Document Q0ZgKM70E0KkDORoqQo3d2eE

ABD00253088 INSTRUCTION MANUAL MODEL 580 DUAL CHANNEL COMBUSTIBLE GAS MONITOR 0585 The information and technical data disclosed by this document may be used and disseminated only for the purposes and to the extent specifically authorized by General Monitors in writing. Such information and technical data are proprietary to General Monitors and may not be used or disseminated except as provided in the foregoing sentence. ABD00253089 GENERAL MONITORS MODEL 580 DUAL CHANNEL COMBUSTIBLE GAS MONITOR 0585 General Monitors, Inc. 3037 Enterprise Street Costa Mesa, California 92626 Telephone (714) 540-4895 Telex 67-8372 ABD00253090 GENERAL MONITORS CONTENTS SECTION I. INTRODUCTION A. Notice B. General C. Sensor Operating Principle II. SYSTEM COMPONENTS A. Sensor Assembly B. Controller III. INSTALLATION INSTRUCTIONS A. Location of Controller B. Rear Terminal Interconnections C. Power Connections D. Battery Backup E. Choosing Sensor Locations F. Sensor Installation G. Alarm Wiring Connections H. Remote Reset Connection IV. START-UP AND OPERATION A. Initial Application of Power B. Checking Factory Adjustments (15V Supply, Current, and Bias Adjustments) C. Alarm Set Point Adjustments D. Calibration E. Check Points for Calibration and Operation V. SYSTEM PROBLEMS AND TROUBLE-SHOOTING A. General B. Maintenance C. Trouble-shooting Table VI. SPECIAL WARNING VII. WARRANTY VIII. GENERAL SPECIFICATIONS IX. SENSORS X. ACCESSORIES A. Calibration Equipment B. Sensor Covers XI. RECOMMENDED SPARE PARTS XII. SCHEMATICS AND DRAWINGS PAGE 1 1 1 3 3 5 5 6 6 8 9 12 13 14 14 15 16 17 19 19 19 21 22 23 24 25 25 27 28-38 ABD00253091 GENERAL MONITORS MODEL 580 DUAL CHANNEL COMBUSTIBLE GAS MONITOR I. INTRODUCTION Page 1 A. NOTICE All information contained in this instruction manual may be used only to install and operate the Model 580 System provided by GENERAL MONITORS, INC. (GMI) The sale of the instrument does not license the user to reproduce GMI drawings, or to utilize any information in this manual without prior written permission. The Model 580 System is easy to install and operate. However, this manual should be read in full, and the information contained herein understood, before attempting to place the system in service. B. GENERAL The Model 580 Dual Channel System is a CSA approved system designed to con tinuously monitor for potentially explosive concentrations of most combustible gases or vapors at two sensor locations. Normally only a periodic calibration check is needed to assure dependable performance. The system operates in the range 0-100% LEL (Lower Explosive Limit) of a particular gas or vapor. There are relatively few combustible gases which should not be monitored; however, as a precaution GMI should always be consulted to verify the feasibility of monitoring any gas or vapor other than those specified at the time of purchase. The Model 580 consists of a controller plus two sensor assemblies. The con troller is fully solid state. It must be mounted in a weather protected, nonhazardous area. Several GMI mounting accessories are available for panel, wall, or 19 inch rack installation. Any GMI low temperature catalytic bead combustible gas sensor assembly may be used with the system. Sensor assemblies may be mounted outdoors in hazardous areas (National Electrical Code Class I, Div. 1, Groups B, C, and D). They must be connected to the controller in accordance with the instructions in this manual. C. SENSOR OPERATING PRINCIPLE A high efficiency source supplies constant direct current to a Wheatstone Bridge circuit. One leg of the bridge is formed by two bead elements in series, con tained within the sensor. These beads are heated by the direct current. The other leg, located on the printed circuit board in the controller, is a resistive divider. With the sensor exposed to clean air, any initial bridge imbalance is Page 2 ABD00253092 GENERAL MONITORS C. SENSOR OPERATING PRINCIPLE (cont.) trimmed out with a zero pot. When a combustible gas/air mixture diffuses into the sensor, it oxidizes on one of the beads (the "active" bead, which has been catalytically treated). The second (reference) bead, inert to combustible gases, compensates for ambient temperature, humidity, and pressure variations. The oxidation at the active bead causes a temperature increase which produces an electrical resistance change and unbalances the Wheatstone Bridge. The difference in resistance between the two beads is proportional to the concen tration of the combustible gas. The signal from the bridge imbalance is amplified at the controller, and is displayed in % LEL on the meter. ABD00253093 Page 3 GENERAL MONITORS II. SYSTEM COMPONENTS A. SENSOR ASSEMBLIES Two SENSOR ASSEMBLIES (See Figure 2) are normally supplied with the system. They are comprised of the sensor, P/N 10001-1, plus the sensor housing, P/N 10252. This sensor assembly is CSA approved for Class I, Division 1, Groups B, C, and D hazardous areas. On some occasions a different P/N sensor and/or sensor housing will have been supplied (see Section IX). The appropriate P/N sensor will have been provided if GMI was made aware of the gas or vapor which will be monitored. Most combustible gases may be monitored, including most hydrocarbons, hydrogen, and carbon monoxide. CAUTION Sensors have a different sensitivity to each gas. GMI should be consulted if a sensor is expected to detect more than one gas, to recommend the best calibration gas. A variety of sensor covers may be purchased. They provide extra protection from wind, weather, and dust. See Section X for information to aid in select ing the best sensor cover for various conditions. In the event the system is to have only one active channel, P/N 10102 dummy sensor should be substituted for one of the sensors. Otherwise the MALF (mal function) LED indicator for the unused channel will remain lit. B. THE CONTROLLER The Model 580 is a dual channel system in which the controller continuously monitors the inputs from the two sensors. The sensors are monitored indepen dently (i.e., they are not scanned, nor are the signals summed). Each channel has its own constant current sensor drive. The controller automatically dis plays the signal from the higher reading channel on the meter. The meter is linearly scaled from 0-100% LEL. A green CHANNEL IDENTIFICATION LED is provided for each channel. They are lo cated on the front panel. The Channel I.D. LED of the higher reading channel is illuminated when the controller is in automatic mode. A manual override pushbutton switch, positioned between the two Channel I.D. LED's, allows the operator to check the reading on the second channel at any time. Both channels share three alarm circuits: MALF (malfunction), LOW (low gas), and HIGH (high gas). The channels also share a malfunction LED indicator (amber), a low alarm LED indicator (amber), and a high alarm LED indicator (red) . Page 4 ABD00253094 GENERAL MONITORS B. THE CONTROLLER (cont.) The alarm