QIRF REFRIGERANT GAS TRANSMITTER/SENSOR INSTALLATION OPERATION AND MAINTENANCE MANUAL QUATROSENSE ENVIRONMENTAL LTD. 5935 OTTAWA STREET, PO BOX 749 RICHMOND, ONTARIO CANADA K0A 2Z0 PHONE: (613) 838-4005 FAX: (613) 838-4018 Web: www.QELsafety.com Email: QEL@QELsafety.com QIRF Operation And Maintenance Manual QIRF Operation Manual May. 01, 2012 85050-301-000 Rev C 1 Table Of Contents READ BEFORE OPERATING...................................................................................................................3 1. GENERAL INFORMATION.............................................................................................................3 1.1 P RINCIPLE OF O PERATION ..................................................................................................................3 1.2 K EY F EATURES ..................................................................................................................................4 1.3 A PPLICATIONS ....................................................................................................................................4 1.4 S PECIFICATIONS .................................................................................................................................5 2. INSTALLATION.................................................................................................................................7 2.1 S ENSOR L OCATION .............................................................................................................................7 2.2 P HYSICAL D IMENSIONS ......................................................................................................................7 2.3 G AS S AMPLING ..................................................................................................................................8 2.4 M OUNTING AND S YSTEM W IRING ......................................................................................................8 2.4.1 Terminals......................................................................................................................................9 2.4.2 Power Supply................................................................................................................................9 2.4.3 Wire and Cable...........................................................................................................................10 2.4.4 Digital Connection.....................................................................................................................10 2.4.5 RS-485 Terminator.....................................................................................................................10 2.4.6 RS-485 Driver Replacement.......................................................................................................11 2.4.7 4-20mA or 2-10VDC Analog Output..........................................................................................11 2.4.8 Relays Output.............................................................................................................................12 3. FUNCTION AND CONFIGURATION...........................................................................................13 3.1 QIRF W ORKING M ODE ....................................................................................................................13 3.2 S YSTEM I NITIALIZATION ...................................................................................................................13 3.3 K EYPAD ...........................................................................................................................................13 3.4 S TATUS LED....................................................................................................................................15 3.4.1 RS485-TX/RX:..........................................................................................................................15 3.4.2 Relay1-3 LED:..........................................................................................................................15 3.5 L ATCHED R ELAY R ESET ...................................................................................................................15 3.6 H USH B UZZER AND H ORN ................................................................................................................15 3.7 QIRF M AIN M ENU T REE .................................................................................................................15 3.8 M ENU “1_S YSTEM S ETTING ”...........................................................................................................17 3.8.1 System Settings...........................................................................................................................18 3.9 M ENU “2_Z EROING C ALIBRATION ”..................................................................................................20 3.9.1 Equipment Required...................................................................................................................20 3.9.2 Zeroing Calibration Procedure..................................................................................................20 3.10 M ENU “3_S PAN C ALIBRATION ”.......................................................................................................22 3.10.1 Span Calibration Procedure..................................................................................................22 3.11 M ENU “4_O UTPUT T ESTING ”...........................................................................................................23 3.12 M ENU “5_S ITE S ERVICE ".................................................................................................................23 3.13 M ENU “6_R ELAY D ATABASE ”.........................................................................................................24 3.13.1 Relay Configurations.............................................................................................................24 3.13.2 Relay Database Flow Chart..................................................................................................26 3.14 M ENU “7_A-O UT D ATABASE ”.........................................................................................................27 3.15 M ENU “8_B UZZER D ATABASE ”.......................................................................................................28 3.16 M ENU “9_O UTPUT D ISABLE ”...........................................................................................................28 3.17 M ENU “10_S IMU D ISABLE ”.............................................................................................................28 4. MODBUS PROTOCOL SUPPORTED BY QIRF..........................................................................28 5. MAINTENANCE...............................................................................................................................29 QIRF Operation And Maintenance Manual QIRF Operation Manual May. 01, 2012 85050-301-000 Rev C 2 5.1 DVM C ONNECTION FOR 4-20 M A MEASUREMENT ...........................................................................29 5.2 4 M A AND 20 M A O UTPUT C ALIBRATION ..........................................................................................29 6. TROUBLESHOOTING....................................................................................................................30 QIRF Operation And Maintenance Manual QIRF Operation Manual May. 01, 2012 85050-301-000 Rev C 3 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. 