ESP PGU-P Operating Manual

Toxic gas detection system

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SSS-903 Toxic Gas Detection System

Information and technical data disclosed in this document

may be used and distributed only for the purposes and to

the extent specifically authorized by ESP Safety Inc.

ESP Safety Inc. Reserves the right to change published

specifications and designs without prior notice

Date

3/21/13

Part

Number:

Description:

OPERATING MANUAL

Model SSS-903 Transmitter and Controller

Model PGU-IR Infrared Optical Gas Sensor

Model PGU-P Photo Ionization Gas Sensor

Model PGU-E Electrochemical Gas Sensor

Model PGU-C Catalytic Bead Gas Sensor

Revision History

Revision

Addition; Appendix II

Warranty & Return Policy

10060-001

Rev:

SSS-903 TG-E

Date:

Install Guide

Page:

Description

08/15/2017

1 of 53

Approved

A. Burgos

Table of Contents

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Summary of Contents for ESP PGU-P

Page 1 Information and technical data disclosed in this document may be used and distributed only for the purposes and to the extent specifically authorized by ESP Safety Inc. ESP Safety Inc. Reserves the right to change published specifications and designs without prior notice Revision History...
Page 2: Table Of Contents
Calibration Procedures ......................33 Non-Invasive Calibration Magnet Procedure ..............33 Non-Invasive Calibration Procedure with HART Communicator……………………………..….33 Bench Test Calibration Procedure with ESP Commander ..........438 Unpacking A New SSS-903 ....................44 Appendix 1 Explosion Proof Design……………………………………………… ....…………45 Appendix 2 Warranty & Return Policy ....……………………………………………………46...
Page 3: General Information
Non-invasive calibrations can be performed in the field using an included magnetic wand or a HART communicator. A device descriptor file is available from ESP Safety for use with a HART communicator. Calibration can also be performed with an included Windows PC application, ESP Commander. Both HART and ESP Commander applications can supply real time output of...
Page 4: Specifications Of Sss-903 With Pgu Sensors
3 User Programmed Alarm Relays 1 Fault Condition Relay GT Sensor Interface to SSS- Digital RS-485 Modbus RTU 903 Receiver *Note All ESP Safety gas detector products can be interfaced with the SSS-903 Sensor Types / Model Electrochemical: PGU-E Infrared: PGU-IR Photo Ionized: PGU-P...
Page 5 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 5 of 53 Install Guide Page: Dimensions Diagram of SSS-903 Receiver All dimensions are in mm...
Page 6 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 6 of 53 Install Guide Page: Table 1: SSS-903 with PGU-E Electrochemical Gas Sensor Range, Accuracy and Response Times Using Gas Specific Electrochemical Detectors *Response Time is the time to reach a percentage of final reading when gas concentration is equal to full scale of the sensor range of detection.
Page 7 7 of 53 Install Guide Page: Table 2: SSS-903 with PGU-P Photo Ionization Gas Sensor: Range, Accuracy and Response Times Using Gas Specific Photoionized Detectors *Response Time is the time to reach a percentage of final reading when gas concentration is equal to full scale of the sensor range of detection.
Page 8 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 8 of 53 Install Guide Page: Table 3: SSS-903 with PGU-IR Infrared Optical Detection: Range Accuracy and Response Times Using Gas Specific IR Detectors *Response Time is the time to reach a percentage of final reading when gas concentration is equal to full scale of the sensor range of detection.
Page 9 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 9 of 53 Install Guide Page: Table 4: SSS-903 with PGU-C Catalytic Bead Sensor: Range Accuracy and Response Times Using Catalytic Bead (pellisor) sensor specifically for detection of hydrogen *Response Time is the time to reach a percentage of final reading when gas concentration is equal to full scale of the sensor range of detection.
Page 10 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 10 of 53 Install Guide Page: Certifications CE 0539 II 2 G 94/9/EC ATEX: Ex d[ia] IIC T4 (Tamb 75°C) IP 66 Ex d [ia] IIC T4 (Tamb 75°C) IECEx: IP 66 1 Ex d [ia] IIC T4 X T= -60°C..75°C IP 66 EN 60079-0: 2006...
