Instruction Manual TA2102

TA-2102 Two Wire Loop Powered

smarter Transmitter

Instruction Manual

Operating Voltage: 10-30 VDC

Mil-Ram Technology, Inc.no false alarms

4135 Business Center DriveFremont, CA 94538

Ph (510) 656-2001Fax (510) 656-2004

Web: www.mil-ram.com

M I L - R A M T E C H N O L O G Y

Ammonia, NH3Boron Trichloride, BCl3Bromine, Br2Carbon Monoxide, COChlorine, Cl2Chlorine Dioxide, ClO2Dichlorosilane, SiH2Cl2Fluorine, F2Hydrogen Bromide, HBrHydrogen Chloride, HClHydrogen Cyanide, HCNHydrogen Fluoride, HFHydrogen Iodide, HIHydrogen Peroxide, H2O2Hydrogen Sulfide, H2SNitric Acid Vapors, HNO3Nitrogen Dioxide, NO2Oxygen, O2Ozone, O3Sulfur DioxideSilicon Tetrafluoride, SiF4Sulfur Dioxide, SO2Sulfuric Acid Vapors, H2SO4

Arsine, AsH3 Tungsten Hexafluoride, WF6Phosphine, PH3 Tetrachlorosilane, SiCl4Diborane, B2H6Hydrazine, N2H4 Many More GasesSilane, SiH4

Range:

Administrator

IMPORTANT

Warning: This equipment should only be installed by personnel experienced and qualified in the installation of such equipment. Warning: This instruction manual must be read and understood by all individuals responsible for the installation, operation, calibration and maintenance of the equipment.

Warning: Electrochemical gas sensors are not designed or intended for on-line continuous gas analysis or operation in a constant (or near constant) background of gas. Such conditions of continuous or very frequent gas exposure will significantly reduce sensor life and require more frequent gas calibrations. Sensors operated under these or similar conditions are excluded from any warranty. Additionally, sensors operated under these conditions will require more frequent recharging (or replacement) to maintain gas sensitivity. It is recommended that spare sensors be maintained to reduce down-time under such conditions.

Warning: Electrochemical gas sensors are not designed or intended for exposure to high concentrations of gas (in excess of full scale gas concentration). Depending on sensor type, the concentration, duration and frequency of exposure, gas sensitivity will be degraded. Sensors operated under these conditions are excluded from any warranty. Additionally, sensors operated under these conditions will require more frequent maintenance related to calibration and recharging (or replacement) to maintain gas sensitivity. Electrochemical sensors do NOT have an unlimited capacity to react gas and depending on levels and frequency of exposure, can become chemically saturated and therefore, unresponsive to gas. It is recommended that spare sensors be maintained to reduce down-time under such conditions.

Warning: Do not attempt to repair or modify instrument. If repair is needed, contact Mil-Ram Technology to obtain a Returned Material Authorization (RMA) number and further assistance.

WARNING: As is the case for all electronic circuit boards, the smarter Transmitter includes electronic components that can be damaged by static electricity. Circuit boards should only be handled when absolutely required and with power removed. Personnel should always touch earth grounded junction box prior to handling circuit board. This will discharge any stored energy. Hold circuit board by edges only. Do not touch either surface of board or any electrical components or circuit traces.

WARNING: Electronic assemblies are sensitive to lightening damage. Always install proper lightening arrestor with the transmitter to reduce likelihood of damage in lightening prone areas.

WARNING: Electromagnetic radiation can interfere with the normal operation and performance of the smarter Transmitter. Radio communications equipment, including hand-held radios (walkie-talkies) should be used at a safe distance from the transmitter and sensor. Safe distances vary depending on radio frequency, power and environmental factors. Typically, a distance of at least 3 meters should be observed and increased accordingly, if any interference is observed. Electromagnetic radiation can damage electronic components.

WARNING: Properly seal all junction box conduit entry fittings to exclude water and liquid from entering box. Water or liquids will damage circuit boards and require immediate replacement.

