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EsiWelma s.r.l. CENTRALIZED GAS DETECTION AND CONTROL SYSTEM FOR INDUSTRIAL ENVIRONMENTS Sensigas EW40 INSTALLATION AND OPERATING MANUAL Rev. Data Page Total pages Type / N. EW095.605 November 2010...
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EsiWelma s.r.l. Rev. Data Page Total pages Type / N. EW095.605 November 2010...
EsiWelma s.r.l. CONTENTS GENERAL ..........................6 ......................6 EANING OF SYMBOLS ....................6 AZARDOUS GAS THRESHOLD DESCRIPTION OF SYSTEM....................8 INSTALLATION ........................11 UCE 40… ..............11 NSTALLATION OF THE CONTROL UNIT ..................13 NSTALLATION OF THE DETECTORS ...15 NSTALLATION OF THE ELAY MODULES ISPLAY MODULES AND THE LARM MODULES 3.3.1...
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EsiWelma s.r.l. OPERATING MODES ......................50 ....................50 LARM OPERATING MODE 7.1.1 Direct mode......................50 7.1.2 Parking mode......................50 ................52 LARM DIGITAL INPUT OPERATING MODE ................54 LARM DIGITAL OUTPUT OPERATING MODE SYSTEM STATUS........................56 ........................56 AIL STATUS ......................56 CTIVATED STATUS ......................56 EACTIVATED STATUS ........................57 ESIDUAL LIFE .........57...
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EsiWelma s.r.l. DIMENSIONS ........................87 12.1 UCE40… ....................87 CONTROL UNIT 12.2 MAR40 , MDD40 MID40 ....88 RELAY MODULE DISPLAY MODULE AND ALARM MODULE 12.3 D (UR.40.E, UR.40.I) ..................88 ETECTORS 12.4 UR.40.S ......................89 DETECTORS 12.5 UR.40.L ......................89 DETECTORS ELECTRICAL DIAGRAMS....................90 SYSTEM TABLE (FACSIMILE) ..................92 INSTALLATION DATA......................93...
EsiWelma s.r.l. GENERAL This chapter provides some information on the characteristics of the gases and on the installation criteria for gas detection devices before the description of the EW40 system. It is not essential to read this chapter to install and commission the system described in this manual.
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EsiWelma s.r.l. For toxic gases such as carbon monoxide (CO), the hazard level must be considered also in relation to the duration of the person's exposure in the polluted environment. The table below shows risks from exposure to carbon monoxide (CO). Carbon monoxide is...
EsiWelma s.r.l. % VOL LEL % (methane gas) 1.000.000 impossible combustion Possible combustion range 100.000 Lower Explosive Limit 10.000 Limit value range of gas detectors 1.000 0,01 0,001 0,0001 Fig. 1.1 DESCRIPTION OF SYSTEM The system (called EW40) is formed of a control unit UCE40... and field devices that communicate by means of a shared line (BUS) and a dedicated master protocol (PEW40).
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EsiWelma s.r.l. Al sistema di Al sistema di Al sistema di Al sistema di To Monitoring supervisione supervisione supervisione supervisione System (option) (opzionale) (opzionale) (opzionale) (opzionale) 8 5 8 5 8 5 8 5 8 5 8 5 8 5...
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EsiWelma s.r.l. The UR.40.. detectors come in four models (E, S, I, L) and their use depends on the protection mode required: Application Protection mode Part number Group II Classified (hazardous) Category 2G areas UR.40.E Ex d IIC T6 : -20...
EsiWelma s.r.l. Product code: UR _ 40 _ _ UR _ 40 _ _ Model: Certified to • E: ATEX II 2G Ex d IIC T6 • E: ATEX II 2G Ex d IIC T6 • S: ATEX II 3G Ex nA d IIC T6 •...
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EsiWelma s.r.l. 1. fit the device into the cover frame (Fig. 3.1) position the cover frame (Fig. 3.2) 3. knock out a 136x136 mm opening in the front panel of the electric board (Fig.3.3) 4. insert the control unit into the knock-out and push it from the outside towards the inside until it fits into position 5.