set points for the two gas alarm circuits (high and low) are fully adjustable from 0 to 100% LEL. Normally it is recommended that the low alarm be set fairly low (for example, 25% LEL) and that the high alarm be set no higher than 60% LEL. This may vary from one application to another. The alarm set point adjustments are located on the right hand side of the control ler (when facing it). Access to the adjustments is gained by sliding the controller slightly forward from its mounting. GMI recommends that a wiring service loop be utilized for connections to the rear panel, to facilitate access to these adjustments. One alarm relay is provided for each of the three alarm circuits. These re lays are common to both channels. Whenever the sensor signal (meter reading) of either channel exceeds the low or the high alarm set point, the alarm relay is activated. The malfunction relay is activated upon certain problem condi tions such as low power, power outage, sensor connections being loose at the controller or sensor housing, or severed cable. The low and high alarm relays are DPDT rated 3 amps at 117 VAC, resistive. The malfunction relay is SPDT, 3 amps at 117 VAC, resistive. CAUTION Do not utilize an inductive load without reading Section III. F. The standard Model 580 provides latching operation (requiring manual reset) of the high alarm circuit, and non-latching operation (automatic reset) of the low alarm and malfunction circuits. On special order the Model 580 can be provided with any combination of latching or non-latching low and high alarms. The malfunction alarm is always non-latching. The standard gas alarm relays are normally deenergized (with power applied) but they can be supplied normally energized on special order. The malfunction relay is always normally energized. The reset button for cancelling latched alarm circuits is located at the bottom of the front panel. The circuits will only reset if the gas concentration has fallen below the set point level. A green "READY" LED is also provided on the front panel. When illuminated, this indicates that system operation is normal. On the left hand side of the front panel is a recessed toggle switch having two positions. The "OP" (operating) position is for normal use. In "CAL" position, used for calibration and for setting alarm set points, alarm circuits are bypassed to prevent activation of external equipment, and the "MALF" LED flashes to indicate "out of normal operating condition". ZERO and SPAN calibration potentiometers for each channel are located behind the front panel. They are accessible from the front panel by using a small screwdriver. ABD00253095 GENERAL MONITORS III. INSTALLATION INSTRUCTIONS Page 5 A. LOCATION OF THE CONTROLLER The Model 580 Controller must be installed in a weather protected, non-hazardous area. The following mounting hardware is available to facilitate instal lation: 49mm (2") panel mount frame 98mm (4") panel mount frame (2 controllers) 483mm (19") rack frame (8 controllers) Blank panel (one for each unused position in 19" frame) 49mm (2") wall mount bracket 98mm (4") wall mount bracket (2 controllers) P/N 10201-1 P/N 10199-1 P/N 10200-1 P/N 10187-1 P/N 10195-1 P/N 10202-1 Mounting should be as free from shock and vibration as possible. Caution should be taken not to mount the controller in close proximity to radio trans mitters or similar equipment, even though the controller is RFI resistant. Care should be taken to assure adequate ventilation. Do not mount the controller in a manner which will restrict the natural convection air flow from normal ambient air. The controller operating temperature range, including self-heating is -18C to +66C (0F to 150F) B. REAR TERMINAL INTERCONNECTIONS As an aid in wiring and in servicing, the Model 580 controller is supplied with removable plugs for the rear terminations. The plugs are held securely in the header assemblies by a locking ramp {See Figure 1). To complete the inter connection wiring, the external connections should be made to the screw termina tions of the plugs. If it is more convenient, the plugs may be removed from the controller by depressing the locking ramp, pulling them straight out and making the external connections to them. The plugs should then be replaced making sure they are seated fully and the locking ramp is locked into its proper position. NOTE It is important that a wiring service loop be utilized to ensure access to the alarm set point adjustments and to unplug the controllers from the interconnecting wiring when unnecessary Page 6 ABD00253096 GENERAL MONITORS C. POWER CONNECTIONS The system operates on nominal line power of 117 VAC, 50/60HZ or 24 VDC. Power must remain disconnected until all other wiring connections are made. (NOTE: To eliminate accidental system shutdown, GMI does not provide a power on-off switch.) If AC is to power the system, connect the line power supply to the TB-1 ter minals LINE, NEUTRAL, and GROUND (L, N, and ($) ) located on the rear of the controller. Refer to Figure 1. Use accepted commercial wiring practices. Primary DC power may be utilized instead. Use any 24V nominal direct current supply. No. 14 wire should be used to prevent excessive voltage drop, and the run should be as short as possible. Connect the positive supply to 24 VDC (+) and the negative supply to 24 VDC (-) on the terminal block. An internal diode protects the system in the event of inadvertent supply reversal. D. BATTERY BACKUP An emergency battery backup may be employed on a system normally powered by AC. A customer furnished battery may be connected as shown. No manual or relay switching is require.d. Note that there is no provision for battery charging. A customer furnished battery charger should be used to keep the battery charged to the battery manufacturer's recommended level. The cable length (battery to controller) should be as short as possible. Should an AC power failure occur, the 24 Volt battery supplies current through the diode to the controller cir cuitry DO NOT USE MORE THAN A 24 VOLT BATTERY. The battery rating (ampere-hour capacity) is dictated by the length of time you expect power outages to last. A Model 580 requires approximately 1 ampere (peak) at 24 VDC. General Monitors recommends that a Lead-Acid type battery be used. This type battery can be expected to last for several years with minimum maintenance. Out Battery Charger ~- 24 Volt _____ Battery DC In Model 580 Out t DC IN ABD00253097 Page 7 OUTLINE DRAWING AND REAR TERMINAL CONNECTIONS Page 8 ABD00253098 GENERAL MONITORS E. CHOOSING SENSOR LOCATIONS Several variables are involved in selecting locations to install sensors to assure the detection of combustible gases. There are no hard and fast rules defining the optimum location. However, the following general suggestions should be considered in regard to particular conditions at the site a Model 580 is being installed. (1) Vapor Density Whether the gas/vapor to be monitored is lighter or heavier than