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Detcon 1000 Operator's Installation And Instruction Manual

H2s e-chem/ co2 process analyzer
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H
S E-Chem/ CO
2
Operator's Installation and Instruction Manual
Detcon Model 1000 H
1. The Model 1000 Series gas sample-conditioning assembly.
2. The Model DM-624 H
2
December 4, 2018• Document #3208• Revision 0.8
Model 1000
Process Analyzer
2
SAMPLE
AIR
FLOW
FLOW
SAMPLE
FLOW
S/CO
Analyzer consists of two major assemblies:
2
2
S Electrochemical and Model IR-640/IR642 CO
DETCON, Inc.
4055 Technology Forest Dr. Suite 100,
The Woodlands, Texas 77387
Ph.281.367.4100 / Fax 281.298.2868
www.detcon.com
+
+
24VDC
18-36
OUT
VDC
2.1A
IN
gas sensors.
2

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Summary of Contents for Detcon 1000

  • Page 1 FLOW Operator’s Installation and Instruction Manual Detcon Model 1000 H S/CO Analyzer consists of two major assemblies: 1. The Model 1000 Series gas sample-conditioning assembly. 2. The Model DM-624 H S Electrochemical and Model IR-640/IR642 CO gas sensors. DETCON, Inc.
  • Page 2 This page left intentionally blank Shipping Address: 4055 Technology Forest Dr. Suite 100, The Woodlands Texas 77381 Mailing Address: P.O. Box 8067, The Woodlands Texas 77387-8067 Phone: 888.367.4286, 281.367.4100 • Fax: 281.292.2860 • • www.detcon.com sales@detcon.com Model 1000 H2S E-Chem/CO2 Manual...

  • Page 3: Table Of Contents

    13.1 DM-624 H S Sensor ........................... 35 13.2 IR-640/IR-642 CO Sensor......................... 36 Spare Parts ............................. 37 Warranty ..............................41 Flow Diagrams ............................42 Wiring Diagram ............................. 45 Appendix C ............................... 46 Revision Log ..............................46 Model 1000 H2S E-Chem/CO2 Manual...
  • Page 4 Figure 28 Analyzer with Air Dilution Spare Parts ..................... 40 Figure 29 Unit Flow Diagram ..........................42 Figure 30 Unit Flow Diagram with dilution ....................... 43 Figure 31 Pump Box Flow Diagram ........................44 Figure 32 Wiring Diagram ..........................45 Model 1000 H2S E-Chem/CO2 Manual...

  • Page 5: Introduction

    The analyzer requires a constant, liquid-free, 10±2 psig sample pressure, which is provided by the customer or may be supplied by Detcon as a separate gas sample handling system. The on-board gas sample conditioning system includes a stainless steel pressure gauge (0-30 psig), and a Genie membrane filter to provide the analyzer with absolute condensate liquid protection.

  • Page 6: Figure 2 Construction Of Electrochemical Sensor

    1000 H2S EChem/CO2 Detcon MicroSafe™ Model DM-624, toxic sensors are non-intrusive “Smart” sensors designed to detect and monitor for H2S gas in parts per million (ppm). One of the primary features of the sensor is its method of automatic calibration, which guides the user through each step via instructions displayed on the backlit LCD.

  • Page 7: Figure 3 Functional Block Diagram

    250 VAC, 5 amps @ 30 VDC and coil rated at 24 VDC. Gold plated program jumpers are used to select either the normally open or normally closed relay contacts. Figure 5 Connector Board Terminals Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 3 of 47...

  • Page 8: Ir-640/Ir-642 Description (Sensor #2)

    1.2 IR-640/IR-642 Description (Sensor #2) Figure 6 IR-640 Detcon MicroSafe™ Model IR-640 carbon dioxide gas sensors are non-intrusive “Smart” sensors designed to detect and monitor CO gas in the 0-5% range. Using air dilution, the IR-640 can be used to measure 0-15%.

  • Page 9: Figure 7 Sensor Diagram

    Figure 7 Sensor Diagram Non-dispersive infrared (NDIR) optical sensor The Detcon NDIR sensor is designed as a miniature single piece “plug-in replaceable” component, which can easily be changed out in the field. The NDIR sensor consists of an infrared lamp source, two pyroelectric detectors, and an optical gas sample cavity.