EsiWelma s.r.l. Screw clamp Screw clamp Fig. 3.5 – Inserting hooking clamps Fig. 3.6 – UCE 40…: flush panel mounting Installation of the detectors The detectors must be wall-mounted at whatever height is appropriate for the type of gas to be detected (Fig.
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EsiWelma s.r.l. Use the information below to correctly position the detectors: • 20-30 cm from the floor to detect gases heavier than air (LPG or Gasoline Vapours) • 20-30 cm from the ceiling to detect gases lighter than air (Methane) •...
EsiWelma s.r.l. The number of detectors to be installed for correct coverage of an environment are proportionate to the height and area of the room itself. This parameter (see installation guidelines) depends on a wide range of variables; the graph below should be seen as an aid and NOT AS INSTALLATION GUIDELINES.
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EsiWelma s.r.l. Fig. 3.10 – Fixing the modules to DIN rail To unhook the devices from the support rail, insert small screwdriver into the slot of the spring situated bottom enclosure (Fig. 3.11). Fig. 3.11 – Unhooking slot Rev. Data...
EsiWelma s.r.l. 3.3.2 Flush panel mounting Mount as follows: prepare a piece of DIN rail no shorter than 160 mm with holes on the side to pass through dedicated tie rods (Fig. 3.12) knock out a 46x106 mm opening on the front panel of the electric board and drill two holes on the sides for the tie-rods to pass through (line them up with the DIN rail holes (Fig.
EsiWelma s.r.l. Numbering the field devices After installation, all the field devices must be numbered as follows: Attach a clearly visible label to each detector and write a progressive identification name on each one, from 1 to N, where N is the number of detectors installed. The...
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EsiWelma s.r.l. CONFIGURATION OF THE LAYOUT AND NUMBER OF DEVICES DETECTORS Gas detected Position of detector Gas detected Position of detector ALARM MODULES AM position Alarm I-1 Signal I-1 Alarm I-2 Signal I-2 Alarm I-3 Signal I-3 Alarm I-4 Signal I-4...
EsiWelma s.r.l. ELECTRICAL CONNECTIONS After the control unit and the field devices have been installed and table 3.1 has been filled in, the electrical connections must be made. This operation must be performed by qualified and trained personnel who work in compliance with laws in force.
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EsiWelma s.r.l. When completing the system it is necessary to include a junction box with each field device. Fig. 4.1 below gives a standard example of connection of the field device BUS. The connection line must be unique and the field devices must be connected to it. No branching is permitted.
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EsiWelma s.r.l. junction UR.40.. UR.40.. UCE40.. UR.40.. UR.40.. UR.40.. MDD40 MAR40 INCORRECT CONNECTION Fig. 4.2 – Example of incorrect connection Fig. 4.3 shows a cabling example of the junction box. Junction box From previous next junction box junction box Type of screen connection to bus: GND BUS •...
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EsiWelma s.r.l. The consumed power is calculated as follows: P (total) = P1+P2+P3+……+Pn [Watt] Current (total) = P(total)/12 [Amps] The size of the power supply cable is calculated using the formula below, approximating to the value closest to existing size. In all cases, the minimum distance must be no less than 2.5mm²...
EsiWelma s.r.l. Recognition of the terminal boards All the terminal boards clearly indicate the polarization of both the power and the communication BUS terminals and it is essential never to reverse the connections. 4.3.1 Terminal boards on the control unit The layout of the terminal boards on the control unit is shown in Fig.
EsiWelma s.r.l. 4.3.3 Terminal board of the display module The layout of the terminal board of the display module is shown in Fig. 4.7. BUS Shield BUS Shield BUS Input BUS Input 12 Vdc Power 12 Vdc Power Supply Input Supply Input Fig.
EsiWelma s.r.l. The FA relay energises for a fault of a peripheral assigned to it. As regards the connection of the devices, served by the relays of the RM, make the electrical connections after identifying the terminals of the exchange contact (C =...
