Operation and Maintenance Manual FOR Riken Oxygen Gas Detector Head GD-F4A-1
Operation and Maintenance Manual FOR Riken Oxygen Gas Detector Head GD-F4A-1
Operation and Maintenance Manual FOR Riken Oxygen Gas Detector Head GD-F4A-1
This is a fixed type gas detector (head) and alarm instrument to detect oxygen gas in air. The
gas alarm instrument is a safety instrument, not an analyzer nor measuring instrument to make
quantitative and qualitative analysis or measurement.
Please understand following points and use this detector head correctly.
1. The indication on this detector has some changes against fluctuation of atmospheric
pressure. Especially, take care about alarm action at the time of depression caused by
typhoon.
It may also fluctuate against the environmental (temperature, humidity, etc.) change around
detector head.
2. Alarm level for gas alarm instrument shall be set within the performance of the instrument.
Our standard alarm level is 18% by volume for the prevention of oxygen deficiency.
4. To maintain the performance of this gas detector, the regular maintenance service including
the regular parts replacement and adjustment described in this manual shall be required.
Also every 6 months regular maintenance and gas calibration are required since this is a
safety instrument.
TABLE OF CONTENTS
1.OUTLINE OF THE PRODUCT
1-1. Preface ……………………………………………………………………… 1
1-2. Purpose of use ……………………………………………………………… 1
1-3. Definition of DANGER, WARNING, CAUTION and NOTE ………………… 1
1-4. Method of confirmation for CE marking type ……………………………… 1
3.PRODUCT COMPONENTS
3-1. External drawing……………………………………………………………… 3
3-2. Name of each part and functions…………………………………………… 4
3-3. System composition ………………………………………………………… 4
4.HOW TO USE
4-1. Before using the detector head……………………………………………… 7
4-2. Precautions for installation points…………………………………………… 7
4-3. Maintenance space ………………………………………………………… 7
4-4. How to install ………………………………………………………………… 8
4-5. Caution at wiring construction ……………………………………………… 8
4-6. Applicable cable …………………………………………………………… 8
4-7. Example of cable connection ……………………………………………… 8
4-8. Caution at piping works ……………………………………………………… 10
4-9. Example of piping connection ……………………………………………… 10
5.HOW TO OPERATE
5-1. Preparation for start up …………………………………………………… 12
5-2. How to start the detector head …………………………………………… 12
5-3. How to exit …………………………………………………………………… 12
6.MAINTENANCE
6-1. Maintenance intervals and items …………………………………………… 13
6-2. Calibration
6-2-1. Required kit and tools for calibration…………………………… 14
6-2-2. Performing a zero adjustment …………………………………… 14
6-2-3. Performing a span adjustment…………………………………… 14
6-3. Replacing the sensor
6-3-1. Replacement intervals of the sensor…………………………… 15
6-3-2. How to replace the sensor ……………………………………… 15
6-4. Storage or treatment when not in use for a long period………………… 16
6-5. List of recommendable spare parts for regular replacement …………… 16
8.DEFINITION OF TERMS………………………………………………… 17
9.PRODUCT SPECIFICATIONS
9-1. Standard specifications ………………………………………………… 18
9-2. Standard accessories …………………………………………………… 18
9-3. Optional accessories …………………………………………………… 18
10.DETECTION PRINCIPLE……………………………………………… 19
1.OUTLINE OF THE PRODUCT
1-1.Preface
Thank you for purchasing our fixed type Oxygen Detector Head GD-F4A-1.
First of all, verify that the model number of this product is identical with specifications
described in this manual. This manual is a guide to operation of the GD-F4A-1. All parsons
who use this detector for the first time and who has ever used this detector are requested to
read through the manual to understand the content before use.
1-2.Purpose of use
This is a suction(flow-through) type oxygen detector head applying the galvanic cell type
oxygen sensor and is used in combination with indicator / alarm unit to show oxygen content.
Read the operating manual for indicator / alarm unit as well as this manual.
This unit is designed as drip-proof construction for outdoor installation.
Also, it can be used as intrinsically safe system in combination with zener barrier (option) to be
able to install in hazardous area.
This message indicates that improper handling may cause minor damage
CAUTION on health or assets.