WARNING: Although the smarter Transmitter incorporates a self-calibration feature, this feature is intended to supplement and NOT replace a regular calibration program using a certified gas sample of known concentration. Although the sensors are normally quite stable, it is generally recommended that calibration be performed monthly in the interest of safety. Unusually harsh or severe environments will require more frequent calibration checks. A routine program of field calibration will help determine which transmitters/sensors require more or less frequent calibration and maintenance. This is the only method to accurately determine system performance under the specific site conditions and make appropriate adjustments to the maintenance schedule. Gas calibrations are the only absolute method of assessing transmitter/sensor performance.

WARNING: The smarter Transmitter determines Remaining Sensor Life base on actual field calibration data, sensor life curve and specific electrical characteristics of the sensor. The remaining sensor life is an approximation and does not replace a regular calibration program using a certified gas sample of known concentration to validate sensor response. Near the end of sensor service life, the transmitter will indicate Replace Sensor. At that time, the sensor must be replaced with a new sensor and properly gas calibrated.

FAILURE TO OBSERVE THE ABOVE CAN RESULT IN INJURY, PRODUCT DAMAGE AND/OR UNSAFE CONDITIONS.

Table of Contents I. Description.............................................................................. 1

II. Smarter Features .................................................................... 1 III. Installation .............................................................................. 2 IV. Transmitter Wiring............................................................... 4 V. Transmitter Operation .......................................................... 5 A. Main Information Mode................................................... 6 B. Loop Test ........................................................................... 9 VI. Diagnostic Messages............................................................ 11 VII. Rain/Splash/RF Shield (optional) ...................................... 12 IIX. Sensor Calibration .............................................................. 13 A. Zero Calibration ........................................................... 13 B. Span Calibration ........................................................... 15 IX. Off-Site Sensor Calibration ............................................... 16 X. Self-Calibration................................................................... 17 XI. Remaining Sensor Life....................................................... 17 Installation Drawings Sensor Replacement Electronics Replacement Warranty

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2-Wire Toxic Smarter Transmitter I. Description:

The model TA-2102 smarter Transmitter provides remote detection of a specific toxic gas using Mil-Ram’s patented no false alarms electrochemical sensor technology. The transmitter is two-wire loop powered and transmits a standard 4-20mA signal. The smarter transmitter operates on 10-30 VDC.

II. Smarter Features:

• 2-Wire Loop Powered – operates on 10-30 VDC and generates a standard 4-20mA signal

• Self-Calibration – unattended span calibration adjustments performed every 30 days

based on life curve for sensor

• Auto-Calibration – non-intrusive calibrations using a magnet to activate zero and span switches located behind glass window of explosion-proof junction box – no mechanical adjustments required

• LCD Display – 12 character x 2 line display provides meter readings, calculated values

and diagnostic messages

• Life Remaining – sensor life remaining based on calibration history, life curve for sensor and electrical characteristics of sensor

• Peak Value/15-min. TWA/Number of days since last gas calibration—Transmitter

displays this information on demand

• Loop Test – Output 4/8/12/16/20mA to verify readings and alarms at controller electronics

• Calibration Mode Alarm Inhibit – during span calibration and for a period of 5 minutes

after calibration, the transmitter outputs 4.0mA

• Diagnostics – continuous diagnostics related to both hardware and software operation with auto reset of micro-controller in the event of software failure – provide messages including Replace Sensor, Remaining Sensor Life and Sensor Disconnected

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III. Installation: WARNING: The transmitter LCD display/main circuit board assembly is sensitive to damage by static electricity. Always touch earth grounded junction box before handling/removing electronic circuit board assembly. When handling electronic assembly, hold circuit board by edges only. Do not touch either surface of circuit board. Do not touch electronic components or circuit traces on circuit board. Electronic assemblies are also sensitive to lightening damage. Always install proper lightening arrestor with the transmitter to reduce likelihood of damage in lightening prone areas. For further assistance, please contact Mil-Ram factory.

The sensor is provided with ¾’ NPT external threads opposite the sensing end of the device. The sensor screws into an explosion-proof junction box which houses the smarter electronics. The sensor/smarter electronics/junction box assembly constitutes the transmitter.

Install transmitter as follows:

1. Unscrew cover (with glass window) from junction box.

Junction Box with cover/glass window removed

Removal of LCD display/main circuit board assembly from junction box

Junction box with banana sockets

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2. Remove LCD display/main circuit board assembly by pulling up on face plate at two locations marked PULL (banana jacks secure the assembly in the junction box). Carefully lift assembly from junction box.