air will affect sensor placement. For lighter-than-air gases, sensors should gen erally be placed close to the roof or ceiling in indoor installations. For gases much heavier than air, sensors should generally be located near the floor or ground when there is no air currents in the area. Gases with a density equal to air, or slightly greater than air, will tend to rise, particularly when air currents are present. (2) Air Currents If there are winds, fans, or other sources of air movement, combustible gases might tend to rise or to accumulate in certain sections of a facili ty. Local air currents should be studied to aid in selection of sensor locations. (3) Likely Sources of Gas Emission In general, at least one sensor should be located in close proximity to each point where a leak of a combustible gas is likely to occur. This is particularly important when a liquid having a low volatility is to be monitored. (4) Environmental Factors Avoid installing sensors where they will be unnecessarily exposed to wind, dust, water, shock, or vibration. Observe the temperature range limita tions of sensors, covered in the Specification section of this manual. ABD00253099 GENERAL MONITORS Page 9 (5) Catalytic "Poisons" Sensors will be adversely affected by prolonged exposure to certain mate rials. Loss of sensitivity (i.e. reduced response to combustible gases), or corrosion, may be gradual if such materials are present in low concen trations, or it may be rapid at high concentrations. The more important materials adversely affecting sensors are: Halides (compounds containing chlorine, fluorine, bromine, or iodine) Sulfur compounds such as SO2# ^S, CS2 Heavy metals such as tetraethyl lead. Silicones (often contained in greases and aerosols). Silicones do not chemically attack the sensor. They instead coat the beads and therefore reduce or stop the oxidation of the combustible gas at the catalytically active bead. Acid vapors. Caustic liquids or vapors. The presence of such materials in an area does not necessarily preclude the use of a catalytic bead sensor. The feasibility of using a sensor in such areas must be determined by an analysis of the specific factors in each appli cation. However, sensors used in such areas usually require calibration checks on a more frequent basis than normal, and typically have a shorter life than normal. In many such applications the normal two year warranty would not apply. CAUTION GMI discourages the painting of sensor assemblies for two reasons. First, if the sensor head is painted over, gas will not be able to diffuse into the sensor. Secondly, many paints contain lead compounds which can poison a sensor. F. SENSOR INSTALLATION Various types (P/N's) of sensors can be provided with the Model 580. However, the installation method is identical in all cases. See Section IX for further information. Page 10 5 *I l Q<* V) 0I<V0 V) 8 Q 1 s' k5Id 3Q i5d 5T 5 Qc Ik> SW $Q 3v> *0 8 i 1 N S*%i 5 rvOs* $ 0'S, ABD00253100 V- i > (0 (0 < X o CD AC h- HI o co CM d CM U> CM Q oz < z co Q. Q * o < j<0 .Q > < _1 UJ x _ z O cr x H LU UJ Z UJ UJ CO " < HOO 2 y H C=D a3 z -j sI < . Wz X o > o o CO < x o 2 J o zf UJ a3 5< O CO UJ <0 z5 CO 3 Z -- 2a: UJ HO O CO zz 0*11 -J CO cc o li. UJ CD CM *- a co (0 CM o Ik UJ ce ABD00253101 Page 11 GENERAL MONITORS F. SENSOR INSTALLATION (cont'd) The SENSOR ASSEMBLY (Figure 2) is used most often. It consists of P/N 10001-1 sensor plus GMI P/N 10252 sensor housing. This assembly is CSA approved for NEC Class I, Division 1, Groups B, C, and D hazardous areas. Although sensors are interchangeable between channels, it is recommended that each sensor be used with the channel it was matched with at the factory. The controller is tagged with this information. Each sensor assembly is connected to the controller using 3-conductor stranded cable, and must be installed with conduit in hazardous areas. Total loop re sistance excluding the sensor must not exceed 40 ohms. A separate cable is required for each sensor. GMI recommends the use of shielded cable as a general rule, though in some cases it is not an absolute necessity. Due to the low levels of sensor signal voltages, shielded cable will be required in some installations to guard against extraneous electrical noise. The shield must be enclosed in a suitable insulating outer jacket, and must be grounded only at the rear panel sensor shield ground terminal (see Figure 1). Care must be taken to assure that the shield does not come into contact with the sensor housing or metal conduit. Avoid running sensor cables close to high power cables, radio transmission lines, or cables subject to pulses of high current. Sensor cable connections must be crimped and SOLDERED for stable operation. Use only continuous, unjointed cable runs if possible. Improperly spliced cable can result in corrosion, resistance changes and drift. To connect the cable at the sensor, remove the P/N 10252 housing lid to reveal the terminal strip. The sensor is connected in the housing according to the color designations shown in Figure 2. (The green and orange positions are not used) Sensor cables are connected at the controller to the terminal blocks located along the bottom of the rear of the controller. The channel numbers (1 and 2) are identified to the left of the terminals. Connections are identified, in cluding ground (for shielded cable). Connect the cable so that the terminal color at the sensor housing matches the terminal color at the controller as follows (see Figure 1): Wire Color Black Red White Shield Terminal Number CH 1 SNSR CH 2 SNSR B1 R2 W3 ($) Bl R2 W3 Page 12 ABD00253102 GENERAL MONITORS F. SENSOR INSTALLATION (cont'd) Cable runs should not exceed the following distances (maximum loop resistance of 40 ohms). AWG FEET METERS 20 1900 18 3000 16 4800 14 7600 580 910 1460 2320 IMPORTANT: Sensors should always be mounted pointing downward so that water will not accumulate on the sensor head. Mounting should be as free from shock and vibration as possible, and should be convenient for calibration checks in place. The sensor housing must never be opened when power is on, otherwise the explosion-proof integrity of the sensor assembly is violated. The threads on the housing lid must be fully engaged. IMPORTANT WHEN IT BECOMES NECESSARY TO REPLACE A SENSOR IN AN OPERATING SYSTEM, SEE NOTE ON PAGE 24. G. ALARM WIRING CONNECTIONS The low and high alarm contacts for customer use are DPDT, and are rated 3 amps at 117 VAC, resistive. The malfunction alarm contact is SPDT, 3 amps at 117 VAC, resistive. These contacts are brought out to terminals on the rear of the con troller as follows (see Figure 1): ALARM RELAY Malfunction, Low Alarm, High Alarm, TB-1 TB-1 TB-1 CONTACT CONDITION OPEN 1 2,3 2,3 COM C C C CLOSED 2 1 ,4 1,4 The above chart shows the high and low alarm contacts in the standard de-energized state (with power applied). These two alarm relays are nor mally de-energized unless specially ordered for normally energized