Operating Instructions Sieger System 57 5701 Control System
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System 5701 CONTROL SYSTEM OPERATING INSTRUCTIONS Helping to make a safer world Ensure that you read and understand these instructions BEFORE operating the equipment. Please pay particular attention to the Safety Warnings. WARNINGS The items of equipment covered by this manual are: 1. Not designed or certified for use in hazardous areas. 2. Designed for indoor use only. 3. Not to be exposed to rain or moisture. CAUTIONS 1.
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MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System 5701 CONTROL SYSTEM OPERATING INSTRUCTIONS To: Marketing Communications, Zellweger Analytics Limited, Hatch Pond House, 4 Stinsford Road, Nuffield Estate, POOLE. Dorset. BH17 0RZ. United Kingdom. Tel : Fax : email : From: Address: +44 (0) 1202 676161 +44 (0) 1202 678011 tracy.dawe@zelana.com Tel : Fax : email : I suggest the following corrections/changes be made to Chapter ........... Section ...........
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System 5701 CONTROL SYSTEM OPERATING INSTRUCTIONS CONTENTS Chapter 1. SYSTEM CONCEPT 2. SYSTEM DESCRIPTION 3. CONTROLS AND FACILITIES 4. INSTALLATION INSTRUCTIONS 5. COMMISSIONING AND MAINTENANCE INSTRUCTIONS 6. OPERATING INSTRUCTIONS 7. ENGINEER'S OPERATING INSTRUCTIONS 8. SPECIFICATION 9. ORDERING INFORMATION 10.
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MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 1 - SYSTEM CONCEPT CONTENTS Section Page 1. PRINCIPAL FEATURES 1-3 2. CONSTRUCTION 1-4 FIGURES Figure 1. 2.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 1 - SYSTEM CONCEPT 1. PRINCIPAL FEATURES The 5701 Series Control System is part of the System 57 family and is designed to monitor field mounted industrial gas detectors. The principal features of the system are: * Provides up to 16 channels of gas detection in a standard 19'' subrack using a 3U card format. * Provides up to eight channels of gas detection in a half 19'' subrack using a 3U card format.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 1 - SYSTEM CONCEPT 2. CONSTRUCTION The system consists of individual 1'' (2.54cm) wide cards fitted to a rigid custom rack designed to fit Euro rack cabinets. Two rack widths are available: a. 19 inch with 17 card slots to house up to 16 Channel Control Cards and an Engineering Card. b. Half 19 inch with nine card slots to house up to eight Channel Control Cards and an Engineering Card.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 1 - SYSTEM CONCEPT In a system where the field wiring is required to be connected to the rear of the system, the rack is centrally divided into front and rear sections by a printed circuit board backplane which provides common power and signal routeing between individual Channel Control Cards.
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MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION CONTENTS Section Page 1. INTRODUCTION 2-3 2. RACKS 2-4 3. CABINETS 2-6 4. SINGLE CHANNEL CONTROL CARDS 2-8 4.1 4.2 4.3 4.4 4.5 5. General Single Channel Control Card Sensor Drive Modules Analogue Output Module Single Channel Control Card Physical Layout 2-8 2-9 2-9 2-9 2-10 FIELD INTERFACE AND RELAY CARDS 2-11 5.1 5.2 5.3 5.4 5.5 5.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 1. INTRODUCTION The 5701 Series Control System is a microprocessor based system which displays the reading and status of connected gas detectors. The system provides complex alarm handling facilities with a full maintenance capability.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 2. RACKS Each rack assembly contains a sub-rack, Engineering Card, DC Input Card, key kit and where necessary an interconnecting cable. Dependent upon configuration, the control system is housed in one of four standard size sub-racks as follows: a. Full 19 inch wide by 3U high - Part Number 05701-A-0511, for rear field wiring connections. b.
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MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 3. CABINETS Two wall mounted cabinets are used to house: a. the full width 16 channel front access rack, (Part Number 05701-A-0451) b. or the eight channel half width front access rack. (Part Number 05701-A-0452) A front door on each cabinet provides security and dust protection, while a clear panel in the door allows the channel card displays to be viewed when the door is closed.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION Eight Channel Cabinet Installation Blanking Panel 8-Way AC to DC Power Supply Unit Channel Cards and Engineering Card Interface/Relay Cards and DC Input Card Accessory Plate suitable for mounting DIN rails, circuit breakers, relays, etc.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 4. SINGLE CHANNEL CONTROL CARDS 4.1 General 5701 % LEL 100 80 60 40 20 0 The 5701 Single Channel Control Card provides control, display and alarm facilities for a connected gas detector. The front panel display indicates the gas reading and channel status while LEDs are used for alarms. A push-button is provided for resetting the alarms and selecting the card for use with the Engineering Card.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 4.2 Single Channel Control Card The Single Channel Control Card carries out the control functions for a single loop of gas detection as follows: a. Processes the incoming sensor drive module signal. b. Displays the signal level on the front panel liquid crystal display. c. Compares the signal level with pre-defined alarm limits. d.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 4.5 Single Channel Control Card Physical Layout The physical layout of the Single Channel Control Card is shown below. The Sensor Drive Modules plug into the 14-way connectors J1 and J2 while the Analogue Output Module, when fitted, plugs into J3 and J4. Link LK1, available on MkII cards only, is used when individually powering control cards See Chapter 4, Section 16.2.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 5. FIELD INTERFACE AND RELAY CARDS 5.1 General The Field Interface Card and the four types of relay card provide the interface between a Single Channel Control Card and the field wiring. 5.2 Field Interface Card (Part Number 05701-A-0326) 5.2.1 General For use in systems with master relays. Used on all channels except the master. Provides connections between the sensor and the control card only.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 5.2.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 5.2.