1. General Information 1.1 Principle of Operation The QIRF Smart Sensor is a microprocessor controlled Refrigerant gas Sensor or Transmitter using infrared sensing technology. The concentration of Refrigerant is measured by determining the amount of absorption of light in a specific frequency band. As most gases have their characteristic spectra in the infrared. Those spectra derive from the molecule's composition in such a way that no two molecular gases have the same IR spectrum. IR spectra are the fingerprints of gases, and thus allow gases to be uniquely identified. By transmitting a beam of IR radiation through the air, or through any particular gas volume, and recording how much is transmitted at selected spectral lines, one may decide which gases are present and how much of each. This is a standard and well-proven principle, routinely used in laboratory analyses of chemical species, and is also the basis on which our sensors are made. An IR detector is essentially a temperature sensor and is, therefore, potentially very sensitive to changes in the ambient temperature. However, our QIRF smart sensor modules do it better, faster, and more precisely. The QIRF smart sensors are entirely electronic with no moving parts, and are built around our unique QT Gas Sample Cell with constant temperature control integrated with IR Source and IR Detector together. This makes our IR smart sensors work from -45 ° C to 65 ° C without being susceptible to ambient temperature fluctuations. QIRF Operation And Maintenance Manual QIRF Operation Manual May. 01, 2012 85050-301-000 Rev C 4 Comparing with conventional gas detector, gases to be detected are often corrosive and reactive. With most sensor types, the sensor itself is directly exposed to the gas, often causing the sensor to drift or die prematurely. The main advantage of IR sensor or transmitter is that the detector does not directly interact with the gas (or gases) to be detected. In the QIRF Smart Sensor, the major functional components are protected with optical parts. In other words, gas molecules interact only with a light beam. The IR Source and IR Detector can be treated, making them resistant to corrosion, and are designed such that they are easily removable for maintenance or replacement. 1.2 Key Features • Infrared Sensing Technology • Constant Temperature QT Gas Sampling Cell • Standard RS-485 Output with OptoMux protocol and ModBus protocol • Standard 4-20mA or 2-10VDC Analog Output • Diffusion Sampling module or Pump-thru module • No moving parts in diffusion or pump-thru model • Water and corrosion resistant PVC enclosure NEMA 4, 4X • Addressable from 0 to 31 • 4 magnetic sensors as keypad input • 3 programmable Relays and 3 programmable Buzzers • 2 x 8 character LCD display c/w backlight • Operation at 18-30VDC or 15–24VAC • 3 Relay Status LED, TX Status LED and RX Status LED • CSA/UL approval (pending) 1.3 Applications The QIRF is designed to monitor for the loss of refrigerant gas in a variety of applications: • Mechanical equipment rooms • Propellant filling operations • Solvent cleaning stations • Cold storage and transport facilities • Meat packing plants • Supermarkets and refrigerant storage locations • Other specialty applications using halocarbons QIRF Operation And Maintenance Manual QIRF Operation Manual May. 01, 2012 85050-301-000 Rev C 5 1.4 Specifications Input Power: 24VDC nominal, range 18 to 30VDC, 1.0A DC Total Max. 24VAC nominal, range 15 to 24VAC, 1.0A AC Total Max. Fuse: F1 on Display Board: Polyswitch 1.6A F2 on Display Board: Polyswitch 50mA Polyswitch device resets after the fault is cleared and power to the circuit is removed Sensor: Infrared Refrigerant Gas Detected: User selectable: R11, R12, R22, R114, R123, R134A, R402A, R404A, R407C, R408A, R409A, R410A, R422A, R438A, R507A Available on special order: R13, R14, R21, R23, R31, R32, R41, R113, R115, R116, R125, R143a, R152, R161 … Range: 0 to 100ppm for R123; 0 to 1000ppm for others Accuracy: ± 3% of reading Repeatability: ± 1% of full scale 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: 2 x 8 character display c/w backlight Keypad: 4 magnetic sensors with Magnet tool 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: Double-tap Intermittent Buzzer 2: Intermittent 50% duty cycle Buzzer 3: Continuous QIRF Operation And Maintenance Manual QIRF Operation Manual May. 01, 2012 85050-301-000 Rev C 6 Output Signal: RS-485 with OptoMux protocol • Available Controller: M-Controller Q4 Controller RS-485 with ModBus protocol 4-20mA or 2-10VDC Analog Signal Enclosure Rating: IP 66 & NEMA 4, 4X, 12 & 13 Cover Screws should be torqued to 2.5lbs-in (30cN-m) Operating Temperature: -45 ° C to 65 ° C Ambient Humidity: 5% to 95% RH (non-condensing) Storage Temperature: -45 ° C to 70 ° C Size: 200mm X 120mm X 90mm Weight: Less than 1.5lbs (0.680 kg) QIRF Operation And Maintenance Manual QIRF Operation Manual May. 01, 2012 85050-301-000 Rev C 7 2. Installation 2.1 Sensor Location Several factors should be considered when selecting locations to install sensors. The following general suggestions should be considered to assure the detection of the target gas. Select the most suitable location for each sensor. 1. Air Currents: If there are fans, winds, or others sources of air movement, gases may tend to rise or collect in certain areas of a facility. The local air currents should be assessed to aid in selecting the sensor location. In outdoor situations considerations such as prevailing winds should be accounted for. Air convection can often be more important in determining gas concentrated areas than factors of Vapor Density. 2. Vapor Density: R11, R22, R123 and R134A are heavier than air. Detecting location should be 9 - 18 inch (0.23m to 0.46m) above the floor. 3. Gas Emission Sources: As a rule, at least one sensor should be located in close proximity to each point where a leak is likely to occur. This is particularly important when a liquid having a low volatility is monitored. 4. Environmental Factors: Designed to rugged outdoor use consider the following in selecting locations. Install sensors where they will be protected from wind, dust, snow, water, vibration and shock. 2.2 Physical Dimensions QIRF Operation And Maintenance Manual QIRF Operation Manual May. 01, 2012 85050-301-000 Rev C 8 2.3 Gas Sampling In Diffusion version QIRF, the gas sampling system is composed of a diffusion type gas sample chamber and two vent holes on the enclosure bottom. The gas flows in and out through the two vent plugs on the bottom of the QIRF enclosure. See above picture. In Pump-thru version QIRF, the sampling gas is pumped through the fitting on the bottom of the QIRF enclosure, and passed through the gas chamber, then exhausted out though the fitting on the right side of the enclosure. Pump-thru version QIRF doesn’t have pump inside. For gas sampling and conditioning unit, QEL provides SCS-1 (One channel sampling and conditioning system). 2.4 Mounting and System Wiring NOTE: The Diffusion version QIRF should be mounted 1 foot (30cm) from the floor. Next >