ADMA OPCO On-Site-Training Instrumentation and Control

OJT TASK DETAILS

MODULE NO.: I-9

FIRE and GAS DETECTION SYSTEMS

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MODULE NO. : I-9

MODULE SUBJ.: Fire and Gas Detection Systems
Tasks:
A} Flame Detection System
I-9.1 Understand the function of “UV” flame detector
I-9.2 Describe automatic optical integrity “Oi” function of the “UV” flame
Detector.
I-9.3 Explain how flame detection system responds to fire.
I-9.4 Perform disassembly and re-assembly of flame detector sensor tube.
I-9.5 Perform check out of flame detection system, (a) Manual “Oi” check,
(b) Detector count test.
I-9.6 Perform periodic service of flame detector sensor, (a) Viewing window
cleaning, (b) “Oi” ring cleaning.
I-9.7 Describe how to troubleshoot flame detection system problems.

B} Smoke Detection System

I-9.8 Explain the principle of operation of ionisation smoke detector.
I-9.9 Perform periodic maintenance for ionisation smoke detector.
C} Heat Detection
I-9.10 Describe Heat Detection principle of operation. .
I-9.11 Demonstrate troubleshooting of Fusible Loops, control units and
Monitors.
I-9.12 Demonstrate the ability to explain the fire alarm interface to ESD.

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MODULE NO. : I-9

MODULE SUBJ.: Fire and Gas Detection Systems

Tasks:(Continued)

D} Gas Detection System

I-9.13 Explain principle of operation of the Hydrocarbon Gas Detector.
I-9.14 Perform routine calibration check of gas detectors.
I-9.15 Perform service of gas detector (a) correct malfunctions,
(b) Disassembly and cleaning, (c) detector replacement.
I-9.16 Describe flammable gas detector control card,
(a) Features (b) Front panel LED’s indication.
I-9.17 Demonstrate loop wiring connection from gas detector to controller
cards.
I-9.18 Describe how gas detector card is configured;
a) Link settings b) Potentiometer adjustments.
I-9.19 Perform troubleshooting of a gas detector card by observing LED’s
Indication.

E) Personal H2S Monitor

I-9.20 Describe function of personal H2S monitor.
I-9.21 Perform periodic maintenance of personal H2S monitor;
a) Battery replacement b) Sensor replacement
c) Calibration

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A} Flame Detection System

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MODULE No.: I-9 Fire and Gas Detection Systems

TASK No.: I-9.1
Demonstrate function of “UV” flame detector.

Reference: System Instruction Manual.

Materials: None

Equipment & Tools: None

Conditions: None

Requirements by Developee:
 To study the task and familiarises himself,
 Understand the principle of operation of UV flame detector,
 Describe detector’s cone of vision and response to constant UV source,
 Demonstrate how UV flame detector mounted and wired,
 Describe an understanding to his trainer, and
 Write observations and brief description in his workbook.

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TASK No.: I-9.1 “Continued”

Details:
UV Flame Detector
The fire detector consists of:
 A “UV” sensitive tube to sense the presence of ultraviolet radiation, and
 The electronic circuitry to generate the output signal that is sent to the controller
for processing to determine when an output is to be energised.
All components are mounted inside an explosion-proof enclosure. Detectors equipped
with the patented oil system have a test lamp (source tube) that emits a calibrated UV
test beam and either an external reflective ring or an internal optical arrangement. The
detector has a nominal 80-degree cone of vision with the highest sensitivity lying
along its central axis. A composite view of the detector’s cone of vision and response
to a constant UV source at various relative distances. Since physical attractions,
smoke accumulation, or UV absorbing chemical vapours will prevent UV from
reaching the detectors.

Figure I-9.1A, UV Fire Detector (DET-Tronics C 7050)

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TASK No.: I-9.1 “Continued”

Figure I-9.1B, Detector Cone of Vision and Response to

Constant UV Source

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MODULE No.: I-9 Fire and Gas Detection Systems

TASK No.: I-9.2
Describe Automatic optical integrity “Oi” function of
the “UV” flame detector.

Reference: System Instruction Manual.

Materials: None

Equipment & Tools: None

Conditions: None

Requirements by Developee:

 To study the task and familiarises himself,

 Understand the principle of operation of UV flame controller,
 Describe the Oi feature of the UV flame detector,
 Describe an understanding to his trainer, and
 Write observations and brief description in his workbook.

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TASK No.: I-9.2 “Continued”

Details:

The R7404 Controller incorporates a microprocessor and a programmable-read-only-

memory (PROM) to store and implement the permanent program for operating the
system. The main loop of the operating program continuously cycles through the
Automatic Optical Integrity (oi) test, checking each detector and its wiring.

At the same time, the microprocessor can be interrupted by any one of several status
changes, such as a fault, a “fire” signal from one of the detection zones, or a change
in the setting of the key-lock switch. In the event of a status change, the
microprocessor will take the appropriate action.

The Automatic oi system continuously monitors the operation of the R7404 but does
not monitor external relays or equipment that may be operated from the fire signal
output, the alarm signal output, or the fault signal output. It is important that the
system be manually checked using the NORMAL mode checkout procedure on a
regular basis. The whole system (including external equipment) should be checked
periodically using a UV Test Lamp to simulate a fire.

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MODULE No.: I-9 Fire and Gas Detection Systems

TASK No.: I-9.3
Explain how flame detection system-responds to fire.

Reference: System Instruction Manual.

Materials: None

Equipment & Tools: None

Conditions: None

Requirements by Developee:
 To study the task and familiarises himself,
 Describe the components of the flame detector system,
 Understand the principle of operation of the flame detection system,
 Describe the features of the flame detection system,
 Describe an understanding to his trainer, and
 Write observations and brief description in his workbook.