EsiWelma s.r.l. System structure If the control unit UCE40… is fitted with the optional battery load and protection card, to order at the same time as the actual control unit with code UCE40MPA-CPB, it can provide a power supply to external devices up to a power consumption of 30W with a tolerance of 1W.
EsiWelma s.r.l. 4.4.2 Extended structure When the devices exceed the power that can be managed by the control unit (30±1W) an external uninterruptible power supply (UPS) is necessary. The example below represents a system with three boilers, each one fitted with a gas cut-off solenoid valve.
EsiWelma s.r.l. A warm air heating system created with unit heaters spread throughout a building is shown in Fig. 4.12. A gas shut-off valve and a methane gas detector is set up for each unit heater. URG40.. URG40.. URG40.. URG40..
EsiWelma s.r.l. 4.5.1 Point-to-point communication with RS232 Connection is possible via the CANNON DB9/F “RS232 Interface” connector. Fig. 4.13 a) shows the connector pin-out on the back of the control unit. From table b) it is possible to see that the signals managed are the ones at pins 2, 3, 5.
EsiWelma s.r.l. SYSTEM POWER SUPPLY Once the installation activities and electrical connections are concluded and an instrumental control of their correctness has been carried out, it is possible to power up the system. CAUTION THE SYSTEM POWER SUPPLY MUST BE INSTALLED BY QUALIFIED PERSONNEL TRAINED IN RISKS FROM ELECTRIC SHOCK.
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EsiWelma s.r.l. C O N F I G U R A T I O N M E N U N E W I N S T A L L A T I O N N E W C E N T R A L...
EsiWelma s.r.l. Displays of the status screen The status screen displays identify the operating condition of the overall system. It is separated lengthwise in two areas dedicated respectively to: • cumulative display of the alarms (left area of the window) •...
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EsiWelma s.r.l. Instead, as regards the power supply status, we will have two possible contexts: The first context, shown in figure 5.5, which concerns the condition where the optional battery load and protection card is not installed, where the only display possible is: •...
EsiWelma s.r.l. Possible abnormalities If the BUS connections of a field device are reversed, the control unit does not recognize the signal of the field device on the BUS when the configuration key is pressed. Cabling errors may show up as follows.
EsiWelma s.r.l. The field device concerned can be identified through its steady on LED status. Furthermore, cyclically, with the same period as the messages in Fig. 5.9, the FA relay of the control unit is disengaged (fail signal). IMPORTANT: if the field device with the reversed BUS connection was, for example...
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EsiWelma s.r.l. SENSIGAS Setup keys: change value/status Subscreen enter/exit keys + save settings UCE40 Scroll keys (up-down) Fig. 6.1 – Function of the keys on the control unit UCE40... NOTE If no key is pressed for two minutes, the control unit returns to the stand-by window in Fig.
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EsiWelma s.r.l. SENSIGAS SENSIGAS SENSIGAS SENSIGAS Status LED of 2 Status LED of 2 Status LED of 2 ALARM Threshold ALARM Threshold ALARM Threshold Status LED of 1 Status LED of 1 Status LED of 1 ALARM Threshold ALARM Threshold...
EsiWelma s.r.l. Configuration The operation starts from the status of the control unit and from the field devices left in Chapter 5 and ends with the recognition by the control unit of all the field devices in the new system. After powering up the system, the devices will show the following status: •...
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EsiWelma s.r.l. Complete the configuration as follows: • approach the installed field devices following the order indicated on Table 3.1 (filled in) • remove the detector covers • press the internal configuration button down for about 2 seconds • make sure the status LED starts flashing (one flash every 10 seconds) Once a field device is configured, the screen updates indicating the last field device accepted, thus confirming the recognition;...
EsiWelma s.r.l. After the relay modules are configured, use the same procedure to configure the display modules and if included the alarm modules. N E W I N S T A L L A T I O N S 0 4...
