MODEL: Q8 SERIES NON-INTRUSIVE CALIBRATION GAS TRANSMITTER/SENSOR 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 Q8 Operation And Maintenance Manual 86350-001-000 RB Oct. 03, 2017 1 READ BEFORE OPERATING ................................................................................................................... 2 1. SPECIFICATIONS ............................................................................................................................. 2 1.1 E LECTRICAL /M ECHANICAL S PECIFICATIONS .......................................................................................... 2 1.2 S ENSOR S PECIFICATIONS ........................................................................................................................ 3 2. INSTALLATION ................................................................................................................................ 6 2.1 E NCLOSURES P HYSICAL D IMENSIONS .................................................................................................... 7 2.2 M OUNTING THE TRANSMITTER ............................................................................................................... 7 2.3 R EMOTE M OUNTING THE S MART S ENSOR H EAD A SSEMBLY .................................................................. 8 2.4 T ERMINALS ............................................................................................................................................ 8 2.4.1 Wire and Cable ............................................................................................................................ 8 2.4.2 Digital Connection ...................................................................................................................... 9 2.4.3 Remote Smart Sensor Connection.............................................................................................. 10 2.4.4 RS-485 Terminator and Driver Replacement ............................................................................ 10 2.4.5 4-20mA and 1-5VDC / 2-10VDC Analog Output ...................................................................... 10 2.4.6 Relays Output ............................................................................................................................ 11 2.5 N OTE FOR Q8: ...................................................................................................................................... 11 3. FUNCTION AND CONFIGURATION .......................................................................................... 12 3.1 I NDICATORS ......................................................................................................................................... 12 3.2 T OOL F UNCTION ................................................................................................................................... 13 3.2.1 Enter Main Menu ....................................................................................................................... 13 3.2.2 Hush Buzzer and Relay .............................................................................................................. 13 3.2.3 Reset Latched/Hushed ............................................................................................................... 13 3.2.4 Reset MENU Password .............................................................................................................. 13 3.2.5 Exit Tool Mode .......................................................................................................................... 13 3.3 M AIN M ENU T REE ............................................................................................................................... 14 3.4 M ENU “1_SYSTEM SETUP” .............................................................................................................. 15 3.4.1 System Settings .......................................................................................................................... 15 3.5 M ENU “2_ZERO CAL” ....................................................................................................................... 18 3.5.1 Equipment Required .................................................................................................................. 18 3.5.2 Zeroing Calibration Procedure ................................................................................................. 18 3.6 M ENU “3_SPAN CAL”........................................................................................................................ 19 3.7 M ENU “4_OUT TEST” ........................................................................................................................ 20 3.8 M ENU “5_VIEW SETTING” .............................................................................................................. 21 3.9 M ENU “6_ALARM SETUP” ............................................................................................................... 22 3.10 M ENU “7_RELAY STYLE” ........................................................................................................... 23 3.11 M ENU “8_BUZZER STYLE” ......................................................................................................... 