1. Manuals
  2. Brands
  3. General Monitors Manuals
  4. Control Unit
  5. 4802A
  6. Instruction manual

General Monitors 4802A Instruction Manual

Zero two series control module for combustible gas applications
Hide thumbs
Table of Contents

Advertisement

Quick Links

Model 4802A
Zero Two Series Control Module
For Combustible Gas Applications
The information and technical data disclosed in
this document may be used and disseminated
only for the purposes and to the extent
specifically authorized in writing by General
Monitors.
Instruction Manual
08/05
General Monitors reserves the right to change
published specifications and designs without
prior notice.
Part No.
MAN4802A-EU
Revision
M/08.05

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 4802A and is the answer not in the manual?

Questions and answers

Related Manuals for General Monitors 4802A

Summary of Contents for General Monitors 4802A

  • Page 1 General Monitors. Instruction Manual 08/05 General Monitors reserves the right to change published specifications and designs without prior notice. Part No. MAN4802A-EU Revision...

  • Page 2: Warnings

    Only Catalytic Bead sensors designed by General Monitors will work with the Model 4802A. Any attempt to use a sensor that has not been designed by General Monitors will void the warranty. WARNING - Installation and Maintenance must be carried out by suitably skilled and competent personnel only.

  • Page 3: E C Declaration Of Conformity In Accordance With Ec & Atex Directives

    This equipment has been assured for use as a safety related device under the terms of Directive 94/9/EC EHSR 1.5. General Monitors Ireland Ltd. in order to comply with ATEX will provide this Instruction Manual in a European Language required to operate the product upon request. Should this be necessary, General Monitors Ireland Ltd.

  • Page 4: System Integrity Verification

    Model 4802A System Integrity Verification General Monitors’ mission is to benefit society by providing solutions through industry- leading safety products, services and systems that save lives and protect capital resources from the dangers of hazardous flames, gases and vapors. The safety products you have purchased should be handled carefully and installed, calibrated and maintained in accordance with the respective product instruction manual.
  • Page 5 Model 4802A Periodic System Verification The following system verifications should be performed at least annually: Verify wiring, terminal connections and stability of mounting for all integral safety equipment including, but not limited to: • Power supplies • Control modules • Field detection devices •...

  • Page 6: Quick-Start Guide

    The contents should be carefully removed and checked against the packing slip. If any damage has occurred or if there is any discrepancy in the order, notify General Monitors as soon as possible. All subsequent correspondence with General Monitors must specify the equipment part and serial numbers.
  • Page 7 Model 4802A Quick-Start Guide Control Module Installation A rack or panel mounted chassis will be required when installing any Zero Two Series Module. These chassis’ should be mounted in non-hazardous, weather-protected locations and should be subjected to minimal shock and vibrations. The rack and panel mounted chassis are available in 4, 8, and 16 channel sizes.
  • Page 8 Model 4802A Quick-Start Guide Rear Terminal Connections All wire connections to the Model 4802A are made to the terminal block located at the rear of the chassis. The terminal block accepts 16 AWG to 20 AWG, stranded or solid core wire.
  • Page 9 Model 4802A Quick-Start Guide 1.5.1 A2 Alarm The terminal designations for the A2 alarm outputs are: LABEL TERM DESCRIPTION A2-C1 Relay Common (1 & 2) A2-1 Relay Contact A2-2 Relay Contact A2-3 Relay Contact A2-4 Relay Contact A2-C2 Relay Common (3 & 4)
  • Page 10 Model 4802A Quick-Start Guide The table below refers to the proper open and closed A1 alarm relay contacts while the unit is on power: User Selected Normally Normally Relay State Open Closed Normally A1-C1 & A1-1, A1-C1 & A1-2, Energized A1-C2 &...
  • Page 11 Model 4802A Quick-Start Guide 1.5.4 Other Open Collector Outputs The terminal designation for the Unaccept and the Discrete Calibration / Inhibit Mode outputs are: Label Term Description UA-OC Unaccept Output CAL/INH CAL-Inhibit Mode Output Figure 9 – Terminal Designations for...
  • Page 12 Red Sensor Wire 30d,z White Sensor Wire Figure 11 – Terminal Designations for Sensor Wires NOTE - Only 1 sensor may be connected to a Model 4802A. Figure 12 illustrates the Sensor/Controller connections. Figure 12 – Sensor/Controller Connections 1.5.6 Card Test Switch...
  • Page 13 Model 4802A Quick-Start Guide Figure 14 is a block diagram that shows the switch connections for the Card Test feature. Figure 14 – Switch Connections for Card Test The Card Test Input is provided so that the user can access the Card Test feature remotely.
  • Page 14 Model 4802A Quick-Start Guide Applying Power Zero Two Series Modules do not have an ON/OFF power switch. Each module in the Zero Two Series operates from 24Vdc. Current requirements will vary according to the number and type of modules in the system, as well as the number and type of field devices.
  • Page 15 Model 4802A NOTE - The instrument is now ready to operate! Please consult the manual for more information on the instrument’s many features. NOTE - If you have any problems in the setup or testing of the detector, please refer to the “Troubleshooting Section”, or call the factory direct.

