Q5/Q5 IR-Probe GAS TRANSMITTER/SENSOR Q5 IR-Probe INSTALLATION OPERATION AND MAINTENANCE MANUAL AUTOMATION COMPONENTS, INC. 2305 PLEASANT VIEW ROAD | MIDDLETON, WI 53562 PHONE: (888) 967-5224 FAX: (608) 831-7407 Web: workaci.com Q5 Operation And Maintenance Manual 85950-001-000 RF August 7, 2015 1 READ BEFORE OPERATING ................................................................................................................... 2 1. SPECIFICATIONS .............................................................................................................................. 2 1.1 E LECTRICAL /M ECHANICAL S PECIFICATIONS ........................................................................................... 2 1.2 S ENSOR S PECIFICATIONS ......................................................................................................................... 4 2. INSTALLATION ................................................................................................................................. 6 2.1 E NCLOSURES P HYSICAL D IMENSIONS ..................................................................................................... 6 2.2 T ERMINALS ............................................................................................................................................. 6 2.2.1 Wire and Cable ............................................................................................................................. 7 2.2.2 Q5 Digital Connection ................................................................................................................. 7 2.2.3 RS-485 Terminator ....................................................................................................................... 7 2.2.4 RS-485 Driver Replacement ......................................................................................................... 8 2.2.5 4-20mA and 1-5VDC / 2-10VDC Analog Output ......................................................................... 8 2.2.6 Relays Output ............................................................................................................................... 9 2.2.7 Note for Q5:.................................................................................................................................. 9 2.2.8 Certification: ................................................................................................................................ 9 3. FUNCTION AND CONFIGURATION ........................................................................................... 10 3.1 I NDICATORS .......................................................................................................................................... 10 3.1.1 RS485-TX/RX ........................................................................................................................... 10 3.1.2 Relay 1-3 LED .......................................................................................................................... 10 3.2 T OOL F UNCTION ................................................................................................................................... 11 3.2.1 Enter Main Menu ........................................................................................................................ 11 3.2.2 Hush Buzzer and Relay ............................................................................................................... 11 3.2.3 Reset Latched/Hushed ................................................................................................................ 11 3.2.4 Reset MENU Password .............................................................................................................. 11 3.2.5 Exit Tool Mode ........................................................................................................................... 11 3.3 M AIN M ENU T REE ................................................................................................................................ 12 3.4 M ENU “1_SYSTEM SETUP” .............................................................................................................. 13 3.4.1 System Settings ........................................................................................................................... 13 3.5 M ENU “2_ZERO CAL” ........................................................................................................................ 16 3.5.1 Equipment Required ................................................................................................................... 16 3.5.2 Zeroing Calibration Procedure .................................................................................................. 16 3.6 M ENU “3_SPAN CAL” ........................................................................................................................ 17 3.7 M ENU “4_OUT TEST” ........................................................................................................................ 