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TASK No.: I-9.3 “Continued”

Details:
Flame Detection System
The R7404 is designed for use with 24-volt dc power supplies, but will operate from
any direct current supply between l0 and 38 volts. The unit will tolerate transients
such as those that can occur when fully discharged batteries are placed charge. When
power is present at the R7404 Controller, a continuously energised green LED
indicates it. All other lights and displays on the R7404 panel are normally Off, but
may be periodically checked for operation by, pressing the LAMP TEST button
located directly opposite the POWER light as illustrated in Figure 8. It is not
necessary for the controller to be in the TEST mode when this check is performed.
The R7404 Controller incorporates a microprocessor and a programmable-read-only-
memory (PROM) to store and implement the permanent program for operating the
system. The main loop of the operating program continuously cycles through the
Automatic Optical Integrity (oi) test, checking each detector and its wiring.
At the same time, the microprocessor can be interrupted by any one of several status
changes, such as a fault, a “fire” signal from one of the detection zones, or a change
in the setting of the key-lock switch. In the event of a status change, the
microprocessor will take the appropriate action.
2.2 Fire Response, when the controller receives a “fire” signal from any detector in
the system, it is compared to the stored information of the program. If the signal
frequency is lower than the programmed setting for sensitivity, the lower display on
the front panel of the controller responds with a “3” and the upper display identifies
the first zone affected. If the signal frequency is greater than the programmed
sensitivity setting for a period greater than the pre-set time delay, the following
actions take place
The appropriate solid state zone output(s) is energised. One zone output is available
for each of the eight zones.
The solid state alarm output is energised. The alarm output is activated when any
zone detects a fire.
The ZONE display identifies the first responding zone. The DETECTOR display is
blank.

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TASK No.: I-9.3 “Continued”

The SYSTEM STATUS display shows a “6” indicating fire.

One or more ZONE LEDS turn on (blinking), indicating the zone(s) detecting UV
radiation.
If the selected “voting” criteria have been satisfied, the appropriate Fire Logic output
is energised and the corresponding LED is on.

Note
When a fire signal is no longer present, the ZONE LED(s) and the display indication
will latch until manually reset (ZONE LED emits steady light). The display latch
feature is useful in post-fire analysis as a means of determining fire origin.
The Alarm output is typically used to actuate an external audible alarm when a fire
signal is received from one or more detectors. Since these alarms can be disruptive to
personnel who are responding to the fire emergency, a means for alarm silencing has
been provided. The R7404 is equipped with a TEST/ACCEPT button, which will de-
activate the alarm circuit without interrupting the Zone and Fire Logic outputs. An
optional external silence switch can also silence the alarm.
2.3 Digital Displays, the upper digital display on the R7404 panel identifies both the
detector and zone involved in any “System Status” occurrence. For example, with the
key-lock switch in the TEST position, and a “1” digit showing on the lower display,
the upper display shows which detector and zone is electrically positioned for a
manual Oi test.

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MODULE No.: I-9 Fire and Gas Detection Systems

TASK No.: I-9.4
Perform disassembly and re- assembly of the flame-
detector-sensor-tube.

Reference: System Instruction Manual.

Materials: None

Equipment & Tools: 1. Tool box,

2. 5/32 inch hexagonal (Allen) wrench, and
3. Digital Multimeter.

Conditions: Work permit

Requirements by Developee:
 To study the task and familiarises himself,
 Demonstrate how UV flame detector mounted and wired,
 Perform disassembly and re-assembly of the flame detector,
 Describe an understanding to his trainer, and
 Write observations and brief description in his workbook.

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TASK No.: I-9.4 “Continued”

Details:
Mounting the Detector
The following procedure should be used for mounting and wiring the detectors.
1. Detectors should be located for the best-unobstructed view of the area to be
protected. Detectors must be accessible for cleaning the viewing window and
reflector rings. Care must be taken so that dirt or other foreign material will not
accumulate and obscure the detector-viewing window. For outdoor applications,
the detectors should be pointed downward to prevent the cone of vision from
scanning the horizon, since the detectors can be affected by long duration
lightning flashes or distant arc welding. When practical, mount the detectors so
that the UV test lamp is on top, since dirt accumulation between the window and
the reflector ring can interfere with the Automatic Oi function.
2. Disassemble the detector enclosure by turning the housing cover
counterclockwise. If the detector is equipped with a cover-locking device, loosen
the clamp and disengage the "catch" from the terminal cap. See Figure I-9.4A for
an illustration of the detector assembly and Figure I-9.4B for the optional cover
locking assembly. Power must not be applied to the system while opening the
detector housings, or while plugging in or removing the sensor tube modules.
3. Install the A-, B-, C-, and D-leads to the connections on the terminal block.
4. Remove the UV sensor tube module from its shipping package. When handling
the sensor tube module, be careful not to touch the sensor tube, since oil from the
skin can attenuate UV radiation, reducing the sensitivity of the tube.
5. Using the index pin as a guide, install the sensor module on the detector terminal
block.
6. Re-assemble the detector housing. If the detectors are equipped with cover locking
devices, loosen the clamp sufficiently so that the "catch" can be seated in the blind
hole provided on the terminal cap. (See Figure I-9.4B) The clamp must then be
fastened securely around the detector barrel by tightening with the proper tool.

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TASK No.: I-9.4 “Continued”

Figure I-9.4A UV Detector Assembly

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TASK No.: I-9.4 “Continued”

Figure I-9.4B UV Detector with Cover Locking Assembly

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MODULE No.: I-9 Fire and Gas Detection Systems

TASK No.: I-9.5
Perform check out of the flame detection system
a) Manual “Oi” check. b) Detector-count test.

Reference: System Instruction Manual.

Materials: 1. Cleaning rags, and

2. Recommended Cleaning Solution.

Equipment & Tools: Tool box

Conditions: Work permit

Requirements by Developee:
 To study the task and familiarises himself,
 Understand the principle of operation of UV flame detector,
 Describe manual check procedure of the flame detector Oi feature,
 Describe manual check in normal mode of the flame detector Oi feature
 Describe an understanding to his trainer, and
 Write observations and brief description in his workbook.

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TASK No.: I-9.5 “Continued”

Details:

Checkout Procedure
When testing the system, be sure to secure all output devices to prevent unwanted
activation of this equipment, and remember to place these same devices back into
service when the checkout is complete.

a) Manual Oi Check
1. Place the key-lock switch in the TEST position;
 The FAULT and INHIBIT LEDS turn on.
 Upper right display indicates the zone selected.
 Upper left display identifies the detector of the displayed zone.
 Lower display indicates a “1.”
2. Push and hold the TEST/ACCEPT button.
 A ZONE OUTPUT LED flashes to indicate the zone of the detector being tested.
 Upper left display goes blank.
 Lower display changes to “6” to indicate that the fire threshold has been exceeded
due to the radiation received from the UV source in the detector.
3. Release the TEST/ACCEPT button.
 The ZONE OUTPUT LED remains on steady.
 The upper left display again shows the detector being checked.
 The lower display changes back to a “1.”
4. Push the SELECT button. The controller sequences to the next lower numbered
zone.
5. Repeat the test until all detectors have been checked.
6. Return the system to the normal operating mode after the test is complete.