operation. The malfunction relay is always supplied normally energized. If normally energized, the terminations are: ALARM RELAY CONTACT CONDITION Malfunction, TB-1 Low Alarm, TB-1 High Alarm, TB-1 OPEN 1 1,4 1,4 COM C C C CLOSED 2 2,3 2,3 ABD00253103 Page 13 GENERAL MONITORS ****CAUTION***** Inductive loads (bells, buzzers, relays, contactors, solenoid valves, etc.) con nected to the high alarm, low alarm, and malfunction alarm relays must be clamped down as shown in the diagrams below. Unclamped inductive loads can generate volt age spikes in excess of 1000 Volts. Spikes of this magnitude will cause false alarms and possible damage. GENERAL PURPOSE RECTIFIER DIODE, IE 1N4005 (NOTE POLARITY) METAL OXIDE VARISTOR RATED FOR 150 VRMS GENERAL ELECTRIC V150LA20A OR EQUIVALENT H. REMOTE RESET CONNECTION Remote Reset (of alarm circuits) connections are made to rear panel Terminal Board connection RESET and the 24VDC (-) terminal. If a remote reset switch is used, it must be a "normally open, momentary action" type. NOTE If the system is to be powered from a primary DC power supply or if battery backup is provided, the 24VDC (-) terminal will have two wires when remote reset is used. The diameter of the two wires cannot be larger than a No. 14 wire. Page 14 ABD00253104 GENERAL MONITORS IV. START-UP AND OPERATION A. INITIAL APPLICATION OF POWER Before applying power for the first time double-check all wiring components. The system has a time delay feature. The high and low alarm circuits are dis abled for approximately 45 seconds after power is applied. This feature pre vents false alarms while the sensor circuits are stabilizing. When power is first applied, one of the CHANNEL I.D. LED's will illuminate. This indicates that power is on. The % LEL meter may rise during the initial time delay period while the system is stabilizing. During the time delay period the % LEL meter will settle back to zero unless a gas condition exists (zero adjustment may be necessary with initial power application due to varia tions in wiring). If the amber MALFUNCTION LED lights, there is a defect in the sensing assembly on the channel not showing an illuminated CHANNEL I.D. LED. Check the Trouble-shooting Section of this manual for corrective action. ** NOTE:** A defect in one sensor circuit will not affect the operation of the other channel. B. CHECKING FACTORY ADJUSTMENTS (15V SUPPLY, CURRENT, AND BIAS ADJUSTMENTS) Refer to Figures 3 and 5 in back of this manual. The following adjustments are factory set, and normally do not require adjust ment in the field. We do not recommend that they be checked or adjusted unless the system is not operating properly. If they are adjusted, the 15V Supply must be adjusted first. These adjustments must always be followed by re-cali bration. A 20,000 ohm/volt meter will be adequate for the measurements. All measurements and adjustments described are made on the right hand side of the controller (when facing it). Slide the controller forward until the appropri ate components are exposed. 1. 15V Supply Measure the voltage from the bottom of R134 to ground (the - lead of C22 or C23 respectively are the most accessible points). If adjustment is needed, turn R146 until the voltmeter reads 15 .025 volts. ABD00253105 Page 15 GENERAL MONITORS B. CHECKING FACTORY ADJUSTMENTS 15V SUPPLY, CURRENT, AND BIAS ADJUSTMENTS (cont'd) 2. iurgent Adjustment These adjustments control the constant current to the sensors. For Channel No. 1 connect the voltmeter across R99. If necessary, adjust R108 to 450 + 1.5 mv. For Channel No. 2, connect the voltmeter across R40 and adjust R43. 3. Bias Adjustment Both channels have a bias adjustment, which must IMPORTANT: Be sure that the channel being adjusted on. be has adjusted separately. its Channel I.D. LED For Channel 1, turn the span pot R83 (20 turn pot) fully counterclockwise un til it clicks. Adjust the bias pot (R67) until the meter reads zero. For Channel 2, adjust the span pot (R23) and the bias pot (R6) in the same manner. After adjusting the bias on each channel, turn the associated span pot 7 turns clockwise and leave in the position. Alternately, for Channel 1 the bias may be checked by measuring the voltage between the top of R73 and the bottom of R88, and adjusting the bias pot (R67), if necessary, until 05 mv is read on the voltmeter. For Channel 2 measure the voltage from the top of R8 to the bottom of R28 and (if neces sary) adjust R9 to 05mv. 4. The "meter adjust" pot (R34) should NOT be adjusted unless there is reason to believe someone has tampered with it. To check the "meter adjust", per form the ALTERNATE "bias adjust" check described above and observe the con troller's % LEL meter. If it is not at zero, adjust R34 until the % LEL meter reads zero. NOTE: In summary, do not perform any of the less the system is not performing normally. any of the adjustments are performed. adjustments described above un Re-calibrate the system once C. ALARM SET POINT ADJUSTMENTS Alarm set points are electronic, and are set by adjustment of the HIGH and LOW ALARM pots located on the right-hand side of the circuit board. These pots are R91 (HIGH) and R90 (LOW). Each alarm circuit is common to both channels. To chanqe the setpoints, advance the ZERO pot (a front panel adjustment) of either channel until the % LEL meter reads the concentration you wish to use as the LOW setpoint - usually not to exceed about 35% LEL. Then adjust the LOW alarm pot until the amber LOW alarm LED begins to flash. Further advance the ZERO pot until the HIGH setpoint value is reached on the % LEL meter - usually not to exceed about 60% LEL. Then adjust the HIGH alarm pot until the red HIGH alarm LED begins to flash. Turn the ZERO pot counterclockwise until the meter again reads zero. Page 16 ABD00253106 GENERAL MONITORS C. ALARM SET-POINT ADJUSTMENTS (cont'd) These alarm circuits may be of the latching or non-latching (manual or auto matic) reset type, depending upon how the instrument was initially ordered. A reset switch is provided in the lower half of the instrument panel to reset the alarm circuits as required. Check both set points by moving the meter upscale once again with the ZERO pot and observing the meter reading where the LED's illuminate. When the set points have been checked, re-set the meter to zero with the ZERO pot. NOTE: Up to 5% hysteresis is normal around alarm set points. to prevent relay chatter. If the relays are latching, have to be depressed to deactivate alarm circuits. This is required the RESET will D. CALIBRATION Calibration to the specified gas is initially done at the factory. We recom mend that the Model 580 system be recalibrated upon start-up, and that calibra tion be checked at least every 90 days thereafter. The calibration procedure is as follows: 1 . If the gas alarm relays are not to be activated during calibration (since they might be connected to external devices), move the recessed front panel toggle switch to the "CAL" position. The MALF light will flash and the relays will be held in standby. The meter and gas alarm LED's will function normally. 