Flamgard+
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Transcript of Flamgard+
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1.3 Status Indication
Flamgard Plus includes a local dis
the junction box window. This is s
The display shows the c
the range 0100%LEL and curre
ZERO or CAL. The LED shows th
This is summarised in Table 1.
Operational LED 4-20
state indication outp
Normal S te ad y g re en 4 to 7
operation
Normal S te ad y r ed 7 .2 to
operation
(Alarm 1)
Normal F la sh in g r ed 1 0. 4 t
operation
(Alarm 2)
Over-range F la sh in g r ed 2 4m A
Zero/calibration Flash ing green Config
mode d ep en
(see s
Detector Steady amber 0mA
fault
*As standard, AL1 = 20%LEL and
= RELAY VERSION ONLY
1.1 Product overview
Flamgard Plus is a flameproof flammable gas detector
suitable for use in zone 1 or 2 hazardous areas. It is designed
to detect flammable gas, present in ambient air, at
concentrations not exceeding the Lower Explosive Limit
(LEL) of the target gas for which it is calibrated. A local
display and magnetically operated switches allow non
intrusive oneman calibration without a hot work permit.
Powered by 24 V dc (nominally) FlamgardPlus provides a 4
20 mA signal (sink or source) proportional to the gas
concentration and can also be fitted with optional alarm and
fault relays. For a list of flammable gases that can be
detected, please contact Crowcon.
1.2 Product description
Flamgard Plus comprises four parts; 96HD sensor housing, junction box, amplifier
and terminal board. Diagram 1 details Flamgard Plus. The overall assembly is
certified EEx d IIC T6 in Europe and Class 1, Zones 1&2 AEx d IIC T6 in the USA.The 96HD sensor housing is a modular stainless steel assembly that
dismantles to allow plug in pellistor sensors to be replaced easily (see Diagram
4). The assembly screws into an M20 entry on the junction box.
The junction box is manufactured from marine grade alloy and is
supplied with 2 x M20 (1/2 NPT for USA) cable entries for customer use.
Alternative cable entries are available from Crowcon.
The amplifier plugs into the terminal board, and is held in place by two
captive screws. The amplifier provides power to the pellistor sensor, local
display and controls, and a 420 mA signal proportional to the gas
concentration for connection to a control panel. To remove, turn screws anti
clockwise and use them to pull amplifier out of the enclosure.
All electrical connections are made via the terminal board mounted
in the base of the junction box (see Diagram 2). Optional alarm relays (AL1 &
AL2) and one fault relay (FAULT) are mounted on the terminal board which
may be used to drive local warning devices or connect FlamgardPlus to a
control panel.
FlamgardPlus
Flameproof
Flammable Gas
Detectorwith Nonintrusive Oneman
Calibration
instructions
Installation, operating and maintenance
instructions, MO7192, Issue 6 02/2011
Plus
21 3
5
Diagram 1: Flamgard Plus general arrangement
7 6
UKOfficeCrowconDetectionInstrumentsLtd2BlacklandsWayAbingdonBusinessParkAbingdonOxfordshireOX141DY,UKTel:+44(0)1235557700Fax:+440)1235557749Email:[email protected]:www.crowcon.com
RotterdamOfficeCrowconDetectionInstrumentsLtdVlambloem1293068JG,RotterdamNetherlandsTel:+31104211232Fax:+31104210542Email:[email protected]:www.crowcon.com
USAOfficeCrowconDetectionInstrumentsLtd21KentonLandsRoad,Erlanger,Kentucky410181845USATel:+18005276926or
18005CROWCON+18599571039
Fax:+18599571044Email:[email protected]:www.crowcon.com
SingaporeOfficeCrowconDetectionInstrumentsLtdBlock194PandanLoop#0620PantechIndustrialComplexSingapore128383Tel:+6567452936Fax:+6567450467Email:[email protected]:www.crowcon.com Consider the process conditions. Butane, for instance is normally
heavier than air, but if released from a process line which is at an elevated
temperature and/or under pressure, the gas may rise rather than fall.
The placement of detectors should be determined following
advice of experts having specialist knowledge of gas dispersion, the
plant processing equipment as well as safety and engineering issues.
The agreement reached on the locations of sensors should be
recorded. Crowcon would be pleased to assist in the selection and
siting of gas detectors.
3.2 Mounting
The mounting detail of Flamgard Plus is given in Diagram 1. Flamgard
Plus should be installed at the designated location with the detector
pointing down. This ensures that dust or water will not collect on the
sinter and stop gas entering the detector.
