OPERATING INSTRUCTION MANUAL FOR SMART GAS DETECTOR GD-V77D

Transcript

OPERATING INSTRUCTION MANUAL FOR SMART GAS DETECTOR GD-V77D Page 1 PT2E-0791 FOR USERS Safety precautions OPERATING INSTRUCTION MANUAL FOR SMART GAS DETECTOR GD-V77D 1. Read and understand the instructions in this manual before operating this instrument. 2. Keep manual accessible at all times. 3. This detector cannot be used for any other purpose than what is specified in this manual. 4. Follow all the instructions in this manual, any deviation will compromise the safety, quality and performance of this instrument. 5. We accept no responsibility for an accident caused by the user not following the instructions in this manual. I'"'1/@?9-D!D/8=D D- ' 9/ / " ' " / D D / / / ' ' 11' D / / ' ' ' / 888/ ' D / / = = < = =< / Page 2 PT2E-0791 1 INDEX １．PRODUCT OUTLINE １－１． Preface ……………………………………………………………………… 3 １－２． Application for use ………………………………………………………… 3 １－３． Identification of each signal word ………………………………………… 3 ２．IMPORTANT INSTRUCTION FOR THE SAFETY ２－１． Danｇer items………………………………………………………………… 4 ２－２． Warning items………………………………………………………………… 4 ２－３． Caution items………………………………………………………………… 5 ３．PRODUCT FUNCTION ３－１． External drawing……………………………………………………………… 6 ３－２． Product composition ３－２－１ Major components…………………………………………………… 7 ３－２－２ Unit detaching ……………………………………………………… 8 ３－３． Installation pitch. …………………………………………………………… 9 ３－４． Name of each part and functions ３－４－１ Front view …………………………………………………………… 10 ３－４－２ Inside view …………………………………………………………… 11 ３－５． Block diagram ３－５－１ Electric diagram……………………………………………………… 12 ３－５－２ Tubing diagram……………………………………………………… 12 ４．HOW TO USE ４－１． Before operation……………………………………………………………… 13 ４－２． Installation place …………………………………………………………… 13 ４－３． Caution in the system engineering ………………………………………… 14 ４－４． Grounding …………………………………………………………………… 17 ４－５． Caution at wiring construction …………………………………………… 17 ４－６． Applicable cable ４－６－１ Power/signal cable ………………………………………………… 18 ４－６－２ Relay output signal cable …………………………………………… 18 ４－６－３ Specifications of terminal…………………………………………… 18 ４－６－４ Terminal plate ……………………………………………………… 19 ４－７． Example of cable connection ４－７－１ Connection with indicator/alarm unit(GH-573A, GH-583)………… 19 ４－７－２ Connection with indicator unit, DCS,PLC ………………………… 19 ４－８． Cautions at piping construction …………………………………………… 20 ５．OPERATION METHOD ５－１． Preparation before start up ……………………………………………… 21 ５－２． Basic performance flow……………………………………………………… 21 ５－３． Start up method ５－３－１． Power on …………………………………………………………… 22 ５－３－２． Flowmonitor(Sensor flow) adjustment …………………………… 23 ５－４． Explanation of performance (Detection mode) ５－４－１． Display action. . …………………………………………………… 24 ５－４－２． External output action …………………………………………… 26 Page 3 PT2E-0791 2 ５－５． Maintenance and adjustment ５－５－１． Maintenance mode………………………………………………… 27 ５－５－２． Confirmation of alarm level………………………………………… 28 ５－５－３． Alarm test…………………………………………………………… 29 ５－６． How to finish operation……………………………………………………… 30 ６．KINDS OF ALARM AND ITS FUNCTION ６－１． Kinds of alarm …………………………………………………………… 31 ６－２． Gas alarm ６－２－１． Gas alarm action. ………………………………………………… 31 ６－２－２． Counteraction at gas alarm ……………………………………… 32 ６－２－３． Gas alarm possibility except the case of gas detection………… 32 ７．MAINTENANCE CHECK ７－１． Frequency of maintenance and check items ７－１－１． Daily check………………………………………………………… 33 ７－１－２． Regular maintenance check ……………………………………… 33 ７－１－３． Maintenance contract for regular check ………………………… 33 ７－２． Calibration method (Zero adjustment, calibration with gas, etc.)…………… 34 ７－３． Replacement of sensor and parts …………………………………………… 34 ７－４． Treatment when operation is stopped or its installation place is moved. ７－４－１． Stopping the normal operation…………………………………… 34 ７－４－２． Installation when move its place ………………………………… 34 ７－５． Storage or treatment when not in use for a long time …………………… 35 ７－６． List of recommendable spare parts for regular maintenance……………… 36 ８．TREATMENT AT ABNORMAL CASE ８－１． Trouble alarm………………………………………………………………… 37 ８－２． Counteraction at trouble alarm……………………………………………… 37 ８－３． Before it is thought to be a trouble………………………………………… 37 ８－４． Trouble shooting……………………………………………………………… 38 ９．DEFINITION OF TERMS ………………………………………………… 40 １０．DETECTION PRINCIPLE ……………………………………………… 41 １１．LIST OF PRODUCT SPECIFICATIONS １１－１． Specifications …………………………………………………………… 42 １１－２． Product composition …………………………………………………… 43 １2．WARRANTY ……………………………………………………………… 44 Page 4 PT2E-0791 3 １．PRODUCT OUTLINE １－１．Preface First of all, we wish to express our heartfelt thanks for your purchase of our smart gas detector GD-V77D. This manual is just a guide book to operate our gas detector GD-V77D. Your kind reading of this manual is requested not only for the first user but for already experienced staff. １－２．Application for use This is a fixed type gas detector to be used in semiconductor manufacturing factories, etc. Combustible・toxic gases leaked into ambient air are sampled with internal pump and are detected with semiconductor gas sensor. Detection results(Gas concentrations) are displayed with 4-digit LED indicator. The GD-V77D transmits gas concentration signals with 4～20mADC to upper system. This detector provides 2 relay outputs for outer gas alarm. １－３． Identification of each signal word Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury or serious damage to the product. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury or damage on the human body or object. Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or some damage on the human body or objects. This means “ADVICE” at operation. DANGER WARNING CAUTION * NOTE Page 5 PT2E-0791 4 ２－１．Danger items ２－２．Warning items This is not an explosion proof detector. Never to detect high concentration gas beyond their lower explosive limit. 