2. Locate the ZERO and SPAN potentiometer screwdriver access openings for each channel on the lower portion of the front panel adjacent to the channel identification LED's. 3. Select one channel to calibrate. Assure that the sensing assembly for that channel is in "clean" air. 4. Adjust the appropriate (20 turn) ZERO pot for that channel until the % LEL meter reads zero, using a small thin-blade screwdriver. Make sure that you are adjusting the proper channel zero setting by observing the channel I.D. LED. ABD00253107 GENERAL MONITORS Page 17 D. CALIBRATION (cont'd) 5. Expose the sensor for the channel being calibrated to calibration gas, using the GMI Portable Purge Calibrator (for methane, hydrogen, etc.), P/N 1400150, or Calibration Chamber, P/N 1400200 (for solvents). 6. Adjust the channel's SPAN pot to bring the % LEL meter to the concentra tion matching the calibration gas being used. (NOTE: Gas cylinders are normally labeled either in % LEL or % by volume of the gas. Refer to NFPA Standards No. 325M or other authority for conversions if required. For methane, 50% LEL = 2.5% gas by volume; for hydrogen, 50% LEL = 2.0% gas by volume. 7. Remove the calibration gas, allowing the sensor to return to clean air. Allow sufficient time for the meter reading to stabilize. It should stabilize at or near 0% LEL. If a minor adjustment is required to reach zero, the calibration is acceptable. Adjust the meter to zero with the ZERO potentiometer. If a significant adjustment is necessary to return to zero, repeat the entire calibration procedure. If the same result is observed, perform the checks described in Section IV.B. (NOTE: The bias is the most likely problem.) 8. Repeat the previous steps (1-7) for the other channel. E. CHECK POINTS FOR CALIBRATION AND OPERATION (1) Frequency of Calibration As a rule of thumb GMI recommends that the calibration be checked on each sensor at least every 90 days. If a sensor is installed where it may be subjected to splashing water, mud or dirt accumulation, or adverse gases as described in Section III D.(5), more frequent calibration is recommended. The exact frequency can vary with the severity of conditions and must be established in the field. (2) Observations During Calibration (a) A negative movement of the % LEL meter when the sensor is exposed to calibration gas indicates that the white and black leads of the sensor cable are reversed. Page 18 ABD00253108 GENERAL MONITORS E. CHECK POINTS FOR CALIBRATION AND OPERATION (CONT'd) (b) The SPAN potentiometer is a 20-turn pot. The number of clockwise turns required to obtain the correct meter reading during calibration varies from one gas to another. For a particular gas at a specific concentra tion, a steady increase over a short period of time in the number of turns required to obtain the correct meter reading indicates that the sensor is losing sensitivity and/or has been contaminated. Operators should periodically check how many turns remain in the span pot. GMI highly recommends replacing the sensor while a few turns still remain, since it is probably approaching the end of its useful life. See Section V for additional important information. (3) Background of Combustible Gases In some applications there will be an occasional or continuous presence of "background" combustible gases. Generally this will be a very small % LEL. Usually it is advisable to zero out the background gas concentration during calibration. To do so, isolate the sensor from the surrounding air using a plastic bag (or by placing your hand tightly over the sensor). Observe the reading on the % LEL meter. A gradual drop in reading indicates the pre sence of a background of comubustible gases. With the bag in place, set the meter to read 0% LEL using the zero potentiometer. Remove the bag and pro ceed with normal calibration. (4) CAUTION - Extended Exposure to Combustible Gases Extended exposure of a sensor to a high concentration of combustible gases can introduce stress in the sensing element which may seriously affect performance. Re-calibration should therefore be performed after an alarm due to a high concentration of gas, and the sensor should be replaced if necessary. A meter reading of 100% LEL, or high offscale, may mean an explosive concentration of gas is present. NOTE: The foregoing warning is applicable to all catalytic bead sensors, regardless of manufacturer. ABD00253109 Page 19 GENERAL MONITORS V. SYSTEM PROBLEMS AND TROUBLE-SHOOTING A. GENERAL It is highly recommended that a spare sensor be on hand at all times. While GMI sensors are the most reliable, longest life catalytic bead sensors available, sensor failure tends to be the largest potential cause of real downtime. A full complement of other GMI recommended spare parts should also be on hand. GMI's warranty will be voided if damage results from repair efforts involving replace ment of PC boards or their components, or other system components other than routine replacement of recommended spare parts. It is recommended that defec tive controllers be returned to the factory for repair even if the warranty has expired. B. MAINTENANCE Once installed, the Model 580 system requires little or no routine maintenance other than periodic calibration checks. GMI recommends that a calibration schedule be established and adhered to. GMI also recommends that a log book be kept showing calibration dates and dates of sensor replacement. The removal of particulate matter from accessory sensor covers may be facili tated by the use of an appropriate halogen-free solvent. Water or ethanol are examples of suitable solvents. The sensor cover should be thoroughly dried with compressed air if necessary, before refitting to the sensor body. A calibration check should be made after the cleaned cover has been re-installed because the cleaning process may increase response due to removal of dirt, etc. IMPORTANT SEE NOTE ON PAGE 24 FOR SENSOR REPLACEMENT C. TROUBLE-SHOOTING TABLE The information presented in the following table is designed to correct the more common problems which appear during system startup and operation. Should the various actions suggested in the table fail to restore normal operation, we recommend that the factory be consulted and, if necessary, that the system be returned to the factory for repair. Page 20 i--ii a <H P 33 c P -H o e T5 x C -HH 0) T3 CO H 0) C a) o m ft 4-) s 3 c o sx 0 c 0p H u 4-) O 0) P U *0 M O 3 CO T5 CO c 3 H O CO P rl H CO P P X -H H ft Eh rH H 3M O X CO *I--0I a] a> i-1 tJ 3 H U-l <0 3p 0) (D x> 4-> P -H 4-> 3U 3 co a? a> M U m p CO H OO CO P M CO 333 xP >i p <0 CO P 3 x rl OH o a) M rH nj x> 5 PM CO CO 0 -H P 0) co M rH CO T3 O X 0 0) CM OM U M M ao 3 <M a1 CT> 3 C T3 M a> 4J U O <0 41 3 3 M P 3 rH M 3O3 0 O CO M 0 O M 41 4) 3 3 4) ft 41 H X3 O O 41 u 4) 0 T5 rH H P rH 3 p 3 0 rH 'O O' x: rH 41 co 3 3 3 3M CO cr 3 41 M P X2 0 M 41 POP H