3. Carefully guide brown sensor cable connector through opening in bottom of junction box. Screw sensor into junction box hand tight. Attach sensor connector to bottom of main circuit board at 9-pin brown connector marked SENSOR. Seat the sensor connector fully to lock in place.

4. Install LCD display/main circuit board assembly in junction box by carefully aligning

banana plugs on bottom of main circuit board with sockets in junction box. Gently push (directly above face-plate screws) until banana plugs seat fully in sockets.

5. Replace cover on junction box. 6. Mount junction box to a vertical surface with the perforated end of the sensor

pointing downward. Note: Transmitter junction box should be connected to earth ground using grounding lug provided on outside of box. Proper grounding is required to ensure safe and proper operation of transmitter.

Note: It is generally recommended that the sensor be installed at a location as close as possible to the source of gas.

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IV. Transmitter Wiring:

The smarter transmitter is 2-wire loop powered and operates on 10-30 VDC. Make connections as follows:

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Run two wires from the controller 4-20mA Input and signal common to the power/signal terminals located on the bottom of the main circuit board. The power/signal terminals are non-polarized.

NOTE: The two power/signal wires must be isolated from other wires and should therefore

be shielded or run in metal conduit to avoid electrical pick-up. If a shield is used it should run continuously from the controller electronics to the inside of the transmitter junction box. The shield should be terminated at the controller signal common but left floating (do not attach to anything) inside the transmitter junction box to avoid ground loop interference. Apply electrical tape to exposed shield inside junction box.

The smarter transmitter can be located up to several thousand feet (max. total loop resistance = 500 ohms) from the controller electronics using 18 AWG standard copper wire. V. Transmitter Operation:

The smarter transmitter provides four magnetic switches to access information, test the loop and calibrate the toxic sensor. The switches are activated using a magnet held directly over the switch outside the junction box glass window.

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The switches are designated as follows:

ENTER: A magnetic switch used to enter the main Information Routine to view Peak Value, Remaining Sensor Life, 15-Min. TWA (Time Weighted Average) and Ambient Temperature (degrees C). ENTER switch is also used to escape Loop Test in progress.

UP: A magnetic switch used to enter Zero Calibration mode and increment span calibration gas concentration. The UP switch is also used to proceed with the Loop Test. DOWN: A magnetic switch used to enter Span Calibration mode and decrement span calibration gas concentration. The DOWN switch is also used to exit Loop Test before generating any output. RESET: A magnetic switch used to reset Peak Value and escape Span Calibration mode without performing calibration. A. Main Information Mode: The smarter transmitter displays the following parameters when the Information Mode is entered:

• Peak Value • Remaining Sensor Life • 15-Min. TWA (time weighted average) • Ambient Temperature (degrees C) Upon entering the Information Mode the LCD display will automatically sequence through the parameters.

To enter Information Mode, momentarily hold magnet directly over ENTER switch until LCD display shows the Peak Value

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Note: While Peak Value is displayed, the value can be reset by momentarily holding magnet directly over RESET switch. A successful reset provides the following message on the LCD display Following Peak Value the LCD will automatically proceed to Remaining Sensor Life Next, the LCD will proceed to 15-Min. TWA (Time Weighted Average)

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Next, the LCD will proceed to Ambient Temperature After approximately 5 sec. LCD display will return to normal operating mode to provide gas readings

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B. Loop Test

The smarter transmitter provides a built-in loop test whereby the transmitter outputs 4/8/12/16/20 mA on demand. The generated output signal can be used to verify readings/alarms at the Controller electronics and loop integrity. To enter loop test, hold magnet directly over RESET switch until LCD display shows To escape loop test without generating any output, hold magnet directly over DOWN switch until LCD display returns to normal operating mode

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To proceed with loop test, hold magnet directly over UP switch until LCD display shows

To increment Signal Output, hold magnet directly over UP switch until LCD Increments Output Value. When Output reaches 20 mA the next increment will roll-over to 4 mA.