2. IMPORTANT INSTRUCTION FOR THE SAFETY ○ Power source Before turning the power on, check that the supplied voltage is within the specified voltage. Then, turn the power on. . ○ Necessity of grounding Do not cut the wire for protective ground both inside and outside of instrument. Or, do not disconnect the connection of the ground terminals. ○ Defect of protective function Before starting the operation, check if any defect is not found on the protective grounding. If there is any defect on the protective functions such as protective grounding or fuse, do not start the operation. ○ Fuse To protect the instrument from fire, use the specifically rated fuse. When replacing the fuse, turn off the power inside of the panel, and the power source as well. Do not use fuse that is not specified, or do not make a short-circuit inside of the fuse holder. ○ Operation in gas Do not operate the instrument in a atmosphere of combustible gases, explosive gases or steam. It is very dangerous to operate the instrument under such circumstances. ○ External connections After making the protective grounding, start connecting the instrument to detecting object and other external control circuit. ○ Treatment at gas alarming It is very dangerous if the instrument detects the gas exceeded the alarm points. Take any treatment based on your judgment at that time. WARNING DANGER Page 6 PT2E-0791 5 ２－３．Caution items ○ Do not use a walky-talky around the instrument. The indication might be affected by the electromagnetic wave generated by the walky-talky if it is used near the instrument. When the walky-talky is used, be away enough from the instrument not to affect. ○ Take at least 5 seconds interval when re-turning the power on. Normal operation cannot be performed if the power is re-turned on within 5 seconds. ○ Confirm the float of the flowmonitor is above red bar. If the float gets below the red bar, the correct gas detection cannot be performed. Adjust the flow rate. ○ Equip a dust filter to outside of the detector if it is used in a dusty place. The dust filter depends on a measuring gas. Consult our sales agents. ○ Take care not to drop the cover when taking it out. Dropping the cover might cause a serious injure. Take care. ○ Do not control other equipment by using outputs of this detector. This is not a control equipment. It is prohibited to control other equipment by using outputs of this detector. CAUTION Page 7 PT2E-0791 6 ３．PRODUCT FUNCTION ３－１．External drawing Cable inlet Cable inlet Cable inlet Cable inlet Card holder Flowmonitor Display Page 8 PT2E-0791 7 ３－２．Product composition ３－２－１．Major components This detector is composed of the following units. Wall mounting bracket Detector unit Cover Page 9 PT2E-0791 8 ３－２－２．Unit detaching After taking the cover out, procedure to detach the detector unit from the wall mounting bracket is as follows. １．.Loosen the knurling type screw at the front of detector and remove the cover. ２．.Loosen the screw on the lower part of detector unit. ３．.Remove the detector unit from the wall mounting bracket. ＊NOTE Perform the things above opposite to assemble the unit. When the wiring is arranged, detach the detector unit first. When the detector unit is being taking out, take care not to drop it. If it drops, there might be some damages on yourselves and the instrument. Loosen this screw CAUTION ！ Page 10 PT2E-0791 9 ３－３．Installation pitch Keep the space of this oblique part as the installation space. （１）Install the wall mounting bracket on the wall. （２）Put the detector unit on the wall mounting bracket. （３）Fix the detector unit with screw on the lower port of detector unit. Confirm that the detector unit is surely fixed to the wall mounting bracket after finishing the job. If it is not surely fixed, the detector unit might drop and cause injury or damage itself. CAUTION ！ Fig. 1: Dimension of mounting pitch Wall Page 11 PT2E-0791 10 ３－４．Name of each part & functions ３－４－１．Front view ② ③ ① ④ ⑤ ⑥ ⑦ ⑧ ⑨ ① LED indicator…………………… It indicates the gas concentration.(used at maintenance) ② PW/TR light(Green) ……… For both the power and trouble. Lighting ：The power is on. Normal operation. Flashing ：Trouble ③ ALM１ light(Yellow) ………… It turns ON at (1st) gas alarming. ④ ALM 2 light(Red) …………… It turns ON at (2nd) gas alarming. (ALARM 1 is also ON). ⑤ SKIP light(Green) …….…… It turns ON during the skip mode. (Detection being suspended). It turns flashing at the maintenance mode. ⑥ Flowmonitor ………………… For sample flow confirmation. The standard rate is 500mL/min. ⑦ Knurling type screw ………… It is used at opening/ closing the cover. ⑧ Tubing for sampling ………… GAS IN : Tubing for sample gas in. GAS OUT: Tubing for sample gas out. ⑨ Cable inlet ………………… For the power supply cable, output signal and relay output. Page 12 PT2E-0791 11 ３－４－２．Inside view 【Front view of detector unit】 【Front view of wall mounting unit】 ⑩Power switch (POWER) …… ON/OFF switch for power supply(24VDC). ⑪Fuse ………………………... Fuse for power ⑫MODE switch (Grey)…………. Switch that changes from detection mode to maintenance mode and changes the mode back to the detection mode. ⑬TEST/SET switch(Red)……… Switch that turns the mode into the alarm testing mode, and sets the further mode during the maintenance mode. ⑭FLOW ADJ./▲▼switch……... Switches that adjust the flow rate, looking at the flow monitor. Or, these are used to choose the items at the maintenance mode, to adjust the zero point, span point and to increase the indication at alarm testing. ⑮Pump ………………………... To sample the detection gas. ⑯Sensor ………………………... To detect the sampled gas ⑰Detector unit fixing screw…… To fix the detector unit with wall mounting unit. ⑱Terminal plate ………………... To connect external cables ⑲Flowmonitor …………………. To confirm sample flow rate. ⑮ ⑭ 【Side view of detector unit】 ⑪ ⑱ ⑯ ⑰ ⑲ ⑩ ⑫ ⑬ Page 13 PT2E-0791 12 ３－５．Block Diagram ３－５－１．Electric diagram ３－５－２．Tubing diagram Flow Monitor Sensor Amplifier unit Control unit Display (PW/TR)（ALM1）(ALM2)（SKIP) Operation part （MODE） （FLOW ADJ./▲▼） (TEST/SET) Pump Sensor Low flow sensor Pump POWER INPUT (DC24V) Power supply part Gas alarm contact (ALM1,ALM2) Trouble alarm contact (TROUBLE) *Standard Setting ・Normally de-energized (Energized at an alarm) ・Normally-open contact (Contact closes at an alarm) Alarm contact control part 4～20mA transmission Transmitter Low flow sensor Gas ＩＮ Gas ＯＵＴ Page 14 PT2E-0791 13 4．HOW TO USE ４－１．Before operation Be sure to keep caution items of use not only for first user but for already experienced staff. If not keep these caution items, the unit may be defective and correct gas detection may not be performed. ４－２．