c 4-1 0) o CX 3 4J H C 3 a> *o > a> H T3 CO H T5 P3 O Z 3 3 p 3 o M 0 H . E 4) 41 T5 H t* P 4) rH 41 u O > X3 ai X3 D 41 rl O JS ftQ co CO M p 33 O 3 rH Qd CO H p3 H rl o 4) 3 0 Z xs 3 x: JS X! H &H rl p p CO T5 C 3 co P x HO' 6 x oH * o a; Xo >1 3 3 O' C H Jd fO E 0) M O cm a> 2 O' C rH M s E M cO rH CO CO rH E 3 0) C rH mx 3O PM xa <u 3 4-1 P O <0 a) 3 sp o O f-H CO H 'O 3 M3 O0 H 41 P 33 pH 0 o E3 0 PS3 O oE M 33 rl rH p cc V <0 E 3 M M -rl 4-1 CO C pH P cC a> <H O 10 ft P 3 0 rl -U P 4) rl M3 33 CO 41 41 x: CQ p v 3 CHM M O X P 3c0 CO M O 4-1 iH 3 O s cO M 0) 3 a> o 3 (0 >i X rH 4.1 rH 3 M *M 3V xp 4-> <0 oo CO 4-1 33 O 4) co S M 4) 4) P Oi M3l >. CO jQ >1 T5 P 33 E c0 MM OP cm <0 PS V ft 3 CO S M H -O CO f0 a 4) P P 41 5h CO 33 3 ai rH ft >, P 3 3 MP M3 33 3M M M3 4) 3 -o 3 41 3x 4-1 CO H *0 H 4J O 3> 4) aE >co m E 3 4c)r h4) 3 4) C X0 p CO M p H 4f1t w Eh O z ABD00253110 && 3 CO M 4) ?O04 M 4) a o i- P Cm ft 41 41 O M fO 3H CO ft C 41 H CM Cl, ai o <0 Hft f4t) u 41 rH rH o M 4-1 3 0 0 o 4-1 3 >i O rH H 04 -P ft -H 3 CO co 0ft M 41 ft 5O 0 ft 3 H M 4f1t XO 0 M -rH ft CO 41 M 41 30 CO 3 3 rH H ft 1- CM ft CM M 41 4) CO 4) 53 CO O cu 3 ft M o3 4> p a. > H oQ___ > H Qj a 4-1 -P 3 E U Oi O H 3 41 S 01 M 3 CM 0 in 41 4 2 T3 CM TO 3 iH CO U -H 4) ? x: oo Qt 4<-H1 4-1 5 3 CO ft S $ O 41 AS O r- CM CO rH 3 3 rl E M 41 P rH rH 3 03 M 41 N01 a1 i P Xo H od Eh T-- CM E 41 C H 41 M 2 CO 3 0 41 P M -P 41 ft M 4) 41 rH M x: X5 Op 3 M 35 p -rt H 3 -M 3 <d 3 > & 41 co M rl 3 U Mo 3 x: ft p 41 M 0 M >i M p r) 3O z U 35 O 4) 33O CuO M O 41 3 cm rH > 4f1t ftP O 3 cm uO 41 0 CO X3 3 P 3 M 431 M 41 rH O CO 41 333 3 0 P 3 4) 3 o co ft 3 4) 41 -H O4) P p3 41 xa p3 41 pi 41 3 OO O op E O M 3 3 Xd 3 0 0 ft 3 3 P rH rH O ft ft 41 P 3 iH rH 3 4) 3 3 ft 4) 4) 4) x: o x: 3 cr o cd od ad O U p o 41 cd m1 in co CM o M 41 OM CO CO 0 M 3 4) cr 4) > 4f1t CO 3 H 3 CO O u TO Mft O3 0 P Cr 4> x: 33 co o CO o 3 rH u o CO 4 H MP M3 3U 01 3P 3 3 ri 3 41 O f4)t 41 41 ft 'O Oft 3 (0 CO M M O 0 ft fto w 4) 4) CO P rH P rH rH P CO H 3 3 3 rH rH O *H U3 Oo3 M3 N iH 41 M M 4) o rl E rH P P 3 rH CO 3 MX 3 3 OX 3 0 41 3 O O rH 3 3 0 P Eh 0 O U P U CO p CM CO ** m <x> P O 3 41 U 3 CO p rl 3 O M O' H 3 0 H p e3 MM 33 rH ft ft 0 T~ 3 > rl P o 3 P 3 T5 Q W P , CM PI O 3^ POO OH Q OM raH M 0 0(0 C3 H M y< rH 4) w 41 -P 3 <M M 3 3 41 *5 CO 0 U 41 a X M O' p 4> H 0 X rH P3 H a o 41 W -H Z pp 1*- CO 3M O3 O3 P o 3 CO Oft 3 in P O' 0c 3 rH 0 3 3X T3 rl x: O H co 3 M 4J 4.1 rH 4) *H 3 CM rH S o rH iH CO Si. p3 rH H fftt 3O3 0 0 41 M E 41 4) H P XP Eh s 3 # CN 3 O rM O' P3 U -H 3X 3 CO P3 i-H rH 3P E CO 3 *rl CO U rl PJ M pH 0-- M P 41 3 T3 O0 ae s E3 P M O CO 3 3 s 35 -H rH 3 0 3 3 41 ft UU XP U M 4) 41 CO P 4) E M 3 \ o P rH 33 33 W 3 3P 3 CO 41 3> s c 4) 0 O B x: xa 53 ABD00253111 Page 21 GENERAL MONITORS VI. SPECIAL WARNING Through engineering design, testing, manufacturing techniques, and rigid quality control. General Monitors supplies the finest gas detection systems available. The user must recognize his responsibility for maintaining the gas detection system in operational condition. (1) GENERAL MONITORS recommends a calibration check on a regular schedule. The calibration check should be conducted at least every ninety (90) days. This is the only method of insuring proper system operation and response to combustible gases. More frequent calibration checks are encouraged to spot problems such as mud collecting on the sensor heads, accidental painting over of sensors, etc. A calibration check is defined as the procedure of applying a known concentration of gas to the system sensors while observing the controller. The visual display will indicate the gas concentration, and alarm indicators/ circuits will activate in direct relationship to gas con centration. Calibration adjustments must be made if results are at variance (see CALIBRATION section of this manual). (2) GENERAL MONITORS cautions, as with all equipment of this type, that high levels or long exposure to certain atmospheres will "poison" the sensor catalyst and eventually affect sensitivity. See Section III D. (5) for specific information. Use in such atmospheres requires calibration checks on a more frequent schedule than normal. General Monitors should be consulted for application feasibility determination before installing a system in such atmospheres. (3) GENERAL MONITORS' sensors and sensor housings are designed and tested for use in certain classes of hazardous atmospheres. Explosion-proof integrity cannot be maintained if sensors and sensor housings are operated in other than the "as designed" condition. Terminal access covers of sensor housings must be on. Sensor housing must be installed in accordance with National Electrical Code acceptable practices for the class of hazardous atmosphere. (4) Sensors are designed with sintered metal or screen covers which act as flame arrestors. Do not operate sensors without screen or sintered metal parts in place. (5) GENERAL MONITORS' gas detection systems are primarily SAFETY devices for the protection of personnel and facilities, and must be "always ready". With proper installation, calibration, and maintenance, the system will provide continuous monitoring of hazardous areas. The user must assume all liability for misuse of GENERAL MONITORS' gas detection systems. (6) The system's full two year warranty will be voided if customer personnel or third parties damage the system during repair attempts. Page 22 ABD00253112 GENERAL MONITORS VII. WARRANTY GMI warrants all of its products to be free from defects in workmanship or ma terial under normal use and service within two (2) years (Gas Detection) and (1) year (Flame Detection) from date of shipment. GMI will repair or replace without charge any equipment found to be defective during the warranty period. Final determination of the nature and responsibility for defective or damaged equipment will be made by GMI personnel. Gas detection elements which have been poisoned by contaminants are not included in this warranty. In all cases this warranty is limited to the cost of the equipment. All warranties hereunder are contingent upon proper use in the application for which the product was intended and do not cover products which have been modified or repaired without GMI ap proval or which have been subjected to neglect, accident, improper installation or application, or on which the original identification marks have been removed or altered. GMI's responsibility under the above warranty shall be limited to the repair or replacement at GMI's option at no cost to the purchaser for parts or labor, of any component which fails during the warranty period provided that the purchaser has promptly reported such failure to GMI in writing and GMI, upon inspection, found such component to be defective. The purchaser must obtain shipping instructions for the return of any item under this warranty provision and compliance with such instruction shall be a condition of this warranty. EXCEPT FOR THE EXPRESS WARRANTY STATED ABOVE, GMI DISCLAIMS ALL WARRANTIES WITH REGARD TO THE PRODUCTS SOLD HEREUNDER INCLUDING ALL IMPLIED WARRANTIES OF MER CHANTABILITY AND FITNESS AND THE EXPRESS WARRANTIES STATED HEREIN ARE IN LIEU OF ALL OBLIGATIONS OR LIABILITIES ON THE PART OF GMI FOR DAMAGES INCLUDING, BUT NOT LIMITED TO CONSEQUENTIAL DAMAGES ARISING OUT OF/OR IN CONNECTION WITH THE USE OR PERFORMANCE OF THE PRODUCT. ABD00253113 Page 23 GENERAL MONITORS VIII. GENERAL SPECIFICATIONS CONTROLLER Dimensions: Weight: Mounting Configurations Temperature Range: Power: Meter Readout: Repeatability: Linearity: Alarm Circuits: Status Indicators: Output Signal: Electrical Classification: Warranty: Approx. 