  • Page 10: Figure 9 Principle Of Operation

    LED indicators, magnetic programming switches, an RS-485 communication port, and a linear 4-20mA DC output. Figure 10 Functional Block Diagram Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 6 of 47...

  • Page 11: Enclosures

    All calibration and alarm level adjustments can be accomplished without removing the cover. Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 7 of 47...

  • Page 12: Specifications

    Sensor: 5-year conditional warranty. Transmitter: 2-year warranty (IR-640/IR-642 CO Sensor) Input Voltage 117/220VAC; 18-36VDC Power Consumption 925mA max (22.2Watts), 300 mA nominal (7.2 Watts) @ 24VDC Electrical Classification Non Hazardous Area Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 8 of 47...

  • Page 13: Installation

    29”H X 29”W X 8”D 3. Installation 3.1 Mounting Securely mount the Model 1000 analyzer panel or NEMA 4 enclosure (optional) in accordance with Figure 14. Figure 14 Unit Dimensions 3.2 Gas Connections and Sampling System 1. Install a length of tubing from the desired sample point to the sample inlet port as shown in Figure 15.

  • Page 14: Figure 15 Port Identification

    Vent Vent Over-pressure Relief Vent Port H2S Port CO2 Sample Bypass and Liquid Rejection Exhaust Vent *NOTE: These can be combined to a single vent Figure 15 Port Identification Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 10 of 47...

  • Page 15: Figure 16 Port Identification With Dilution

    Set a flow of 100-200cc/min. and vent to a safe area using ¼ O.D. tubing. 3. Connect to the Over-pressure Relief valve and vent to a safe area. The pressure relief valve is set at Detcon to open at 15-20psig. For convenience sake, the sample bypass and over-pressure relief can be vented together.

  • Page 16: Electrical Connections

    3. Discrete alarm relay contacts are provided for three alarms: Fault, Low and High. The contacts consist of common and choice of normally open or normally closed. Contact output selections are jumper programmable on the sensor connector board. See DM-624 and IR-640/IR-642 wiring diagram for details. Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 12 of 47...

  • Page 17: Relays And Rs-485 Setup (Dm-624 And Ir-640/Ir-642)

    19). There are 256 different ID numbers available, which are based on the hexadecimal numbering system. If RS-485 communications are used, each sensor must have its own unique ID number. Use a jeweler’s screwdriver Model 1000 H2S E-Chem/CO2 Manual Rev 0.8...

  • Page 18: Figure 19 Rs-485 Dip Switches

    (0)-(0). Figure 19 RS-485 Dip Switches Replace the plug-in control circuit and replace the junction box cover. Hexadecimal Table 1 none Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 14 of 47...

  • Page 19: Start Up

    1000 H2S EChem/CO2 4. Start Up Upon completion of all tubing connections and field wiring the Model 1000 Series Process Analyzer is ready for startup. Note that after power is applied, varying readings may occur during sensor warm-up. Allow at least 1 hour to stabilize (24 hours is best).

  • Page 20: Figure 20 Rotameters And Gas Connections

    INLET Sample Source SAMPLE FLOW 3 Way Valve Vent Vent Calibration Port CO2 Port Port Calibration Port H2S Sample or Cal Gas CO2 Figure 20 Rotameters and Gas Connections Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 16 of 47...

  • Page 21: Figure 21 Rotameters And Gas Connections With Air Dilution

    SAMPLE PRESSURE 10 PSIG (CONSTANT) SAMPLE INLET Sample Source 3 Way Valve Vent Port Calibration Port H2S/CO2 Sample or Cal Gas Figure 21 Rotameters and Gas Connections with Air Dilution Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 17 of 47...

  • Page 22: Operating Software

    In normal operation, the display tracks the status of the sensor and gas concentration and appears as: “##.## PPM H2S”. The milliamp current output corresponds to the monitoring level and range of the sensor, where Full Scale is 20mA. Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 18 of 47...