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EsiWelma s.r.l. The screen that comes up is indicated below and from there you go into setting. M A I N M E N U MA I N ME N U S E N S O R A S S I G N M E N T...
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EsiWelma s.r.l. When a gas detector exceeds the set pre-alarm threshold (PR) or threshold one alarm (1t) or a threshold two alarm (2t), the corresponding relays of the assigned relay module are commanded. To move the screen horizontally, press To move down, press To move up, press For example, for the fifth detector to assign, move the pointer to the right as shown below.
EsiWelma s.r.l. Assignment of the alarm modules Following the same procedure as for the association of the sensors, start from the “MAIN MENU”, press until the pointer is positioned over the words “ALL ASSIGNMENT”, then press to enter the sub-screen.
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EsiWelma s.r.l. 1 - 1 1 - 2 1 - 3 1 - 4 R M 0 1 “ “ “ D M 0 1 “ “ “ “ Press the key indicated above to Fig. 6.36 move the pointer to the right...
EsiWelma s.r.l. Sensor operation check After the system is calibrated and started up, it is necessary to make sure the gas detectors are operating correctly. For this purpose, it is necessary to scrupulously perform the following in order to prevent incorrect test actions that could cause permanent damage to the sensing element.
EsiWelma s.r.l. Alarm module operation check Like for the sensors, after the system is calibrated and started up, it is necessary to make sure the alarm modules are operating correctly. For this purpose, terminals + and - of the input to check need to be short-circuited (or the digital status of the system connected to the input needs to be switched);...
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EsiWelma s.r.l. On the other hand, if the display module is correctly configured and assigned, it displays dashes if no assigned detector or AM is in alarm condition; otherwise it displays the status and the main features of the field devices in alarm condition.
EsiWelma s.r.l. OPERATING MODES Several operating modes are possible and can be selected from “CONFIGURATION MENU”: Alarm operating mode During control unit configuration it is decided whether the alarm mode will be: • Direct (default) • Parking. 7.1.1 Direct mode Direct mode is based on the routine operation of the system;...
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EsiWelma s.r.l. M A I N M E N U M A I N M E N U I N S T A L L A T I O N S T A T E C O N F I G U R A T I O N...
EsiWelma s.r.l. Alarm digital output operating mode The outputs have two operating modes that can be selected from the dedicated menu called “OUTPUTS LOGIC”: • Positive mode (default): if there are no alarms, all the relays (both the RM relays and the control unit relays) are energized and de-energize when there is an alarm or fail •...
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EsiWelma s.r.l. To change the command mode for the actuators, it is necessary to enter setting mode. O U T P U T S L O G I C O U T P U T S L O G I C...
EsiWelma s.r.l. SYSTEM STATUS The information in this chapter is useful in order to understand the next chapter. The field devices may be in any of the following operational statuses: • FA (fail) • A (activated) • DE (deactivated) •...
EsiWelma s.r.l. Residual life The control unit can display the residual operational lifetime of the sensor in weeks: this figure is shown on the sensor setting screen as “TIME”. When the operational lifetime descends to zero, the sign becomes negative and the system continues to operate and count down the weeks of operational lifetime but of course there is no guarantee that the sensor is operating correctly.
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EsiWelma s.r.l. The screen above indicates that the following are installed in the system: • one carbon monoxide detector • one relay module • one display module (visible by pressing beginning from the window in Fig. 8.4) • one alarm module (visible by pressing twice from the window in Fig.
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EsiWelma s.r.l. To change the threshold or status parameters of the detector, go to setting and proceed as follows. S 0 1 S 0 1 S E T L E L S E T L E L G A S : C H 4...
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EsiWelma s.r.l. For the RM, start from the main menu, go to the screen as shown in Fig. 8.20 and continue as follows: C H 4 twice Fig. 8.21 Fig. 8.20 Fig. 8.23 Fig. 8.22 In the example considered, we can see that the only relay module in the system is activated and that no alarm threshold has been exceeded.