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 5.3 Double SPCO Relay Card (Part Number 05701-A-0327) 5.3.1 General Provides connections between the sensor and the control card in the same way as the Field Interface Card. In addition, single pole relays provide voltage free contact outputs for the A1 alarm level, A2 alarm level and fault condition. 5.3.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 5.3.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 5.4 Triple SPCO Relay Card (Part Number 05701-A-0328) 5.4.1 General Provides connections between the sensor and the control card in the same way as the Field Interface Card. In addition, single pole relays provide voltage free contact outputs for the A1 alarm level, A2 alarm level, A3 alarm level, fault and inhibit conditions. 5.4.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 5.4.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 5.5 Triple DPCO Relay Card (Part Number 05701-A-0329) 5.5.1 General Provides connections between the sensor and the control card in the same way as the Field Interface Card. In addition, single pole relays provide voltage free contact outputs for 2 x A1 alarm level, 2 x A2 alarm level, 2 x A3 alarm level, fault and inhibit conditions. 5.5.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 5.5.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 5.6 High Integrity Relay Card (Part Number 05701-A-0330) 5.6.1 General Provides connections between the sensor and the control card in the same way as the Field Interface Card. This card is used to provide master alarm functions or a mixture of master and individual alarms. The card is fitted with eight relays, seven of which are fully configurable while the eighth is used for fault alarm.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 5.6.2 Rear Access Connections IMPORTANT Refer to configuration printout, or use the Relays Screen of the Engineering Interface Software, to determine the relay function.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 5.6.3 Front Access Connections IMPORTANT Refer to configuration printout, or use the Relays Screen of the Engineering Interface Software, to determine the relay function.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 6. ENGINEERING CARD The Engineering Card (Part Number 05701-A-0361) is used on a System 57 rack to provide a common interface that enables the user to perform all the required functions to commission and operate each fitted control card.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION One of four optional modules may be fitted to the Engineering Card: a. Master Alarm Update Module This facility provides an indication when a new alarm occurs on any channel in the rack, even if a previous alarm condition already exists. b. Event Printing Module This facility provides time stamped reporting of alarm and fault events as they occur and system status at predetermined regular intervals. c.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 7. DC INPUT CARD 7.1 General The dc power to the rack normally enters the sub-rack via the DC Input Card (Part Number 05701-A-0325). This power may be supplied by the user from an external nominal 24V dc supply. The dc supply is routed through the Engineering Card and sub-rack back plane to all cards in the rack and is protected by a fuse on the DC Input Card.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 7.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 7.3 Front Access Connections Slot Location TB2 1 2 Connections to the Engineering Card optional modules. Functions vary depending upon type of module fitted.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 8. AC TO DC POWER SUPPLY UNITS 8.1 Types of Power Supply Unit There are two types of AC to DC power supply units: a. 8-Way AC to DC Power Supply Unit (Part Number 05701-A-0406) A 1U high half width 19 inch rack mounted unit that contains a single 50W Switched Mode AC to DC Power Supply Module. b.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 8.4 8-Way AC to DC Power Supply Unit Layout Front View Top View Rear View Input ac Supply Voltage 8.5 24V dc Output Voltage. 50W per Fitted Module 16-Way AC to DC Power Supply Unit Layout Optional Sub Unit Input ac Supply Voltage Input ac Supply Voltage 24V dc Output Voltage. 50W per Fitted Module 2 - 29 24V dc Output Voltage.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 8.6 50W Sub-Unit Layout The 50W Sub-unit is fitted with a single 50W Switched Mode AC to DC Power Supply Module as shown below: Top View 50W Switched Mode AC to DC Power Supply Module This type of unit is identified on the identification label as follows: POWER SUPPLY UNIT 05700-A-0405 Iss. 2 INPUT = 85 47 OR 110 - 8.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 2 - SYSTEM DESCRIPTION 9. FRONT PANEL BLANKING PANEL Matching blank front panels are available for fitting to the rack in all unused single channel control card spaces.
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MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 3 CONTROLS AND FACILITIES CONTENTS Section Page 1. INTRODUCTION 3-3 2. SINGLE CHANNEL CONTROL CARD 3-8 2.1 2.2 2.3 2.4 2.5 2.6 3. General Liquid Crystal Display LEDs Reset/Select Push-button Extraction Slot Display Label and Cover 3-8 3-9 3-11 3-12 3-13 3-13 ENGINEERING CARD 3-14 3.1 General 3.2 LED Indicators 3.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 3 CONTROLS AND FACILITIES 1. INTRODUCTION The 5701 Series Control System is equipped to provide the operational and engineering facilities necessary to fully maintain a system of gas detection equipment. Each control card within a rack system displays a sensor reading, alarm status and condition of that channel.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 3 CONTROLS AND FACILITIES e. LTEL Alarm (Long Term Exposure Limit). The LTEL alarm will be activated when the time weighted average concentration of a toxic gas, usually averaged over 8 hours, crosses a preconfigured threshold. When active LTEL will be shown on the message display of the control card. For certain relay cards and configurations, the alarm LED associated during setup to the LTEL alarm will be illuminated. f.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 3 CONTROLS AND FACILITIES j. Voted Alarm* A voted alarm is caused by the simultaneous presence of an identical alarm on more than one control channel within a preconfigured group. The relevant LED (A1, A2, A3, Fault, Inhibit) will illuminate on the control cards with the alarm condition and also on the control card designated the Vote Master Card (unless it is fitted with a High Integrity Relay).