Installation place ・Use the designated dust filter to avoid adsorption of gas or influence caused by ambient dust. ・Stop the suction pump before replacing filter. ・Put the designated dust filter at the inlet of sample tubing if it is used other than clean room. Keep away the system from direct sun drought or where the temperature of the system is drastically changed. The system consists of fine electronics parts. Install them where to be stable not to crush or fall down. Keep the system from the equipment which may give a high frequency in the surroundings and install it. ・Do not put the system jointly each. ・Do not wire the cable in parallel nor take access. .Do not install and make gas detection at the place where the sample gas is deposited. ・In this case, extend the length of sampling hose etc. and sample the gas. This detector requires regular maintenance. Do not install the detector where it is attended with danger at maintenance work. Do not install at places where direct sun drought or where the temperature is drastically changed. Do not install it where vibration or shocks may take place. Keep the system from the equipment which may generate the noise (Unit & cable). Do not install it where the detection gas is deposited around. CAUTION Detection gas sampling from high dusty places. Do not install it where it is attended with danger at maintenance work Page 15 PT2E-0791 14 Do not install the detector at places where; * It is required to stop operation of the equipment where gas detector is installed at maintenance work. * It cannot make maintenance without taking off a part of equipment. * Casing cannot be removed by pipings, rack, etc. Be sure to ground when install. ４－３．Caution in the system engineering Unstable power and noise may cause error of performance and alarm. For the system to use this unit, it is required to make design based on this manual descriptions. （１）Stable power used While the system gets stable at power failure, the external output and alarm contact may be on and the care for it must be taken. In such case, use the standby battery or take an appropriate action in the receiver side. Supply the following power to this unit . Power voltage DC２４Vą１０％ Power failure tolerance time Approx 10msec. （For power failure of 10msec, it re-starts） To warrant the continuous operation, install the standby battery outside. Others Do not contact with power involving high power load and high frequency noise. According to requirement, use line filter and separate it from noise source. （２）Designing to consider radiation When install the closed self-standing control panel, mount the fans in the upper and lower part. Do not install it in an equipment that grounding construction is not enough. CAUTION Do not install it where it is difficult to make maintenance Page 16 PT2E-0791 15 （３）Lightning measures Lightning surge There is the problem “Lightning”. When make outdoor wiring of cable at factory or plants etc or when make a parallel wiring in the same duct with the cable in from outdoor even at the indoor wiring. If the lightning is a huge generation source, the cable is a reception antenna and there is the case that cable connecting instrument is broken. It is impossible to prevent the generation of lightning. If the cable should put in metal tube or laid in the underground, it is impossible to prevent the inductive lightning surge generating from the thunder. Lightning measures There is not the complete countermeasure for it but the following method can be considered. Make the suitable treatment accordingly. a) The transmission signal route is arranged for connection by the optical fiber cable etc. b) Countermeasure by the lightning arrester (Cable safety retainer). There is the way to install the lightning arrester just before the field apparatus and the central control station. Please contact with the manufacturer of lightning arrestor in details. Grounding Surge noise shall be generated from the thunder lightning or except it. To protect detector from these cause, be sure to make grounding. ＊In the lightning rod, there is the circuit to remove the surge voltage to be a cause of damage from field instruments. By installing the lightning rod, the signal may be attenuated. When install the lightning rod, it is required to check the performance in advance. （４）Alarm contact ・Alarm contacts shall be used only for external buzzer and alarm light, and do not use it for the controlling use (such as solenoid valve control etc). When control the external load, the bad influence may be given to the system according to the load characteristics. In such case, the following countermeasure shall be taken to stabilize the action and protect the contact. ・Make relay(contact amplification) with the low voltage relay and operate by connecting CR circuit (Spark Killer: SK) (Diode etc for DC) suited for relay coil directly to relay. ・Add CR circuit to the load side of relay on the request. CAUTION （FOR USE OF NORMALLY-CLOSED CONTACT） Normally-closed contact (Break contact) at de-energized condition may change to open contact in a moment due to physical shock. Whenever alarm signals from gas detectors are used with normally-closed contact, please put delayed-circuit (for about one second) to receiver side of normally-closed contact to avoid such phenomenon. Page 17 PT2E-0791 16 Reference: By the condition of load, CR circuit may be better to install in the contact side but it is required to put in by checking the action of load. ＳＫ：Surge absorption filter C L SK O SK O I R L D Ｖ Ｖ Alarm contact Power supply Relayed relay Power supply ＧＤ－V７７Ｄ (Low voltage relay) －How to think alarm contacts against inductive load－ The spec for alarm contact of GD-V77D is described by the conditions of resistive load. When use the inductive load for alarm contacts, the very high reverse electromotive voltage may be generated and the following trouble tends to be produced. ・Contact part of relay is melted adhesively and the contacts can not work. ・High voltage is put inside of detector unit and then, electrical parts may be damaged. ・As it is big noise, the trouble action may be taken by the reckless drive of CPU. ・Irrespective of inductive load, there is the possibility of unforeseeable noise instruction for contact. Above trouble may be generated * As the inductive load, there are following samples. ・Patlight * External relay * Buzzer * Siren * Fan * Fluorescent lamp *Motor etc. CAUTION ・The inductive load shall not be used in principle (Do not use fluorescent lamp, motor, etc.). ・When use the inductive load, make the contact amplification outside, but the outside relay coil belong, use the relay driven by the low voltage (within AC100V) and it is protected by an appropriate surge killer. Page 18 PT2E-0791 17 ４－４．