3.3 Cabling requirement
Cabling to Flamgard Plus must be in accordance with the recognised
standards of the appropriate authority in the country concerned and
meet the electrical requirements of the detector. Crowcon recommend
the use of steel wire armoured (SWA) cable and suitable explosion proof
glands must be used. Alternative cabling techniques, such as steel
conduit, may be acceptable provided appropriate standards are met.Flamgard Plus requires a dc supply of 1230 V at up to
210 mA. Ensure the minimum dc supply of 12 V is observed at
the detector, taking into account the voltage drop due to
cable resistance.
For example, a nominal dc supply at the control panel of 24 V
has a guaranteed minimum supply of 20 V. The maximum voltage drop
allowed is therefore 8 V. Flamgard Plus can demand up to 210 mA and
so the maximum loop resistance allowed is 38 Ohms. A 1.5 mm2 cable
will typically allow cable runs up to 1500m.
115 (4 ")1
2/
135(5
")
5
1 6
/
200
(8")
83 (3 )"
M20 ( NTP)
CABLE
ENTRY
1/ "2
UNITS
EXTERNALEARTH POINT
STEADY ONINDICATESZERO/CALMODE
ACTIVATED
"UP"
HEIGHT= 115 (4 / ")1 2
4 OFFFIXING HOLES6mm (")
"DOWN"
FLASHINGINDICATES4-20mA/RELAYSINHIBITED
ALARM 1 & 2ADJUSTMENTPOTS
M20 (" NTP)CABLE ENTRY
STATUSLED
LOCALDISPLAY
TESTPOINTS A
TESTPOINTS B
SET BALANCEPOT B
SET BRIDGEVOLTS POT A
Flamgard-Plus
SN:
ZERO
STATUS
Menu
INHIBIT
CAL
LEL
All dimmensions in mm unless otherwise stated
TAMPER PROOFGRUB SCREW(1.5mm ALLEN KEY)
2. DETECTOR CONFIGURATION
2.1 Standard configuration
As standard, FlamgardPlus is factory set as follows:
Current source with 0 mA = Fault
2 mA = Inhibit ie. Zero/Cal mode
420 mA = Normal operation
24 mA = Overrange clamp
AL1 relay Alarm level 1 set to 20%LEL
Normally deenergised, energising on alarm
Contact normally open (NO), closing on alarm
AL2 relay Alarm level 2 set to 40%LEL
Normally deenergised, energising on alarm
Contact normally open (NO), closing on alarm
FAULT relay Normally energised, deenergised on fault
Contact normally closed (NC), opening on fault
Alarm/fault relays automatically reset when alarm or fault has cleared.
INHIBIT Normally selected, ie. when CAL/ZERO selected
current output is forced to 2mA and relays are
held in normal/no alarm state.
Location of links are shown in Diagram 2.
2.2 4-20mA options
To change current source output to sink, set switch to SK position. To
change Inhibit from 2 mA to 4 mA, fit link to 4 position.
2.3 Relay options
To change AL1 or AL2 relay from NO to NC, fit link in the NC position.
To change FAULT relay from NC to NO, fit link in the NO position.
2.4 Inhibit options
To not inhibit 420 mA signal and relays, fit link to N and link to 4.
Diagram 2: Terminal and amplifier layouts Table 1: LED status indicator s
TEST
OUTPUT
40-200mV
POINT
4mA
SK
-
+
SR
OUTPUTOPTIONS
INHIBIT
17 4
N
2
Y
ALARM
RANGE
GAS
NOTUSED ONFLAMGARD PLUS
ALARM1
10
SENSOR
6
5
4
3
1
2
ISOLATE
GND
OTHER
NO
NC
0V NC
NO
RL3
RL2
0V
ALARM 2
4-20mA
10-30V
FAULT
7
8
9
ALARM1
NCN
O
R
L1
ALARM
11
12
OXYGEN
CONTROLEQUIPMENT
GNDISOLA
TE
LINK
INTERNALTERMINAL LAYOUT
ALARMSET POTS
CONTACTREVERSINGLINKS
ALARM 1
FAULT
TO96HDSENSOR
ALARM 2
REAR VIEW OFAMPLIFIER
RELAYCONTACT
=ALARM RELAY VERSION ONLY
Gas Detection You Can Trust
1180
3. INSTALLATION
WARNING
Flamgard Plus is designed for use in Zone 1 and 2 hazardous
areas and is certified EEx d IIC T6 (AEx d IIC T6 in USA).
Installation must be in accordance with the recognised
standards of the appropriate authority in the country concerned.
For more information contact Crowcon. Prior to carrying out any
work ensure local regulations and site procedures are followed.