  • Page 23: Calibration Mode

    ➢ Alarm relay energize state of the fault alarm. The menu item appears as: “FLT ENERGIZED” or de- energized. ➢ Calibration gas level setting. The menu item appears as: “CALLEVEL @ ##PPM” Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 19 of 47...
  • Page 24 Calibration Level Adjustment The Calibration level is adjustable from 10% to 90% of range (10ppm range is adjustable to 10ppm). The menu item appears as: “CAL LEVEL @ ## PPM” Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 20 of 47...

  • Page 25: Software Flow Chart

    1000 H2S EChem/CO2 5.2.4 Software Flow Chart Figure 23 DM-624 Software Flow Chart Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 21 of 47...

  • Page 26: Operating Software (Ir-640/Ir-642)

    Enter the programming menu by holding the programming magnet stationary over “PGM 2” for 15 seconds. When the display changes to “VIEW PROG STATUS”, withdraw the magnet. Scroll through the Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 22 of 47...
  • Page 27 60% of full-scale range. The menu item appears as: “SET ALM2 @ #.##%” Calibration Level Adjustment The Calibration level is adjustable from 10% to 90% of full-scale range. The menu item appears as: “CAL LEVEL @ #.##%” Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 23 of 47...

  • Page 28: Software Flow Chart

    1000 H2S EChem/CO2 5.3.4 Software Flow Chart Figure 24 IR-640/IR/642 Software Flow Chart Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 24 of 47...

  • Page 29: Calibration

    6.1 DM-624 H S Sensor Calibration Material Requirements ✓ Detcon Part Number 327-000000-000 MicroSafe™ Programming Magnet ✓ Span gas cylinder containing H S gas in background N2 (nitrogen) as per the following range table. If available, span gas cylinders in background Methane (natural gas) or air can also be used.
  • Page 30 Section 13, Troubleshooting. c) After span calibration, the alarm relays remain inactive until the sample gas concentration falls below both set alarm levels. The alarms will then become active again. Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 26 of 47...

  • Page 31: Ir-640/Ir-642 Co

    6.2 IR-640/IR-642 CO Sensor Calibration Material Requirements ✓ Detcon Part Number 327-000000-000 MicroSafe™ Programming Magnet ✓ Span Gas containing the applicable CO concentration in air. Span gas concentration is recommended at 50% of full-scale range (which is the factory default). Other concentrations can be used as long as they fall within 10% to 90% of range.
  • Page 32 Alarm 1 and Alarm 2 set point levels. Additional Notes a) Upon entering the calibration menu, the 4-20mA signal drops to 2mA and is held at this level until the sensor returns to normal operation. Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 28 of 47...

  • Page 33: Programming Alarms

    Exit to the programming menu by holding the programming magnet over “PGM1” for 3 seconds, or automatically return to the programming menu in 30 seconds. Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 29 of 47...

  • Page 34: Alarm Reset (Dm-624 And Ir-640/Ir-642)

    8. Program Features Detcon sensors incorporate a comprehensive program to accommodate easy operator interface and fail-safe operation. Program features are detailed in this section. Each sensor is factory tested, programmed, and calibrated prior to shipment.

  • Page 35: Ir-640/Ir-642 Co

    1000 H2S EChem/CO2 Fail-Safe/Fault Supervision Detcon MicroSafe™ sensors are programmed for fail-safe operation. Either fault condition will activate the fault relay, illuminate the fault LED, and cause the display to read its corresponding fault condition: “SIGNAL FAULT”, or “CAL FAULT”. A “SIGNAL FAULT” will also cause the mA output to drop to zero (0) mA.

  • Page 36: Rs-485 Protocol

    RS-485 ID number would require the sensor housing to be opened, thus declassification of the area would be required. See section 3.4 for details on changing the RS-485 ID number. The following section explains the details of the Modbus™ protocol that the Detcon MicroSafe™ sensor supports.
  • Page 37 The following is a typical Slave Response from device # 8: Field Name Slave Address 0000 1000 Function 0000 0011 Byte Count 0000 1100 Reg40000 Data Hi 0000 0010 Reg40000 Data Lo 0110 0100 Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 33 of 47...

  • Page 38: Display Contrast Adjustment

    11. Low Flow Fault Options Model 1000 Analyzers offer two low flow fault option PCB’s. One monitors for low sample gas flow, and the second monitors for low airflow dilution. The Low Flow Fault option for sample gas flow is usually set for the relay contacts to fire at flow rates ≤...

