TQ ENVIRONMENTAL LTD
TQ 4200 Mk II Product Manual
TQ 4200 SERIES
INFRARED
REFRIGERANT LEAK
DETECTION SYSTEM
©
This manual must not be copied or reproduced in part without the express written permission of TQ Environmental LTD. All information contained herein is subject to modification.
TQ Environmental Ltd, Flanshaw Way, WAKEFIELD, W. York’s, WF2 9LP
44 (0) 1924 380700 FAX 44 (0) 1924 361700
TQ ENVIRONMENTAL LTD BS EN ISO 9001
Filename: 4200BM5
Author: G. Thompson
PROPRIETARY
No part of the hardware or documentation may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language or computer language, in any form or by any means, without prior written permission of TQ Environmental LTD
While great efforts have been made to assure the accuracy and clarity of this document, TQ Environmental LTD assumes no liability resulting from any omissions in this document, or from misuse of the information obtained herein. The information in this document has been carefully checked and is believed to be entirely reliable with all of the necessary information included. TQ Environmental LTD reserves the right to make changes to any products described herein to improve reliability, function, or design, and reserves the right to revise this document and make changes from time to time in content hereof with no obligation to notify any persons of revisions or changes. TQ Environmental LTD does not assume any liability arising out of the application or any use of any product or circuit described herein; neither does it convey license under its patent rights or the rights of others.
WARNINGS, CAUTIONS AND NOTES
Warnings identify an operating or maintenance procedure, practice, condition, or statement that, if not strictly followed, could result in death or injury to personnel.
Cautions, which appear elsewhere in this manual, identify an operating or maintenance procedure, practice, condition, or statement that if not strictly followed could result in equipment damage or serious impairment of system operation.
Notes highlight certain operating or maintenance conditions or statements that are essential but not of known hazardous nature as indicated by Warnings and Cautions.
Warnings, Cautions and Notes are included throughout this manual, as required. Additionally, this section contains important Warnings that may not be contained elsewhere within this instruction manual.
SAFETY WARNINGS
- FOR SAFETY REASONS, THE TQ4200 MUST BE INSTALLED, OPERATED AND SERVICED BY QUALIFIED PERSONNEL ONLY. READ AND UNDERSTAND THIS INSTRUCTION MANUAL COMPLETELY BEFORE OPERATING THE TQ4200
- THE OPERATION DESCRIBED IN THIS DOCUMENT IS THE INTENDED USE OF THE TQ4200. TQ ENVIRONMENTAL LTD CANNOT BE HELD RESPONSIBLE IF THE TQ4200 IS USED FOR ANY OTHER PURPOSE OTHER THAN THAT STATED. ANY OTHER USE OF THE TQ4200 WILL CAUSE ANY CERTIFICATES ISSUED TO NOT APPLY.
CONTENTS
SECTIONDESCRIPTION
1.0Introduction
2.0Description
2.1Infrared Sensor
2.2Pneumatic System
2.2.1External Catch-Pot
2.2.2Flow Fail
2.2.3Pressure Sensor
2.2.4Solenoid Valves
2.2.5Sampling Pump
2.2.6DC Electrical Supplies
2.2.7Outputs
3.0System Software
3.1Start-up
3.2Power on reset
3.3System Warm-up
3.4Normal Operating Mode
3.5Entering Passwords
3.6Overview of Menu System
3.6.1Main Menu - Set Time
3.6.2 - Set Date
3.6.3- Calibrate
3.6.4- Change Password
3.6.5- Parameters
3.6.5.1- Set Location
3.6.5.2- Set Gas Type
3.6.5.3- Parameters - Set Alarm 1
3.6.5.4- Parameters - Set Alarm 2 & 3
3.6.5.5- Parameters - Set Alarm 1 Type
3.6.5.6- Parameters - Set Alarm 2 & 3 Type
3.6.5.7- Parameters - Set Dwell Time
3.6.5.8- Parameters - Exit Sub Menu
3.7Overview of the Alarm Operation
3.7.1Alarm Control Functions
3.7.1.1Main Menu- Mute Alarm
3.7.1.2- Reset Alarm
3.7.1.3- Display Alarms
3.7.1.4- Erase Alarms
3.8Technician Mode
3.8.1- Set No of Zones
3.8.2- SkipZone Number
3.8.3- Calibrate Pressure
3.9Main Menu- Exit Menu
SECTIONDESCRIPTION
4.0Operation
4.1System Warm-up
4.2Normal
4.3Alarms -
4.3.1- System Fault
4.3.2- Gas Level Alarms
4.3.2.1- Mute Alarms
4.3.2.2- Reset Alarms
5.0Drawings
6.0Maintenance
7.0Parts List
8.0Fault Finding
8.1Analyser NVRAM Fault
8.2OMNICA NVRAM Fault
8.3Sensor Communications Fault
8.4OMNICA Communications Fault
8.5Zero Filter Blocked Fault
8.6Flow Fail Fault
8.7No Pressure Fault
8.8Sensor Drift Fault
8.9Sensor Fault
Appendix ‘A’Project Specific Information*
* See section Sub Index for contents
1.0INTRODUCTION
The TQ4200 is an Aspirated Infrared Refrigerant Leak Detection System (IRLDS). This system utilises infrared gas analysing technology to detect the signatures of the designated gas, thus eliminating any nuisance alarms from other gases, a selection of which are mentioned below;
a) Hydrogen
b) Carbon Monoxide
c) Carbon Dioxide
d) Hexane
e) Heat resistance aluminium paint fumes
f) Epoxy finishing paint fumes.