3.1 Location
There are no rules which dictate the siting and location of detectors,
however, considerable guidance is available from BS EN 50073:1999
British Standard Code of Practice for the Selection, Installation, Use and
Maintenance of Apparatus for the Detection and Measurement of
Combustible Gases or Oxygen. In the USA refer to the National
Electrical Code (NEC 1999). Similar international codes of practice may
be used where applicable. In addition certain regulatory bodies publish
specifications giving minimum gas detection requirements for specific
applications.
The detector should be mounted where the gas is most likely
to be present. The following points should be noted when locating
flammable gas detectors:
To detect gases which are lighter than air (eg methane), detectors
should be mounted at high level and Crowcon recommend the useof a collector cone (Part No. C01051).
To detect heavier than air gases (eg butane), detectors should be
mounted at low level.
When locating detectors consider the possible damage caused by natural
events e.g. rain or flooding. For detectors mounted outdoors Crowcon
recommend the use of a Weatherproof Cap (Part No. C01442).
Consider ease of access for functional testing and servicing.
Consider how the escaping gas may behave due to natural or forced
air currents. Mount detectors in ventilation ducts if appropriate.
1. INTRODUCTION
Table 2 shows maximum cable dis
C SA R es is ta nc e ( Oh
mm2 (awg) Cable
1.0 (17) 18.1
1.5 (15) 12.1
Table 2: Maximum cable dista
Acceptable cross sectional area
provides guidance only, actual c
should be used to calculate maxi
3.4 Electrical connections
All connections are made via the
of the junction box (see Diagram
colour coded and should be ter
coded terminal (terminals 4, 5 &
and 3 (420mA signal) are con
Flamgard Plus is factory set as
specified otherwise when ord
configuration). Diagram 3 summa
Note: The junction box and cabdetector or control panel to l
interference and to ma intain ele
Note: The junction box for the F
marine-grade alloy, and has a po
taken during installation to prote
environments could result in pai
boxes. This in no way compromi
as the marine-grade alloy junctio
environments.
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4.3Sensorreplacement/servicingofdetectors
WARNING
ThisworkshouldbecarriedoutbyCrowconoranapproved
servicecentreunlesssuitabletraininghasbeenreceived.
FlamgardPlususesthe96HDsensorhousingwhichallowstheuserto
replacethesensors,gasketsandsinterifnecessary.Anexplodedview
ofthe96HDsensorhousingisgiveninDiagram4.Thefollowing
proceduremaybefollowedwhenservicingaFlamgardPlusdetector.
aSwitchoffandisolatepowertothedetectorrequiringattention.
bOpenthedetectorJunctionboxbylooseningthetamperproofgrub
screwandremovingthelidbyrotatingitanticlockwise.
cRemovetheamplifier.
dDisconnectthe3sensorwiresfromtheterminalboard(terminals4,
5&6).
eUnscrewthecomplete96HDsensorhousingfromthejunctionbox.
Note:Ifaspare96HDsensorhousingcompletewithnewsensoris
availableignorestepsftokandreturntheold96HDtoCrowcon
oranapprovedservicecentreforrepair.
fOpenthe96HDsensorhousingbyremovingthefourAllenhead
screwsfromtheTopCapwitha3mmAllenkey.
gRemovethesensorfromtheTopCapPCB.Flammablesensors
haveanextrablacksleevewhichmaybeseparatefromthesensor.
Thisisnormalandthesleevemaybereused.
hFitthereplacementsensorcheckingthepartnumberiscorrect.This
partnumberislabelledonthemainbodyofthedetector.
iInspectthegasketsandreplaceifnecessary.
jThesinterassemblywillonlyneedtobereplacedifithasbecome
blockedbydustoroil.Suchblockagecausestheresponsetimeof
thedetectortobeslowandmayaffectsensitivity.Toremovethe
11
jAllowthegasreadingtostabilise.
kPlacetheendoftheCROMagovertheUPorDOWNarrow
padstomakethedisplayreadthecorrectconcentration.
lIfthecontrolequipmentdisplayrequiresadjustmentconsultthe
operatingmanualfortheequipment.
Returningtonormaloperation(NORMALMode):
nPlacetheendofCROMagovertheMENUpad.Alldecimalpoints
willdisappearandthebacklightwillturnoff.ThegreenstatusLED willbeonsteadily(assumingnogasispresentatthedetector).
oThedetectorisnowoperational.
Note:AlwaysreturnthedetectortoNORMALmodetoavoidleaving
thedetectorinapermanentlyinhibitedstate.