To decrement Signal Output, hold magnet directly over DOWN switch until LCD display decrements Output Value. When Output reaches 4 mA the next decrement will roll-over to 20 mA. To exit LOOP TEST, hold magnet directly over ENTER switch to return to normal operating mode.

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VI. Diagnostic Messages:

The LCD display provides the following fault messages during normal operation Relay Definitions:

The 2-Wire smarter Transmitter does not provide local relay outputs. However, external relays are often used at the controller electronics to provide appropriate alarms at pre-set

alarm points. The following definitions are provided for general information. Non-latching: when alarm set point is reached and exceeded, relay is activated (open contacts close and closed contacts open). When gas concentration falls below alarm set point, relay automatically resets to original state. Latching: when alarm set point is reached and exceeded, relay is activated (i.e. open contacts close and closed contacts open). When gas concentration falls below alarm set point, relay does not reset to original state. The relay must be manually reset using a switch. Energized: Power is normally applied to relay such that normally open contacts are closed and normally closed contacts are open. When the alarm set point is reached or exceeded, the relay changes to the power down state.

Sensor cannot be calibrated—Requires immediate replacement

Sensor has been disconnected from main circuit board—transmitter outputs 2.4mA— install sensor as described in Section III, steps 1-6, above

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Non- Energized: Power is normally not applied to relay such that normally open contacts are open and normally closed contacts are closed. When alarm set point is reached or exceeded, the relay changes state. VII. Rain/Splash/RF Shield (Optional)

A black anodized aluminum shield offers protection to the sensor from rain, splashing, radio frequency (RF) and mechanical shock.

The upper portion of the housing is provided with internal and external 3/4” NPT threads. The external threads screw into the explosion-proof junction box which houses the remote amplifier. The sensor screws into the 3/4” NPT internal threads. The lower portion of the housing consists of a cylinder with bottom plate; the housing is perforated to allow gas entry. The cylinder is secured to the upper housing with four set screws.

Install the shield as follows: 1. Screw upper portion of housing into junction box.

2. Carefully guide brown sensor cable connector through housing into junction box. Screw sensor into housing hand tight. Attach sensor connector to bottom of main circuit board at connector marked SENSOR. Seat the sensor connector fully to lock in place.

3. Position lower portion of housing (cylinder) around sensor. Push upper edge of cylinder over upper housing. Tighten four set screws to secure cylinder.

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VIII. SENSOR CALIBRATION: NOTE: A routine program of calibration should be employed to ensure proper

operation/performance of the sensor and system. Although the sensors are normally quite stable, it is generally recommended that calibration be performed monthly in the interest of safety.

Sensor calibration is performed at the smarter transmitter using a gas sample of known concentration. To calibrate the sensor, follow the steps outlined below. NOTE: The sensors are factory calibrated with gas prior to delivery. Field calibrations must be

performed with an appropriated gas sample of known concentration. A. Zero Calibration:

1. In clean gas-free air, momentarily hold magnet over ZERO CAL switch until LCD display shows

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When zero calibration is complete, the transmitter will return to normal operation to provide meter readings. Note: If ambient air is not known to be gas-free, apply zero air (cylinder) using calibration Cup

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B. Span Calibration:

1. Momentarily hold magnet over SPAN CAL switch until LCD display shows Note: To exit span calibration mode without performing calibration, momentarily hold Magnet directly overt RESET switch.

2. Momentarily hold magnet directly over UP or Down switch to increment or decrement calibration gas concentration. When proper gas concentration is displayed, hold magnet directly over ENTER switch to advance to next display

3. Apply span calibration gas of exact concentration shown on LCD display using calibration cup.

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4. When span calibration is complete, the transmitter will return to normal operation to provide meter readings. Note: during span calibration and for a period of 5 minutes after calibration, the smarter transmitter outputs 4.0mA to prevent activation of alarms at the controller electronics.

5. Remove calibration cup and allow sensor to recover. LCD display will show recov-

ery of sensor to zero. IX. Off-Site Sensor Calibration:

The smarter transmitter Toxic gas sensors include an EEprom encapsulated inside the sensor housing. The EEprom retains all set-up parameters (alarm set points, relay operation/function, etc.) and sensor calibration factors. Therefore, the sensors can be calibrated in the instrument shop (i.e. off-site) with Mil-Ram Remote Calibration Electronics (contact factory) and the sensors re-installed in the field without further calibration. Upon installing the sensors, the field installed transmitter electronics automatically up-loads the calibration data to properly configure the transmitter.