Page 11 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 11 of 53 Install Guide Page: SSS-903 Receiver Operation The SSS-903 is physically designed to perform in a wide range of hazardous environments and harsh weather conditions. Employing a durable enclosure that can withstand these conditions and even explosion is key to the operation and function of the device.
Page 12 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 12 of 53 Install Guide Page: Figure 2- SSS-903 LED Indicators Green Calibration Alarm Mode 1 2 3 Operational Status Green – Normal Operation Yellow – Alarm Active Red – Fault Condition Figure 3 - SSS-903 LCD Display Graphic Display...
Page 13 The current is measured and processed by the PGU-P sensor, generating the signals that are passed to the SSS-903 receiver via RS-485. Each detector is factor programmed for the gas requested by the customer at the time of purchase.
Page 14 PGU-E Electrochemical Gas Sensor Theory of Operation Figure6 – TG-E Detector The PGU-P sensor contains electrode in contact with an electrolyte. The target gas diffuses into the sensor through a membrane and comes into contact with electrodes where it is oxidized. The electrochemical reaction results in an electric current that passes to PGE-P microcontroller and from there to the SSS-903 receiver.
Page 15 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 15 of 53 Install Guide Page: PGU-C Catalytic Bead Gas Sensor Theory of Operation Figure7 – TG-C Detector The PGU-C catalytic bead sensor oxidizes the target gas on the surface of a heated alumina bead.
Page 16 The detector module may be replaced in the field with a one that is intended for use to detect the same gas. If a different gas is required a replacement PGU module must be ordered from ESP Safety or their representative. Aside from detector or filter replacement there are no user serviceable parts in the PGU sensor.
Page 17: Data Communication
ESP-Commander may require a customer provided translation device. All ESP Safety gas detector models have the ability to interface with ESP Commander in RS-485 “daisy chain” networked installations. Modbus is also available in a single point to point interface (one SSS-903 to One port of a control system as a data signal that is imbedded in the +4 to 20mA analog output.
Page 18: Important Safety Information
Be sure to read and understand the entire instruction manual before installing or operating the gas detection system. The products described in this document can be used with a variety of ESP-Safety gas detector models to provide earlywarning of the presence of a toxic or explosive gas mixture.
Page 19: Physical Installation Procedure
Personnel exposure sensor location should include the potential leak source and perimeter of personnel. Use of ESP Safety PGUAES open field detectors should be considered for these areas. Consideration should be given to providing easy access for maintenance personnel. Maintenance Access PGU sensor location should also take into account the proximity to contaminants that may foul the PGU sensor prematurely.
Page 20: Physical Installation Quick Guide
Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 20 of 53 Install Guide Page: Physical Installation Quick Guide...
Page 21 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 21 of 53 Install Guide Page: Tools Required 18-Inch Adjustable Crescent (Spanner Wrench) with 2-inch or greater span for installation and removal of PGU sensor/Sensors 2-MM “Flat Head” screwdriver for protective cover lock screw and wire terminal block clamps #2 Phillips Head Screwdriver for Ground Connector Physical The SSS-903 can be physically mounted in a number of ways.
Page 22 Note: The SSS-903 remote configuration option can be utilized with any gas analyzer equipped with the standard RS-485 (Modbus RTU) output and a power consumption of 24 VDC. This includes all of ESP Safety’s toxic gas PGU sensors and ESP’s SGOES Combustible Gas Detector.
Page 23 Paladin Model GripP – 1117 Shielded 14 AWG Stranded wire Multi-gauge wire stripper (Recommended) shown above ESP safety recommends a Ferrule that is crimped onto the wire for better connectivity and ease of 6mm Insulated Crimp On Ferrule insertion into the terminal block.