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TASK No.: I-9.5 “Continued”

The Automatic Oi system continuously monitors the operation of the R7404 but does
not monitor external relays or equipment that may be operated from the fire signal
output, the alarm signal output, or the fault signal output. It is important that the
system be manually checked using the NORMAL mode checkout procedure on a
regular basis. The whole system (including external equipment) should be checked
periodically using a UV Test Lamp to simulate a fire.
b) Manual check in normal mode
The whole system should be checked periodically with a UV test lamp to make sure
that the detectors are not obstructed, that the area "seen" by the detector has not
changed, and that there is no fault in the Oi circuit.
Secure all output loads connected to the controller outputs to prevent unwanted
activation.
1. Place the key-lock switch in the NORMAL position.
2. Shine the UV test light into a detector-viewing window.
 The corresponding ZONE LED turns on and flashes, indicating the zone in
which, the detector is located.
 The upper display shows the first zone activated.
 The lower display shows a “6.”
 The appropriate FIRE LOGIC LED(s) turns on if voting requirements are met.
3. Turn off the UV source.
 -FIRE LOGIC LED(s) stays on (if illuminated).
 -ZONE LED stays on but stops flashing. The numeral indicating the first zone
to respond to the UV signal is shown in the upper display, and the numeral "6"
remains in the lower display.
4. Repeat the test for all detectors in the system.
5. After all detectors have been checked, reset the system by turning the key-lock
switch to the RESET position, then turn it to the NORMAL position.
6. Restore power to output loads or remove any mechanical blocking devices.

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MODULE No.: I-9 Fire and Gas Detection Systems

TASK No.: I-9.6
Perform periodic service of flame detector sensor
a) Viewing window cleaning. b) Oi ring cleaning.

Reference: System Instruction Manual.

Materials: Cleaning rags and cleaning solution.

Equipment & Tools: 1. Tool box,

2. Service kit of the flame detector, and
3. Digital Multimeter.

Conditions: Work permit

Requirements by Developee:
 To study the task and familiarises himself,
 Describe the periodic service of the flame detector,
 Demonstrate how UV flame detector mounted and wired,
 Describe an understanding to his trainer, and
 Write observations and brief description in his workbook.

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TASK No.: I-9.6 “Continued”

Details:
Periodic Service of Flame Detector Sensor
Maintenance, the detector requires no periodic calibration. However, to maintain
maximum sensitivity, the quartz window must be kept clean at all times. Even a small
amount of certain UV absorbing materials can significantly reduce the sensitivity of
the detector. The window and Oi ring should be thoroughly cleaned on a regular
basis. The nature and amount of contaminants present in the environment will
determine the length of time between periodic cleanings.
Remove the Oi ring (if used) and clean the quartz window thoroughly, all the way to
the edge. Also clean the Oi ring. When re-installing the reflective ring, hold it by its
tabs to avoid leaving fingerprints on the reflective surface. Re-install the ring so that
the split is 180 degrees from the Oi test lamp (opening down to prevent water build-
up). If corrosive contaminants in the atmosphere cause the reflective rings to
deteriorate to the extent that it is no longer possible to restore them to their original
condition, they must be replaced.
Use a clean cloth or tissue to clean the window. DO NOT use commercial glass
cleaning tissues. Many of these contain a silicone substance that remains on the
cleaned surface and will absorb UV radiation

Note
Remove power to the controller or switch the unit to the Bypass or Test mode when
cleaning the detector windows. It is possible to create a static charge on the windows
during cleaning, which could result in an unwanted activation of the controller’s
outputs.
Two rubber O-rings on the barrel of the detector housing are used to ensure the
watertight integrity of the detector Periodically the housing should be opened and the
O-rings inspected for breaks, cracks, or dryness. To test them remove the ring from
the detector housing and stretch them slightly. If cracks are visible, the ring should be
replaced. If they feel dry to the touch, a thin coating of lubricant should be applied.

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TASK No.: I-9.6 “Continued”

When re-installing the rings, be sure that they are properly seated in the groove on the
housing. It is imperative that these O-rings be properly. Installed and in good
condition. Failure to properly maintain these rings can allow water to enter the
detector and cause premature failure. The life expectancy of rubber O-rings can vary
considerably, depending on the amount and nature of contaminants that are present in
the environment. The person responsible for maintenance of the system must rely on
experience and common sense to determine how frequently the rings should be
inspected.

The detector requires no periodic calibration. However, to maintain maximum

sensitivity, the viewing windows should be cleaned on a regular basis. The nature and
amount of contaminants present in the environment will determine the length of time
between periodic cleanings.

A test form is required for recording maintenance performed on the system.

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MODULE No.: I-9 Fire and Gas Detection Systems

TASK No.: I-9.7
Demonstrate how to troubleshoot flame detection
system problems.

Reference: System Instruction Manual.

Materials: Cleaning rags and cleaning solution

Equipment & Tools: 1. Tool box, and

2. Repair kit

Conditions: Work permit

Requirements by Developee:
 To study the task and familiarises himself,
 Understand the Oi diagnoses of flame detector troubles,
 Describe the Oi feature of the UV flame detector,
 Describe an understanding to his trainer, and
 Write observations and brief description in his workbook.

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TASK No.: I-9.7 “Continued”

Details:
Troubleshooting
The Automatic Oi feature continuously checks the system for various faults that can
occur. If a fault should be detected, the FAULT LED will turn on. If the fault is in the
detector or wiring, the upper displays will indicate which zone and detector is
affected. The lower display will indicate by code number the type of fault. If the fault
is in the microprocessor circuitry, the FAULT LED will turn on, but the displays will
remain blank. See in reference doc. the attached table for a detailed explanation of the
status/fault code numbers on the lower digital display, and the corresponding detector
identification numbers on the upper digital display.
The R7404 is not designed to be repaired by the customer in the field. If a problem
should develop, first carefully check for proper wiring and programming. If it is
determined that the problem is caused by an electrical malfunction, the unit must be
returned to the factory for repair.