Grounding Make grounding with inside or outside terminals marked Ｅ Be sure to make grounding before putting power ON. ４－５．Caution at wiring construction WARNING ！ Bolt for earth Bolt for earth CAUTION ・When make wiring construction, take care not to damage the internal electronics circuit. ・When handle the detector unit, put in at horizontal position. If put it vertically, it tends to fall back and damage the detector. ・For power cable, and signal cable, they should not be laid out with motive power cable such as motor etc. ・When use twisted cable, take care not to contact a part of core cable with other core cable. Be sure to make grounding for safety purpose and to keep stable operation of this unit. Do not connect each wire with gas pipe. Make grounding corresponding to D-class grounding (Grounding resistance : below 100 ohms) Page 19 PT2E-0791 18 ４－６．Applicable cable ４－６－１．Ｐｏｗｅｒ/Signal cable [3-wire 4～20mA version] Power & signal cable : Use CVVS 1.25mm2, 3-core cable [4-wire 4～20mA version] Power cable : Use CVV 1.25mm2, 2-core cable Signal : Use CVVS 1.25mm2, 2-core cable ４－６－２．Relay output signal cable Relay contact cable : Use VCTF 0.75mm2, 6-core cable ４－６－３．Specifications of terminal Terminal specifications ●Rated voltage : AC250V ●Rated current : 13A Connectable conditions ●Cable : 0.14mm2～1.5mm2 ●Cable with barterminal : (w/o insulation sleeve) : 0.25mm2～0.5mm2 ●Cable with barterminal (with insulation sleeve) : 0.5mm2～1.0mm2 ●Length of naked wires : Approx 6mm ●Screw clamp torque : 5～8kg. ●Applicable screw driver : Minus screw driver(width below 3mm) Appropriate bar terminal When use the bar terminal, the following can be used. Bar terminal :Model AI series(Phoenix contact make) Terminal lug tool :Model CRIMPFOX UD 6(Phoenix contact make) CAUTION Be sure to use the exclusive bar terminal. When used with other make bar terminal than above, the function of this detector can not be warranted. CAUTION Size of leading cable to GD-V77D is upto 1.25mm2 When use the cable exceeding 1.25mm2., use the junction box etc. Page 20 PT2E-0791 19 ③ ⑤ ④ ⑥ ＋２４V GND Sig ４－６－４．Terminal plate １ ２ ３ ４ ５ ６ ７ ８ ９ 10 11 12 ４－７．Example of cable connection ４－７－１．Connection with indicator/alarm unit (GH-583, GH-573A): (3-wire type) Short circuit ４－７－２．Connection with indicator unit, DCS, PLC (4-wire type) Trouble contact ALM２ contact ALM１ contact 4～20mA ＋ ― ＋ ・. GH-583 ・. GH-573A DC24V ＊.NOTE Terminals 4 & 5 are not in use. 2 3 4 5 E GD-V77D Detector E 1 2 3 4 5 6 E E ＤＣ２４Ｖ (+) (-) GND Sig ・. Indicator(RM-582,etc.) ・. Upper system(DCS, PLC) GD-V77D Detector 1 6 ＊NOTE In case of 4-wire type, power supply unit(DC24V) is required separately. ― Page 21 PT2E-0791 20 ４－８．Caution at piping construction （１）Piping port of detector For this detector, PT 1/4 male screw thread is cut for sampling pipe port(GAS IN, GAS OUT) and polypropylenes union is provided. As this is deviated from the kind of gas used, specify it at the time. This pipe used is φ6（OD）－φ4（ID）PTFE tube. When make piping, take care not to leak by putting accessory sleeve. The kind of piping material is different by kind of detection gas. （２）Sample flow rate ●. The flow rate of this detector is above 500cc/min. ●. When suck from removed place, consult the nearest agent or RIKEN KEIKI. （３）Piping material For detection gas, there is strongly adsorptive gas and corrosive gas. By considering these points, this must be decided.. CAUTION It is required to decide the connection tubing(length, material). Contact the nearest agent or RIKEN KEIKI for detail. WARNING This is designed to draw sample gas in an atmosphere of atmospheric pressure. When the exceeding pressure is given to the sampling pipe(GAS IN, GAS OUT), the internal pipe is removed and it is dangerous by the leak of detection gas. Use it so that the excessive pressure cannot be given. For exhaust gas, after detection, exhaust it to the safety zone by connecting the exhaust hose to GAS OUT on the bottom of detector. Union Inner Sleeve Pipe Page 22 PT2E-0791 21 5.OPERATION METHOD ５－１．Preparation before start up ● Before marking power on, take care of the following. If do not keep this, there is the danger of electrical shock and damage of detector. （１）Make grounding. （２）Check that the wiring with outer unit is made correctly. （３）Check that the power voltage is within the rating. （４）During adjustment, there is the case to work alarm relay contact. Arrange not to affect the outside even if the contact work. （５）Check that the dust filters are connected correctly or not. （６）For security purpose, check that it is a designated rated fuse or not. ５－２．Basic performance flow Normally this is used in detection mode after making power on. CAUTION Filters are designated by kind of detection gas. Power on Preparation for start-up Initial clear (Approx 25 sec.) Detection mode Alarm test mode TEST/SET switch (Press for about 3 sec.) MODE switch (Press for about 3 sec.) Maintenance mode ・Confirmation of alarm level (ALM1，ALM2) Page 23 PT2E-0791 22 ５－３．Start up method ５－３－１．Power on ●. Before making power on, check that this detector is connected correctly. ●. The position of power switch is located on the front panel(Open front window). ●. When turn the ON/OFF power switch to right, it gets “ON” and when turn to left, it gets “OFF”. ●. When make power switch “ON”, the POWER light turns on and the pump start working after 15 seconds. ●. Initial clear (Approx 25 sec.) ・Detector system check ・Output signal : Approx 2.5mA ・Alarm, trouble action shut-off (Alarm light, contact) Power switch The semiconductor type sensor to be used with this detector requires warm-up time for stabilization. Warm-up time varies according to the non-electricity time. Take an appropriate treatment referring to the table below. Total non-electricity time Required warm up time Within 24 hours Above 4 hours Within 72 hours Above 24 hours Within 10 days Above 2 days Within 1 month Above 7 days Within 3 months Above 14 days Above 3 months Above 1 month Alarm action and output signal will not be stable during warm-up time. When make power ON, announce it to respective department beforehand to avoid any abnormal actions. CAUTION Page 24 PT2E-0791 23 ５－３－２．Flowmonitor(Sensor flow) adjustment ●. Check that the ball in glass pipe of the flowmonitor is above red line. ●. When the ball is not above red line, adjust it by turning the flow adjusting switch (FLOW ADJ/▲▼). Flow adjusting switch Flowmonitor Red line Page 25 PT2E-0791 24 ５－４．