CE marking
CE marking label
1
2. IMPORTANT INSTRUCTIONS FOR THE SAFETY
2-1.Danger cases
DANGER
In case of non-explosion poof system, do not use this unit at the place where combustible gas
may exist.
2-2.Warning cases
WARNING
・Do not cut the wire for protective ground both inside and outside of instrument. Or, do not
disconnect the connection of the ground terminals.
・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, do not start the
operation.
・It is very dangerous if the instrument gives oxygen deficiency alarm.
Take appropriate measures based on your judgment at that time.
・Perform gas calibration at proper interval.
・Do not change or remodel the circuit/structure of this unit.
・Do not disassemble the sensor since there is a electrolyte inside.
If your finger touches the electrolyte, wash your finger away with water immediately.
2-3.Caution cases
CAUTION
・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.
・Do not control other equipment by using outputs of this detector.
This is not control equipment. It is prohibited to control other equipment by using outputs
of this detector.
CAUTION
・Do not use this detector head expect for the measurement of oxygen content in a mixture of air
and combustible gas or vapors, or a mixture of air and toxic gases.
・When cleaning this unit, do not use dry cloth but use the wet cloth not to change the static
electricity on plastic part.
2
3.PRODUCT COMPONENTS
3-1.External drawing
(For U-bolt)
(For U bolt)
Gas inlet
Cableinlet
inlet Sensor
Cable
Gas inlet
Sensor
Cable inlet
3
3-2.Name of each part and functions
④ ⑧
③
⑥
⑦
⑨ ②
⑤
3-3.System composition
(1) Intrinsically safe system
Indicator
Detector
head
/alarm
unit
4
! WARNING
Hazardous Non-hazardous
area area
Li Lo
Ci Co
Lw
Cw
2.The safety retainer to be connected with oxygen detector shall have linear characteristics and
be passed the type approval as it is.
Also it shall satisfy the following conditions.
(1) Rating of safety retainer
Max voltage of intrinsic-safety circuit : Below 28V
Max current of intrinsic-safety circuit : Below 600 mA
Max power of intrinsic-safety circuit : Below 0.75W
(3) Relations between allowable inductance (Lo) and allowable capacitance (Co)
of intrinsic-safety circuit, and external wiring inductance (Lw) and capacitance(Cw)
of intrinsic-safety circuit.
Lo ≧ Li + Lw
Co ≧ C + Cw
(4) When making wiring connection for intrinsic-safety circuit, take care not to induce
an electric current and voltage which will spoil the performance of intrinsically safe
by the electromagnetic induction or electrostatic induction to the intrinsic-safety
circuit.
5
(2) Non-explosion proof system
Indicator/alarm
Detector
head
unit
2
CVVS-2C 1.25mm
or equivalent (MAX 600m)
Drip-proof housing
Sensor lead
Terminal strip
Oxygen
sensor
Cable gland
Gas inlet
Shielded cable
Gas outlet
6
4.HOW TO USE
WARNING
Do not install the detector head and cable at the following points.
・Place to get direct rays of the sun.
・Places closed to high temperature and/or emission of electromagnetic wave.
・Place with vibration or shocks.
・Place where the mounting part is weak and it is easy to come out.
・Place where it is difficult to make maintenance and inspection.
・Place unable to secure grounding.
・Places where the temperature is drastically changed.
・Places exceeding operating temperature and humidity.
4-3.Maintenance space
A certain maintenance space must be secured around the detector head, so that the maintenance
staff can perform the safe and correct maintenance work. Pay due attention to secure this space
during work plan and execution.
7
2B pipe
4-4.How to install (O.D. 60.5mm)
! CAUTION
・When make wiring construction, take care not to damage the internal electronics circuit.
・When handle the detector unit, put it at horizontal position. If put it vertically, it tends
to fall and damage the detector.
・Power cable and signal cable shall not be laid down together 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.
4-6.Applicable cable
Signal transmission : CVVS 1.25mm2, 2C or equivalent
Transmission distance : Within 600m at full lengths
Cable O.D. : φ8-φ11mm
8
(2) In case of intrinsically safe system
You can build the intrinsically safe system by adding
optional zener barrier between detector head and indicator/alarm unit.
① Lead the applicable cable through cable inlet and connect to the terminal strip.