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X. Self-Calibration:

The smarter transmitter provides unattended self-calibration features whereby every 30 days the micro-controller electronics increments the span calibration based on the typical life curve for the sensor type. When a field calibration is performed with a gas sample of known concentration, the life curve is re-extrapolated based on actual calibration data. Note: The self-calibration feature is intended to supplement and not replace a regular calibration program using a certified gas sample of known concentration. Although the sensors are normally quite stable, it is generally recommended that calibration be performed monthly in the interest of safety. Unusually harsh or severe environments may require more frequent calibration checks.

XI. Remaining Sensor Life:

The smarter transmitter determines Remaining Sensor Life based on actual field calibration data, sensor life curve and specific electrical characteristics of the sensor. The remaining sensor life is an approximation and does not replace a regular calibration program using a certified gas sample of known concentration to validate sensor response. Near the end of sensor service life, the transmitter will indicate Replace Sensor. At that time the sensor must be replaced with a new sensor to ensure proper calibration.

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Mil-Ram Technology, Inc. Fremont, CA 94538

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Note: Transmitter junction box should be connected to earth ground using grounding lug provided on outside of box. Proper grounding is required to ensure safe and proper operation of transmitter.

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If a shield is used, it should run continuously from the controllerelectronics to the inside of the transmitter junction box. The shieldshould be terminated at the controller power common but left floating(do not attach to anything) inside the transmitter junction box toavoid ground loop interference. Apply electrical tape to exposedshield inside junction box.

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Sensor Replacement Instructions

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Sensor Installation The electrochemical toxic sensor is provided with ¾’ NPT external threads opposite the sensing end of the device. The sensor screws into the explosion-proof junction box that houses the smarter electronics. The sensor/smarter electronics/junction box assembly constitutes the transmitter.

Install sensor as follows:

1. Remove power from transmitter. 2. Unscrew cover (with glass window) from junction box.




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Warning: The transmitter LCD display/main circuit board assembly is sensitive to damage by static electricity. Always touch earth grounded junction box before handling/removing electronic circuit board assembly. When handling electronic assembly, hold circuit board by edges only. Do not touch either surface of circuit board. Do not touch electronic components or circuit traces on circuit board. Electronic assemblies are also sensitive to lightening damage. Always install proper lightening arrestor with the transmitter to reduce likelihood of damage in lightening prone areas. For more assistance, please contact Mil-Ram factory.

3. Remove LCD display/main circuit board assembly by pulling up on face-plate at two

locations marked PULL (banana jacks secure the assembly in the junction box). Carefully lift assembly from junction box.

4. Remove Existing Sensor: Unplug existing sensor from main circuit board at 9-pin

brown connector marked SENSOR. Carefully guide brown sensor cable connector through opening in bottom of junction box. Install factory provided shorting clip on brown sensor connector to protect memory chip (embedded inside sensor) from static damage during handling and shipment.

NOTE: if existing sensor is to be returned to Mil-Ram factory for service, package sensor in sealed plastic jar originally provided by Mil-Ram. Ensure jar is sealed properly to prevent sensor leakage during shipment. This jar also protects the sensor from large pressure changes encountered during air shipment.

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5. Install Replacement Sensor: Carefully guide brown sensor cable connector through opening in bottom of junction box. Screw replacement sensor into junction box hand tight. Attach sensor connector to bottom of main circuit board at 9-pin brown connector marked SENSOR. Seat the sensor connector fully to lock in place. (Note: the sensor connector is keyed to indicate proper orientation)



7. Replace cover on junction box.

8. Apply power (10-30VDC) to transmitter.

See TA-2102 Instruction Manual for operation details and calibration instructions.

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Electronics Replacement Instructions

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Electronics Installation

The Model TA-202 smarter Transmitter includes an electronic module (LCD display/main circuit board assembly) housed inside the explosion-proof junction box. The electronics powers and operates the sensor, measures the sensor signal and processes the signal to provide a standard 4-20mA output signal. The electronics further provides local LCD meter indication and continuous diagnostics. The sensor/smarter electronics/junction box assembly constitutes the transmitter.