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B} Smoke Detection System

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MODULE No.: I-9 Fire and Gas Detection Systems

TASK No.: I-9.8
Explain the principles of operation of the ionisation
smoke detectors.

Reference: Manufacturer Operation and service Manual.

Materials: None

Equipment & Tools: None

Conditions: None

Requirements by Developee:
 To study the task and familiarises himself,
 Understand the principle of operation of ionisation smoke detectors,
 Understand the principle of operation of photoelectric smoke detectors
 Describe how the smoke detector respond the smoke,
 Describe the feature of the smoke detector,
 Describe an understanding to his trainer, and
 Write observations and brief description in his workbook.

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TASK No.: I-9.8 “Continued”

Details:
Ionisation Smoke Detectors
Ionisation smoke detectors are specifically designed to meet the stringent
performance requirements of industrial and municipal fire detection/alarm systems.
These detectors are arc less likely than ionisation detectors to produce false alarms.
See figures I-9.8A and 8B.
Operation, Ionisation smoke detectors contain a unique optical sensing chamber
designed to sense the presence of smoke particles produced by a wide range of
combustion sources. A new custom integrated circuit incorporates signal processing
to reduce false alarms and sample/hold circuitry to provide easy field metering of
sensitivity.
Ionisation smoke detector is powered by 24 Vdc, will respond to a brood spectrum of
fire, including the earliest incipient stage before there is visible smoke or flame or
noticeable heat at the detector. The ionisation chamber contains two charged plates
and an alpha source that ionises the air molecules. When products of combustion
enter the chamber, they impede the flow of ions. This reduces the flow of current
between the plates and causes a voltage shift that triggers the alarm through a field
effect transistor (FET). The alarm horn will sound as long as the combustion products
are present. When the chamber is cleared the unit will automatically reset.
The unit contains a set of SPDT and SPST alarm operated contacts for the control of
supplementary external equipment such as an additional audible device, equipment
fans, or as a releasing device. A SPST trouble operated supervisory relay is also
provided.
The detector is equipped with a “Power On” LED located on the face of the unit.
When the unit is in an alarm condition the horn will sound and the Power LED will
go out until the unit automatically resets.
The unit is supplied with a pair of interconnect leads so that it may be interconnected
with other units. If any of the interconnected units alarm, the horn will sound in it and
in all interconnected units. The power on LED will “Go Out” on the unit which
initiated the alarm while the slave unit LED’s will “Stay On”.

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TASK No.: I-9.8 “Continued”

Figure I-9.8A, Photoelectric Smoke Detector

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TASK No.: I-9.8 “Continued”

Figure I-9.8B, Ionisation Type Smoke Detector

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MODULE No.: I-9 Fire and Gas Detection Systems

TASK No.: I-9.9
Perform periodic maintenance for ionisation smoke
detector.

Reference: Manufacturer Operation and service Manual.

Materials: Cleaning rags and cleaning solution

Equipment & Tools: 1. Tool box, and

2. Digital Multimeter.

Conditions: Work permit

Requirements by Developee:
 To study the task and familiarises himself,
 Describe the periodic service of the ionisation smoke detector,
 Demonstrate how ionisation smoke detector mounted and wired,
 Describe an understanding to his trainer, and
 Write observations and brief description in his workbook.

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TASK No.: I-9.9 “Continued”

Details:
To insure that the ionisation smoke alarm, is always capable of performing its vital
function, a built-in test feature has been provided, when a magnet is applied to the,
area between the LED and, outside rim of the detector case, a hidden reed-switch is
activated, which will initiate a functional alarm condition. This tests the ionisation
chamber, the electronic circuitry, and the horn.

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C} Heat Detection System

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MODULE No.: I-9 Fire and Gas Detection Systems

TASK No.: I-9.10
Describe heat detection principle of operation

Reference: Manufacturer Operation and service Manual.

Materials: None

Equipment & Tools: None

Conditions: None

Requirements by Developee:
 To study the task and familiarises himself,
 Understand the principle of operation of heat detector,
 Describe the component of the heat detector,
 Describe how heat detector respond heat,
 Describe an understanding to his trainer, and
 Write observations and brief description in his workbook.

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TASK No.: I-9.10 “Continued”

Details:
Heat Detectors
The Thermo-tech anticipation heat detectors operate within a controlled range of two
to three degrees of its set point, regardless of the speed or rate of temperature rise.
These detectors activate whenever the ambient air temperature reaches the detector
setting, eliminating the thermal time lag inherent in conventional heat detectors.
Principles of operation, The rate anticipation heat detector responds and activates the
fire alarm immediately whenever the ambient temperature reaches the pro-set
temperature setting. Under rapid heat rise conditions, the rate anticipation detector
respond one to three degrees ahead of the setting, When temperature drops back
down below the protection level, the detector automatically resets itself.

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MODULE No.: I-9 Fire and Gas Detection Systems

TASK No.: I-9.11
Demonstrate troubleshooting of fusible loops, control
units and monitors.

Reference: OJT Instructor to arrange reference doc for fusible

loop relevant to each working area.

Materials: None

Equipment & Tools: Tool box, and

Digital Multimeter.

Conditions: Work permit

Requirements by Developee:
 To study the task and familiarises himself,
 Understand the principle of operation of fusible detection system,
 Understand the location of fusible loop system in his working area,
 Be able to read schematic diagram of fusible loop system,
 Understand the colour codes of fusible plugs temperature setting,
 Describe an understanding to his trainer, and
 Write observations and brief description in his workbook.

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MODULE No.: I-9 Fire and Gas Detection Systems

TASK No.: I-9.12
Demonstrate the ability to explain the fire alarm
interface to ESD.

Reference: OJT Instructor to arrange reference doc of fire alarm

interfaces to ESD relevant to each working area.

Materials: None

Equipment & Tools: None

Conditions: None

Requirements by Developee:
 To study the task and familiarises himself,
 Understand the purpose of interfacing fire system to plant ESD,
 Describe the interface system components,
 Be able to read interface schematic diagram,
 Describe an understanding to his trainer, and
 Write observations and brief description in his workbook.

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D} Gas Detection System

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MODULE No.: I-9 Fire and Gas Detection Systems

TASK No.: I-9.13
Explain the principle of operation of hydrocarbon gas
detector

Reference: DET-TRONIC instruction manual for Point Watch

“IR” hydrocarbon gas detector.