4.2Routinemaintenance
Theoperationallifeofthepellistorsensordependsontheapplicationfor
whichitisbeingused.Suchadeviceshouldworksatisfactorilyforupto
5yearsinidealconditions.Sitepracticeswilldictatethefrequencywith
whichdetectorsaretested.Crowconrecommendthatdetectorsbegas
testedatleastevery6monthsandrecalibratedasnecessary.Tore
calibrateadetectorfollowstepsgivenin4.1.
Pellistorscansufferfromlossofsensitivitywhenthereisa
presenceofpoisonsorinhibitorssuchassilicones,sulphides,chlorine,
leadorhalogenatedhydrocarbons.FlamgardPlususespoisonresistant
pellistorstomaximisetheoperationallife.Inapplicationswheresuch
compoundsarepresentcontinuously,werecommendtheuseof
XgardIRorIRmax,Crowconsfixedpointinfraredflammablegas
detectors,whichareimmunetosuchpoisonsandinhibitors.
5.SPAREPARTSANDACCESSORIES
DescriptionPartnumber
M20to1/2inchNPTadaptorM02125
M20to3/4inchNPTadaptorM02281
Gasket1M04452
Gasket2M04128
SinterremovaltoolM01614
CollectorConeC01051
CeilingMountingBracketM01401
WeatherproofCapC01442
ReplacementCROMagC01697
96HDsensorhousingcompletewithsensorS01749*1
ReplacementsensorS01673*1
SinterassemblyS01781
AmplifierS01865
TerminalboardS01846
RelayboardS01847
LoctiteNo.243ContactCrowcon
CalibrationgasContactCrowcon
1718
ued)
nalrelaysaremadeviathe6way
nthebaseofthejunctionbox(see
ed1A@30Vdc.
4.OPERATION
WARNING
Priortocarryingoutanyworkensurelocal
regulationsandsiteproceduresarefollowed.Neverattempttoopenthedetectororjunctionboxwhenflammablegasis
present.Ensurethattheassociatedcontrolpanelisinhibited
soastopreventfalsealarms.
4.1CommissioningProcedure
aOpenthejunctionboxofthedetectorbylooseningthetamperproofgrubscrewandremovingthelidbyrotatingitanticlockwise.
bRemovetheamplifierandcheckthatallelectricalconnectionshave
beenmadeandarecorrectasperDiagram3.
cReplacetheamplifierandclosethejunctionboxensuringthatall
screwshavebeenrefittedcorrectly.
dApplypowertothedetector.ThestatusLEDwillshowasteady
greenindicatingnormaloperation.
eLeavethedetectortostabilisefor12hours.
Zeroingthedetector(ZEROMode):
fPlacetheendofCROMagovertheMENU.GreenStatusLEDwill
flash.DecimalpointaboveZEROwillilluminate.Displaybacklight
willilluminate.DecimalpointaboveINHIBITmayflashiftheoption
hasbeeninternallyselected.
gWithnoflammablegaspresentatthedetector,placetheendofthe
CROMagkeyovertheUPorDOWNarrowpadstomakethe
displayreadzero.
Calibratingthedetector(CALMode):
hPlacetheendoftheCROMagovertheMENUpad.Thedecimal
pointabovethewordCALwillilluminate.Otherindicationsremain
unchanged.
iApplycalibrationgastothedetectorataflowrateof0.5litres/min.
Crowconrecommend50%LELgasforcalibrationpurposes
(contactCrowconforthesupplyofcalibrationgas.)
4.4ChangingAlarmLevels(RelayVersionOnly)
WARNING
ThisworkshouldbecarriedoutbyCrowconoranapprovedservicecentreunlesssuitabletraininghasbeen
received.Beforeattemptingtochangealarmlevelsensure
thedetectorisinfreshairandnoflammablegasispresent.
AsstandardtheAL1andAL2alarmlevelsarefactorysetat20%LEL
and40%LELrespectively.Tochangeeitheralarmlevel:
aSwitchoffandisolatepowertothedetectorrequiringattention.
bOpenthejunctionboxofthedetectorbylooseningthetamperproof
grubscrewandremovingthelidbyrotatingitanticlockwise.
cRemovetheamplifierfromtheterminalboard.
dEnsurethattheINHIBITlinkissettoN.
eRefittheamplifiertotheterminalboardensuringthatallscrewshave
beensecuredcorrectly.
fApplypowertothedetectorandallowthedetectortostabilise.
gPlacetheendofCROMagovertheMENUpad.Thedecimal
pointabovethewordZEROwillilluminate.
hWithnoflammablegaspresentatthedetector,placetheendofthe
CROMagkeyovertheUPorDOWNarrowpadstomakethe
displayreadthedesiredalarmlevel.