Page 24: Wiring Requirements
Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 24 of 53 Install Guide Page: General Wiring Requirements Caution: All cable/conduit entries must be sealed with an appropriate and certified sealing plug and cable gland. The use of industrial grade, armored field cable is recommended. If installing the PGU sensor in a hazardous area using remote configuration, armored cabling is required for the Probe/Sensor connection to the SSS-903 receiver.
Page 25 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 25 of 53 Install Guide Page: Figure 19 - Power Board Connecting Terminal Block Locations Terminal Block X-3 Terminal Block X-1 Terminal Block X-2 Terminal Block X-4...
Page 26 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 26 of 53 Install Guide Page: Table 6 SSS-903 Connections Connection Label Function Terminal Block X1 Not Used RS485B ModBus RTU Interface RS485A ModBus RTU Interface Digital Ground +24V +24 VDC Power (From External Source) Terminal Block X2 Bridge from X1 SCR for Daisy Chain configuration RS485B...
Page 27 Electric Code (ANSI/NFPA 70) Caution: Connection Conduit, Barrier Glands, and Epoxy Sealants are to meet EN-50018/IEC 60079-1 Standards Caution: ESP Safety Inc. Recommends use of shielded cable with 14AWG conductors reaching a span no greater than 3,900 ft. (1200 meter)
Page 28 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 28 of 53 Install Guide Page: Figure 21 - Comprehensive Wiring Diagram for Multiple use Configuration...
Page 29 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 29 of 53 Install Guide Page: Figure 22 - Connecting the SSS-903 to ESP Safety UPES Multichannel Controller Figure 23 - Connecting the SSS-903 Using 3 Wire Analog Interface Method...
Page 30 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 30 of 53 Install Guide Page: Figure 24 - Connecting the SSS-903 Using 4 Wire Analog Interface Method...
Page 31: Power Up And Stand Alone Operation Of The Sss-903
Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 31 of 53 Install Guide Page: Power up and Stand Alone Operation of the SSS-903 Once the mounting, cabling, and alarm relay installation has been completed, the SSS- Installation 903 is ready to begin the power-on sequence. Before applying power to the system for the first time, review the steps below: Review Prior to Verify that the SSS-903 has been properly mounted.
Page 32: Rs-485 Modbus Digital Communication And Operation
RS-485 Modbus Digital Communication and Operation The Modbus interface is used for communication to all ESP Safety Detector models. Up to 480 devices can be connected in a Daisy Chain method. Modbus® RTU protocol uses ASCII/Hex data for communication and allows all SSS-903 functions to be transmitted using this method.Modbus protocol is a Master-Slaves protocol.
Page 33: Calibration Procedures
Wand that is included with every SSS-903 unit. Required Equipment For Figure 29 - Equipment for Magnetic Wand Calibration Non-Invasive Calibration ¼” PVC Tubing Magnetic Wand ESP Safety Zero Gas and Span Gas disposable canister for the appropriate gas. ESP Safety Magnetic Wands...
Page 34 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 34 of 53 Install Guide Page: Non-Invasive Magnetic Wand Calibration Procedure...
Page 35 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 35 of 53 Install Guide Page: Purging The working area must be free of any Gas or contaminants. Connect the nipple of Sensor’s collection chamber to the Zero Gas Cylinder with PVC tubing. Apply magnetic wand to SSS-903 calibration point.
Page 36 Factory calibration of the PGU sensor is performed using a gas flow rate of 0.3 LPM (Litres Per Minute). ESP Safety recommends that field calibration of PGU sensors is performed at the same flow rate. Using non-recommended flow rates may result in calibration errors.
Page 37: Non-Invasive Calibration Procedure With Hart Communicator
Non-Invasive field calibration can be performed on SSS-903 detectors with a HART communicator. Establish communication between the HART Communicator and the SSS-903 by attaching the ESP Safety-supplied cable to the HART connection port of the SSS-903 Zero Calibration using a HART Communicator...