Materials: None

Equipment & Tools: None

Conditions: None

Requirements by Developee:
 To study the task and familiarises himself,
 Understand the principle of operation of the gas detection sensor,
 Be able to describe gas detector sensor in your working area,
 Describe an understanding to his trainer, and
 Write observations and brief description in his workbook.

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TASK No.: I-9.13 “Continued”

Details:
Gas Detection Sensor
The catalytic gas detection sensor (FigureI-9.13A) contains two detector elements,
which are heated by a supply derived from the associated electronic control
equipment. One element is sensitive to the presence of flammable gas, the element
temperature increasing in response to catalytic oxidation of the gas. The resultant rise
in resistive value of the sensitive element, proportional to gas concentration, is
processed by the electronic control equipment to operate indicator and alarm circuits.
The second element has negligible response to all gases, but compensates for effects
of changes in ambient temperature.

FigureI-9.13A, Gas Detection Sensor-General View

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MODULE No.: I-9 Fire and Gas Detection Systems

TASK No.: I-9.14
Perform routine calibration check of gas detectors.

Reference: DET-TRONIC instruction manual for Point Watch

“IR” hydrocarbon gas detector.

Materials: Recommended test gas bottles

Equipment & Tools: 1. Tool Box, and

2. Digital Multimeter

Conditions: Work Permit.

Requirements by Developee:
 To study the task and familiarises himself,
 Understand the purpose of testing gas sensor,
 Be able to perform calibration procedure of gas sensor,
 Describe wiring connections of gas detector,
 Describe an understanding to his trainer, and
 Write observations and brief description in his workbook.

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TASK No.: I-9.14 “Continued”

Details:
Gas Detection Sensor Calibration
When commissioning and testing the gas detection system, the sensors (Figure I-
9.14A) must be gassed using the following procedures:
To calibrate the zero reading, ensure an atmosphere free from combustible gasses (if
necessary apply zero test gas or instrument air). Allow the system to stabilise, and
follow the detailed procedure in reference manual. Consult your trainer.

To calibrate the span, apply the test gas and after the stabilisation period. Follow the
detailed procedure in reference manual.
Notes:
1. For calibrating Catalytic Sensors the test gas should be mixture of gas in air, as the
detector requires oxygen for correct operation.
2. It is recommended that sensors should be calibrated with the type of gas to be
detected.
3. Alternatively, where a sensor with a Catalytic Detector Assembly installed is to be
calibrated with a different gas to the type of gas to be detected.
Gassing the Sensor

To test and calibrate the gas detection system the following items of equipment are
required:
1. Calibration Gas Test Kit and a bottle of the appropriate test gas.

2. Extending Gassing Probe Assembly appropriate to the Gas Test Kit.

3. Where sensor accessories are not fitted, a sample Flow Housing will be required
for accurate sensor calibration.

4. A suitable plastic bag.

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TASK No.: I-9.14 “Continued”

Calibration Gassing Procedure;

The gassing procedure will vary slightly depending on the accessibility of the sensor
and the accessories fitted.
 For a sensor without accessories and in an accessible position, fit the plastic bag
over the sensor, leaving a small gap at the neck in order that the displaced air may
escape. Connect the calibration gas test kit. If not in an accessible position use the
extending gassing probe assembly.
 For a sensor with collecting cone or weather proof housing, connect the
calibration gas test kit to the gassing nozzle, or the permanently connected
pipeline, if fitted.
 For a sensor with a sample flow housing, shut off the sample flow, disconnect the
input pipeline and connect the calibration gas test kit to the input nozzle of the
flow housing. Having connected the calibration gas test kit, proceed as follows:
1. Open the valve of the calibration gas test kit and set the flow rate to 2.0 ± 0.5 litres
per minute.
2. Apply gas for a minimum period of 60 seconds.

3. Set up the control system as instructed in the Control System Manual.

4. On completion, shut off the test gas, disconnect the calibration gas test kit and
restore the installation to its normal state.

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TASK No.: I-9.14 “Continued”

Figure I-9.14A, Gas Detector Wiring Connections

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MODULE No.: I-9 Fire and Gas Detection Systems

TASK No.: I-9.15
Perform service of gas detector element
a) Isolate and correct malfunctions.
b) Disassembly and cleaning. c) Detector replacement.

Reference: Gas Detection System Vendor Manual

Materials: Cleaning rags and cleaning solution

Equipment & Tools: 1. Tool Box, and

2. Digital Multimeter

Conditions: Work Permit

Requirements by Developee:
 To study the task and familiarises himself,
 Be able to perform periodic service of gas detector,
 Describe an understanding to his trainer, and
 Write observations and brief description in his workbook.

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TASK No.: I-9.15 “Continued”

Details:
Gas Detection Sensor Maintenance
Maintenance of gas detection sensor consists of:
1. Cleaning the sensor,
2. Replacing the gasket and filter, and
3. Calibration at regular intervals, the period depending on the environment in which
the sensor is located.
In the event of exposure to a contaminant or prolonged exposure to high
concentration of gas, the sensor should be operated for 24 hours in a clean
environment and then re-calibrated. Whenever cleaning takes place, a new filter must
be fitted and the following precautions observed:
a) Isolate the power supply from the sensor by withdrawing the associated control
module from the installation.
b) Do not remove the sensor from the installation.

c) Safeguard the sinter against contamination of any sort, including cleaning fluids.

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MODULE No.: I-9 Fire and Gas Detection Systems

TASK No.: I-9.16
Describe flammable gas detector control card
a) Features b) Front panel LED’s indication

Reference: Gas Detection System Vendor Manual

Materials: None

Equipment & Tools: None

Conditions: None

Requirements by Developee:
 To study the task and familiarises himself,
 Understand the features of the flammable gas detector control card,
 Describe card specifications,
 Be able to perform routine maintenance and troubleshooting of the card,
 Describe an understanding to his trainer, and
 Write observations and brief description in his workbook.

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TASK No.: I-9.16 “Continued”

Details:

Flammable Gas Detector Control Card

Figure I-9.16A Flammable Gas Detector Card Front View

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TASK No.: I-9.16 “Continued”

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TASK No.: I-9.16 “Continued”

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TASK No.: I-9.16 “Continued”

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MODULE No.: I-9 Fire and Gas Detection Systems

TASK No.: I-9.17
Demonstrate loop-wiring connection from gas
detectors to controller cards.