Install electronic module as follows:

1. Remove power from transmitter. 2. Unscrew cover (with glass window) from junction box.




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Warning: The transmitter LCD display/main circuit board assembly is sensitive to damage by static electricity. Always touch earth grounded junction box before handling/removing electronic circuit board assembly. When handling electronic assembly, hold circuit board by edges only. Do not touch either surface of circuit board. Do not touch electronic components or circuit traces on circuit board. Electronic assemblies are also sensitive to lightening damage. Always install proper lightening arrestor with the transmitter to reduce likelihood of damage in lightening prone areas. For further assistance, please contact Mil-Ram factory.

3. Remove LCD display/main circuit board assembly by pulling up on face-plate at two

locations marked PULL (banana jacks secure the assembly in the junction box). Carefully lift assembly from junction box.

4. Disconnect Sensor: Unplug sensor from main circuit board at 9-pin brown connector marked SENSOR.

5. Disconnect power/signal wires from Terminal Block TB1 (Green 2-pin Connector

block). Remove LCD display/main circuit board assembly and immediately store in static shield bag to protect during handling and shipment. (Note: Replacement electronics are shipped in a grey, static shield bag). Warning: Never wrap electronic circuit board in plastic, paper or other material as the board will be damaged by static electricity. Use only approved static shield bag designed for protection of sensitive electronic components.

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6. Connect Power/Signal Wires to Replacement Electronics: Attach power/signal wires to Terminal Block TB1.

7. Connect Sensor: Attach sensor connector to bottom of main circuit board at 9-pin

brown connector marked SENSOR. Seat the sensor connector fully to lock in place. (Note: the sensor connector is keyed to indicate proper orientation)



9. Replace cover on junction box.

10. Apply power (10-30VDC) to transmitter.

See Model TA-2102 Instruction Manual for operation details and calibration instructions.

MIL-RAM TECHNOLOGY, INC.

TOXIC GAS DETECTION INSTRUMENTS AND SENSORS - WARRANTY

1. Warranty- Seller warrants that this product will be free from mechanical defect or faulty

workmanship for a period of twelve (12) months from date of shipment or one (1) year from installation, whichever occurs first, provided it is maintained and used in accordance with Seller's instructions and/or recommendations. This warranty does not apply to expendable or consumable parts whose normal life expectancy is less than one (1) year such as, but not limited to, non-rechargeable batteries, sensor elements, filter, lamps, fuses etc. The Seller shall be released from all obligations under this warranty in the event repairs or modifications are made by persons other than its own or authorized service personnel or if the warranty claim results from physical abuse or misuse of the product. No agent, employee or representative of the Seller has any authority to bind the Seller to any affirmation, representation or warranty concerning the goods sold under this contract. Seller makes no warranty concerning components or accessories not manufactured by the Seller, but will pass on to the Purchaser all warranties of manufacturers of such components. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED, IMPLIED OR STATUTORY, AND IS STRICTLY LIMITED TO THE TERMS HEREOF. SELLER SPECIFICALLY DISCLAIMS ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE.

2. Exclusive Remedy-It is expressly agreed that Purchaser's sole and exclusive remedy for breach of

the above warranty, for any tortious conduct of Seller, or for any other cause of action, shall be the repair and/or replacement at Seller's option, of any equipment or parts thereof, which after examination by Seller is proven to be defective. Replacement equipment and/or parts will be provided at no cost to Purchaser, F.O.B. Seller's Plant. Failure of Seller to successfully repair any nonconforming product shall not cause the remedy established hereby to fail of its essential purpose.

3. Exclusion of Consequential Damage- Purchaser specifically understands and agrees that under no

circumstances will seller be liable to purchaser for economic, special, incidental or consequential damages or losses of any kind whatsoever, including but not limited to, loss of anticipated profits and any other loss caused by reason of nonoperation of the goods. This exclusion is applicable to claims for breach of warranty, tortious conduct or any other cause of action against seller.

This warranty covers instruments and parts sold (to users) only by authorized distributors, dealers and representatives as appointed by Mil-Ram Technology, Inc.

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Instruction Manual TA2102