  • Page 16: Table Of Contents

    Model 4802A Table of Contents Warranty Statement ......................i Warnings ......................i E C Declaration of Conformity in accordance with EC & ATEX Directives ......ii System Integrity Verification ....................iii Quick-Start Guide ......................v 1.1 Upon Receipt of Equipment ..................v 1.2 Sensor Location Considerations ................
  • Page 17 Model 4802A Installation ......................3 3.1 Upon Receipt of Equipment ..................3 3.2 Control Module Installation..................3 3.3 Rear Terminal Connections..................4 3.3.1 A2 Alarm ......................5 3.3.2 A1 Alarm ......................6 3.3.3 Fault Alarm ..................... 6 3.3.4 Other Open Collector Outputs................ 7 3.3.5 Sensor Connections..................
  • Page 18 Model 4802A 5.3 Calibration Mode ....................22 5.4 Setup & Setup Check Modes ................. 25 5.4.1 Entering the Password ................. 26 5.4.2 Inhibit Mode....................27 5.4.3 A2 Alarm Options ..................28 5.4.4 A1 Alarm Options ..................30 5.4.5 Calibration Level Option................31 5.4.6 Fault/Inhibit Option ..................
  • Page 19 6.6.4 Operating Humidity Range................48 6.7 Engineering Specifications ..................49 6.7.1 Zero Two System ..................49 6.7.2 4802A Control Module ................. 49 6.8 Volatile Liquids and Solvents ................. 51 6.9 Engineering & Technical Drawings ................ 52 6.9.1 Outline & Terminal Connections..............52 6.9.2 Final Assembly ....................
  • Page 20 Figure 15 – Terminal Designations for Analog Output ............xii Figure 16 – Analog Signal Connections .................xii Figure 17 – Rear Power Connections..................xiii Figure 18 – Model 4802A......................1 Figure 19 – Control Module Coding Strip ................3 Figure 20 – Wire Strip Length ....................4 Figure 21 –...
  • Page 21 Figure 72 – Recommended Maximum Cable Lengths Between Module & Sensor ..... 47 Figure 73 – Maximum Allowable Cable Lengths Between Analog Output Connections On Control Module ........................47 Figure 74 – Outline and Terminal Connections 4802A............52 Figure 75 – Final Assembly, 4802A..................53...
  • Page 22 Model 4802A 2.0 Introduction This chapter provides a brief description of the Model 4802A, its features & benefits and a list of some of its applications. More detailed information on the features and benefits listed in Section 2.2 will be presented in later chapters.

  • Page 23: Features & Benefits

    Allows the user to insert or remove a module while power is applied to the system, without damage to any of the components in the system. Applications The General Monitors Model 4802A is a Combustible Gas Control Module designed for Zero Two Series Applications. Below is a partial list of applications: • Refineries •...

  • Page 24: Installation

    If any damage has occurred or if there is any discrepancy in the order, notify General Monitors as soon as possible. All subsequent correspondence with General Monitors must specify the equipment part and serial numbers.