53mm x 175mm x 294mm (2.1"W x 6.9nH x 11.5"D) Approx. 1.8kg (3.8 lb.) Rack, panel, wall, weatherproof enclosure -18C to +66C (0F to 150F) 105-130 VAC/50-60 Hz 205-255 VAC/50-60 Hz 22-30 VDC. 7 watts nominal (117VAC) Range 0-100% Lower Explosive Limit (% LEL) 2% full scale 5% full scale Independent HIGH, LOW, and MALFunction circuits common to both channels. HIGH and LOW DPDT 3 Amp relays @ 117 VAC, resistive. MALFunction relay SPDT, 3 Amps @117 VAC, resistive. MALFunction relay is normally energized, non-latching, HIGH (latching) and LOW (non-latching) alarm relays are normally de-energized. All above specifications are standard. Options are available. Flashing amber for LOW alarm; flashing red for HIGH alarm; green for READY (power on-after time delay ends); flashing amber for MALFunction; green Channel I.D. LED for each channel. None General purpose (non-hazardous, indoors) Two years SENSOR Type: Temperature Range: Response Time: Zero Drift: Typical Life: Electrical Classification: Warranty: Cable: Diffusion, low temperature catalytic bead Standard Industrial Types: Combustible Gas; Solvent Special; High Temperature Combustible Gas; High Temperature Solvent Special. -55C to +93C (-65F to +200F) standard; high temperature special to 200C (400F). Typically 6 second time constant when exposed to 50% LEL of Methane gas. Less than 5% per year 3 years in normal service NEC Class I, Division 1, Groups B, C, and D Two years 3 wire maximum cable length allowable between controller and sensor assembly with one way resistance of 20 ohms (total 40 ohms loop): AWG METERS FEET 20 580 1900 18 910 3000 16 1460 4800 14 2320 7600 Page 24 ABD00253114 GENERAL MONITORS IX. SENSORS The following is a list of GMI sensors available for use with the Model 580 System: P/N 10001-1 Standard Industrial Combustible Gas Sensor. Used for most hydrocarbons and hydrogen. Temperature range -55C to 93C (-65F to +200F). 10001-1R Same as P/N 10001-1 except greatly improved resistance to poisons such as HMDS (Hexamethyldisiloxane) and H2S. 10014-1 High Temperature Standard Industrial Combustible Gas Sensor. Same as P/N 10001-1 except it may be used at temperatures up to 200C (400F) 10058-1 10058-1R 10022-1 Same as P/N 10001-1 except sensor body is stainless steel. Same as P/N 10058-1 except greatly improved resistance to poisons such as HMDS (Hexamethyldisiloxane) and H2S. Similar to P/N 10001-1 except PTB approved. 10059-1 Same as P/N 10022-1 except body is constructed of stainless steel. 10015-1 High temperature equivalent of P/N 10022-1. in temperatures up to 200C (400F). It may be used P/N 10001-1, 10058-1, 10022-1, and 10059-1 sensors are CSA C22.2 No. 152-- 1976 certified. P/N 10252 sensor housing is normally used in the Western Hemisphere. PTB approved housings are normally used in Europe. Special NOTE: SENSOR REPLACEMENT When it becomes necessary to replace a sensor in an operating system, the following precautions must be taken. 1 ) If possible, the area should be declassified and power removed from the Model 580 controller. 2) If power cannot be removed from the controller, a temporary jumper should be placed between the terminals of the black and white leads in the sensor housing until the new sensor leads are securely tightened. Then remove the jumper before replacing the sensor housing cover. If this procedure is not followed there is a strong possibility that the new sensor will be burned out during its installation. ABD00253115 GENERAL MONITORS X. ACCESSORIES Page 25 A. CALIBRATION EQUIPMENT Calibration accessories may be purchased from GMI. Contact the factory or your local representative for technical or ordering information. The P/N 1400200 Portable Calibration Chamber is used to calibrate sensors for any specific combustible vapor which has a flash point below ambient temperature. The customer must provide his own sample of the liquid to use with the chamber. GMI provides a microliter syringe for exact measurement of volumes to be used. Instructions for use are provided with the chamber. GMI P/N 1400150 portable purge calibrators are available for several common gases, including hydrogen, methane, ethane, propane and butane. The portable purge calibrator is a ready-for-use assembly including a lecture bottle contain ing approximately 50% LEL of the gas ordered, plus regulator and an adaptor which fits over the sensor. Replacement cylinders are also available. B. SENSOR COVERS The information below is of a general nature. GMI or your local representative should be contacted for specific recommendations. NOTE: If sensor covers are used they should remain in place during calibration. If they are going to be cleaned, the sensor should be recalibrated after the sensor cover is re-installed. Although several of the available covers do not effect sensitivity or response time themselves, accumula tions of dust, dirt, water, etc., may do so. (1) Dust Guard Assembly (P/N 10110) The dust guard assembly is a simple, threaded stainless steel (type 303) cylinder with a disposable wire screen at one end. It is easily unscrewed for cleaning and/or replacement of the screen. The screen material is stainless steel (type 316) with a nominal 40 micron mesh. This accessory is specially designed to prevent dust and particulate matter from reach ing the sensor flame arrestor. Such debris can plug the screen and limit the amount of gas reaching the active surface of the sensor. When the dust guard is installed, this problem is minimized and sensor response is virtually unchanged. The dust guard is also available in a kit (P/N 10044) with twelve replaceable screens. It can be used as an effective windscreen, and is recommended for corrosive, windy or high temperature environments. A typical application would be in the area surrounding a drying oven. Page 26 ABD00253116 GENERAL MONITORS B. SENSOR COVERS (Cont'd.) (2) Porex Dust Cover (P/N 10071) This cover is a disposable porous plastic dust guard which eliminates the problem of fine particles plugging the sensor flame arrestor. The material used is high density polyethylene with a 250 micron mesh. It consists of a cylindrical barrel with one end closed, which screws in place on the sensor body. Due to the small pore size which restricts the gas diffusion path, porex dust covers may depress