Reference: Gas Detection System Vendor Manual

Materials: None

Equipment & Tools: None

Conditions: None

Requirements by Developee:
 To study the task and familiarises himself,
 Be able to trace loop wiring connections of flammable gas detector,
 Be able to identify the flammable gas detectors in your working area,
 Describe an understanding to his trainer, and
 Write observations and brief description in his workbook.

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TASK No.: I-9.17 “Continued”

Details:

Figure I-9.17A Flammable Gas Detector Wiring Diagram

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MODULE No.: I-9 Fire and Gas Detection Systems

TASK No.: I-9.18
Demonstrate how gas detector card is configured
a) Link settings b)Potentiometer adjustments

Reference: Gas Detection System Vendor Manual.

Materials: None

Equipment & Tools: None

Conditions: None

Requirements by Developee:
 To study the task and familiarises himself,
 Understand the purpose of card configuration,
 Describe the function of each link setting,
 Be able to adjust alarm settings threshold,
 Be able to set-up the card,
 Describe an understanding to his trainer, and
 Write observations and brief description in his workbook.

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TASK No.: I-9.18 “Continued”

Details:

Link Settings and Adjustments

 Input Set-up (Links A and B)

These links are used for card set-up and factory testing and should not be adjusted.
Link A should always be fitted between pins 2 and 3. Link B should not be fitted.
 Analogue Output Option (Link C)
When the link is fitted between pins 1 and 2 the analogue output will be forced to 2
mA whenever the card is in the inhibit condition. If the link is between pins 2 and 3
the analogue output will continue to track the display on the card, 0-100% FSD =
4-20 mA.
 Input Option (Link D)
When the link is fitted between pins 1 and 2 the detection of 2 mA on the input signal
will cause the card to go into the inhibit condition. If the link is between 2 and 3 the
presence of a 2 mA signal will merely be displayed as a negative reading.
 Fault Condition Latch (Link E)
If the link is fitted between pins 1 and 2 then a fault condition will have to be reset
manually by pressing the reset button. If the link is between pins 2 and 3 then the
fault condition will disappear as soon as the fault itself disappears. If the Alarm
Latching link is not set (2/3) then the fault condition will not latch.
 Alarm Latching (Link F)
If the link is fitted between pins 1 and 2 then alarms and faults (note condition of link
E) will have to be reset manually. Fitting the link between pins 2 and 3 will cause the
alarm and fault conditions to reset as soon as the appropriate hazard has cleared
below the alarm threshold, or the fault has cleared, whichever is appropriate.

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TASK No.: I-9.18 “Continued”

 Constant Display (Link G)

If the link is fitted then the two digit display will be permanently on. Otherwise it will
automatically be blanked once the displayed value enters the blanking threshold,
typically ±5% FSD.

 Analogue Output - 2 mA adjustment (RV1)

The card has the facility of forcing the analogue output to 2 mA whenever an inhibit
condition is in effect. This potentiometer is used to achieve this. It is factory set and
should not be adjusted.
 Zero Adjust (RV2)
This potentiometer adjusts the zero setting of the measured concentration display and
is factory set. Do not alter this potentiometer.
 Span Adjust (RV3)
This potentiometer adjusts the card to correctly interpret a 20 mA input signal as
FSD. This potentiometer is factory set and should not be adjusted.
 Analogue Output - 4 mA adjustment (RV4)
The analogue output is set for a 4-20 mA output when the display reads between 0%
FSD and 99% FSD. The potentiometer is used to correctly scale the offset to read 4
mA when the display is reading 0. It is factory set and should not be adjusted.
 Analogue Output - 20 mA adjustment (RV5)
The analogue output for the card is set to mirror the input 4-20 mA signal. This
potentiometer is factory set to ensure that a display of 99% FSD will give 20 mA on
the analogue output. This potentiometer should not be adjusted.

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TASK No.: I-9.18 “Continued”

 Alarm 1 Set Point (RV6)

With the card powered through a 64 way uncommitted extender card (stock no.
C03233) allowing access to RV6, and the four position mode switch on the front
panel in the "Al" position, the set point for the first level of alarm may be adjusted.
As the potentiometer is altered so the display will change.
NOTE: The alarm 1 threshold must always be set lower than the alarm 2 threshold.
 Alarm 2 Set Point (RV7)
With the card powered through a 64 way uncommitted extender card (stock no.
C03233) allowing access to RV7, and the four position mode switch on the front
panel in the "AT' position, the set point for the second level of alarm may be adjusted.
As the potentiometer is altered so the display will change.
NOTE: The alarm 2 threshold must always be set higher than the alarm I threshold.

 Blanking Threshold (RV8)

As standard the card is set up to blank the display when the reading is less than ±5%
FSD. This may be adjusted by altering RV8. To set up accurately the zero setting
must also be adjusted.
NOTE: This procedure must only be carried out by a qualified personnel.

1. Confirm there is 0 shown on the display.

2. Put the card onto a 64 way uncommitted extender card (stock no. C03233).

3. Put the four position switch into the "CAL" position.

4. Adjust the zero potentiometer, RV2, to whatever blanking set point is required.

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TASK No.: I-9.18 “Continued”

5. Assuming this set point is below any alarm levels, move the four position
switch rack to the "NORM" position.

6. Adjust RV8 until the display blanks.

7. Switch the four position switch back to the "CAL" position.

8. Adjust the zero potentiometer, RV2, back to read zero on the display.

9. Remove the 64 way extender card and re-fit the card.

10. Confirm that the display still reads zero before switching the four position
switch back to the "NORM" position.

Setting Up the Card

Before the card can be set up and the channel calibrated it is assumed that all field
cabling for the channel has been completed, the sensor installed as per the relevant
manual, and that power is available on the panel although it should be isolated to start
with.
To complete this procedure a 64 way uncommitted extender card (C03233) is
required. This will allow adjustments to be made to the card whilst it is powered up.
Before power is applied fit a 64 way uncommitted extender card in the rack. Fit the
DI-861 or DI-862 to the extender and ensure all the connections are firm and suitably
supported. Power may then be applied.
Depending on the type of detector connected to the card there may be a warm-up
period that would have to be observed. Refer to the documentation accompanying the
detector for details of any such delays.
Note: If a detector clamps its signal line to less than 2 mA at any time then the
control card will interpret this as a fault although it may not actually be the case.