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 3 CONTROLS AND FACILITIES m. Falling Alarm A falling alarm is caused by a falling level of the parameter being measured crossing a preconfigured threshold and will also cause the associated alarm LED to illuminate. n. Latched Alarm A latched alarm is an alarm that will remain active even though the level monitored no longer crosses the alarm threshold. The alarm LED will remain lit until the alarm reset is operated. o.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 3 CONTROLS AND FACILITIES Control Card Versions Since the original launch of System 57 several new features have been added to enhance the capabilities of the 5701 Control Card. The key features for each software version are illustrated in the following table.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 3 CONTROLS AND FACILITIES 2. SINGLE CHANNEL CONTROL CARD 2.1 General The Single Channel Control Card provides the necessary power supplies to the associated sensor and conditions the incoming sensor signal. The received sensor signal is then processed by the microprocessor and the resultant value and any necessary alarm action, depending on the channel configuration, is carried out.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 3 CONTROLS AND FACILITIES 2.2 Liquid Crystal Display 2.2.1 General The LCD provides a display of the connected sensor reading and its status, or if maintenance is being carried out on the sensor, information on the sensor set points and calibration data. The display can be divided into four parts: 5701 % LEL 100 80 Analogue Display. 60 40 20 Message Display 0 Digital Display. Icon Display. 2.2.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 3 CONTROLS AND FACILITIES 2.2.3 Digital Display The digital display is a four character, seven segment display which provides either an indication of the sensor gas reading or a value relating to a function selected from the Engineering Card. Depending on the sensor range and the configuration setting, the digital display shows a gas value to either no decimal place (the default setting) or to one decimal place. 2.2.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 3 CONTROLS AND FACILITIES 2.3 LEDS Five LEDs on the front panel of the control card indicate the operational status of the channel as follows: a. FAULT - Amber LED The fault LED provides an indication in the event of a sensor hardware failure, if the sensor signal is outside pre-defined limits or if the channel card has detected a hardware or software fault. b.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 3 CONTROLS AND FACILITIES 2.4 Reset/Select Push-button The front panel RESET/SELECT push-button provides four functions depending upon how it is operated: a. Alarm Reset The RESET/SELECT push-button, when pressed momentarily, resets any latched alarm, non active alarms, faults, warning or information messages, clears the display peak reading indicator and will acknowledge an update if such a condition is present.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 3 CONTROLS AND FACILITIES 2.5 Extraction Slot An extraction tool is used in conjunction with the extraction slot, just below the select push-button, to remove the card from the rack. The extraction tool is provided as part of the Key Kit (05701-A-0550) supplied with each rack assembly.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 3 CONTROLS AND FACILITIES 3. ENGINEERING CARD 3.1 General The Engineering Card provides facilities to allow each control card to be interrogated and to allow normal maintenance functions such as calibration to be carried out. It also acts as a connecting point for the engineering interface which allows each card to be configured. 3.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 3 CONTROLS AND FACILITIES 3.3 Engineering Push-buttons 3.3.1 General The Engineering Card push-buttons control various functions depending on the type of control card fitted and whether the Engineering Key is fitted. 3.3.2 Up Push-button ( ) When the up push-button ( ) is operated, it increases the value of those functions that can be adjusted. 3.3.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 3 CONTROLS AND FACILITIES 3.3.8 ALARMS Push-button When the ALARMS push-button is operated, the display of the selected control card provides an indication of that card's level and type (rising or falling) of each alarm level (A1, A2, A3, STEL, LTEL). If the Engineering Key is fitted to the Engineering Card, adjustments can be made to the alarm levels, within pre-defined limits, and additional test facilities become available.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 3 CONTROLS AND FACILITIES The rack clock is located in the Engineering Card, however since the Engineering Card has no display, a control card must be selected to enable the time and date to be displayed. It does not matter which control card is selected. If the Engineering Key is fitted to the Engineering Card, the time and date can be adjusted. 3.3.
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MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS WARNING For installations in the EU, refer to EN60079-14:1997, ‘Electrical Installations in Hazardous Areas (other than mines). Additionally, the code of practice regarding Selection, installation, use and maintenance of apparatus for the detection and measurement of combustible gases or oxygen must be complied with. Refer to EN 50073.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS CONTENTS Section Page 1. INTRODUCTION 4-5 2. UNPACKING 4-6 3. LOCATION 4-7 4. CABLING 4-8 5. POWER REQUIREMENTS 4-9 6. VENTILATION 4-11 7. PRELIMINARIES 4-12 8. CABINET INSTALLATION 4-13 9. PANEL INSTALLATION 4-16 10. RACK INSTALLATION 4-18 11. SENSOR INSTALLATION 4-19 11.1 11.2 11.3 11.4 11.5 11.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 13. 14. SENSOR CONNECTIONS 4-25 13.1 13.2 13.3 13.4 13.5 4-25 4-25 4-28 4-31 4-56 General Catalytic Sensor Connections 4 - 20mA Loop Powered Sensor Connections 4 - 20mA Transmitter Connections IS Series 2000 Toxic Transmitter Connections OUTPUT CONNECTIONS 4-61 14.1 14.2 4-61 4-62 Relay Outputs Analogue Output 15. REMOTE INPUT CONNECTIONS 4-65 16. DC POWER CONNECTIONS 4-67 16.1 16.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 1. INTRODUCTION A summary of the System 57 controller installation procedures is shown below: a. Unpack and check the equipment. b. Identify a suitable location and check the cabling requirements. c. Confirm the power supply requirements. d. Install the Cabinet, 19" Mounting Frame or Panel Cutout as required. e. Fit the System 57 rack into the Cabinet, 19" Mounting Frame or Panel Cutout.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 2. UNPACKING On receipt: a. Carefully unpack the equipment observing any instructions printed on or contained in the packaging. b. Check the contents for transit damage and against the packing note for deficiencies. c. Locate the configuration sheet supplied with the unit and confirm that each channel card type and settings are compatible with the proposed sensors.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 3. LOCATION The control system must be installed in a safe area such as a control or equipment room, away from sources of heat, with adequate ventilation and protected from the weather. There are two different System 57 rack configurations to accommodate either front or rear field wiring entry. Each configuration is available in half or full 19" width. The three most common mounting methods are: a.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 4. CABLING The field terminals on the Field Interface and Relay Cards accept up to 2.5mm˝ single or multi-stranded wire. Cables should be routed carefully to avoid physical and environmental hazards such as mechanical stress and high temperatures.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 5. POWER REQUIREMENTS The System 57 operates from a nominal 24V (18V to 32V) dc power supply input which can be derived from various sources including the mains ac, via a separate ac to dc power supply unit, local plant dc supply and/or battery backup dc supply.
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MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 6. VENTILATION The System 57 Control System provides the facility for a large number of channels in a very small space. In heavily populated racks, especially those with many catalytic input control cards or relays configured for normally energised operation, it is possible for the heat dissipation to cause a significant rise in temperature both within the rack and in an area close to the rack.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 7. PRELIMINARIES Ensure that each control card is compatible with the proposed sensor/ transmitter to be connected to that control card. Ensure that where an AC to DC Power Supply Unit is to be used, this is compatible with the local mains ac supply voltage and that the PSU power rating is adequate for its individual system load.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 8. CABINET INSTALLATION Two cabinets are available, an 8-way to accommodate the 8-way front access rack and a 16-way to accommodate the 16-way front access rack. The cabinet must be secured to a wall, or other suitable vertical surface, as follows: (1) Knock out the bottom gland-plate entries as appropriate for the system cabling and fit the glands before mounting the cabinet.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS Cabinet Dimensions: 630 8 way 337 16 way 540 268 All dimension shown in mm. Wall Mounting Bracket Hole Locations 8 way 16 way Cabinet Mounting Brackets 367 57 100 430 27 15 100 9 15 15 36 All dimension shown in mm. 9 10.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 16 Channel Cabinet Installation Blanking Panel 16-Way AC to DC Power Supply Unit Channel Cards Engineering Card Interface/Relay Cards DC Input Card Accessory Plate (suitable for mounting DIN rails, circuit breakers, relays, etc.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 9. PANEL INSTALLATION All racks and the AC to DC Power Supply Units are suitable for panel installation and are installed as follows: (1) Cut out a suitable aperture to accommodate the System 57 rack and power supply unit (where required) using the dimensions shown: Rack Table of Sizes (mm) A A B B C E D C E Mounting Holes 7mm D Rack Assembly C D 57.0 37.8 132.5 287.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS AC to DC PSU Table of Sizes (mm) A B 8.4 43.6 31.8 5.9 PSU Assembly A B Clearance Width Height 8 Way 279.4 261.9 222 41 16 Way 482.6 465.1 443 41 (2) Insert the rack into the aperture and secure using M6, or similar bolts, through the four mounting holes located upon the front flange plates. (3) Ensure adequate support at the rear of rear access racks.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 10. RACK INSTALLATION The 16-way 3U high rear access and 6U high front access racks are suitable for mounting in standard 19" (483mm) wide Mounting Frames. These are fitted as follows: (1) Insert the rack into the 19" Mounting Frame and secure using M6 or similar bolts through the four mounting holes located on the front flange plates. (2) Ensure adequate support at the rear of rear access racks.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 11. SENSOR INSTALLATION 11.1 General Always install the sensors in accordance with the Sensor Operating Instructions. In general, sensors for lighter than air gasses should be located at a high level and sensors for heavier than air gasses should be located at a low level. Do not install the sensors: a. Where the normal air flow may be impeded. b.