18 3.8 M ENU “5_VIEW SETTING” ............................................................................................................... 19 3.9 M ENU “6_ALARM SETUP” ................................................................................................................ 20 3.10 M ENU “7_RELAY STYLE” ............................................................................................................ 21 3.11 M ENU “8_BUZZER STYLE” .......................................................................................................... 22 3.12 M ENU “9_A-OUT SETUP” ............................................................................................................. 22 3.13 M ENU “A_ALL DISABLE” ............................................................................................................ 23 3.14 M ENU “B_SIMULATION” ............................................................................................................. 23 3.15 M ENU “C_SITE SERVICE” AND “D_FACTROY SET” ................................................................. 23 4. MODBUS PROTOCOL SUPPORTED BY Q5 ............................................................................... 23 5. MAINTENANCE ............................................................................................................................... 24 5.1 DVM CONNECTION FOR 4-20 M A MEASUREMENT ................................................................................. 24 5.2 4 M A AND 20 M A O UTPUT C ALIBRATION ............................................................................................... 24 5.3 S MART S ENSOR A SSEMBLY R EPLACEMENT .......................................................................................... 25 5.3.1 Disassembling ............................................................................................................................ 25 5.3.2 Replacement Procedure.............................................................................................................. 25 5.3.3 Replacement Parts ...................................................................................................................... 26 5.3.4 Accessories ................................................................................................................................. 28 6. TROUBLESHOOTING .................................................................................................................... 29 Q5 Operation And Maintenance Manual 85950-001-000 RF August 7, 2015 2 READ BEFORE OPERATING All individuals who have or will have the responsibility of using, maintaining, or servicing this product must carefully read this manual. The product will perform as designed only if it is used, maintained, and serviced in accordance with the manufacturer’s instructions. The Q5 is a state-of-the-art transmitter that can operate as an independent, stand-alone system or as part of an integrated system. The Q5 connects with analog and digital signals to virtually any controller, PLC, or DCS. Setup procedures are simplified with user friendly push buttons and LCD menus. The Q5 IR-Probe is a Q5 with a remote sensing probe that uses the technique of NDIR (Non Dispersive Infrared) to monitor the presence of hydrocarbons and carbon dioxide. The distance between the Q5 and the IR-Probe can up to 100 meters. A 5 meter cable is included in the package. 1. Specifications 1.1 Electrical/Mechanical Specifications Input Power: 24VDC nominal, range 18 to 30VDC, 0.3A DC Total Max. 24VAC nominal, range 15 to 24VAC, 0.3A AC Total Max. (AC must not be grounded) Fuse: F2 on Main Board: Polyswitch 750mA Polyswitch device resets after the fault is cleared and power to the circuit is removed. Sensor: Combustible gases: Catalytic or NDIR Toxic gases and Oxygen: Electrochemical Carbon Dioxide: Non-Dispersive Infra-Red (NDIR) Sampling: Diffusion or Pump-through Panel Indicators: 5 Status LED’s • RS-485 TX Status (Green) • RS-485 RX Status (Green) • Relay1 Status (Red) • Relay2 Status (Red) • Relay2 Status (Red) Display: LCD graphic display c/w backlight Keypad: 3 capacitive touch sensing Keys: F1, F2, F3 Q5 Operation And Maintenance Manual 85950-001-000 RF August 7, 2015 3 Relays: 3 Relays SPDT, Dry contacts • 1.0A maximum at 30 VDC (resistive load) • 0.3A maximum at 125VAC (resistive load) Buzzer: 80 db at 10 cm, 2700 Hz Buzzer 1, 2, 3: Programmable tone Tone: chirp once / chirp twice / 50% duty cycle / constant ON Output Signal: RS-485 with ACI Controller Protocol • Available Controller: M-Controller & Q4 Controller RS-485 with ModBus protocol 4-20mA and 2-10VDC Analog Signal Output Enclosure Rating: IP 66 & NEMA 4, 4X, 12 & 13 Operating Temperature: -40 C to 70 C, depends on sensor specification Ambient Humidity: 5% to 95% RH (non-condensing) Storage Temperature: 0 C to 40 C, depends on sensor specification Size: 150mm X 90mm X 65mm Weight: Less than 0.5lbs Q5 Operation And Maintenance Manual 85950-001-000 RF August 7, 2015 4 1.2 Sensor Specifications Code Gas Symbol Gas Density Span Operating Temperature 16 Methane CH4 Lighter 0 - 100%LEL -10C to +50C 17 Propane C3H8 Heavier 0 - 100%LEL -10C to +50C 18 Hydrogen H2 