sensor response by as much as 40% and increase response time by a few seconds. Because of this, the sensor must never be calibrated with the porex dust cover off. The porex dust cover is inexpensive and therefore maybe considered a disposable item, although it may be cleaned and re-used several times. It is recommended for extremely dusty or windy environments, but should not be used for applications in which it will be exposed to temperatures in excess of 80C (180F). (3) Sintered Stainless Steel Dust Guard (P/N 1800822) The construction of this accessory is similar to P/N 10110 above, but it has a 3mm (1/8" > thick sintered stainless steel disc at one end. The body material is stainless steel. It has an internal thread for installa tion on the sensor body. This dust guard provides protection from fine particulates and windy environments. It should be used only in dry loca tions because of the tendency of the sintered disc to absorb water, which would then act as a gas diffusion barrier until the disc dried out again. This dust guard reduces sensor response, so it must never be removed for calibration. (4) Splash Guard (P/N 10117) The Splash Guard is a rugged ABS plastic cylinder which screws into place over the sensor body. It contains a series of internal baffles which are designed to deflect water away from the sensor flame arrestor. A stainless steel mesh may be inserted into the open end of the Splash Guard. The Splash Guard is recommended for areas where heavy rain or frequent equip ment hosedowns occur. (5) Sensor Flow Chamber (P/N 10066) The General Monitors' Sensor Flow Chamber is constructed of aluminum (op tional stainless steel construction available). The chamber has an intern al thread into which a sensor may be screwed, and two threaded ports which accept 1/4 inch tube fittings. The chamber is designed for insertion into a sampling system. ABD00253117 GENERAL MONITORS XI. RECOMMENDED SPARE PARTS One Model 580 For up to Two Years Operation Page 27 ITEM 5 6 7 8 9 14 DESCRIPTION LENS - Amber LENS - Red LENS - Green FUSE, .5 amp, 110 VAC FUSE, 2 amps, 110 VAC Sensor PART NUMBER 939-048 939-049 939-047 951-200 951-015 Per original order QTY 1 1 1 2 2 1 FINAL ASSEMBLY COMBUSTIBLE GAS MONITOR DUAL CHANNEL MODEL 5 8 0 Page 28 ABD00253118 t, > S' S.S V -> a * i / ., $ 5 55* S `: . y ftr 09 j \ 'fil* 1 r* C * si .iTij^ 1! ' :\i i '? * i ; ? - w ; L j S ; *SS- k$Zu! ** i ? f [I O 9 1 5 <r. t r * O *. - \ a $!< w * * k 1k/.> S!i r" !r* i 5 I: * 9 i 9** S: i :s if 8; i? i Is i ; * l5 SS % *> si! it s-is t*f a* y s \ ;r t ,; s f I i K i I, S | SsEs B s 1 s* I '!' S 3 Ss I If. u i -1l I S3 3s 3O r. 0 Uf)!o s2 rS f> i1 :- -- -l <M -- 4 1 1V FIG. 3 2 0 7 0 0 G) IL iu oc SCHEMATIC DIAGRAM, CONTROL ELECTRONICS & POWER SUPPLY ABD00253119 0) CM i/i Qc K CM _ Vj > aii: 2 OQ ^ 5IL' s!5! su5j it'r> 5 og: l* tzo2t;oO<"*Cu<k*ij a5< FIG. 4 SHT 1 (REF 2 0 7 0 2 L) -i CM O N O CM IL UJ FIG. 4 SHT 2 SCHEMATIC DIAGRAM, CONTROL ELECTRONICS & POWER SUPPLv Page 30 ABD00253120 (REF 20 7 0 3 A) FIG.5 OPTION TABULATION, CONTROL ELECTRONICS PAGE. 31 ABD00253121 (RIP ao 710K) FIG. 6 SHT 1 CCA, CONTROL ELECTRONICS COMMON COMPONENTS ABD00253122 ABD00253123 Page 33 3 5 3 > A<o *"51 K*) Jr 3; *> Nrrj "i 8 Otv' *) N >tv0 & <%\* *1 NN a Cvh ISs n Vi 5 5? X 5 9. D N v> * f) <v *r 0 5 $ $ ? ii K* K V? <* s 5' 5 S s N\N* 5 51 * VSs. *.*14 2? $$ O' *Isfit w4 * 9 : | *** sfIlf vS ?s 4M 9^ \J s (J IK 8 S' 8 8 f sa f S e8 9 8 * 5' 8 d 5f V * I 1 is V i VSJ i i i K* s K S 0 9 50IT> I1 Nf0tj a5? sK*. a p\ 4 V|fry fs X cf*N A > KV<*, A A| hi a i !! %1 t $ I i % i! uS if uSr <>1i" <0 ! <* s 9 1 aa A O' > O' 0) O' 0*>> s i >0 % fWt| *CM i a I Ufti 55ft 1i s fv 9 N Oi S S K. 1 l S !! !i \ f 9 * r c % s is 1 9 I 1 1 I 8 i i 1 i f s ? is s 1 I 8 i i 1 a S0sf 1 i 1i 0*. m 5 8 l a*i O' % 5 1 Q p Cj i f 1 i N s J A S0 S5 a 5? A *i <y A s1 i 8 in - GJ <M - N - - (fl N - <v M - - ft Vi W a H N - cv ' tn m N ej ftj 0, tv > 'i ( w - N - V ' N > - -cv <M ' - a Vi N *( -> M - fM N N N N 't m i a 5 5 OOvv S 9 3! 5 s N9 A 8 %9 * TINi 4 1 5 sD ! i 8 R R fc R 1q 5R R < **59 K* 3 3 4 t\>* 3 4 3 H 5 Kv 335 $ l 9 3 *K 8 a r NK 5 53 <N' 0\ < 4 il 0 s* 0 Cl 0 a o44 9 4M5) 1 ? ? 1 j 5 1 > !f 1 I i t ! P S 3 1 1 l a V o 5*v I $ V $* V I * s ! k s<d 5 3* \ eN S "3 nJOf v' N \ S 5} ? ss iiII ot i N J? s 1 s1MttJ s * 9v ? I <g 5' 8 *! ** I S' *S' aN* s s I 8 X 5< s \ i Vt iN 8 * i N ? i 1 $ >v 8 15 I ** 9 ?| N 5 1 1 2 $ i 9 11 *J rC SJ 2 SV' t8 s $ II 1' *** 3f * S' i* s, ?K S *1 1 3 R* if 5 ^ i R i if 1 x"i' w<r R <? 8 8 t ij c 8 I 1 i k o $ *' On a1 S Ii 1' S 5 < V W Js s N8Rftt*f ft * 3 I # I it 1 iw 8 <v 3 3 H ft 3' ? t9t* 8 t M | a' si 5? s s af * I s' *N i N* ao | 8 i fKNt NM* n 09 j i i "i 1 i l imft N A 4 4 K s i s l N 8 5 K* X N K * Cr>K\ fv X AK>. Art. a* JN IV9N (N 9? K. J R0 K J S Ps 5 0 i "3<> J 5 4 VAK. 5 O**N Ri K. 1 I >O' j i oI%N 8>A< ! O>' 5 K<4. A 5N Nint.' fv X N *> foi r*s >*4. AA w0> Oi 3 K* A a I>AS t> <% A 8 KV. A t A9*1 tv 0 %o K A ? * X i A** PS X i I N - N* (1 ' <s <a 4 N N - - - - -- ' '- --- -- '- ---- 4 D M CN - - " - h- N OJ > > - - - - ~ A - 91 A * - o N 4 "1 N N | - - - o> M* N "i - - - - ' 9 - y \s *> tt iX O s 1 5 tN 4 Vj * 5 N 1|* 3 s sH a K ri 51 A >A $ X 01 A Sp* t 1 k S sft | 1 ft Nl Qw g a <2 4 * 5ft a M i P a z J e 2 <*j I 9L 8s ! $ s I 5 * i i 8| 1 i I N I > 1 1 M S I k ? w 3 s * $ 3 I * s 5 9 1 s 91 % u 5! ? 1 3 N N 3 | 3 Ntj *> > 10 4A v I 1 c3 9i 0 sa - - - -- 'M - N N 3 - - - -- S N - - - N N *> M l s o 1 3 # i 5 * 8 3 8 8 v, 1 ? v > o H ?N o (f) O zcn ot h-w o== uj O Jd uiS jO OO (DC7 o o CM H I CO (0 0 LL o o T" N o CM IU cc Page 34 ABD00253124 o (7) 00 t- 4 in * m - aE I SOI *6 9 8 1 8 PQ * ain? iJ 55 * O0J * o a a cc 1e UccJ Ea r\j (VI * Ai 8 03 2 Z 5 4o>0 4m o h5 Pd N <\J 1I 1 -- - ' 8 s CM KO KV1> a | 948-104 | CCA, LATCHING MODES - COMMON COMPONENTS (REF 20 704A) FIG.7 / } SLEEVE 2 PIC'S ABD00253125 (REF 20 70S CD F IG .8 CCA. RELAY OPERATIONS COMMON COMPONENTS Page 36 ABD00253126 rn OJ oJ OJ ro O C\J oi GO I- sO in m OJ - a 01 GO r- 'D in <r\ OJ cn to cn C 5 in fmO O o t Ct OJ (0* OJ OJ <o / OJ oJ 0- r 4 a O' CL CL a: <T in CQ GO / 9 <T rO OJ OJ CL QC 4 9 in Oi <* m oQ Q o a* .J < P P2 scl o o2 O u Pr oO P o oz S o (j H 2 Q Q. 2 O 13 hi 13 CD CD I sfl I cn vO cn 3D 0. a 99 I u X 0 h- K ? 01 1/1 M * ^0 in -VI* 9 5 3s ,0 S" 3 5 5 9 *9 d 3 d 01 <T * OJ 0) <j N d p in 9 in rri vO 99 ^r a CL CL a a gg <n tn UJ n t/i in UJ UJ u cn UJ or CL CL CL CL dd O OJ9 in r 5 CL CL UJ 2 (D a a 2 UJ < CL 1 6Q UJ UJ LJ oz a z oz hi hi UJ fe \y--< hx-: u UJ9 LJ 9> QaO UJ UJ UJ _J _J m OJ - wa O 4 OJ h-' CL CJ O CL < O T CD z s t oO 5 sc ^ z _j s a n Q UJ 8a CJ O CJ ro O o0 0.J !m 01 N. n rn O 3" in in in 01 Cl ai OJ o> M- O rn OJ 00 01 OJ m- t-- r- r~ r~ 9- a CTi Cl 01 *r 01 -a 0 CM CM in in O' r- 'chf * 01 01 r- <D OJ OJ CM mmm * CO GO 03 01 <0T1 0M1- OJ CD ^r 01 ao O S r- Q OJ a --- OJ OJ OJ OJ OJ OJ OJ - m c - < FIG. 9 CCA, DISPLAY BOARD 101990 FIG. 10 RACK ASSEMBLY, PANEL MOUNT Page 37 ABD00253127 Page 38 ABD00253128