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TASK No.: I-9.18 “Continued”

Turn the four position switch to the "A2" position and adjust RV7 until the correct
valve for the second level of alarm. Turn the switch to the "Al" position and adjust
RV6 until the desired set point is achieved.

NOTE: When setting the alarms the alarm 2 level must always be greater than the
alarm 1 level.

Finally turn the four position switch to the "NORM" position. The card is now ready
for calibration.

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MODULE No.: I-9 Fire and Gas Detection Systems

TASK No.: I-9.19
Perform troubleshooting of gas detector card by
observing LED’s indication.

Reference: Gas Detection System Vendor Manual

Materials: None

Equipment & Tools: 1. Tool box, and

2. Digital Multimeter.

Conditions: Work Permit.

Requirements by Developee:
 To study the task and familiarises himself,
 Understand the diagnoses LED’s function,
 Be able to troubleshoot flammable card system problems,
 Describe an understanding to his trainer, and
 Write observations and brief description in his workbook.

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TASK No.: I-9.19 “Continued”

Details:

Troubleshooting

The format of this section is designed so that the user picks the description which,
matches the problem and then follows down the list of things to do until the problem
goes away.

The blanking threshold cannot be set.

1. If the display will not go out, ensure that link G has not been fitted.

2.If the display will not come on ensure that the card is not in the over range
condition.

3. Set the blanking as per the instructions under the Link Settings and Adjustments
section.

The fault LED is on and the pilot LED is off, no other LED is illuminated.

1 Press the lamp test/reset button for one second and release.

2. Check that a head voltage is getting to the terminals that the field cables attach to.
Assuming the problem is a cable problem a voltage should be observed here. If no
voltage is observed then this would indicate either a card failure or in the connectors
between the control rack and the terminals.

3. Remove the card from the rack and use a resistance meter to locate the cable
fault. Once it has been rectified then use the meter again to confirm that the
sensor is not damaged.

4. If the card is still in fault then confirm return current from the detector. This is
done by disconnecting the signal from the field terminals and reconnecting the
circuit with a milliammeter in series with the signal line.

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TASK No.: I-9.19 “Continued”

The current should be between 2 and 20 mA for the control card to be out of fault. If
it is and the fault will still not reset when the cable is reattached then there is an
internal card or rack fault.

The over range LED is on and will not reset.

1. Disconnect the signal line and insert a milliammeter in series with it. The
observed current should be less than 20 mA. If it is above this then the detector
or sensor may be at fault. If the signal current is within acceptable parameters
then a card or rack fault is indicated.

The display will not come on and the card is not in over range.

1. If the display comes on when the read button is pressed then the blanking
threshold is too high. Try turning resetting it by following the procedure in the
Link Settings And Adjustments section.

2. If the display does not come on even when read is pressed but the LEDs
illuminate when the card reset button is pressed, then the card is faulty and
must be replaced.

No LEDs are illuminated and the display is not on.

1. If the problem is isolated to one card then check the fuse on the card. If it is
more extensive than that then check the power to the control rack.

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E} Personal H2S Monitor

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MODULE No.: I-9 Fire and Gas Detection Systems

TASK No.: I-9.20
Describe function of personal H2S monitor

Reference: Manufacturer Instruction Manual for H2 S monitors.

Materials: None

Equipment & Tools: None

Conditions: None

Requirements by Developee:
 To study the task and familiarises himself,
 Understand the function of H2S monitor,
 Describe how H2S sensor works,
 Be able to operate H2S monitor and diagnose the indication,
 Describe an understanding to his trainer, and
 Write observations and brief description in his workbook.

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TASK No.: I-9.20 “Continued”

Details:

Portable H2S Monitor

H2S monitor and indicator designed to detect presence of hydrogen sulphide and
indicate concentration at any time. It can be used intermittently or continuously, and
will sound an alarm at two pre-set levels, typically, 10 and 50 ppm. It also features a
self-illuminating LCD display, which lights when instrument is used in dark areas.
Long-life dry cells are standard, and rechargeable cells optional.
The monitor has an all solid-state electronic circuit, with all components on a single
etched circuit board. There is no need to open the instrument in normal operation;
however, It can be disassembled by removal of one screw for access to the internal
adjustments, and for repair.
The battery used to supply power to the instrument consists of two size AA dry cells
in series. Optionally, the Instrument can be supplied with two rechargeable nickel-
cadmium size AA batteries.
H2 S Detector
The H2 S detector is a plug-in cell assembly in a plastic enclosure with pins to retain
the detector in a bayonet-type socket at top of panel. A perforated cap at the top (or
sensitive) end allows the surrounding atmosphere to diffuse In and reach the active
part of the cell.
H2 S. detection occurs in an electrochemical cell consisting of two precious metal
electrodes immersed in an acid electrolyte, each electrode being mounted on a porous
fluorocarbon membrane. H2S in the atmosphere surrounding the detector diffuses
through the membrane at a rate proportional to the partial pressure of H 2S. This H2S
enters into an electrochemical reaction which produces a current directly proportional
to the concentration and the current in turn is amplified in the instrument circuitry to
produce a reading in ppm, and trigger alarms at preset points.

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TASK No.: I-9.20 “Continued”

Alarm Functions
 Rising gas - When concentration reaches10 ppm, (Low Alarm) a pulsing tone will
sound and the LED (red lamp) will flash.
 High alarm - When concentration reaches 50 ppm, the audible alarm will change
to a continuous steady tone and the red LED will glow steadily.
 Low Battery Alarm - When battery capacity is exhausted, alarm buzzer will give
a continuous steady tone.
Operation

The following steps should be followed for normal routine operation:

a) Instrument is usually shipped with sensing cell removed and pecked separately.
b) Reinstall it in socket on top of instrument. and wait an hour before proceeding.
c) Instrument must have batteries in it during this period.
d) While in a normal air location, turn POWER switch to ON.
e) Observe meter reading. Set to 00.0, by turning ZERO adjustment using a fingertip
or small screwdriver, turn clockwise to increase reading.
f) Press CHECK button momentarily, reading should suddenly rise and then
gradually return toward zero; during this transition, buzzer should emit from one
to three pulsing tones. When button is released, the reaction will cause a negative
reading, which will recover in a few seconds.
This test verifies operability of system, end cannot be completed successfully if the
cell Is removed, disconnected or has an internal open circuit.
Instrument is now adjusted and ready for a day's use as an H2 S indicator or monitor.
This monitor can be carried or worn during normal activities, and will actuate alarm
whenever H~S content rises above l0 ppm, producing a pulsing tone from the buzzer
and a pulsing red light. The pulsing tone and red light continue if gas continues to rise
and will change to a steady tone if gas concentration reaches 50 ppm. The LED red
lamp wills then also, glow steadily.