Explanation of performance (Detection mode) ５－４－１．Display action There are following two kinds of displays. (1)LED display ：Shows gas concentrations. (2)LED light ：Shows power/trouble (PW/TR), 1st gas alarm (AL1), 2nd gas alarm (AL2) and skip(SKIP) condition. *Contents of indications by LED light are different from the condition of the unit. Action of LED light ○：Light off ●：Light on ◎：Flashing Preparation Power ON Initial clear(Approx 25 sec.) Detection mode ● ○ ○ ○ PW/TR ALM1 ALM2 SKIP ● ○ ○ ○ PW/TR ALM1 ALM2 SKIP LED display Only PW/TR light illuminates at detection mode and LED display shows detected gas concentration. Gas alarm condition ● ● ● ○ PW/TR ALM1 ALM2 SKIP When detect gas above AL1, AL2, it shows gas concentrations and AL1, AL2 alarm lights turn ON. Page 26 PT2E-0791 25 Zero suppression ● ○ ○ ○ PW/TR ALM1 ALM2 SKIP During detection mode operation, below +10% of full scale shows as “0”. ● ○ ○ ○ PW/TR ALM1 ALM2 SKIP WARNING When it shows 「-0」, the accurate gas reading is impossible. Ask to our nearest agent or RIKEN KEIKI to make zero adjustment and gas calibration. ● ○ ○ ○ PW/TR ALM1 ALM2 SKIP Trouble condition When any of trouble arises on detector, content of trouble is shown. （LED display） （Content of trouble） Ｅ－００ System trouble Ｅ－０１ Sensor disconnection or not yet connected. Ｅ－０５ Low flow ● ○ ○ ○ PW/TR ALM1 ALM2 SKIP During detection mode operation, this shows actual reading from above +10% of full scale. The right 「-0」 is displayed when it gets down to minus(-)side more than 10% of full scale. Page 27 PT2E-0791 26 ５－４－２．External output action 4～20mA output version (1)Signal transmission method : Electric current transmission (not isolated) (2)Transmission path : CVVS (3)Transmission distance : Below 1Km (4)Max loop load : 300Ω at 24VDC (5)Status signal levels ①.Detection mode : 4～20mA(depends on gas concentration) ②.Gas alarm : 4～20mA(depends on gas concentration) ③.Initial clear : 2.5mA(Fix) ④.Maintenance mode : 2.5mA(Fix) ⑤.Alarm test : 4～20mA(depends on gas concentration) ⑥.Trouble alarm : 0.5mA(Fix) ⑦.Point skip : 2.5mA(Fix) (6)Power interruption : 0mA Relations between gas concentration and output are shown below; CAUTION 4～20mA output has been adjusted. Even if re-adjustment is required after installation, do not operate without our permission. Please contact with our nearest agent or RIKEN KEIKI if it is required. ２.５ｍＡ ４ｍＡ ２０ｍＡ ２２ｍＡ Full scale Gas concentration Output 0 10％ of full scale (Zero suppression level) Detection mode Maintenance mode Page 28 PT2E-0791 27 ５－５．Maintenance and adjustment ５－５－１．Maintenance mode When make each adjustment, make it on maintenance mode. ※Content of menu Select by FLOW ADJ.／▲▼ switch Select by FLOW ADJ.／▲▼ switch Select by FLOW ADJ.／▲▼ switch ● ○ ○ ○ PW/TR ALM1 ALM2 SKIP Press MODE switch for 3 sec. ● ○ ○ ◎ PW/TR ALM1 ALM2 SKIP Maintenance mode starts １－１：Unused １－２：Confirmation of alarm level １－３：Regular maintenance ● ○ ○ ◎ PW/TR ALM1 ALM2 SKIP ● ○ ○ ◎ PW/TR ALM1 ALM2 SKIP CAUTION Do not operate 「1-3: Regular maintenance mode」 and 「1-A;Confirmation of address」 without our permission. Please contact with our nearest agent or RIKEN KEIKI if it is required. WARNING When maintenance mode starts during gas alarm, alarm contact and external output signal(gas alarm signal) will be cancelled. １－A：Confirmation of address ● ○ ○ ◎ PW/TR ALM1 ALM2 SKIP Page 29 PT2E-0791 28 ５－５－２．Confirmation of alarm level This is used to check alarm levels. ①Press MODE switch for above 3 seconds, and maintenance mode starts. ②Select 「1-2」 with FLOW ADJ.／▲▼ switch. ③Press TEST／SET switch to check the 1st alarm level (ALM 1). Press TEST／SET switch again to check the 2nd alarm level (ALM 2). ④To return detection mode, press MODE switch for above 3 seconds. SKIP light turns OFF which shows detection mode. ● ○ ○ ◎ PW/TR ALM1 ALM2 SKIP ● ○ ◎ ◎ PW/TR ALM1 ALM2 SKIP After completion of this operation, be sure to return detection mode(Only PW/TR light turns ON) by pressing MODE switch. When leave it alone on maintenance mode, this returns detection mode automatically after 10 hours. ● ○ ○ ○ PW/TR ALM1 ALM2 SKIP WARNING CAUTION To change alarm levels, please contact with our nearest agent or RIKEN KEIKI. ＊. Note ● ◎ ○ ◎ PW/TR ALM1 ALM2 SKIP ● ○ ○ ◎ PW/TR ALM1 ALM2 SKIP Page 30 PT2E-0791 29 ５－５－３．Alarm test This section is used to confirm the transmission condition to the outer equipment by giving same gas concentration signal(gas concentration data) output. ①Press TEST/SET switch for above 3 seconds to start alarm test mode. When it gets to alarm test mode, both SKIP light and display flash. ②Increase the reading with FLOW ADJ/▲▼ switch. When it reaches the first alarm level, AL1 light turns on. When it reaches the second alarm level, AL2 light turns on. ● ● ○ ◎ PW/TR ALM1 ALM2 SKIP When make alarm test, (transmission test) announce it to respective department beforehand. Carry it out after making proper treatment(External signal output, alarm contact). Alarm contact does not work during alarm test even if the reading reaches alarm level. To confirm the operation of alarm contact, additional setting is required. Please contact with our nearest agent or RIKEN KEIKI. ● ○ ○ ◎ PW/TR ALM1 ALM2 SKIP WARNING ＊. Note. ● ● ● ◎ PW/TR ALM1 ALM2 SKIP Page 31 PT2E-0791 30 ５－６．How to finish operation When finish this operation, turn off power switch of this detector unit and turn off the main power(DC24V). WARNING ・When finish this operation, do it after making point skip with the upper system (Centralized system). ・When finish this operation, check the external output and function of outer equipment to be connected with external alarm contact. Then, judge whether power can be shut off or not. ・When alarm contact is set on energized condition(optional), alarm contact works when power supply(DC24V) to this unit is OFF. In case of energized alarm contact, only power switch of this unit shall be put OFF. ・In case of detecting high adsorptive gases, turn off the power after making cleaning enough by fresh air. Page 32 PT2E-0791 31 ６．KINDS OF ALARM AND ITS FUNCTION ６－１．Kinds of alarm There are two kinds of alarms － gas alarm and trouble alarm － in this detector. Gas alarm : When the detection gas reaches to preset alarm level or exceeds it, this starts to function. 