g) Epoxy finish white base paint fumes.
h) Bioguard water based paint
i) Methane
The TQ4200 system has the capability of monitoring up to 16 sample points by sequentially cycling through each location. Individual sample lines can be configured to detect differing refrigerant gases.
The TQ4200 is currently programmed to monitor the following refrigerants:
a) R12
b) R22
c) R114
d) R134a
e) R404A
f) R407C
g) R403B
h) R236fa
Each sample point will also have three individual alarm trip levels. Any gas sample concentration reaching the ‘low’, ‘high’ and ‘high-high’ trip levels will operate the common alarm relays and provide an output to actuate audible/visual alarm devices.
The TQ4200 front panel provides the operator interface via four pushbuttons and a backlit LCD display. During normal operation the LCD display will provide the ‘location’, ‘gas type’ and sample ‘concentration’ for each individual location.
The TQ4200 also has the ability to store the last twenty alarms which can be displayed in alarm/time/date format in time order.
Each of the sample transport lines are constantly monitored for flow restrictions. In the event of a reduction or loss of flow, a ‘system flow alarm’ will be initiated.
The TQ4200is available in either ‘top’ or ‘bottom’ entry versions for sample lines and cabling, at 85-264V 50/60 Hz.
PART NODESCRIPTION
370-520TQ420016-way bottom entry 85-264V
370-522TQ4200 8-way bottom entry 85-264V
2.0DESCRIPTION
2.1Infrared Sensor (GD134, GD137)
The operation of the infrared sensor within the TQ4200 has been developed from the infrared heat source detector utilised in the thermal imaging cameras measuring infrared radiation.
These detectors have now developed into non-dispersive infrared analysers.
Dispersive analysers use a wide band of infrared to identify a gas, the none-dispersive type narrows the wavelength specific to a gas. The narrow infra-red band produced is passed through the gas sample and a gas specific to this wavelength will absorb this infrared depending on the concentration. The electronics converts this absorption of infrared into an electrical signal for processing.
The narrowing of the band of infrared light is produced utilising filters made of specific material such as calcium fluoride, sapphire, etc.
The light source is modulated by a mechanical chopper to give a high performance on very small signal. This modulated light source together with a reference sensor, which is not exposed to the gas sample, gives a very accurate signal for a concentration of the target gas.
2.2Pneumatic System
The gas sample is brought into the TQ4200 at approximately 4 litres/min from one of the 15 sample lines, into the solenoid bank manifold by a diaphragm pump and presented to the infrared sensor.
A particulate filter is fitted before the pump. (Please refer to Figure 3 & 4).
2.2.1External Catch-Pot
The external catch-pot will remove the majority of moisture within the sample line. If the bowl is allowed to fill the catch-pot will automatically shut-off the sample line causing a flow fail alarm.
2.2.2Flow Fail
The flow fail is detected by the PCB mounted differential pressure switch sensing across a differential pressure tube (See Figure 4).This PCB will provide an alarm output when there is a reduction in air flow.
2.2.3Pressure Sensor
A pressure sensor monitors the air pressure in the vent line of the TQ4200 to provide the electronics with pressure information when calculating the gas concentration. This pressure sensor is also a PCB mounted device.
2.2.4Solenoid Valves
The solenoid valves in either an 8-way or 16-way configuration, are mounted on an eight way common manifold and have 24V DC operating coils. Fitted within the solenoid valve connector covers are back EMF diodes and LED indicators.
The common manifold also provides the individual sample line inlet ports. Each port is 1/8” BSP and can be fitted with a union connector to suit the transport tubing. (Note: these inlet connectors are not included with the standard unit).
2.2.5Sampling Pump
The sampling pump is a single ended unit power by 24VDC from the internal power supply. The pump is fitted with viton diaphragm and seals, and requires very little maintenance. Flow rate for this application is 4 litres/hour.