Page 38 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 38 of 53 Install Guide Page:...
Page 39 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 39 of 53 Install Guide Page: Figure x-xx: Sensor Trim Select Figure x-xx: Detailed Setup Step 3: Step 4: Highlight and select the 6 Sensor Trim item. From the Sensor Trim Display, highlight and select 3 Zero Trim Figure x-xx: Warning Message 2 Figure x-xx: Warning Message...
Page 40 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 40 of 53 Install Guide Page: Span Calibration using a HART Communicator Figure x-xx: Online Display Figure x-xx: Device Setup Step 1: Step 2: From the Online Display, select 1 Device Setup Highlight and select the 2 Detailed Setup item.
Page 41 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 41 of 53 Install Guide Page: Figure x-xx: Warning Message 2 Figure x-xx: Warning Message Step 6: Step 7: Select gas calibration. Apply concentration gas. When the displayed gas Lower Concentration (choose for mid-span) value is stable, select ‘OK’.
Page 42 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 42 of 53 Install Guide Page: Step 9: Reapply zero gas. The green ‘CAL’ LED on the SSS- 903 will flash for approximately three minutes as the readings stabilize. When calibration is complete, the green ‘CAL’...
Page 43: Bench Test Calibration Procedure With Esp Commander
Detector units being calibrated. Caution: Before the calibration and verification procedure, inspect the SSS-903 for any mechanical damages to the enclosure and/or sensor elements. Please contact the ESP Safety Inc. service department for further information...
Page 44 Install Guide Page: The following equipment is required for ESP Commander calibration of the SSS-903: ESP Safety Inc. SSS-903 Calibration Kit for Methane Gas (Part Number 24011-xxx) Power supply: output voltage 0-30VDC with adjustable current limit (no less than .05mA) Digital Multimeter (Optional) Plastic or vinyl tube –...
Page 45 Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 45 of 53 Install Guide Page: Figure 40 - Wiring Diagram for Bench Calibration...
Page 46 RS-485 to USB converter. Select The COM port for the link between the PC and converter ESP Commander will scan for all devices connected (via MODBUS communication protocol) Select the device to be calibrated by “double...
Page 47 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 47 of 53 Install Guide Page: Figure 42 -ESP Commander Operating Screen Display and Function: Device Model Detection Gas Device relay state Calibration Values Device Address Alarm Values Version Graph of Alarm events...
Page 48 PGU sensor inlet nipple. Using the Zero Gas Cylinder, purge the the cup and PGU sensor by inserting the tubing from the Zero Gas Cylinder and passing approximatly one Liter of Gas into the sensor. Figure 44- Zero Cal Purge using ESP Commander...
Page 49 The SSS-903-903 will show Zero Attached the Span Gas Cylinder with the mixture value as required. Figure 46 -Span Cal with ESP Commander Start a flow into the Calibration cup. After about 60 seconds, the count will top out. Set this as Span or the user selected Max % of the LEL.
Page 50 Warranty ESP Safety Inc, 555 North First Street San Jose, CA 95112 USA, guarantees the SSS-903 will be free of manufacturing defects for 5 years after date of commissioning, provided the customer follows all guidelines pertaining to installation, operation, and maintenance detailed in this Operating Manual.During this warranty period, the manufacturer will correct any failures detected...
Page 51: Appendix 1 Explosion Proof Design
Part 10060-001 Rev: Number: Description: SSS-903 TG-E Date: 08/15/2017 51 of 53 Install Guide Page: Appendix I: Explosion Proof Design...
Page 52: Appendix 2 Warranty & Return Policy
ESP to require that the buyer provide proof of purchase such as the original invoice, bill of sale or packing slip to establish that the product is within the warranty period.
Page 53 53 of 53 Install Guide Page: Return Material Authorization (RMA) Number Contact ESP Safety Inc. at +1-408-886-9746 to obtain a Return Material Authorization (RMA) n umber. Please provide the following information during your call: -Company Name -Product Type -Serial Number...

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Pgu-e Sss-903 Pgu-ir Pgu-c