《Non-latched mode》 * Trouble alarm : Trouble is detected in the detector and it gives an alarm as trouble alarm. Except system trouble “E-00”, it is non-latched. When return to normal from trouble condition, it starts again from the performance «Initial clear» after power on. [See “8. TREATMENT AT ABNORMAL CASE”] ６－２．Gas alarm ６－２－１．Gas alarm action (1)Display ①Gas concentration display When exceed detection range, LED display shows “∩∩∩∩”. ②Power light (POWER : Green) It keeps continuous lighting. ③Alarm light (ALM1 : Orange), (ALM2 : Red) There are two alarm levels. When the reading goes to alarm preset level or exceeds it, this turns to on. (2)External output ①4～20mA output Electric current in proportion to gas concentration is output. In case of over scale, the maximum output is approx 22mA ②Alarm contact When gas concentration reaches preset alarm level or exceeds it, the relay contact for outer alarm works. Relay contact is a non-latched condition. It returns automatically when gas concentration decreases under preset alarm level. 『Alarm pattern』 Alarm delay time(2 sec.) Alarm delay time(2 sec.) Alarm light(ALM 1) Alarm contact(Terminal 7，8) Alarm ｌight（ALM 2） Alarm contact(Terminal 9，10) ALM2 Alarm level ALM1 Alarm level C o n c e n tratio n ＊ NOTE Alarm levels are adjusted at 1/4(1st alarm) and 1/2 (2nd alarm) of full scale as standard. To prevent error of performance, this is provided with alarm delay time for 2 seconds. Page 33 PT2E-0791 32 ６－２－２．Counteraction at gas alarm Reaction to leak gas The counteraction at gas alarm shall follow to the client rule and immediate reaction shall be required. Generally, the following action is taken. ①Confirmation of indication value. ②Based on gas alarm control concentration, it keeps the safety by keeping away people from the monitoring area. ③When gas concentration display is continued, close the gas valve and confirm that gas concentration gets lower enough. ④Suppose that the leak gas is to remain and provide yourself with protection attire and tool away from danger, go to the leak site and check the gas residual condition by portable gas detector. ⑤After checking that there is no danger, the treatment for gas leak shall be taken. ６ － ２ － ３ ． Gas alarm possibility except the case of gas detection It may respond to interference gas For interference gases, contact the nearest agent or Riken Keiki. It may be caused by drifting due to the change of long time elapsed sensor Check the reading by daily check and make calibration through authorized service agent whenever necessary. It may be caused by the noise generated from spherical machine Revision of installation location, wirings and the addition etc. of noise measure parts between instrument and detector shall be required. This specific measures shall differ from the condition of each site. It may receive a temporarily noise such as by thunder lightning etc. When the cause and effects are understood, the measure for surge according to the condition can be taken. ＊ NOTE Instantaneous gas leak may get lower at confirmation time. Except gas alarm, it gets alarm condition temporarily by noise or any other accidental conditions. Page 34 PT2E-0791 33 ７．MAINTENANCE CHECK This is an important for security and safety. To maintain the security and enhance the reliability of safety, the regular maintenance check for it shall be absolutely necessary. ７－１．Frequency of maintenance and check items. ７－１－１．Daily check This is the check items carried out by customer. ①Check of flowmonitor Check that the ball in flowmonitor of this unit is above red line. ②Check of PW/TR light. In normal operation, the light is at on condition. ③Check of LED reading Check that LED reading is “0”. If it is not “0”, check that gas is free around gas sample point. ④Check and replacement of dust filter While this unit is working, ball in flowmonitor shall be positioned above red line. If it is below the red line, adjust it with FLOW ADJ/▲▼switch to ▲. Even though it cannot move up, the filth of dust filter can be considered. Replace it with new one or check the flow path(clog, bend or crack of tubing). ７－１－２．Regular maintenance check The following items shall be checked at regular check. ①Daily check ②Cleaning of this unit ③Adjustments ④Function check ⑤Parts replacement(Refer to 7-6 Recommendable spare parts list) ⑥Others ７－１－３．Maintenance contract for regular check To maintain the safety operation of the unit, it is recommended to keep the maintenance contract with service agent for regular maintenance, adjustment and overhaul etc including the gas sensitivity adjustment. For the detail of maintenance contract, contact our nearest service agent or Riken Keiki. If the reading is not “O” in spite of no gas around gas sample point, ask to our nearest agent or RIKEN KEIKI to make zero adjustment and gas calibration. CAUTION Page 35 PT2E-0791 34 ７－２．Calibration method(Zero adjustment, calibration with gas, etc.) ７－３．Replacement of sensor and parts. ７－４．Treatment when operation is stopped or its installation place is moved. ７－４－１．Stopping the normal operation Make the power switch off on the front side. Make the power (DC24V) off at the supply side. ７－４－２．Installation when move its place When move its place, refer to “4-2. Installation place”. Then, for wiring construction, refer to “4-5. Caution at wiring construction”. When move its installation place, make shortest the power interruption time. CAUTION When move its installation place, be sure to make gas calibration. The re-adjustment work including gas calibration shall be requested to contact our nearest agent or Riken Keiki. CAUTION For replacement of sensors and parts etc, contact our nearest agent or Riken Keiki. CAUTION For gas calibration, contact our nearest agent or Riken Keiki. Page 36 PT2E-0791 35 ７－５．Storage or treatment when not in use for a long time. This detector shall be stored in the following environment condition. ①Temperature ：0℃～40℃ ②Humidity ：30%RH～85%RH(Non-condensing) ③Environment condition：To be an environment where there is no generation of gas, solvent and vapor etc. CAUTION The semiconductor type sensor to be used with this detector requires warm-up time for stabilization. Warm-up time varies according to the non-electricity time. Take an appropriate treatment referring to the table below. Total non-electricity time Required warm up time Within 24 hours Above 4 hours Within 72 hours Above 24 hours Within 10 days Above 2 days Within 1 month Above 7 days Within 3 months Above 14 days Above 3 months Above 1 month Alarm action and output signal will not be stable during warm-up time. When make power ON, announce it to respective department beforehand to avoid any abnormal actions. Page 37 PT2E-0791 36 7－６．