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MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 11.3 Cable Resistance Guide A guide to the resistance of various copper cable sizes is given below: Solid Copper Conductor Cross Sectional Area (mm˝) Maximum resistance at 20°C (ohm/km) 0.50 0.75 1.00 1.50 2.50 38.0 25.3 19.0 12.6 7.6 Stranded Copper Conductor Cross Sectional Area (mm˝) Maximum resistance at 20°C (ohm/km) 0.50 0.75 1.00 1.50 2.50 36.8 24.5 18.4 12.3 7.4 11.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 11.5 4-20mA Loop Powered Sensors: The maximum line resistance of cabling for a 4 - 20mA loop powered sensor varies with the voltage drive requirements of the type of sensor installed. It is also subject to a 20V maximum loop drive voltage. Maximum line loop resistance is calculated as follows: RL Where: RL Vs = = 20 - Vs = 0.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 12. CONTROL CARD SENSOR DRIVE MODULE CONFIGURATION 12.1 General The sensor drive modules fitted to the Single Channel Control Cards have configuration links that effect the operation of the sensor. The following sections identify the links to allow the configuration to be inspected. 12.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS be accommodated. A link is closed by fitting the jumper provided so that the two pins of the link are connected.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 13. SENSOR CONNECTIONS 13.1 General WARNING Incorrect connection of the sensor wires may cause damage to both the sensor and System 57. CAUTION The sensors connections must always be made with the System 57 unit in an unpowered state. Isolate power supplies at their source before making connections. Ensure that any external dc backup battery supply is also disabled.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS The sensor cable screen or steel wire armour (or braid), as appropriate, should be connected to the system (protective) earth. This can be achieved where the cable enters the cabinet by using a metal cable gland, or by other suitable means, and avoiding any screen 'tails' within the cabinet.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS Single Channel Control Card Catalytic 05701-A-0302 Fitted with Catalytic Sensor Drive 05701-A-0284 Note: Where a sensor is earthed locally, either to the Earth Stud or through the sensor casing or mounting, to avoid earth loops the screen sheath of the cable should only be connected at one end, i.e., at the sensor or at the Interface/Relay Card.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 13.3 4 - 20mA Loop Powered Sensor Connections Loop powered sensors require a two wire connection and the sensor documentation will indicate the positive and negative loop connections, usually brown and blue respectively.
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MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 13.4 4 - 20mA Transmitter Connections CAUTION The power provided by the Single Channel Control Card is derived from the dc input to the System 57 (18V to 32V). Check that the transmitter to be connected is compatible with the actual supply voltage used.
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MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS Single Channel Control Card 4 - 20mA 05701-A-0301 Fitted with 4 - 20mA Sensor Drive 05701-A-0283 Link Positions LK12 Note: 1. 2. Where a sensor is earthed locally, either to the Earth Stud or through the sensor casing or mounting, to avoid earth loops the screen sheath of the cable should only be connected at one end. ie. At the sensor or at the Interface/relay Card.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS Single Channel Control Card 4 - 20mA 05701-A-0301 Fitted with 4 - 20mA Sensor Drive 05701-A-0283 Link Positions LK12 LK10 Note: 1. 2. Where a sensor is earthed locally, either to the Earth Stud or through the sensor casing or mounting, to avoid earth loops the screen sheath of the cable should only be connected at one end. ie. At the sensor or at the Interface/relay Card.
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MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 13.5 IS Series 2000 Toxic Transmitter Connections If the measuring resistance is in the positive supply line, a single safety barrier can be used.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS If the measuring resistance is in the negative supply line, a double safety barrier must be used.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS In this configuration the 4 - 20mA link on the Series 2000 sensor is NOT fitted.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS If the measuring resistance is in the positive supply line, a single safety barrier can be used.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS If the measuring resistance is in the negative supply line, a double safety barrier must be used.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 14. OUTPUT CONNECTIONS 14.1 Relay Outputs Note: 1. The FAULT relay is permanently configured for normally ENERGISED operation in the non-fault condition. 2. Unless the High Integrity Relay Card is fitted, the INHIBIT relay (where fitted) is permanently configured for normally DE-ENERGISED operation in the non-inhibit condition. 3.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS The alarm relays may be configured for either normally de-energised or normally energised operation. Check the configuration sheet supplied with the system to determine the operating mode of the relays on each channel. The energisation mode of the relays can be reconfigured easily using a computer attached to the Engineering Port. Contact Zellweger Analytics or your local agent for more information.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS The analogue output can be configured for 0 - 20mA or 4 - 20mA output modes. Check the configuration sheet supplied with the system to determine the factory configured operating mode. The operating mode can be reconfigured easily using a computer attached to the Engineering Port. Contact Zellweger Analytics or your local agent for more information.
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MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 15. REMOTE INPUT CONNECTIONS CAUTION Connecting voltages in excess of 32V to the remote inputs may cause permanent damage to the Single Channel Control Card. There are two remote inputs, RESET and INHIBIT, which are individually configurable for active high or active low operating modes. Check the configuration sheet supplied with the system to determine the factory configured operating modes.