  • Page 25: Rear Terminal Connections

    FSD. This deviation will disappear following removal of the field. Functionality is otherwise unaffected. Rear Terminal Connections All wire connections to the Model 4802A are made to the terminal block located at the rear of the chassis. The terminal block accepts 16 AWG to 20 AWG (1.5mm 0.75mm ), stranded or solid core wire.

  • Page 26: A2 Alarm

    Model 4802A For the rear terminal designations refer to Figure 21 below: Figure 21 – Rear Terminal Designations 3.3.1 A2 Alarm The terminal designations for the A2 alarm outputs are: LABEL TERM DESCRIPTION A2-C1 Relay Common (1 & 2) A2-1...

  • Page 27: A1 Alarm

    Model 4802A 3.3.2 A1 Alarm The terminal designations for the A1 Alarm outputs are: Label Term Description A1-C1 Relay Common (1 & 2) A1-1 Relay Contact A1-2 Relay Contact A1-3 Relay Contact A1-4 Relay Contact A1-C2 Relay Common (3 & 4)

  • Page 28: Other Open Collector Outputs

    Model 4802A The Fault outputs are always normally energized when power is applied to the module. The contact ratings for the A2 & A1 alarm and Fault relays are 4A @ 30V RMS/42.4V Pk, 3A @ 30 VDC, Resistive, maximum.

  • Page 29: Sensor Connections

    The terminal designations for the Sensor wires are: Label Term Description 26d,z Black Sensor Wire 28d,z Red Sensor Wire 30d,z White Sensor Wire Figure 30 - Terminal Designations for Sensor Wires NOTE - Only 1 sensor may be connected to a Model 4802A.

  • Page 30: Card Test Switch

    Model 4802A Figure 31 illustrates the Sensor/Controller connections. Figure 31 – Sensor/Controller Connections 3.3.6 Card Test Switch The terminal designation for the Card Test Input is: Label Term Description Switch Connection Figure 32 – Terminal Designation for Card Test Input Figure 33 is a block diagram that shows the switch connections for the Card Test feature.

  • Page 31: Figure 34 - Terminal Designations For Analog Output

    Model 4802A 3.3.7 Analog Output Signal The terminal designations for the Analog Output Signal are: Label Term Description Analog Signal (plus) Analog Signal (minus) Figure 34 – Terminal Designations for Analog Output NOTE - If the Analog Signal is not used a jumper must be placed between 20d & 22d.

  • Page 32: Applying Power

    These are not true sensor poisons, but reduce sensor response. Other damaging materials, which attack the sensor physically, include mineral acids and caustic vapors. The presence of such poisons and vapors does not exclude the use of General Monitors Catalytic Bead Sensors. A careful analysis of ambient conditions should be undertaken and the customer should be aware that sensor calibration might need to occur at more frequent intervals.

  • Page 33: Installation Instructions For The Sensor

    Greater separations are required where long parallel cable runs are unavoidable. Avoid running instrument cable trenches close to lightning conductor earth pits. General Monitors do not recommend the use of cable shoes or crimps on any junction box or housing wiring terminals. Poor crimping can cause bad connection when unit experiences temperature variations.
  • Page 34 Model 4802A The cable screens (drain wires) are interconnected in the housing as shown in figure 12. The drain wire entering the junction box must be terminated on the SCReen terminal to isolate it from all other circuits. It must not be connected to the sensor circuitry at any point.

  • Page 35: Operation

    General Maintenance Once the Model 4802A has been installed, very little maintenance is required other than periodic checks to verify the integrity of the system. • The user should evaluate conditions at the sensor site to determine how frequent calibration checks should be performed.

  • Page 36: Accepting Alarm Conditions

    During a fault the display will indicate a fault code (“F” followed by a digit). If the sensor attached to the Model 4802A is seeing gas in excess of 100% of full scale, this output will generate a signal between 20 and 21.7mA (not proportional). An over range condition is indicated by a flashing digital display reading full-scale (99).