② Connect the optional zener barrier between this unit and indicator/alarm unit at
non-hazardous area. (See below fig.)
③ Connect the other side of the cable to the indicator/alarm unit side.
④ Connect the shield’s drain wire to ground on the indicator/alarm unit.
max. 600m
Zener
barrier(MTL761Pac)
D u I
e n n
t
e 3 1 i
t d
i
c
t c
o a
t
r o
h r
/
e
a a
d l
a
4 2 r
m
Connection cable
Connection
cable
Hazardous area Non-hazardous area
WARNING
・ Ground the zener barrier separately corresponding to the A-class grounding with ground
resistance of 10Ω or less.
・ Use the specified cable.
・ For system installation, operation and maintenance, take care not to damage the intrinsically
safe design.
・ The power of the indicator/alarm unit shall be turned on after completion of all wirings. If
each wiring is carried out in the power on condition, short-circuit between terminals or an
electrical shock may be occurred.
! CAUTION
・ Do not alter, nor remodel the parts, etc.
・ Use the circuit breaker as for the power of indicator/alarm unit. Also it shall be mounted
nearby indicator/alarm unit and be specified that it is for power interruption of
indicator/alarm unit.
* NOTE
・ When wiring, read the operating manual for the connected indicator/alarm unit.
9
4-8.Cautions at piping works
WARNING
・ This unit is designed to sample the gas in an atmospheric pressure. Do not give an excessive
pressure to gas inlet and outlet of this unit.
・ Connect the exhaust pipe to the gas outlet located at the bottom of this unit and exhaust
the sampled gas to an area known to be non-hazardous.
! CAUTION
・ Use Φ8(O.D)-1t copper pipe and so on for piping.
・ Carry out piping works as straight as possible.
Excessively high load may cause burden on the suction pump, shortening the effective life of
the pump.
When bends the pipe, secure R (radius of curvature) enough to avoid loading to the piping.
・ Determine the suction side piping length while considering the response time. When the
gas is sampled from the piping end (gas detection point), the response time of the gas
detection sensor itself + delay time caused by the piping length becomes equivalent to the
detector response time.
・ Be sure to attach the gas suction port at the end of gas detection point.
・ Be sure to put dust filter in front of gas detector. If sampled gas contains water and
corrosive gases, removal device is required separately.
Detection
point
Gas OUT
P 1.0±0.3L/min
Flow control
Pump valve
Flow meter
Dust filter
10
(2) In case of pressurized sample gas
GD-F4A-1
Detection
point
Gas OUT
1.0±0.3 L/min
Flow control valve
Flow meter
Dust filter
GD-F4A-1
Detection Instrumentation air
point Air consumption:1~3NL/min
Pressure:0.1~0.34MPa
Aspirator
Dust filter Flow meter Flow control
valve
! CAUTION
It is also possible to apply air aspirator unit to sample the gas by utilizing
instrumentation air. In this method, pressure to the sensor must be kept as
small as possible and make it to -26hPa at a maximum.
As the load to oxygen sensor is high on this method, aspirator suction method
shall be used only when the pump cannot be used.
If the sample gas pressure would fluctuate, use the constant flow rate control
valve to keep the constant flow rate.
Exhaust the sampled gas to open air in principle. When make piping to exhaust
side necessarily, choose the piping diameter to keep the pressure loss due to the
length of piping within 13hPa.
11
5.HOW TO OPERATE
WARNING
! CAUTION
・ At the new installation, adjust the reading in indicator/alarm unit according to 「6-2.
Calibration」. Adjustment is done by indicator/alarm unit since the detector head has
no function for adjustment. Refer to operating instructions for the connected
indicator/alarm unit.
5-3.How to exit
① Stop the sample gas supply to this unit by turning off the pump switch, etc.
② This system stops operation by putting off the power in indicator/alarm unit, since this
unit has no power switch.
12
6.MAINTENANCE
Gas detection and alarm instrument is kept in continuous operation over a long time and must
perform a vital role as a safety device. For this purpose, periodical inspection must be made.
The High-pressure Gas Safety Act in Japan sets forth the obligation of periodical inspection of
the gas detection and alarm instrument.
- Maintenance Contract –
Be sure to perform the regular maintenance since this is an instrument for security and
safety. If this detector head founds defective, contact RIKEN KEIKI immediately.