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EsiWelma s.r.l. The relay assigned to the pre-alarm is activated, its contact switches and, in the example shown below for a basic structure, the warning lamp switches on. Press and the XX will disappear and be replaced by (--) and the pre-alarm relay will go back to idle.
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EsiWelma s.r.l. For the DM, start from the main menu, go to the screen as shown in Fig. 8.20 and continue as follows: C H 4 three times Fig. 8.33 Fig. 8.32 Fig. 8.35 Fig. 8.34 press down the two Fig.
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EsiWelma s.r.l. For the AM, start from the main menu, go to the screen as shown in Fig. 8.20 and continue as follows: C H 4 four times Fig. 8.39 Fig. 8.38 Fig. 8.41 Fig. 8.40 In the example considered, we can see that the only alarm module in the system is...
EsiWelma s.r.l. AUXILIARY FUNCTIONS The UCE40… control unit can be used to access other detailed information useful for the operator both to learn the system status at any time and in order to make any changes to alarm parameters of associations.
EsiWelma s.r.l. Display adjustment It is possible to change the contrast and backlighting on the display from the window shown below, with access from the main menu, then pressing D I S P L A Y S E T T I N G S...
EsiWelma s.r.l. Alarm reset This has the purpose of recognizing the alarms and of restoring the normal operations (See Par. above). Obviously “ALARM RESET” is only valid if manual alarm reset has been selected. From the main menu, press until the words “ALARM RESET” appear.
EsiWelma s.r.l. Aligning alarm thresholds When the operator has made too many changes to the alarm threshold set-points and/or wants to return to a more standard situation, from the "THRESHOLD ALIGNMENT" menu these settings can be cumulatively changed. After making a cumulative change to the alarm threshold set-points it is still possible to change them again individually on the configuration pages of each sensor.
EsiWelma s.r.l. Modbus address Before connecting the UCE40... control unit to a monitoring system, the operator must make sure the Modbus address for the protocol messages is correct. The default Modbus address is 5, but it is possible to select a different value from 1 to 64. When selecting it is necessary to make sure there are no conflicts with any other Modbus field devices in the monitoring system.
EsiWelma s.r.l. Modbus Baud Rate The UCE40... control unit must be connected to monitoring system at a communication rate that can be selected from 9600, 19200 or 38400 bps. This is the same rate used for the RS232 or RS422 connection.
EsiWelma s.r.l. Modbus port The UCE40... control unit can be connected to a monitoring system with one of the two communication ports that can be selected between RS232 or RS422. On the “MODBUS PORT” page, the type of communication port can be changed as follows:...
EsiWelma s.r.l. 9.10 Transferring data The identification strings of the field devices can be customized for easy recognition of any alarms or events. This can be carried out using dedicated PC software so the set of identification strings for each field device can be sent to the UCE40... control unit. The strings are transferred from the UCE40...
EsiWelma s.r.l. 10 CHANGES TO AN ALREADY OPERATING SYSTEM This chapter looks at changes that may need to be made to an already operating system. Special commands to add and replace field devices and to replace the control unit are included.
EsiWelma s.r.l. When a field device is deleted, its address becomes available. It is brought up again if the field device is being replaced with another one of the same type (see command "REPLACE DEVICE"). After the cancellation operation is completed, press to leave the screen (twice to go back to the main menu).
EsiWelma s.r.l. 10.4 Adding peripheral A field device needs to be added if the system is being extended. In this case, it is necessary to reconsider then consumption table and check that the new situation is compatible with the power source and that the cable size is still adequate. This command can also be used in the event of an incomplete initial configuration.
EsiWelma s.r.l. CAUTION: If a display module is added to a system that is already hosting sixteen, the control unit shows the following screen. A D D D E V I C E WA R N I N G : N O...
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EsiWelma s.r.l. For system reset, go to “INSTALLATION RESET” from “MAIN MENU” by continuing to press M A I N M E N U M A I N M E N U C O N F I G U R A T I O N...