  • Page 37: Resetting Latched Alarms

    Model 4802A There is a unique situation that may occur with some frequency in certain applications. An alarm may occur and the operator will accept this alarm by pressing the Master Accept Button. If the alarm output is latching and the condition at the sensor returns to normal (safe) the alarm output will need to be reset, as previously stated in Section 4.4.

  • Page 38: Card Test Feature

    Card Test. This can be treated as a functional test of a Zero Two System Fault Diagnostics In addition to the Fault LED on the front panel, the Model 4802A provides a fault code on the digital display whenever a fault condition occurs. The Fault Codes that can appear on the digital display are summarized below.

  • Page 39: F8 - Failed To Complete Setup

    Model 4802A 4.8.8 F8 - Failed to complete setup This fault may occur during or immediately after the Setup Mode. Press the Master Reset Switch on the Facilities Module to clear this fault. 4.8.9 F9 - Calibration check period exceeded If the calibration checks gas is left on the sensor for more than 6 minutes, this fault will occur.

  • Page 40: User Interfaces

    Types of User Interfaces User interfaces are provided so that the operator may interpret and direct the Model 4802A in the performance of its various functions. User interfaces (Figure 38) consist of a digital display, status indicators and a Mode/Select switch.

  • Page 41: Calibration Check Mode

    Zero. Figure 39 – Portable Purge Calibrator * The Calibration Check Mode cannot be entered if the 4802A is in alarm. Enter the Calibration Check mode by pressing and holding the Mode/Select switch until the CAL LED begins to flash (about ten seconds). When the CAL LED begins to flash, release the Mode/Select switch.
  • Page 42 Model 4802A When the Mode/Select switch is released, the display will indicate a flashing pair of bars (- -) for about ten seconds. When the display indicates a flashing 0, apply the test gas to the sensor (open the valve on the cylinder and the ON/OFF valve) and wait for a few seconds. The display will begin to go up scale as the sensor sees the gas.

  • Page 43: Calibration Mode

    Model 4802A Calibration Mode To calibrate the Model 4802A, follow the procedure listed below: 1. Make sure the calibration gas is the same concentration as the user specified calibration level. 2. Make sure the sensor is seeing clean air. 3. Place the cup from the portable purge calibrator over the sensor (Figure 41).

  • Page 44: Figure 43 - Ac Display During Cal Mode

    Apply the gas by opening the valve on the cylinder and the ON/OFF valve and watch the display change from AC to CP as the sensor sees gas (Figure 44). If the display does not change from AC to CP after six minutes, the Model 4802A will return to normal operation.

  • Page 45: Figure 45 - Cc Display During Cal Mode

    Remove the gas and watch the display return to normal operation, 0, when the new calibration values have been stored in the EEPROM. If the unit cannot store the new calibration values in the EEPROM, the Model 4802A will display an “F7” fault code (EEPROM verification failure, Figure 46). If an F7 calibration fault occurs, it will be necessary to replace the Model 4802A.

  • Page 46: Setup & Setup Check Modes

    • The Setup Check Mode allows the user to view the operating parameters of the Model 4802A, whereas the Setup Mode allows the user to change the operating parameters of the Model 4802A. • Entering the optional Password is only available in the Setup Mode.

  • Page 47: Entering The Password

    Model 4802A Figure 47 – Entering Setup and Setup Check Modes 5.4.1 Entering the Password This option applies to the Setup Mode only: • If the password option is enabled, the right digit of the display will be blank and a 0 will appear in the left digit on the display (Figure 48).

  • Page 48: Inhibit Mode

    In is displayed, will cause the unit to enter the Inhibit mode by inhibiting the alarm outputs. As the unit enters the Inhibit mode, the Model 4802A will automatically return to normal operation. If it is desired to enter the Setup Mode, do not press the Mode/Select switch for the five seconds that In is displayed.

  • Page 49: A2 Alarm Options

    Model 4802A 5.4.3 A2 Alarm Options Next, the A2 LED will be flashing while the Energized/De-Energized option is displayed (Figure 50). The display will indicate the current selection, (En or dE). Press the Mode/Select Switch to toggle the selection. De-Energized is the factory default for this selection.