List of recommendable spare parts for regular maintenance No. Name of parts Maintenance interval Replacement Interval(year) Q’ty/unit 1 Pump (without diaphragm) 6 months 1～3 1 2 Pump diaphragm 6 months 1～2 1 3 Pump holder 1year 3～6 1 4 Internal tubing (Rubber) 6 months 3～6 1 5 Internal tubing (PTEE) 6 months 3～8 1 6 Fuse 1 year 8 1 7 Main PCB －－－ 7～8 1 8 Sub PCB －－－ 9～10 1 9 Packing 1 year 3～6 1 10 O-ring (Sensor adaptor) 1 year 3～6 1 11 O-ring (Chamber) 1 year 3～6 1 12 O-ring (Flowmonitor part) 1 year 3～6 2 13 Flowmonitor ass’y 1 year 7～8 1 14 Dust filter (Outside use) 6 months 0.5～1 1 * The above replacement interval is just a standard and it depends upon operating conditions. Also, this does not show a guarantee period. Replacement interval changes according to the result of regular maintenance check.. * PCB is caused by deterioration of capacitor, etc. * Use pre-adjusted PCB when it is required to replace. ＊. Note Page 38 PT2E-0791 37 ８．TREATMENT AT ABNORMAL CASE ８－１．Trouble alarm Flashing of PW/TR light ・When PW/TR light is flashing, it is the condition that the following trouble may be caused. Research its cause and take an appropriate action. ・The output of detector at trouble shall be as follows. Output from GD-V77D: 0.5mA(Fix) LED display Trouble content Main cause E-00 System trouble Memory trouble in the detector E-01 Abnormal of sensor connection Connector contact failure, Sensor cable disconnection E-05 Low flow Filth of filter or deterioration of pump ８－２．Counteraction at trouble alarm When any trouble was found on this gas detector, contact our nearest agent or Riken Keiki. If trouble should take place, we try best to search its cause and prevent its cause. ８－３．Before it is thought to be a trouble It may be originated from disconnection and short circuit between units. ・Check the wirings around the related equipment as well as this detector. There is the case that operation of detector is not correct including piping work etc. ・Re-check the detection system and contact our nearest agent or Riken Keiki. There is the case of electrical line trouble such as shut-off of power. ・This will be treated by the re-check of stand-by battery, power line filter, insulation transformer etc or those addition. Page 39 PT2E-0791 38 ８－４．Trouble Shooting (1) PW/TR light is not ON. (Power is not supplied.) ・Is it OK with power cable connection ? Connect power cable. ・Is fuse disconnected ? Search the cause of disconnection and replace it after making counter-measures. ・Is power voltage normal ? Supply the rated power voltage. ・Is this power switch turned on ? Make power switch ON. (2) Abnormal performance ・Sudden serge noise can be considered. When recover it, turn off the power and turn on the power again for re-start of operation. When such takes place often times, take an appropriate action for noise. (3) No calibration available ・Is the concentration of calibration gas correct ? Prepare the appropriate calibration gas. ・There is the possibility for decreasing of sensor sensitivity. The sensor replacement is required. (4) PW/TR light flashing. ①.System Trouble “E-00” ・Memory trouble inside of detector. Contact our nearest agent or Riken Keiki. ②.Sensor connection trouble “E-01” ・Non-connection of sensor, contact failure of connector and disconnection of sensor cable. Check “whether sensor is connected” or “the sensor cable connector is connected to the sensor or amplifier board.” If can not be recovered, contact our nearest agent or Riken Keiki. ③ Low flow trouble “E-05” ・Drop of pump function Even though the ball of flowmonitor can not be up the red line with FLOW ADJ/▲▼ switch, replace the pump with new one. ・Check that the detector unit is mounted firmly or the fixing screw of detector unit is fastened firmly. ・Due to the clog of dust filter, the pump can not suck. Replace the dust filter with new one. ・The pipe at gas-inlet side or gas-outlet side is broken or clogged． In this case, repair the defective part. Page 40 PT2E-0791 39 (5) Slow Response ・Is the dust filter clogged ? Replace the dust filter. ・Is the pipe at gas inlet side or gas outlet side broken or clogged ? Repair or replace defective part. ・Check whether detector unit is firmly connected. (6) Fuse disconnection ・The detector does not operate at all. ・The trouble of detector or trouble of external power source can be considered. Search this cause and after taking its measures, replace the fuse with the designated one. * NOTE The rating of this fuse for this detector is 125V 2A Page 41 PT2E-0791 40 Flowmonitor Gas sample flow rate supplied to the sensor is indicated. The standard flow rate of this detector is 500cc/min. Low flow alarm When the sample flow rate to the sensor is dropped, this is the function to give an alarm. PW/TR light flashes and “E-05” is shown on LCD. External output signal The external output signals of this detector head are as follows; ・Gas concentration signal output, status signal(working condition): Electric current signal. ・Alarm contact output (1st, 2nd, trouble) External dust filter When use it at dusty atmospheric place, it is recommended to put on dust filter outside. The kind of filter is different by the detection gas. Please ask to our nearest agent. PPM This is the unit of gas concentration showing a volume at a part per million. Calibration By using calibration gas etc, it seeks relations between instrument reading, display value or set value and true value. Maintenance mode When make maintenance of detector, cut off the alarm contact and the output of signal showing the maintenance mode condition is displayed on the external output signal. By this, the maintenance is carried out independently on this detector. Press MODE switch for above 3 seconds, and the maintenance mode starts. Initial clear The reading will be unstable for a few seconds after power on. In this moment to prevent the error of running, the alarm contact shall be cut off. Then, signal output showing initial clear condition is given on external output. Zero suppression This is the function to blur the environment change or the