! WARNING
・This is a safety instrument and the maintenance every 6 months or more is
mandatory to ensure the safety. If the unit is used by continuously without
maintenance, the sensor sensitivity may change, resulting in failure of correct
detection.
* NOTE
・Be sure to inform sections concerned beforehand when performing alarm test or
gas calibration. For the equipment connected with output signal from
indicator/alarm unit, perform them after disconnecting the output signal.
・Special trained engineer for gas detection instrument can perform maintenance
work accurately and efficiently.
・Then, it is recommended to contact RIKEN KEIKI for maintenance.
13
6-2.Calibration
Perform gas calibration at new installation, 6 months maintenance and sensor replacement.
14
6-3.Replacing the sensor
6-3-1.Replacement intervals of the sensor
To maintain the reliability of the measurement, it is recommendable to replace the sensor
periodically. Our oxygen sensor has an enough life span. However, the actual life is
depending on the operating conditions. Then, replace the sensor once a year as the
tentative deadline for the replacement cycle.
Lead-wire (black)
Lead-wire (white)
Sensor
Sensor stopper
Sensor holder
! CAUTION
・Be sure to carry out gas calibration after sensor replacement. If not, correct gas detection
may not be performed.
15
6-4.Storage or treatment when not in use for a long period
Oxygen sensor is a kind of cell and will continue to consume its life even though it is not
used. When detector head is not used for a long period, take out the sensor from detector
head and store it at following environment to make lower the consumption of sensor.
* NOTE
・The replacement interval will change depending on operating condition and it does not
mean the warranty period.
Replacement interval changes according to the result of regular maintenance.
16
7.MEASURES AT ABNORMAL CASE
8.DEFINITION OF TERMS
Galvanic cell
Galvanic cell type oxygen sensor that produces a current proportional to the oxygen content
permeated through the membrane. Refer to 「10. DETECTION PRINCIPLE」 for details.
Zener barrier
Safety retainer for explosion protection by limiting the energy of electric current within a
non-ignition level.
CVVS
This is a kind of connecting cable between indicator/alarm unit and oxygen detector head.
CVVS means a “Polyethylene insulated and vinyl sheathed control cable with shield”.
Calibration
By using standard (calibration) gas, adjust gas reading in indicator/alarm unit to match the
calibration gas concentration.
17
9.PRODUCT SPECIFICATIONS
9-1.Standard specifications
Model : GD-F4A-1
Detection principle : Galvanic cell method
Target gas : Oxygen in air
Sampling method : Sample-drawing(flow-through type)
Signal transmission : Sensor output direct transmission
Transmission cable : CVVS 1.25mm2 , 2C cable or equivalent
Transmission distance : Max 600m with CVVS 1.25mm2, 2C cable
(between indicator/alarm unit and detector head)
Applicable zener barrier : MTL 761Pac
Cable entry : Cable gland (Applicable cable O.D. : φ8~φ11mm)
Piping connection : Rc 1/8, φ8-1t(Provided with coupling)
Operating temperature : -10~40℃
Operating humidity : Below 90%RH (Non-condensing)
Structure : Wall mounting/2B(50A) pole mounting
Kind of explosion proof : Intrinsically safe(when zener barrier is used)
Explosion proof class : ExiaⅡCT4X(when zener barrier is used)
Outer dimension : Approx. 175(H)×140(W)×86(D)mm
Weight : Approx. 1.5kg
Painting color : Munsell No.2.5Y9/2 half tone
* Specifications subject to change without notice.
9-2.Standard accessories
・Operating manual
・Sensor
9-3.Optional accessories
・U-bolt (for nominal diameter 2B)
・Zener barrier (MTL761Pac)
18
10. DETECTION PRINCIPLE
(1) Structure
In a resin container, there are noble metal electrode as cathode and lead electrode as anode
immersed in an electrolyte.
A part of container is opened and put a membrane over there. A lead wire from each electrode
(anode and cathode) is led to take out an electrical output across a temperature compensation
thermistor net work.
Structure of galvanic cell type oxygen sensor is shown below.
Membran
Gold electrode
(Cathode)
Lead electrode
Electrolyte
(Anode)
Output terminal
Thermistor
19