EsiWelma s.r.l. 11 TECHNICAL SPECIFICATIONS 11.1 Control unit The control unit is housed in a flame-resistant plastic enclosure for flush panel installation with clear protection cover for display and keypad. Its main specifications are: 14 Vdc power supply ÷ Consumption 6W (13W with fully discharged buffer battery; see option)
EsiWelma s.r.l. The keypad has the following commands: Arrows to scroll up and down the screen <enter> Move from the screen to the next level of information <reset/escape> Return to previous page. If in setting, it must be pressed for 5...
EsiWelma s.r.l. 11.2.1 Detectors (UR.40..) The various detectors available are described in Chap.2 – Description of the system. They are formed of an enclosure, whose specifications are tied to the protection mode (ATEX and non), with an IP65 or IP55 protection rating depending on the model, containing the electronics, and of a sensor whose type depends on the gas to be detected.
EsiWelma s.r.l. 11.2.2 Relay module (MAR40) The modules are formed of a flame-resistant plastic enclosure suitable for mounting on DIN rail. Each relay module contains four relays, in addition to the control and communication electronics; the four relays have the previously mentioned functions below assigned: •...
EsiWelma s.r.l. The main technical specifications of the MAR40 relay module are: Power supply: 11÷14Vdc Absorbed power: 2.5 W (max) Protection rating: IP20 (IP40 if mounted in electric board) Command relay: voltage free SPDT contact 250Vac 8(5)A 0 ° C ÷ 50 ° C Room temperature allowed: 20% ÷...
EsiWelma s.r.l. A series of devices are included on the terminal board for configuration of the module as shown in Fig. 11.3 below. SENSIGAS SENSIGAS MDD40 MDD40 E1, E2 E1, E2 BUS termination jumpers BUS termination jumpers Configuration key Configuration key...
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EsiWelma s.r.l. The modules are fitted with a dedicated interface for connection to the communication BUS. Each module is also fitted with a button (S1) for commissioning, that allows automatic acquisition and direction by the control unit. The control unit can also be used to set the positive or negative mode of the module,...
EsiWelma s.r.l. 12 DIMENSIONS 12.1 UCE40… control unit Fig. 12.1 – Dimensions of UCE40... control unit Rev. Data Page Total pages Type / N. EW095.605 November 2010...
EsiWelma s.r.l. 12.4 UR.40.S detectors Fig. 12.4 – Dimensions of UR.40.S detectors 12.5 UR.40.L detectors Fig. 12.5 – Dimensions of UR.40.L detectors Rev. Data Page Total pages Type / N. EW095.605 November 2010...
EsiWelma s.r.l. 13 ELECTRICAL DIAGRAMS Fig. 13.1 – Standard electrical diagram with system power supply from UCE40… (version UCE40MPA-CPB required) Rev. Data Page Total pages Type / N. EW095.605 November 2010...
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EsiWelma s.r.l. Fig. 13.2 – Standard electrical diagram with system power supply from UPS Rev. Data Page Total pages Type / N. EW095.605 November 2010...
EsiWelma s.r.l. 14 SYSTEM TABLE (FACSIMILE) CONFIGURATION OF THE LAYOUT AND NUMBER OF DEVICES DETECTORS N. Gas detected Position of detector Gas detected Position of detector ALARM MODULES AM position Alarm I-1 Signal I-1 Alarm I-2 Signal I-2 Alarm I-3...
EsiWelma s.r.l. 15 INSTALLATION DATA Installer stamp and To be filled by Installer signature Installation site and/or room: Product order number: Part Number: Manufacturing date: Installation date: Replacement date: Remarks …………………………………………………………………. …………………………………………………………………. …………………………………………………………………. …………………………………………………………………. …………………………………………………………………. …………………………………………………………………. …………………………………………………………………. …………………………………………………………………. Rev. Data...
EsiWelma s.r.l. 16 ROUTINE CHECKS To be filled in by Installer / Service Personnel Signature Date Description Rev. Data Page Total pages Type / N. EW095.605 November 2010...
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