influence of interference gas. Alarm delay time To prevent the alarm error by noise intruded from the outside, this is the function to suspend the running temporarily. ９. DEFINITION OF TERMS Page 42 PT2E-0791 41 Alarm response time It is the time until the alarm is given when exposed to gas concentration of 1.6 times alarm preset level. (This does not involve the time when connect suction pipe outside) Alarm response time for this detector is within 30 seconds. Point skip For the convenience of maintenance etc, the function of gas detection is stopped temporarily. The model GD-V77D is based on the semiconductor method. The gas sensitive semiconductor sensor is composed of the sintered metal oxides(SnO2, ZnO, etc) and the heater. In the sintered metal oxides, one pair of electrode is embedded. In the presence of explosive or toxic gases, the gas molecules are adsorbed on its surface. This, in turn, causes move of free electrons in the semiconductor, with increase in electric resistance for deductive gases or decrease in electric resistance for oxide gases corresponding to the concentration of explosive or toxic gases. This change of electric resistance is detected with electrodes and outputs as gas concentration. . . . . . ＶH . . . . . Ｖs ＲⅬ Ｖｏ . . . . . RL: Load resistance Vo : Output voltage VH: Heater voltage Vs : Sensor voltage 1０. DETECTION PRINCIPLE Page 43 PT2E-0791 42 11―1. Specifications Model : GD-V77D Transmission method : Electric current transmission method, 3-wire(or 4-wire), 4～20mADC Gas concentration signal : 4～20mA(Linear upto 22mA) Initial clear signal : 2.5mA Maintenance signal : 2.5mA Trouble signal : 0.5mA, non-isolated (max. load : 300Ω at 24VDC) Applicable sensor : Semiconductor sensor Detection gas : Toxic gases・combustible gases Detection range : Depends on detection gas Gas detection method : Sample drawing method(with low flow alarm detection circuit) Sample flow rate : 500cc/min External tubing : φ6-φ4 PTFE tubing (Provided with P.P. coupling) Gas alarm : 2 levels (Non-lutched mode) Preset level : Depends on detection gas and range. Indication : LED light Relay output : Dry contact, normally-open for both 1st and 2nd alarm, rated 0.25A at 125VAC/0.5A at 24VDC(Resistive load). Alarm delay time : Within 30sec(Time to get an alarm when exposed to gas concentration of 1.6times alarm level, excluding delay by external tubing). Initial clear time : 25 sec. after power ON. Zero suppression level : 10% of full scale Self-diagnostic function Contents : Low flow, system error, sensor disconnection. Trouble indication : Flashing of POWER light, message of content. Relay output : Dry contact, normally-open, rated 0.25A at 125VAC/0.5A at 24VDC(Resistive load). Display function Gas concentration : 4 digit LED(7 segment) Status : LED light ①Power/trouble indication: PW/TR(continuous/flashing) ・Normal……Green/continuous ・Trouble……Green/flashing ②Gas alarm 1st: ALM1 light on (Orange) 2nd: ALM2 light on (Red) Normal……Light off Alarm ……Orange, Red light on ③Maintenance: SKIP light flashing ④Function interruption : SKIP light on ・OFF during measurement, ON at SKIP. 1１ LIST OF PRODUCT SPECIFICATIONS Page 44 PT2E-0791 43 Setting : By remote PC (Use exclusive cable) Power source Required voltage : 24VDC±10% Consumption : Approx 10W Applicable cable : CVVS, 1.25mm2, 3-core (*When power cable and signal cable are separated, use following cables) Power source : CVV 1.25mm2, 2-core Signal : CVVS 1.25mm2, 2-core Operating condition Temperature : 0～40℃ Humidity : 30～85%R.H.(standard) (Consult with us other humidity). Structure : Box type, wall mounting type Outer dimensions : 70(W)X170(H)X153(D)mm Weight : Approx 2.0kg. . １１－２．Product composition Standard compositions ・. Gas detector GD-V77D ・. Accessories. Dust filter ……1 pce. Gas inlet/outlet cap……2 pcs. Fuse……Depends on ordered quantity Q’ty/order Fuse supplied 1 ～ 10 sets 1 pce 11 ～ 20 sets 2 pcs. 21 ～ 50 sets 3 pcs. 51 sets and above 5 pcs. Specifications subject to change without notice for improvement * NOTE Page 45 PT2E-0791 44 1２．WARRANTY RIKEN KEIKI STANDARD WARRANTY FOR FIXED GAS DETECTION INSTRUMENTS RIKEN KEIKI CO., LTD. warrants gas alarm equipment manufactured and sold by us to be free from defects in materials and workmanship for a period of one year from date of shipment form RIKEN KEIKI CO., LTD. Any parts found defective within that period will be repaired or replaced, at our option, free of charge, F.O.B. factory. This warranty does not apply to those items which by their nature are subject to deterioration or consumption in normal service, and which must be cleaned, repaired or replaced on a routine basis. The alarm contact output specified in this system is provide for the use of buzzer and lamp to be communicated to the other external place than the system installed. But to secure the safety, there may be the case that the following interlocking performance shall be made by use of alarm contact output from customers. 1. Stop the gas supply. 2. Stop the action of system which uses gas. 3. Let the services exhaust fan operated. 4. Let stop the work of the staffs in the area by the auto paging system and escaped to the outside from there 5. Let the alarm transmitted to a remote place by auto communication system. 6. Let the alarm transmitted by the lamp and buzzer to this area and that area. 7. Others But, we do not assume the responsibility for the secondary damage, which may be generated by this interlocking action because it is not in our scope of recognition. Then, we cannot strike the sales contract or the manufacture in the scope to reimburse this secondary damage. Warranty is voided by abuse including rough handling, mechanical damage, operation, alteration, or repair procedures not in accordance with instruction manual. This warranty indicates the full extent of our liability, and we are not responsible for removal or replacement cost, local repair costs, transportation cost, or contingent expenses incurred without our prior approval. This warranty covers instruments and parts sold (to users) only by authorized distributors, dealers and representatives as appointed RIKEN KEIKI CO., LTD.. We do not assume the indemnification for any accident or damage caused by the operation of this gas monitor and our warranty is limited to the replacement of parts or our complete goods.

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