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MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 16. DC POWER CONNECTIONS 16.1 General CAUTION The ratings of power supplies should be checked by calculating a system power budget as outlined in Section 5. IMPORTANT The System 57 must be earthed DC power is connected to the System 57 via the DC Input Card terminal block TB1. The DC Input Card provides diode isolation to permit the connection of two separate power supplies. eg.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 16.2 Individually Powered Control Cards Note: In individually powered control systems a DC connection is still required to the DC Input Card in order to provide power to the Engineering Card. Individually powered control cards may be required where the local or other regulations dictate individual connections in order to achieve the highest integrity for power distribution.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 17. AC TO DC POWER SUPPLY UNIT CONNECTIONS WARNING The AC to DC Power Supply Unit must be earthed. The input supply to the AC to DC Power Supply Unit may be: a. an ac supply of 85V to 264V at 47Hz to 440Hz. b. a dc supply of 110V to 340V (Refer to Zellweger Analytics for information on dc supplies). The supply must be fused at 6A maximum at the supply source. eg. At the distribution panel.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS AC to DC PSU 50W Sub-Unit AC to DC PSU 50W Sub-Unit Earth Stud AC Input Supply L N Earth Stud System Earth Brown Blue Green/Yellow E L N DC Input Card TB1 Brown Blue Green/Yellow E Intermediate Terminal Block * 12 ** 11 * 10 ** 9 8 Auxiliary 24V DC Supply (eg.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS 18. UPGRADING THE AC TO DC POWER SUPPLY UNITS WARNING High voltages exist within the AC to DC Power Supply Unit. Disconnect from the ac supply for a period of at least five minutes before removing the top cover and carrying out any maintenance or upgrade operation. 18.1 General There are two types of AC to DC Power Supply Unit, an 8-Way 50W and 16-Way 50W.
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MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS Front View 50W Switched Mode AC to DC Power Supply Module 50W Switched Mode AC to DC Power Supply Module 50W Switched Mode AC to DC Power Supply Module 50W Switched Mode AC to DC Power Supply Module Top View Rear View Input AC Supply Voltage 24V 100W DC Earth Input AC Output Stud Supply Voltage 24V 100W DC Output Earth Stud 16-Way AC to DC Power Supply Unit (200W) 18.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 4 - INSTALLATION INSTRUCTIONS (5) Insert the module, with the same orientation as the already fitted module, into the vacant position inside the 50W Sub Unit and secure using the washers and long nuts retained in Step (3).
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MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 5 - COMMISSIONING AND MAINTENANCE INSTRUCTIONS CONTENTS Section Page 1. GENERAL 5-3 2. START UP PROCEDURE 5-4 3. CALIBRATION 5-6 4. MAINTENANCE 5-7 5. ERROR CODES 5-8 5.1 5.2 5.3 5.4 5.5 5.6 6.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 5 - COMMISSIONING AND MAINTENANCE INSTRUCTIONS WARNING High ac mains voltages may be present at the system power supply unit and at the relay terminals of the interface cards. Appropriate safety precautions must be taken when commissioning or servicing the system. IMPORTANT Commissioning and maintenance of the system should be carried out by trained authorised personnel only. 1.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 5 - COMMISSIONING AND MAINTENANCE INSTRUCTIONS 2. START UP PROCEDURE A detailed check of the system wiring should be carried out prior to this start-up procedure. Start-up the system as follows: (1) Ensure that the system power supply is switched off. (2) Disconnect the power supply connections to the DC Input Card by removing the two part connector TB1. Remove terminal block TB2 if used.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 5 - COMMISSIONING AND MAINTENANCE INSTRUCTIONS (14) Check the operation of the connected sensor by checking the BEAD mA and mV SIGNAL for a catalytic sensor or the mA SIGNAL for a 4 - 20mA sensor. (15) Repeat Steps (11) to (14) for the remaining control cards in the rack.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 5 - COMMISSIONING AND MAINTENANCE INSTRUCTIONS 3. CALIBRATION Leave the connected sensors to stabilise for a suitable period as specified in the sensor manual. Adjust the sensor head current of catalytic sensors as described in Chapter 7 Section 7 to the required value as indicated in the sensor operating instructions.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 5 - COMMISSIONING AND MAINTENANCE INSTRUCTIONS 4. MAINTENANCE To ensure that the system functions correctly, maintenance should be carried out on a regular basis as dictated by the site regulations and instructions for the type of sensor being used. For installations in the EU, EN 50073 should be followed. The system should be maintained in a clean condition and kept free from dust and grease.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 5 - COMMISSIONING AND MAINTENANCE INSTRUCTIONS 5. ERROR CODES 5.1 General Operating errors within the system are indicated on the LCD message display as an error code. The error codes used and their meaning are listed in the following sections.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 5 - COMMISSIONING AND MAINTENANCE INSTRUCTIONS 5.2 Self Test Faults Error Code 99 Error Code Meaning RAM Failure. S/W Card Fault Latch Status Signal All Non Active Yes Yes All Non Active Yes Yes All Non Active Yes Yes All Non Active Yes Yes RAM stores the working values during operation.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 5 - COMMISSIONING AND MAINTENANCE INSTRUCTIONS Error Code 95 Error Code Meaning Vps Plug-in Fitted. S/W All Card Fault Latch Status Signal Non Active Yes Yes 1V1 Non Only Active Yes Yes The Vps plug-in is used to set the Vps reference and is not suitable for operating sensors.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 5 - COMMISSIONING AND MAINTENANCE INSTRUCTIONS Error Code 90 Error Code Meaning S/W Card Fault Latch Status Signal Not applicable 1Vx - - - High Integrity Relay Fault. 2Vx Non Active Yes Yes S/W Card Fault Latch Status Signal All Non Active Yes No All Non Active Yes Conf. All Non Active Yes Conf The actual and demanding states of the high integrity relay outputs do not match.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 5 - COMMISSIONING AND MAINTENANCE INSTRUCTIONS Error Code Error Code Meaning S/W Card Fault Latch Status Signal Card In Wrong Slot 1Vx Active No No The card in wrong slot message is displayed if a channel card has been moved to a different slot from the one that it had been calibrated for.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 5 - COMMISSIONING AND MAINTENANCE INSTRUCTIONS Error Code 83 Error Code Meaning Current Setting Fault (Catalytic Sensors Only) S/W Card Fault Latch Status Signal 2Vx Only Non Active Yes Yes All Active No No All Non Active Yes Conf The current setting fault message is displayed when the control card is unable to set or maintain the correct operating current for a catalytic sensor.