The electrical supply to the pump is wired through Fuse 4 (See Figure 5).
2.2.6DC Electrical Supplies
The DC electrical supplies for the TQ4200 are provided by its internal 110 Watt power supply unit. This is a universal input device and will accept an input of 85 to 250 Volts AC. (See Figure 5).
The mains input to the TQ4200 unit is connected to TBF-01 and then to a fused isolator via the EMC suppresser.
2.2.7Outputs
Outputs from the TQ4200 are in the form of:-
-Volt Free Contacts for Alarm 1, 2 and 3
and Common Fault
-24V DC @ 100mA for Visual Alarm
-24V DC @ 100mA for Audible Alarm
-One 4-20mA analogue output
RS485 Modbus
4-20ma Output with respect to concentration (0-2000ppm)
4-20ma Output with respect to location (1ma per location)
2.2.7MODBUS O/P
The MODBUS bus output can be connected to any MODBUS configurable device. The standard register addresses and communications protocol are defined as follows:-
Input Register(0x04) / Starting Address (High) / Starting Address (Low) / Number of Registers (High) / Number of Registers (Low) / Number of Bytes
Station Number
Read (0x04)
Write (0x10) / 0x00 / 0x10 / 0x00 / 0x01 / 2
Zone 1 Conc. / 0x00 / 0x00 / 0x00 / 0x01 / 2
Zone 2 Conc. / 0x00 / 0x01 / 0x00 / 0x01 / 2
Zone 3 Conc. / 0x00 / 0x02 / 0x00 / 0x01 / 2
Zone 4 Conc. / 0x00 / 0x03 / 0x00 / 0x01 / 2
Zone 5 Conc. / 0x00 / 0x04 / 0x00 / 0x01 / 2
Zone 6 Conc. / 0x00 / 0x05 / 0x00 / 0x01 / 2
Zone 7 Conc. / 0x00 / 0x06 / 0x00 / 0x01 / 2
Zone 8 Conc. / 0x00 / 0x07 / 0x00 / 0x01 / 2
Zone 9 Conc. / 0x00 / 0x08 / 0x00 / 0x01 / 2
Zone 10 Conc. / 0x00 / 0x09 / 0x00 / 0x01 / 2
Zone 11 Conc. / 0x00 / 0x0A / 0x00 / 0x01 / 2
Zone 12 Conc. / 0x00 / 0x0B / 0x00 / 0x01 / 2
Zone 13 Conc. / 0x00 / 0x0C / 0x00 / 0x01 / 2
Zone 14 Conc. / 0x00 / 0x0D / 0x00 / 0x01 / 2
Zone 15 Conc. / 0x00 / 0x0E / 0x00 / 0x01 / 2
Zone 16 Conc. / 0x00 / 0x0F / 0x00 / 0x01 / 2
Discrete Inputs
(0x02) / Starting Address (High) / Starting Address (Low) / Number of Registers (High) / Number of Registers (Low) / Number of Bytes
Alarm Status / 0x00 / 0x00 / 0x00 / 0x01 / 2
Input Number
Alarm 1 / 0
Alarm 2 / 1
Alarm 3 / 2
Fault / 3
Communications Protocol
Baud Rate / Data Bits / Parity / Stop Bits / Transmission / Error Check
19200 / 8 / Even / 1 / RTU / CRC-16
3.0 SYSTEM SOFTWARE
This section explains in detail the system set-up and operation of the TQ 4200 main board. Four keys are used to navigate through and access the system software functions, namely: MENU, SELECT, UP, and DOWN.
3.1 System Start-up
When the system is powered on or a hardware system reset occurs, the TQ 4200 main board will boot up showing the Start-up screen in Figure 3-1 below:
Figure 3-1Start-up Display
3.1.1NVRAM Test
The TQ 4200 will perform an internal non-volatile memory self-test. The result of the test being displayed on the LCD as shown below:
Figure 3-2NVRAM Self Test
3.2Power-on Reset*
The power-on reset function is used to load the default data into the system. The user must initiate the power-on reset by pressing and holding the SELECT key, UP key, and DOWN key simultaneously for approximately two seconds when the power is turned on.
If the user does not initiate a power-on reset then the system will begin initialisation by downloading the previous parameters into system memory from the non-volatile serial RAM. This stage is indicated on the liquid crystal display by Figure 3-3 shown below:
Figure 3-3 System Initialisation Display
* The system start up is only required on the very first power up or if any data
becomes corrupt.