Lighter 0 - 100%LEL -10C to +50C *19 Combustible LEL 0 - 100%LEL -10C to +50C *20 Ethylene C2H4 Slightly Lighter 0 - 100%LEL -10C to +50C *21 Iso-Butane C4H10 Heavier 0 - 100%LEL -10C to +50C *22 Iso-Pentane C5H12 Lighter 0 - 100%LEL -10C to +50C *23 Methanol CH3OH Lighter 0 - 100%LEL -10C to +50C *24 Benzene C6H6 Lighter 0 - 100%LEL -10C to +50C *25 Acetone CH3CO Lighter 0 - 100%LEL -10C to +50C *26 Butanol, n-Butane BUTAN Heavier 0 - 100%LEL -10C to +50C Code Gas Symbol Gas Density Span Operating Temperature 0 Oxygen O2 0 - 25%VOL -30C to +55C Code Gas Symbol Gas Density Span Operating Temperature 1 Carbon Monoxide CO Slightly Lighter 0 – 250ppm -20C to +50C 1 Carbon Monoxide CO Slightly Lighter 0 – 1000ppm -20C to +50C 2 Hydrogen Sulfide H2S Heavier 0 – 25ppm -20C to +50C 2 Hydrogen Sulfide H2S Heavier 0 – 100ppm -20C to +50C 3 Sulphur Dioxide SO2 Heavier 0 – 6ppm -20C to +50C 5 Nitrogen Dioxide NO2 Heavier 0 – 10ppm -20C to +50C 6 Hydrogen H2 Lighter 0 – 1000ppm -20C to +50C 6 Hydrogen H2 Lighter 0 – 2000ppm -20C to +50C 7 Hydrogen Cyanide HCN Lighter 0 – 50ppm -20C to +50C 9 Ammonia NH3 Lighter 0 – 100ppm -30C to +50C 9 Ammonia NH3 Lighter 0 – 1000ppm -30C to +50C 11 Ozone O3 Heavier 0 – 1ppm -20C to +40C 13 Chlorine Cl2 Heavier 0 – 5ppm -20C to +50C 14 Chlorine Dioxide ClO2 Heavier 0 – 2ppm -20C to +40C 96 Arsine AsH3 Heavier 0 – 1ppm -20C to +40C 97 Phosphine PH3 Heavier 0 – 5ppm -20C to +40C Q5 Operation And Maintenance Manual 85950-001-000 RF August 7, 2015 5 97 Phosphine PH3 Heavier 0 – 1ppm -20C to +40C 98 Silane SiH4 Heavier 0 – 50ppm -20C to +40C 99 Germane GeH4 Heavier 0 – 2ppm -20C to +40C 100 Diborane B2H6 Slightly Lighter 0 – 2ppm -20C to +40C 4 Nitric Oxide NO Slighter Heavier 0 –100ppm -20C to +50C 8 Hydrogen Chloride HCl Heavier 0 – 30ppm -20C to +40C 12 Ethylene Oxide ETO Heavier 0 – 20ppm -20C to +50C 101 Hydrogen Bromide HBr Heavier 0 – 30ppm -20C to +40C Code Gas Symbol Gas Density Span Operating Temperature 15 Carbon Dioxide IR-CO2 Heavier 0 – 5000ppm -20C to +50C 15 Carbon Dioxide IR-CO2 Heavier 0 – 5%VOL -20C to +50C 15 Carbon Dioxide IR-CO2 Heavier 0 – 20%VOL -20C to +50C 15 Carbon Dioxide IR-CO2 Heavier 0 – 100%VOL -20C to +50C 16 Methane IR-CH4 Lighter 0 – 100%LEL -20C to +50C 16 Methane IR-CH4 Lighter 0 – 100%VOL -20C to +50C *NOTE: Mounting Heights - Low = 9-18 inches (0.25-0.5 meters) from floor - Mid = 4-6 feet (1.25-1.75 meters) from floor - High = 9-18 inches (0.25-0.5 meters) from ceiling Q5 Operation And Maintenance Manual 85950-001-000 RF August 7, 2015 6 2. Installation 2.1 Enclosures Physical Dimensions The enclosure is a NEMA 4 rated enclosure and can be wall mounted with 4 screws. To maintain the NEMA rating, it is important that the conduit opening is sealed upon installation. 2.2 Terminals Q5 Terminals Q5 Operation And Maintenance Manual 85950-001-000 RF August 7, 2015 7 2.2.1 Wire and Cable Terminal blocks TB1 to TB7 accept 12 AWG to 24 AWG wire. Use 16 AWG or 18 AWG wire for the power supply in long wiring runs, which can be up to 1km (1,000 meters) long. We recommend using BELDEN 9841 for communications. This wire has 120 ohm input impendence, which will eliminate RS-485 communication problems. 2.2.2 Q5 Digital Connection 2.2.3 RS-485 Terminator The terminator on each end of the RS485 run is designed to match the electrical impedance characteristic of the twisted pair wire, and will prevent signal echoes from corrupting the data on the line. The terminator should be enabled on BOTH ends of the RS485 run. Short and medium length ModBus/485 runs can operate without the terminating resistor. Longer runs Q5 Operation And Maintenance Manual 85950-001-000 RF August 7, 2015 8 may require the terminating resistors. But adding terminator dramatically increases power consumption. Factory default setting is disabled terminator. The Q5 supplies this resistor on the main board, and it is chosen using a jumper at J4. • J4 1-2: Terminator Disabled / OFF (default) • J4 2-3: Terminator Enabled / ON 2.2.4 RS-485 Driver Replacement RS-485 lines in heavy industrial environments are sometimes subjected to magnetic disturbances causing sufficient inducted power surges to damage the driver integrated circuit (IC). This IC (U6) has a socket on the circuit card for ease of replacement in the field. 2.2.5 4-20mA and 1-5VDC / 2-10VDC Analog Output The Q5 provides one-channel 4-20 milliamp analog outputs and programmable 1-5VDC / 2- 10VDC analog output at the same time. The maximum output impedance is 600 ohms for the 4-20mA output. The maximum output current is 10 mA for the 1-5VDC/2-10VDC output. Test point SIG+ and SIG- are used to measure the current inline when the Q5 is working in the field. The 1-5VDC/2-10VDC output can be selected through the menu. Default setting is 1-5VDC output. The analog output may be defined in complex ways allowing assignment of different values to both 4 milliamps and 20 milliamps. You may even assign a gas concentration to 4 mA, which is higher than the concentration assigned to 20 milliamps. The Q5 will draw a straight line between them. There is no need to assign gas concentration to 1V-5VDC/2V-10VDC. When Next >