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 5 - COMMISSIONING AND MAINTENANCE INSTRUCTIONS Error Code Error Code Meaning S/W Card Fault Latch Status Signal In some instances this error can be caused by short circuits in the sensor or cabling. The channel card should be calibrated and its operation checked.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 5 - COMMISSIONING AND MAINTENANCE INSTRUCTIONS Error Code Error Code Meaning S/W Card Fault Latch Status Signal If required, this function can be disabled using the Engineering Interface Software configuration program.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 5 - COMMISSIONING AND MAINTENANCE INSTRUCTIONS Error Code Error Code Meaning S/W Card Fault Latch Status Signal This indicates that the output from the sensor is too low due to either: a. a faulty sensor which may be poisoned or damaged. b. the calibration gas is incorrect. Check the calibration gas bottle certificate and age. c. sticky gas such as chlorine or ammonia is not reaching the sensor.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 5 - COMMISSIONING AND MAINTENANCE INSTRUCTIONS Error Code 72 Error Code Meaning Calibration Gas Too High S/W Card Fault Latch Status Signal All Active S/W Card Fault Latch Status Signal No No The calibration gas too high message is displayed during calibration when the calibration gas is adjusted to a level above the pre-configured level.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 5 - COMMISSIONING AND MAINTENANCE INSTRUCTIONS Error Code 64 Error Code Meaning Timeout Error S/W Card Fault Latch Status Signal All Active No No All Active No No Not applicable. 1Vx - Communications Error 2Vx Active Yes No S/W Card Fault Latch Status Signal All Active No No All Active No No Backplane command timed out. Reset card by removing power to the card. If problem persists, replace the card.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 5 - COMMISSIONING AND MAINTENANCE INSTRUCTIONS 6. FAULT FINDING The following table provides a guide to diagnosing various conditions within the operation of System 57. Action Fault The Engineering Card front panel power on ( ) green LED extinguished. Disconnect TB1 and measure the voltage between the +24V dc and 0V terminals. If the voltage is correct, remove the DC Input Card and check the fuse FS1.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 5 - COMMISSIONING AND MAINTENANCE INSTRUCTIONS Action Fault An error message is displayed. Check the error code tables in Section 5 for explanation. The FAULT LED illuminated. Check the message display for an error code. See Section 5 for explanation of error codes. is Check sensor connection and operation. The INHIBIT LED is illuminated. Wait for at least 255 seconds to see if the LED extinguishes.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 5 - COMMISSIONING AND MAINTENANCE INSTRUCTIONS Action Fault The ALARM LED is illuminated but there is no relay operation. Check to see if the channel is in the inhibited condition and if necessary remove the inhibit. Check to see that the type of relay interface card fitted can support the expected alarm. Check the channel card configuration to see that the relay is configured for the expected operation.
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MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 6 - OPERATING INSTRUCTIONS CONTENTS Section Page 1. GENERAL 6-3 2. USER OPERATING ROUTINES 6-4 3. CONTROL CARD 6-5 3.1 3.2 3.3 3.4 6-5 6-5 6-5 6-5 4. Reset Reset TWA Calculations Select Deselect ENGINEERING CARD 6-6 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 6 - OPERATING INSTRUCTIONS 1. GENERAL These operating instructions refer to the facilities available for general operation and interrogation of the system without the Engineering Key fitted. Facilities that may effect the way the system operates are covered in the Engineer's Operating Instructions Chapter 7 which refers to facilities available when the Engineering Key is fitted.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 6 - OPERATING INSTRUCTIONS 2. USER OPERATING ROUTINES Depending upon which keypad function push-buttons are operated, the following user operating routines may be performed: Channel reset. Channel select. View alarm levels. Catalytic sensor current check. Sensor signal monitoring. Accept an update alarm. View clock/calendar. Initiate a maintenance record printout.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 6 - OPERATING INSTRUCTIONS 3. CONTROL CARD 3.1 Reset To reset a channel control card, briefly push and release its front panel RESET/SELECT push-button. This will: a. Reset all latched and non-active alarms associated with the control card. b. Cancel all latched and non-active warning messages. c. Reset the peak reading display. d. Acknowledge an update condition should one be present. 3.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 6 - OPERATING INSTRUCTIONS 4. ENGINEERING CARD 4.1 General The Engineering Card push-button functions will only operate if a channel card is selected. See Section 3.3.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 6 - OPERATING INSTRUCTIONS (2) Push the BEAD mA push-button and the selected channel card display will indicate the configured bridge current. eg. 200mA. (3) Push the reject ( ) push-button or wait 30 seconds to exit the Bead mA mode. 4.5 View Alarm Level Settings The operation of the ALARMS push-button allows the viewing of the alarm threshold point and alarm type (rising or falling) for each alarm set point A1, A2 and A3.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 6 - OPERATING INSTRUCTIONS 4.6 Sensor Signal Monitoring The operation of the SIGNAL push-button allows the monitoring of the selected channels sensor signal value. The displayed parameter is dependent upon the type of sensor drive module fitted to the selected channel card.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 6 - OPERATING INSTRUCTIONS (2) Push the CLOCK push-button and the selected channel card display will indicate the present time. Note: The clock uses the 24 hour format. (3) Push the CLOCK push-button a second time and the selected channel card display will indicate the present day, month and year. Notes: 1. The display format for day and month can read either DD.MM or MM.DD depending on the configuration of the system. 2.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 6 - OPERATING INSTRUCTIONS 21/07/97 11:06 ** Card info ** Slot : 01 Card type : 5701 Sensor type : 4-20 mA S/W : v02.40 Serial No : 22411C01 Range : 0 - 100 Units : %LEL Sensor : Series 2000 Combustible Gas : Methane Tag : Vent 23C First span : 21/07/97 Last span : 21/07/97 Cal. rem. : 06 months A1 : 0020 %fsd A2 : 0050 %fsd A3 : 0075 %fsd STEL Threshold : 010.0 %fsd Value : 0.000 %fsd Time interval : 10 min. LTEL Threshold : 010.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 6 - OPERATING INSTRUCTIONS To output a summary of the whole rack, proceed as follows: (1) Plug a RS232 printer into the Engineering Card serial port. (2) Push the up ( ) and down ( ) buttons simultaneously without any channel card being selected and the following data will be printed: 21/07/97 11:05 ** Rack info. ** Card type : Engineering card S/W : v02.