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TASK No.: I-9.20 “Continued”

Range for linear output is about 0-80 ppm. The display has three digits and readings
are in ppm units to the nearest 0.1. For example, 5 ppm would indicate 05.0, 25 ppm
as 25.0, 50 ppm as 50.0. Readings can increase above loo but should not be relied
upon for accuracy.
Normal battery life with standard dry cells is loo hours of daylight -use, 50 hours if
used entirely in dark areas. If optional nickel-cadmium rechargeable batteries were
used, good practice would be to recharge overnight after every 24 hours of operation.
If battery voltage drops to a point which, indicates the batteries are nearing the end of
their capacity, the instrument will go into low battery alarm, indicated by continuous
audible tone. At this point, dry cells must be replaced or nickel-cadmium cells
recharged.
A Repeater Buzzer is available as an accessory. The buzzer is fitted with a lapel clip
so it can be fastened to collar where it can be heard easily even in a high-noise
environment. To use, simply plug buzzer cable into repeater socket. Both the Internal
and the repeater buzzers will sound simultaneously.
For remote measurement such as checking a confined area before entry, extension
cables are available in 5 meter and l0 meter lengths (approximately 15 and 30 feet).
a) To use, remove the sensor from its socket by pressing down on it lightly and
turning it counter clockwise.
b) Install sensor in the socket provided on the end of the cable.
c) Insert plug end of cable into sensor socket on the Instrument.
d) Verify operation as indicated on Operation, Sections B, C and D.
e) Temperature range is -10°C (+15°F) to (+104°F).

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MODULE No.: I-9 Fire and Gas Detection Systems

TASK No.: I-9.21
Perform periodic maintenance of personal H2S
monitor:
a) Battery replacement. b) Sensor replacement.
c) Calibration.

Reference: Manufacturer instruction Manual for H2 S monitor.

Materials: Cleaning rags

Equipment & Tools: 1 Screw-driver set, and

2. Digital Multimeter

Conditions: None

Requirements by Developee:
 To study the task and familiarises himself,
 Be able to perform periodic calibration of the monitor,
 Understand alarm limits of the measured gas,
 Be able to perform periodic service and routine maintenance of the unit,
 Describe an understanding to his trainer, and
 Write observations and brief description in his workbook.

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TASK No.: I-9.21 “Continued”

Details:
H2S Calibration
Instrument should be calibrated not less than every 3 months using a known H 2S
sample. Calibration gas is available from Gas-Tech. To calibrate, allow a known
sample to flow over the outer face of the H2S cell end «etch digital display.
Flow rate should be more then 200 cc/min, but instrument is not flow sensitive so
adjustment is not critical.
While cell is exposed to sample, note reading. If not correct, turn SPAN control,
using a small screwdriver. Turn clockwise to increase reading.
Alarm Adjustment
The three alarm functions are independently adjustable when the Instrument-case is
removed to expose the circuit board components.
The adjustments are as follows:
 Low Alarm adjustment, VR 5, is the upper of the two potentiometers found at
lower left centre of circuit board. To reduce alarm setting, turn the potentiometer
clockwise. Initial setting is 10 ppm.
 High Alarm adjust potentiometer, VR 6, is located Just below the Low Alarm
potentiometer, and is used in the same way, but turn clockwise to, Increase alarm
setting, Initial setting is 50 ppm.
 Low Battery alarm adjustment, VR 4 is located to the right of off-on switch. It
is factory- set and normally should not be changed in the field.
 Bias voltage Adjustment, VR3, is located to right of SPAN adjust, end is factory
set.

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TASK No.: I-9.21 “Continued”

Maintenance
Battery, Batteries need replacement when dry cells are being used or recharging
when nickel-cadmium batteries are used when, with the power switch on, the buzzer
sounds continuously even though the readout is be-low 50 ppm. Batteries must not be
allowed to run down past the point where the low battery alarm comes on. If they do
go completely dead or nearly deed, it is necessary to replace them or recharge them
and then allow the Instrument to stabilise for one hour before calibration or use.
Replacement or recharging of battery cells should be done in a non-hazardous area.
To remove dry cells, turn Instrument upside down and turn the knurled retaining cap
found on the bottom in the direction Indicated for OPEN. Remove the cap and the old
batteries. Replace with two A6 or AA size dry cells with + end of each battery
entering cavity first. Replace retaining cap and verify operation.
If nickel cadmium cells are being' used, remove 6.batteries as above end snap the
batter16s Into the holder provided with the battery charger. Plug the battery charger
Into an AC outlet overnight. Do not leave connected for longer then- 16 hours.
Replace after charging as for dry cells above.

H2 S Sensor, The H2 S sensor is a plug-in assembly, which is easily replaced but is

not field-repairable. It should be replaced.
When the instrument cannot be set to 00.0.in normal air.
When the reading on a known H2 S concentration cannot be brought to the correct
value by use of the SPAN control.
When the reading becomes erratic, or is strongly effected by position or movement of
detector.
When instrument will not respond to the check switch even though cell is in place.
The cell is secured in a bayonet-type socket on the top of the instrument to the right
of the digital display. To remove it, press down lightly and turn counter clockwise.
To reinstall, position the cell in socket and turn clockwise.

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TASK No.: I-9.21 “Continued”

When cell needs replacement, a new or reactivated cell should be installed. The old
one should be sent to Gas-Tech for reactivation, which is done at a flat rate. H2 S cell
is guaranteed to operate satisfactorily for a period of 6 months from date of purchase.
If it fails within that time, it will be reactivated at no charge. Cells are date-coded,
and removal of the label voids the warranty. After the new cell is installed, allow for
e I hour stabilisation period before attempting to use the instrument

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