3.3System Warm-up
When the TQ 4200 main board is powered on or a hardware reset is applied, the system will undergo a warm-up period. This warm-up period will last no longer than 2 minutes and the liquid crystal display will be as shown in Figure 3-4 below:
Figure 3-4Warm-up Period Mode
If the warm-up period is unsuccessful and 15 minutes has elapsed since the power has been turned on, the system will select the System Fault mode.
N.B. Due to the temperature changing within the cabinet the sensor will take time to obtain 95% accuracy. After 8 hours the system will reached its peak accuracy. The systems are therefore designed for continuous operation and should not be powered down as necessary.
When the system has settled, any opening of the door on the cabinet will reduce the accuracy again of the system. Therefore several hours are required for true readings to be obtained. This is dueto the fact explained in section one where originally these sensors were used for thermal imaging and the difference in temperatures affects their accuracy.
Additionally the detector and reference elements in the system have different coefficients of heat dissipation which results in loss of accuracy.
3.3.1Internal System Leak Test
After the warm-up period is complete the system will initiate a Pressure Test. This will test for any internal leaks within the system.
Figure 3-5Pressure Test
3.3.2Sensor Auto-Zero
At initial start up the system will initiate a sensor auto-zero. This will then be performed at the end of every cycle.
Figure 3-6Sensor Auto-Zero
3.4Normal Operating Mode
The TQ 4200 main board has two distinct modes of operation: the Normal Operating Mode and the Menu Mode. After system initialisation, the TQ 4200 main board will automatically select the Normal Operating Mode. In this mode the system will scan each zone location sequentially, displaying on the liquid crystal display the current zone location, the sampled gas, and the sampled gas concentration in parts per million (ppm). This information is displayed as shown in Figure 3-7 below:
Figure 3-7Normal Operating Mode
When selecting a particular zone location, its corresponding solenoid is activated in order to sample the gas concentration. At the end of the ‘solenoid on’ sequence the sampled gas concentration is measured and compared with two user defined alarm levels. If the sampled gas concentration has exceeded the stored alarm levels then an appropriate alarm relay will be activated. The display will confirm the alarm condition by displaying the zone location, alarm number, and alarm status. An example of an alarm condition is shown in Figure 3-8 below, together with either the first and second red alarm LED’s.
Figure 3-8Example of Alarm Condition
A more detailed discussion of alarm conditions will be presented in section 4 of this manual.
3.5Entering Passwords
To gain access to the Menu Mode, the user must enter a password (four-digit code). The numbers must be selected and entered one at a time. The UP and DOWN keys are used to scroll through the numbers. When the desired number is displayed, pressing the SELECT key will ENTER that number. The entered number will be blanked out after the SELECT key is pressed to ensure restricted access to the menu system. The cursor will now move to the next digit to the right of the blanked out digit and pressing the UP and DOWN keys will again change the number as required.
Figure 3-9Display Password Prompt
After the four digits have been entered the system will check the entered password against the correct password. If the entered password is correct, the display will indicate this by displaying that the password has been accepted. The system will now select the Menu mode. If the entered password is incorrect the display will indicate this by displaying that the password is invalid. If the entered password is invalid, the user is again prompted to enter a password. (System default Password number is 6197).
3.6Overview of the Menu System
The menus are accessed from the Normal Operating Mode by pressing the MENU key. A password must be entered by the user to access the Menu Mode. Once the password has been accepted, the user will be presented with the Menu Screen. The menu may be navigated by pressing the UP and DOWN keys, which will enable the user to scroll through the menu items. The menu items will wrap around from the last menu item to the first menu item and vice-versa. For example, if the UP key is pressed when the last menu item, EXIT MENU,is displayed, the first menu item, SET TIME, will be displayed. Conversely, if the DOWN key is pressed when the first menu item, SET TIME, is displayed, the last menu item, EXIT MENU, will be displayed. To select the desired menu item, the user must press the SELECT key.
3.6.1Main Menu - Set Time
When the SET TIME menu item is entered from the display, shown below in Figure 3-10, the system time may be altered. This real time clock will remain active and maintain an accurate time even when power to the system is turned off.
Figure 3-10Set Time Menu Option
If the SET TIME menu item is selected the user will be prompted to enter the desired hours and minutes. The time is configured in the 24-hour clock mode. The SET TIME menu item display is shown in Figure 3-11 below. When first entered, the ‘hours’ value will flash indicating that this is the active field. Pressing the UP and DOWN keys will alter this field. To accept the displayed value the user must press the SELECT key. The ‘minutes’ value will now flash enabling the user to alter this field. Pressing the SELECT key again will set the minutes value. The SELECT key in this menu item acts as a toggle between selecting the ‘hours’ field and the ‘minutes’ field. When the desired time has been set the user must press the MENU key to exit the SET TIME menu item and return to the main menu.