  • Page 50: Figure 52 - A2 Alarm Set Point Option

    Model 4802A The last A2 alarm option to appear on the display will be the alarm set point (trip level). If this level is reached or exceeded the A2 alarm outputs will activate. The display (Figure 52) will indicate the current A2 alarm set point (10 to 60 in increments of 5).

  • Page 51: A1 Alarm Options

    Model 4802A 5.4.4 A1 Alarm Options Next, the A1 LED will be flashing while the Energized/De-energized option is displayed (Figure 53). The display will indicate the current selection, (En or dE). Press the Mode/Select Switch to toggle the selection. De-Energized is the factory default for this selection.

  • Page 52: Calibration Level Option

    Model 4802A The last A1 alarm option to appear on the display will be the alarm set point (trip level). If this level is reached or exceeded the A1 alarm outputs will activate. The display will indicate the current A1 alarm set point (Figure 55). Press the Mode/Select switch repeatedly, until the desired A1 alarm set point appears on the display (10 to the A2 set point in increments of 5).

  • Page 53: Fault/Inhibit Option

    Ac or nA (Figure 57). An Ac selection specifies that the Model 4802A will activate the Fault circuit while the unit is in the Inhibit Mode. A nA selection specifies that the Model 4802A will not activate its Fault circuit when the unit is placed in the Inhibit Mode.

  • Page 54: Figure 59 - Card Test Ramp Time

    Model 4802A 5.4.7 Card Test Options After the Fault/Inhibit option has been selected, the user will select the ramp time (3 or 10 seconds) and whether or not the alarm outputs will activate during a Card Test. The display will indicate ct for about five seconds (Figure 58) followed by the ramp up time (3 or 10) during the card test (Figure 59).

  • Page 55: Figure 61 - Password Enabled/Disabled Option

    Model 4802A NOTE - Selecting nA option for the Card Test will not inhibit the Fault or A1/A2 alarm circuits in the event of a malfunction or gas condition. 5.4.8 Password Options Once the Card Test options have been selected, the user will either enable or disable the password option (Figure 61).

  • Page 56: Inhibit Mode

    5 seconds. This sequence will repeat for as long as the unit is in the Inhibit Mode. The Inhibit Mode is provided so that the operation of the Model 4802A can be verified without tripping external devices that are connected to the A1 and A2 alarm outputs.

  • Page 57: Password Option

    It is recommended that the operator fill-in the selections in the proper blanks and then use this page as a reference while programming the Model 4802A. The blocks shown below indicate the order of options in the Setup Mode. To the right of each block is a description of the choices that are available for that option.

  • Page 58: Appendix

    6.0 Appendix Principle of Operation General Monitors uses a low temperature catalytic bead to detect the presence of combustible gases and vapors. These gases and vapors are found in many applications. The catalytic bead converts the combustible gases and vapors to heat.

  • Page 59: Spare Parts And Accessories

    This chapter provides a description of the types of field devices (sensors), and the accessories, which can be used with the Model 4802A. 6.2.1 Sensors General Monitors offers a variety of Catalytic Bead Sensors with sensor bodies and flame arrestors: 11159-1 Stainless steel, CSA, ATEX, GOST approved, (120ºC max)

  • Page 60: Sensor Housing

    Model 4802A 6.2.2 Sensor Housing General Monitors offers an explosion proof housing that is rated for use in Class I, Division 1, Group B, C & D or European Zones 1 & 2. hazardous locations (see Figure 64). The housing entries are tapped for ¾ NPT threads. The sensor connects to one of these entries, while the other entry is for conduit runs.

  • Page 61: Splash-Guard & Tga-1

    Once the sensor is installed/operating in the field, no attempt should be made to disconnect the sensor, the conduit of the housing lid without removing power from the Model 4802A, as such an act would compromise the explosion proof integrity of the field device.

  • Page 62: Duct Mounting Plates

    Figure 68 – Dust Guard Assembly Kit Picture 6.2.5 Duct Mounting Plates General Monitors produces a Duct Mounting Plate (P/N 10041) for applications that require the sensor to be mounted in air-conditioning or heating duct. The Duct Mounting Plate is easy to install (Figure 69).