  • Page 39: Troubleshooting

    3. Check Span Calibration gas for valid concentration in nitrogen gas. 4. Re-calibrate with known good span gas. 5. If problem persists, the sensor may need to be replaced. Contact factory. Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 35 of 47...

  • Page 40: Ir-640/Ir-642 Co Sensor

    1. Unplug transmitter module and re-plug transmitter, this may clear the fault. 2. Remove lower section of IR Sensor housing and determine if IR light source is on and blinking. 3. If light source is not blinking replace IR sensor. Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 36 of 47...

  • Page 41: Spare Parts

    960-202200-000 Condensation Prevention Packet (replace annually) Condulet Cover with Window Plug in Transmitter Module Connector Board O-Rings Sensor Housing Assembly Condulet Base Replacement Cell Figure 25 DM-624 Replacement Parts Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 37 of 47...

  • Page 42: Figure 26 Ir-640/Ir-642 Replacement Parts

    960-202200-000 Condensation Prevention Packet (replace annually) Condulet Cover with Window Plug in Transmitter Module Connector Board O-Ring Sensor Housing Assembly Condulet Base Replacement Cell Figure 26 IR-640/IR-642 Replacement Parts Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 38 of 47...

  • Page 43: Figure 27 Analyzer Spare Parts

    0.5LPM Air Rotometer Genie Membrane Filter DM-624 CO2 Sensor Housing Assembly Transmitter CO2 Replacement Cell Module H2S Sensor Head in SS Housing H2S Plug-in Replacement Sensor Figure 27 Analyzer Spare Parts Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 39 of 47...

  • Page 44: Figure 28 Analyzer With Air Dilution Spare Parts

    Genie Membrane Filter DM-624 CO2 Sensor Housing Assembly Transmitter CO2 Replacement Cell Module H2S Sensor Head in SS Housing H2S Plug-in Replacement Sensor Figure 28 Analyzer with Air Dilution Spare Parts Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 40 of 47...

  • Page 45: Warranty

    Detcon, Inc., further provides for a five year fixed fee service policy wherein any failed transmitter shall be repaired or replaced as is deemed necessary by Detcon, Inc., for a fixed fee of $65.00. The fixed fee service policy shall affect any factory repair for the period following the two-year warranty and shall end five years after expiration of the warranty.

  • Page 46: Flow Diagrams

    1000 H2S EChem/CO2 16. Flow Diagrams 24VDC 18-36 2.1A SAMPLE FLOW FLOW SAMPLE FLOW Figure 29 Unit Flow Diagram Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 42 of 47...

  • Page 47: Figure 30 Unit Flow Diagram With Dilution

    1000 H2S EChem/CO2 24VDC 18-36 2.1A SAMPLE FLOW FLOW Figure 30 Unit Flow Diagram with dilution Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 43 of 47...

  • Page 48: Figure 31 Pump Box Flow Diagram

    1000 H2S EChem/CO2 Sample Air Flow Flow Fault Fault Figure 31 Pump Box Flow Diagram Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 44 of 47...

  • Page 49: Wiring Diagram

    4-20mA Output RS-485 In Sensor 1 Sensor 2 RS-485 In Assembly Assembly RS-485 Out RS-485 Out Pump Assembly Ferrite Cylinder Ferrite Cylinder To Cell To Cell Figure 32 Wiring Diagram Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 45 of 47...

  • Page 50: Revision Log

    02/24/09 Updated Manual to Word, many corrections 09/04/09 Update Spare Parts 05/24/11 Updated drawings to reflect Detcon aluminum condulet and new DC/DC converter. Approvals column added to revision log 09/19/11 Updated notation in section 3.3 regarding VDC input to match...
  • Page 51 Shipping Address: 4055 Technology Forest Dr. uite 100, The Woodlands Texas 77381 Mailing Address: P.O. Box 8067, The Woodlands Texas 77387-8067 Phone: 888.367.4286, 281.367.4100 • Fax: 281.292.2860 • • www.detcon.com sales@detcon.com Model 1000 H2S E-Chem/CO2 Manual Rev 0.8 Page 47 of 47...

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