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MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 7 - ENGINEER'S OPERATING INSTRUCTIONS CONTENTS Section Page 1. GENERAL 7-3 2. ENGINEERING OPERATING ROUTINES 7-4 3. UNLOCKING THE ENGINEERING CARD 7-5 4. SELECTED CARD OPERATIONS 7-6 5. CHANNEL INHIBIT 7-7 6. ALARM CONFIGURATION AND RELAY TEST 7-8 7. CATALYTIC SENSOR BRIDGE CURRENT ADJUSTMENT 7-11 8. ZERO SIGNAL CALIBRATION 7-12 9. SPAN SIGNAL CALIBRATION 7-14 10.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 7 - ENGINEER'S OPERATING INSTRUCTIONS 1. GENERAL The engineer's operating instructions refer to the additional facilities available to setup and maintain the system. Because the operation of the system can be altered or impeded by these functions, they can only be performed when the Engineering Card is unlocked by the Engineering Key.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 7 - ENGINEER'S OPERATING INSTRUCTIONS 2. ENGINEERING OPERATING ROUTINES Depending upon the which keypad function push-button is operated, the following engineering operating routines may be carried out: Channel Reset. Channel Select. Channel Inhibit. Alarm Configuration and Relay Test. Catalytic Bridge Current Adjustment. Zero Signal Calibration. Span Signal Calibration. 1st Span Signal Calibration. Sensor Signal Monitoring.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 7 - ENGINEER'S OPERATING INSTRUCTIONS 3. UNLOCKING THE ENGINEERING CARD To unlock the Engineering Card, plug the Engineering Key into the Engineering Card front panel socket. The Engineering Card Unlocked LED ( ) will illuminate to indicate that it is unlocked. External Engineering Port Engineering Key Note: Inserting and then removing the Engineering Key resets the Engineering Card communications failure warning indication.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 7 - ENGINEER'S OPERATING INSTRUCTIONS 4. SELECTED CARD OPERATIONS The operation to be carried out on the selected control card is chosen by pushing one of the following Engineering Card control push-buttons: Once an operation has been selected, there are four control push-buttons which may be used to manipulate the operation as required. These are: a.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 7 - ENGINEER'S OPERATING INSTRUCTIONS 5. CHANNEL INHIBIT Pushing the Engineering Card INHIBIT push-button toggles the selected control card inhibit mode between on and off. When the inhibit mode is set to on, either locally from the Engineering Card or remotely by the Remote Inhibit input, the selected control card: a. inhibit relay, if fitted, is actuated. b. INHIBIT LED is illuminated. c.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 7 - ENGINEER'S OPERATING INSTRUCTIONS 6. ALARM CONFIGURATION AND RELAY TEST The alarm configuration and relay test operation cycles through eight different stages, A1, A2, A3, STEL, LTEL, TESTAI, A2. A3, TESTSTEL and TESTLTEL. In the first three stages the alarm LEDs and relays are not effected.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 7 - ENGINEER'S OPERATING INSTRUCTIONS repeat Steps (4) to (6) for the A2 threshold points setting. (8) Push the Engineering Card ALARMS push-button a third time and repeat Steps (4) to (6) for the A3 threshold points setting. (9) Push the Engineering Card ALARMS push-button a fourth time and repeat Steps (4) to (6) for the STEL threshold points setting.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 7 - ENGINEER'S OPERATING INSTRUCTIONS TESTLTEL. Note: 1. 2. A selected control card may be deselected while in the TEST mode by pushing the selected control card front panel RESET/ SELECT push-button. The simulated gas level and relay states will remain set allowing several control cards to be tested simultaneously. When the control card is reselected the card will return to the TEST mode.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 7 - ENGINEER'S OPERATING INSTRUCTIONS 7. CATALYTIC SENSOR BRIDGE CURRENT ADJUSTMENT The operation associated with the BEAD mA push-button only applies when a control card has been selected that is configured for a catalytic input. The pressing of the push-button with other types of control cards selected has no effect and a warning is displayed to this effect.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 7 - ENGINEER'S OPERATING INSTRUCTIONS 8. ZERO SIGNAL CALIBRATION To select the zero operation, proceed as follows: (1) Plug the Engineering Key into the Engineering Card front panel socket and check that the Unlocked LED ( ) is illuminated. (2) Push and hold the required control card RESET/SELECT pushbutton for approximately 1.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 7 - ENGINEER'S OPERATING INSTRUCTIONS (7) (8) The selected control card will display oooo on the message display while the Control Card carries out the following: a. Zeroes itself at the current sensor signal, providing this is within the configured upper and lower zero signal limit values. The control card will then automatically return to the normal selected state. b.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 7 - ENGINEER'S OPERATING INSTRUCTIONS 9. SPAN SIGNAL CALIBRATION Note: If a new sensor is being calibrated for the first time, use the 1st Span procedure in Section 10. To select the span operation, proceed as follows: (1) Plug the Engineering Key into the Engineering Card front panel socket and check that the Unlocked LED ( ) is illuminated.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 7 - ENGINEER'S OPERATING INSTRUCTIONS (5) Apply the span gas at a flow rate and for a time according to the selected channels sensor instruction manual. Notes: 1. Apart from oxygen, every sensor should be zeroed before being spanned. See Section 8. 2. Although a Span Gas as low as 15% of the fsd value of the sensor may be used, it is recommended that a value of 40% or above is used.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 7 - ENGINEER'S OPERATING INSTRUCTIONS 10. FIRST TIME SPAN SIGNAL CALIBRATION When the 1st SPAN push-button is pressed, the operation of the selected control card is similar to when the SPAN push-button is pressed. To carry out the first time span calibration, proceed as indicated in Section 9 Steps (1) to (6) but push the 1st SPAN push-button. Note: 1.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 7 - ENGINEER'S OPERATING INSTRUCTIONS 11. SENSOR SIGNAL MONITORING The operation of the SIGNAL push-button allows the monitoring of the selected channels sensor signal value. The displayed parameter is dependent upon the type of sensor drive module fitted to the selected channel card.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 7 - ENGINEER'S OPERATING INSTRUCTIONS 12. SETTING THE CLOCK/CALENDAR Note: This operation requires a control card to be selected but the operation has no effect on the selected control card, which is used as a display device only. To set the clock time and calendar date, proceed as follows: (1) Plug the Engineering Key into the Engineering Card front panel socket and check that the Unlocked LED ( ) is illuminated.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 7 - ENGINEER'S OPERATING INSTRUCTIONS displayed numerical value as required to set any new date and time. Note: Pressing the push-button at any time during the above sequence will return the Engineering Card to the selected mode without changing the clock time and calendar date. (9) Press the push-button to set the Engineering Card real time clock to the new date and time, and return the control card to the selected mode.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 7 - ENGINEER'S OPERATING INSTRUCTIONS 13. MAINTENANCE RECORD PRINTOUTS For details of maintenance record printouts, refer to Chapter 6 Section 4.8.