  • Page 63: Calibration Equipment

    Model 4802A 6.2.6 Calibration Equipment The Model 4802A uses a Portable Purge Calibrator (Figure 70) or the 3 Liter Chamber (Figure 71), to accomplish calibration. The calibration and calibration check procedures and use of the Portable Purge Calibrator is explained in Sections 5.2 and 5.3.

  • Page 64: Calibration Check Mode

    3. The reading will stabilize after one or two minutes. 4. Remove the sensor from the chamber and allow it to see clean air. When the display has stopped flashing and indicates a few % LEL and then zero (0), the Model 4802A has returned to normal operation.

  • Page 65: Calibration Equipment And Part Numbers

    Model 4802A 6.2.10 Calibration Equipment and Part Numbers 6.2.10.1 Portable Purge Calibrator Assembly: with 50% LEL Methane Gas 1400150-M with 50% LEL Hydrogen Gas 1400150-H with 50% LEL Ammonia Gas 1400150-A with 50% LEL Butadiene Gas 1400150-BD with 50% LEL Butane Gas...

  • Page 66: Applications

    50% LEL 6.3.6 Accuracy The accuracy the 4802A is limited by the accuracy of the standard used to calibrate the system. For many combustible gases, obtaining a high accuracy standard that is suitable for field calibration use may be difficult (about the best accuracy of gas concentration achievable is +/-5%, using a permeation system with good temperature control).

  • Page 67: Stability

    Place the 4802A in the original storage container that was shipped with the unit. This container guards against contamination from solvents, lubricants, humidity, etc. In the case of long-term storage, the 4802A should be stored as above in a cool, dry, place, preferably between 0 and 20ºC.

  • Page 68: Electrical Specifications

    6.5.2 Electrical Classification The Sensor is rated for used in Class I, Division 1, Groups B, C & D or European Zones 1 & 2. The Model 4802A is designed for use in non-hazardous environments. 6.5.3 Relay Contact Rating 4A @ 30V RMS/42.4V PK, 3A @ 30VDC resistive. DPDT for A1 & A2, SPDT for Fault.

  • Page 69: Environmental Specifications

    Model 4802A Environmental Specifications 6.6.1 Operating Temperature Range Sensor (11159-1) -40°F to +248°F -40°C to +120°C Sensor (11159-2) -40°F to +356°F -40°C to +180°C 4802A 0°F to +150°F -18°C to +66°C 6.6.2 Storage Temperature Range 4802A -40°F to +150°F -40°C to +66°C 6.6.3 Pressure Limits...

  • Page 70: Engineering Specifications

    The system shall consist of Zero Two Series component modules as manufactured by General Monitors, Lake Forest California, U.S.A. or General Monitors, Galway, Ireland.
  • Page 71 Model 4802A The control module shall have a 100% backward compatible option available at the time of order. The control module, with sensor, shall be capable of calibration with the following display prompts during the calibration routine: AC = Calibration routine activated, CP = Calibration in progress and CC = Calibration complete.

  • Page 72: Volatile Liquids And Solvents

    Model 4802A Volatile Liquids and Solvents Volatile liquids and solvents are not supplied by General Monitors. This page provides a listing of volatile liquids and solvents and the respective volumes required (in microliters) to produce a 50% LEL vapor concentration in the 3 Litre Portable Calibration Chamber (P/No.

  • Page 73: Engineering & Technical Drawings

    Model 4802A Engineering & Technical Drawings 6.9.1 Outline & Terminal Connections Reference Drawing # 11221 Figure 74 – Outline and Terminal Connections 4802A...

  • Page 74: Final Assembly

    Model 4802A 6.9.2 Final Assembly Reference Drawing # 11220-1 Figure 75 – Final Assembly, 4802A...

  • Page 75: Zero Two Series Modules

    Model 4802A 6.10 Zero Two Series Modules Model 2602A Zero Two Series Control Module for Hydrogen Sulfide Gas Applications Model 4802A Zero Two Series Control Module for Combustible Gas Applications Model TA102A Zero Two Series Trip Amplifier Module for Combustible Gas Applications...

Table of Contents