24 3.12 M ENU “9_A-OUT SETUP” ............................................................................................................ 24 3.13 M ENU “A_ALL DISABLE” ............................................................................................................ 24 3.14 M ENU “B_SIMULATION” ............................................................................................................ 25 3.15 M ENU “C_SITE SERVICE” AND “D_FACTROY SET” ................................................................ 25 4. MODBUS PROTOCOL SUPPORTED BY Q8 .............................................................................. 25 5. MAINTENANCE .............................................................................................................................. 26 5.1 DVM CONNECTION FOR 4-20 M A MEASUREMENT ................................................................................ 26 5.2 4 M A AND 20 M A O UTPUT C ALIBRATION ............................................................................................... 26 5.3 S MART S ENSOR A SSEMBLY R EPLACEMENT ......................................................................................... 27 5.3.1 Disassembling ............................................................................................................................ 27 5.3.2 Replacement Procedure ............................................................................................................. 27 5.3.3 Replacement Parts ..................................................................................................................... 29 6. TROUBLESHOOTING .................................................................................................................... 32 Q8 Operation And Maintenance Manual 86350-001-000 RB Oct. 03, 2017 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 Q8 is a state-of-the-art transmitter that can operate as an independent, stand-alone system or as part of an integrated system. The Q8 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. 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) 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 magnetic switches: F1, F2, F3 Relays: 3 Relays SPDT, Dry contacts • 1.0A maximum at 30 VDC (resistive load) • 0.3A maximum at 125VAC (resistive load) Q8 Operation And Maintenance Manual 86350-001-000 RB Oct. 03, 2017 3 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: Aluminium Pressure Die–Casting Entries: 2X ¾ NPT 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: 145mm X 190mm X 130mm Weight: Less than 1.8kg 1.2 Sensor Specifications Q8 O2 Top Assembly Code Gas Symbol Span O2 Sensor SKU# 86330-002-000 0 Oxygen O2 0-25%VOL 6300-0037 Q8 IR Top Assembly Code Gas Symbol Span NDIR Sensor SKU# 86330-004-001 15 Carbon Dioxide CO2 0 – 5000ppm 6300-0059 86330-004-002 215 Carbon Dioxide CO2 0 – 2%VOL 6300-0056 86330-004-003 315 Carbon Dioxide CO2 0 – 5%VOL 6300-0058 86330-004-004 415 Carbon Dioxide CO2 0 – 20%VOL 6300-0057 86330-004-005 216 Methane CH4 0-100%LEL 6300-0061 86330-004-006 316 Propane C3H8 0-100%LEL 6300-0062 Q8 Operation And Maintenance Manual 86350-001-000 RB Oct. 03, 2017 4 Q8 LEL Top Assembly Code Gas Symbol Span LEL Smart Sensor Assembly 86330-003-301 301 Methane CH4 0-100%LEL 86330-013-301 86330-003-302 302 Acetic Acid C2H4O 0-100%LEL 86330-013-302 86330-003-303 303 Acetone C3H6O 0-100%LEL 86330-013-303 86330-003-304 304 Ammonia NH3 0-100%LEL 86330-013-304 86330-003-305 305 Benzene C6H6 0-100%LEL 86330-013-305 86330-003-306 306 Butyl Acetate C6H12 0-100%LEL 86330-013-306 86330-003-307 307 Cyclo-hexane C6H10 0-100%LEL 86330-013-307 86330-003-308 308 Cyclo-pentane C5H10 0-100%LEL 86330-013-308 86330-003-309 309 Decane C10H2 0-100%LEL 86330-013-309 86330-003-310 310 Dioxane C4H8O 0-100%LEL 86330-013-310 86330-003-311 311 Ethane C2H6 0-100%LEL 86330-013-311 86330-003-312 312 Ethanol C2H6O 0-100%LEL 86330-013-312 86330-003-313 313 Ethyl Acetate C4H8O 0-100%LEL 86330-013-313 86330-003-314 314 Ethylene C2H4 0-100%LEL 86330-013-314 86330-003-315 315 Hydrogen H2 0-100%LEL 86330-013-315 86330-003-316 316 Iso-Butyl Methyl Ketone (Iso-BMK) C6H12 0-100%LEL 86330-013-316 86330-003-317 317 Iso-Butane C4H10 0-100%LEL 86330-013-317 86330-003-318 318 Iso-Butyl Alcohol C4H10 0-100%LEL 86330-013-318 86330-003-319 319 Iso-Octane C8H18 0-100%LEL 86330-013-319 86330-003-320 320 Iso-Pentane C5H12 0-100%LEL 86330-013-320 86330-003-321 321 Iso-Propyl Alcahol (IPA) C3H8O 0-100%LEL 86330-013-321 86330-003-322 322 Methanol CH4O 0-100%LEL 86330-013-322 86330-003-323 323 Methyl Ethyl Ketone (MEK) C4H8O 0-100%LEL 86330-013-323 86330-003-324 324 n-Butane C4H10 0-100%LEL 86330-013-324 86330-003-325 325 n-Heptane C7H16 0-100%LEL 86330-013-325 86330-003-326 326 n-Hexane C6H14 0-100%LEL 86330-013-326 86330-003-327 327 Nonane C9H20 0-100%LEL 86330-013-327 86330-003-328 328 n-Pentane C5H12 0-100%LEL 86330-013-328 86330-003-329 329 n-Propanol C3H8O 0-100%LEL 86330-013-329 86330-003-330 330 n-Propyl Alcahol C3H8 0-100%LEL 86330-013-330 86330-003-331 331 Propane C3H8 0-100%LEL 86330-013-331 86330-003-332 332 Propylene C3H6 0-100%LEL 86330-013-332 86330-003-333 333 Styrene Monomer C8H8 0-100%LEL 86330-013-333 86330-003-334 334 Toluene C7H8 