iUsingalonginstrumentscrewdriver,turntherelevantALARMSET
potmountedontheterminalboard(seeDiagrams1&2)toadjust
thealarmlevel.TrippingoftheALARM1levelrelayisconfirmedby
thestatusLEDturningasteadyred.TrippingoftheALARM2level
relayisconfirmedbytheStatusLEDflashingred.
jOncethealarmlevelhasbeenset,placeendofCROMagoverthe
UPorDOWNarrowpadsandresetthedisplaytoreadzero.
kPlacetheendoftheCROMagovertheMENUpadtoreturnthe
detectortonormaloperation,ie.Nodecimalpointsdisplayed,
backlightoffandtheStatusLEDindicatingsteadygreen.
lCheckthatthedetectoroperatescorrectlybyapplyingtestgasas
necessary.
mSwitchoffandisolatepowertothedetector.
nResetjumperswhichmayhavebeenchangedinstepdabove.
oReplacetheamplifierandclosethejunctionbox,ensuringthatall
screwshavebeenrefittedcorrectly.
pApplypowertothedetectorandallowtostabilisebeforechecking
correctoperation.
qRecalibrateifnecessaryaspersection4.1.
Notes:
AreaClassifications:-
Zone0:Anareaclassified,asZone0willhaveignitable
concentrationsofflammablegases,vapoursorliquidspresentcontinuouslyorforlongperiodsof
timeundernormaloperatingconditions.
Zone1:Anareaclassified,asZone1islikelytohave
ignitableconcentrationsofflammablegases,
vapoursorliquidspresentundernormaloperating
conditions.
Zone2:Anareaclassified,asZone2isnotlikelytohave
ignitableconcentrationsofflammablegases,
vapoursorliquidspresentundernormaloperating
conditions.
toFlamgardPlusDiagram4:96HDassembly
1516
d)
614)isrequired.LoctiteNo243
assemblythreadstomaintain
kingtimetoensurethatthe3mm
edintoposition.
hejunctionboxensuringthatthe
correctly.
tivescrewsarefastenedsecurely.
acrossTestPointsAandadjust
VMreadscorrectly(seeTable3for
acrossTestPointsBandadjust
reads0mV. ngtofastenthetamperproofgrub
uregivenin4.1.
tAComment
mV)
Poisonresistant
Poisonresistant
Leadresistant
Earlymodel
Lowpower
ForHalogens
Ammoniaoraviationfuel
Earlymodel
dinthisdetectorshouldbe
ectedfromexposuretosilicones,
retothesecompoundswill
hesensor,andrenderthesensor
*1
FlamgardPlusmaybefittedwitharangeofpellistorsensorsdependingon
thespecificapplication.Thecorrectsparesensorpartnumberisitemised
onthesensorhousinglabel.
5.SPECIFICATION
Dimensions200x115x115mm(8x41/2x4
1/2)
Weight2.2kg(4.8lbs)
Material96HDsensorhousing:316Stainlesssteel
Junctionbox:Marinegradealloy
Temperaturerange1055oc(14131
oF)
Humidityrange099%RH,noncondensing
IngressprotectionIP65
ExplosionprotectionFlameproof
ApprovalcodesII2GExdIICT6Gb(+55oc)
ULClass1,Zones1&2,AExdIICT6
SafetyCertNo.Sira03ATEX1124
StandardsEN600790,EN600791:2007,UL2279
ZonesCertifiedforuseinZone1orZone2
areas.(seeareaclassificationssection)
GasgroupsIIA,IIB,IIC
Operatingvoltage1230Vdc
OperatingcurrentRelayversion:210mA(maximum)
Nonrelayversion:160mA(maximum)
Detectoroutput420mAsourceorsinkselectable
0mA=Fault
2mA=Inhibit(4mAoption)
420mA=0100%LEL
24mA=Overrange
Relaysoutputs2xAlarmrelaysSPNO(SPNCoption)
1xFaultrelaySPNC(SPNOoption)
Contactrating1A@30Vdc
(PartNoMO4128)
NEOPRENEGASKET1
GASKET
2
TOPCAP&SENSORPCB
MAINBODY
SINTER
(PartNoSO1781)SINTERASSEMBLY
(PartNoMO4452)
SLEEVE
PELLISTOR
ALLENHEADSCREWS
4OFFM4X12MM
4-20mA
12-30V
0V
FLAMGARD-PLUS
SINK
2
+V
3
1
0V
CONTROLEQUIPMENTSAFEAREA
sensorsattestpointA