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MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 8 - SPECIFICATION CONTENTS Section Page 1. APPROVALS AND STANDARDS 8-3 2. ENVIRONMENTAL 8-3 3. RFI/EMC CONFORMITY 8-3 4. POWER SUPPLIES 8-3 5. INDIVIDUAL MODULE PARAMETERS 8-4 5.1 5.2 5.3 5.4 5.5 5.6 5.7 8-4 8-4 8-5 8-6 8-6 8-7 8-8 Interface/Relay Cards Single Channel Control Card Catalytic Bridge Module 4 - 20mA Input Module Analogue Output Module Engineering Card DC Input Card 6. CABINET ASSEMBLIES 7.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 8 - SPECIFICATION 1. APPROVALS AND STANDARDS Designed to comply with: EN50054 General Requirements (Combustible Gases). EN50057 Performance (100 LEL). EN50058 Performance (100 V/V). EN50271 Software and Digital Technologies. Meets Exe isolation requirements for 50V operation. EXAM BBG Pruef- und Zertifizier GmbH, EC-type examination certificate BVS 04 ATEX G 001 X.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 8 - SPECIFICATION LV Directive 73/23/EEC Constructed in accordance with good engineering practice. Guided by the principles of EN 61010/1 1990/1992. 4. POWER SUPPLIES Power Consumption : (System) Dependent upon configuration. See Chapter 4, Section 5. External DC Power Supply: 18V to 32V to DC Input Card. External AC Power Supply: 85V to 264V at 47Hz to 440Hz. (Using optional AC to DC PSU). 5.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 8 - SPECIFICATION 5.2 Single Channel Control Card Four-Part Liquid Display: Analogue Display: Digital Display: Message Display: Icon Section: 25 segment. Four character. Four character. Power On/Card Select. LEDs: A1, A2, A3 gas alarms. Fault and Inhibit. Push-Button: Alarm Reset/Card Select. Alarm Setting Point Resolution: In 1% fsd steps. Display/Alarm Point: Linearity: Repeatability: ±1% fsd. ±1% fsd.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 8 - SPECIFICATION 5.3 Catalytic Bridge Module Drive: Constant Current. Current Adjustment: Electronic in 1mA steps. Current Adjustment Ranges: Range 1 Range 2 Range 3 Range 4 219mA to 283mA. 166mA to 230mA. 118mA to 182mA. 70mA to 134mA. Maximum Drive Voltage: 10V. Protection: Protected against short circuit and open circuit. Maximum Line Resistance: 40 ohms (including sensor) at 250mA.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 8 - SPECIFICATION Measurement Signal Range: 0 to 25mA. Maximum Line Resistance: 500 ohms loop resistance including sensor. Isolation Breakdown Voltage: 5.5 More than ±50V dc to system 0V. Analogue Output Module Output Compliance Range: 40V. Protection: Short circuit protected. Reverse voltage up to 36V dc. Transient voltage of less than 60V dc. Configuration: Isolated current sink.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 8 - SPECIFICATION Push-Button: Operating: Up ( ) and Down ( ). Reject ( ) and Accept ( ). Print (Up and Down together). Functions: Bead mA Zero Span Inhibit Alarms Signal 1st Span Clock Power Consumption: 1.5W (typical). DC Supply: 18V to 32V dc. Dimensions: Height: Width: Depth: Weight: 152g. 5.7 112mm. 25mm. 170mm. DC Input Card DC Supply: 18V to 32V dc. Dimensions: Height: Width: Depth: Weight: 129g.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 8 - SPECIFICATION Environmental Protection: IP54. Hinged: Left hand side. Lock: Right hand side. Colour: RAL 7015 slate grey. Mounting Bracket Holes: 10mm diameter. Rack Mounting: Universal 19 inch profile. 19 inch width and half 19 inch width. Earthing Points: Main cabinet M6. Door M5. Mounting Plate: Galvanised steel.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 8 - SPECIFICATION Cabinet Mounting Brackets 27 15 9 36 9 10.2 10 All dimension shown in mm. 7. RACK ASSEMBLIES Rack Assemblies Contains: Engineering Card. DC Input Card. Interconnect Cable. (front access rack only). Material: Galvanised steel. Earthing Point: M5 stud. Mounting: Universal 19 inch and half width. (19 inch mounting). Power Consumption: 1.5W. Supply Voltage: 18 to 32V dc.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 8 - SPECIFICATION Table of Sizes (mm) Rack Assembly A B C D E Depth 8 Way Rear Access 279.4 261.9 57.0 37.8 132.5 287.6 8 Way Front Access 279.4 261.9 190.5 37.8 266.0 217.6 16 Way Rear Access 482.6 465.1 57.0 37.8 132.5 287.6 16 Way Front Access 482.6 465.1 190.5 37.8 266.0 217.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 8 - SPECIFICATION Leakage Current: 0.75mA maximum per 50W Module. Overload Protection: Operates at more than 105% of rated full load and recovers automatically. Safety Approvals: 50W Module approved to UL1950, IEC950, CSA 22.2 No 234. Output Voltage: 24V ± 10% dc. Output Configurations: Half 19'' Rack: 50W or 100W. Full 19'' Rack: 50W, 100W, 150W or 200W. Earthing Point: M5 stud. Weight: Half 19'' Rack 50W: 900g.
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MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 10 -SPECIAL CONDITIONS FOR SAFE USE ACCORDING TO EC-TYPE EXAMINATION CERTIFICATE BVS 04 ATEX G 001 X The following special properties have to be considered at operation of the control unit: When operated with remote sensors with 4-20 mA interface the specifications of the 4-20 mA interface and the behaviour below 4 mA and above 20 mA have to be considered.
MAN0443.P65 Issue 13 Aug 04 05701-M-5001 A02279 5701 Control System CHAPTER 10 -SPECIAL CONDITIONS FOR SAFE USE ACCORDING TO EC-TYPE EXAMINATION CERTIFICATE BVS 04 ATEX G 001 X - - - - - Irrespective of the operating mode of the analogue output, the “fault level” and “inhibit level” shall be configured to different values outside the measuring range. The signalling of faults and inhibits at the analogue output shall be activated.
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