.0 Programming Sensors 7.1 Alarm Levels Both alarm 1 and alarm 2 levels are factory set prior to shipment. Alarm 1 is set at 20% of full-scale range; alarm 2 at 40% of full-scale range. Both alarms can be set in 0.01% increments from 10 to 90% of full-scale range.
Model 1000 CO2 7.4 Calibration Gas Level If the calibration gas level setting does not equal the calibration span gas concentration, or the calibration gas level needs to be changed, adjust the calibration gas level setting so that it is equal to the calibration span gas concentration. a) Enter the programming menu by holding the programming magnet stationary over “PGM 2” for 30 seconds until the display reads “VIEW PROG STATUS”, and then withdraw the magnet.
Model 1000 CO2 The following conditions will cause a calibration fault: 1 - Zero calibration cannot converge. 2 - Auto span cannot converge (too noisy or too unstable). 3 - Span gas is not applied before 1 minute elapses. Fail-Safe/Fault Supervision Model IR-640/IR-642 MicroSafe™ sensors are programmed for fail-safe operation.
Model 1000 CO2 However, any change to the RS-485 ID number would require the sensor housing to be opened, thus declassification of the area would be required. See section 3.4 for details on changing the RS-485 ID number. The following section explains the details of the Modbus™ protocol that the Detcon MicroSafe™ sensor supports. Code 03 - Read Holding Registers is the only code supported by the transmitter. Each transmitter contains 6 holding registers which reflect its current status.
Model 1000 CO2 Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 1-Alarm 2 Relay is energized 1-Alarm 1 is ascending 1-Alarm 1 is normally energized 1-Alarm 1 is latching 1-Alarm 1 Relay is energized 1-Fault is normally energized 1-Fault is latching 1-Fault Relay is energized 0-Alarm 2 Relay is not energized 0-Alarm 1 is descending 0-Alarm 1 is normally de-energized 0-Alarm 1 is non-latching 0-Alarm 1 Relay is not energized 0-Fault is normally de-energized 0-Fault is non-latching 0-Fault Relay is not energ
Model 1000 CO2 2 - Remove gas inlet adapter and tubing connections to expose sensor housing (see illustration page 35). 3 - Remove lower half of sensor housing using an Allen wrench (3 screws). 4 - Remove existing optical sensor and replace with new optical sensor. 5 - Re-install lower half of sensor housing. 6 - Restore system power (if classified) or plug in transmitter module and replace enclosure cover (if unclassified).
Model 1000 CO2 13.0 Spare Parts Part# 327-000000-000 351-152021-400 360-205421-024 360-2424GH-030 943-200000-000 943-010013-505 823-101085-882 350-300000-000 348-900000-000 350-523081-02K 308-091000-030 942-400123-2X5 942-400123-005 926-405502-015 926-405502-020 500-002042-000 370-365878-111 370-287724-332 390-000088-000 Description Programming Magnet 24 VDC Pump Assembly 24 VDC Power Supply 24V DC-DC Converter Activated Carbon Scrubber 500 CC Fixed Flow Regulator Genie Membrane Filter 0.
Model 1000 CO2 14.0 Warranty Detcon Inc., as manufacturer, warrants under intended normal use each new Model 1000 Series H2S Process Analyzer gas detection system to be free from defects in material and workmanship for a period of one year from the date of shipment to the original purchaser. All warranties and service policies are FOB the Detcon Inc. facility located in The Woodlands, Texas. Sensor Transmitter Detcon, Inc.
Model 1000 CO2 15.0 Gas Flow and Wiring Diagrams PART NO. MODEL NO. SERIAL NO. INPUT VOLTAGE FREQUENCY CURRENT LOAD AREA CLASSIFICATION detcon inc. AIR INLET SAMPLE FLOW 3200 A-1 Research Forest Dr. The Woodlands, TX 77381 www.detcon.com AIR AIR FLOW SAMPLE PRESSURE 10 PSIG (CONSTANT) Sample Input SAMPLE INLET SAMPLE Vent Vent CALIBRATE Vent Figure 17 Unit Flow Diagram Model 1000 CO2 Instruction Manual Rev. 2.
Model 1000 CO2 Sample Flow Fault Air Flow Fault Figure 18 Pump Box Flow Diagram Model 1000 CO2 Instruction Manual Rev. 2.
Model 1000 CO2 Red 18AWG 30 + + 18-36 VDC IN 24VDC OUT 2.
Model 1000 CO2 Appendix C Revision Log Revision Date 2.0 3/30/09 2.1 06/01/11 2.2 9/19/11 Model 1000 CO2 Instruction Manual Changes made Combined Low range and High range CO2 manuals into one Updated drawings and Spare parts list. Added Revision Log Updated notation regarding VDC input in section 3.3 to match wiring diagram Rev. 2.