0-100%LEL 86330-013-334 86330-003-999 999 Other LEL 0-100%LEL 86330-013-999 Q8 Operation And Maintenance Manual 86350-001-000 RB Oct. 03, 2017 5 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 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 *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 Q8 Operation And Maintenance Manual 86350-001-000 RB Oct. 03, 2017 6 2. Installation Warnings: Q8 is designed for installation and use in Zone 1 or 2 hazardous areas in many countries including Europe and for Class 1 Division 1 or 2 area applications in North America. Installation must be in accordance with the recognized standards of the appropriate authority in the country concerned. Access to the interior of the detector, when carrying out any work, must only be conducted by trained personnel. Before carrying out any work ensure local regulations and site procedures are followed. Appropriate standards must be followed to maintain the overall certification of the detector. For installations where conduit is used, and the sensor is mounted directly to the Q8, there must be a “Seal Fitting” installed for each of the cable gland entries within 18 inches of the Q8. For installations where the smart sensor head assembly will be mounted remotely from Q8, an additional “Seal Fittings” will be required: One at each of the conduit entries for the power/signal/relay contact outputs and one at the sensor wiring entrance. The total distance of the location of these Seal Fittings is 18 inches. (e.g. If all 3 gland entries are to be used, 3 Seal Fittings should be located, each within 6 inches of the wiring entrance). If using an anti-seize compound, the threads should be thinly coated with an approved silicone free compound e.g. petroleum jelly. To reduce the risk of ignition of hazardous atmosphere, de-classify the area or disconnect the equipment from the supply circuit before opening the detector enclosure. Keep assembly tightly closed during operation. Never attempt to open a junction box/enclosure or replace/refit the sensor in potentially hazardous atmospheres while power is still applied to the transmitter. The detector must be earthed/grounded for electrical safety and to limit the effects of radio frequency interference. Earth/ground points are provided inside and outside the unit. Ensure that all screens/instrument earth/clean earth wiring is earthed/grounded at a single point (either at the controller or detector - BUT NOT BOTH) to prevent false alarms due to earth/ground loops. Take care when handling sensors as they may contain corrosive solutions. This equipment is designed and constructed as to prevent ignition sources arising, even in the event of frequent disturbances or equipment operating faults. The sensor head must be fitted with the supplied weather protection, and mounted so that the sinter is pointing downward to provide ingress protection IPX6. Q8 Operation And Maintenance Manual 86350-001-000 RB Oct. 03, 2017 7 2.1 Enclosures Physical Dimensions 2.2 Mounting the transmitter The Q8 transmitter has an integral mounting plate consisting of two mounting holes on the transmitter body. The transmitter may be fixed directly to a surface mounting. The Q8 Sensor/Transmitter should be mounted where the gas to be measured is most likely to be present. This location will be dependent on the source of the target gas and whether that gas is lighter or heavier than air. Air circulation and mixture should also be taken into account. 3/4"NPT cable/conduit entries on UL/CSA versions. Where possible, the sensor/transmitter should be mounted where it is accessible for the purposes of routine re-calibration and periodic sensor replacement. Sufficient room should be left to allow the enclosure cover to be removed and the connection of the calibration adapter to the sensor assembly. For sensor element replacement there will need to be enough room to reach into the sensor assembly. NOTE: Avoid mounting the electronics near 600 VAC switchgear and other sources of radio frequency and/or electromagnetic interference. While RFI/EMI protection is built in to the electronics, excessive levels of interference may cause instability in the output signal. Warning: GROUNDING - The industrial explosion-proof metal enclosure must be connected to a safety ground, either locally or back at the monitor, in order to provide immunity to Electromagnetic Interference. Q8 Operation And Maintenance Manual 86350-001-000 RB Oct. 03, 2017 8 2.3 Remote Mounting the Smart Sensor Head Assembly The Smart Sensor Head can be equipped with Q8 locally or remotely. For installations where the smart sensor head assembly will be mounted remotely from Q8, the max distance between Q8 and Remote Smart Sensor Head is 100 meters. The Remote Smart Sensor Head Assembly is not included in the Q8 standard package, it must be ordered separately. NOTE: • Conduit or Approved Hazardous Location Cable connecting the remote sensor and Transmitter must have Sealing Fittings at both ends within total distance 18"(350mm). • Hazardous Location Cable and Sealing Fittings must be approved for Class 1. Div 1 Group B,C,D Hazardous Locations. 2.4 Terminals 2.4.1 Wire and Cable Terminal blocks TB1 to TB8 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. Next >