Crowcon Hydra Addressable Gas Detection System · 2019. 7. 17. · Addressable Gas Detection System Manual Hydra32 System Manual 1 Issue 2, February 2013 INTRODUCTION The Crowcon

Crowcon Hydra32Addressable Gas Detection System

Installation and Operation Manual

M07043Issue 2February 2013

Addressable Gas Detection System Manual

Hydra32 System Manual 1Issue 2, February 2013

INTRODUCTION

The Crowcon Hydra32 Addressable Gas Detection System is designed to monitor toxicand/or flammable gas hazards. The system must be installed and operated in accordancewith these instructions. No components of this system are certified for use in a hazardousarea.

WARNING

The equipment described in this instruction manual has mainsvoltages applied to it. Ensure correct safety procedures are adoptedbefore working on the equipment.

The equipment described in this manual is designed for detection offlammable and/or toxic gases. Ensure local safety procedures areadopted before carrying out any maintenance or calibration work.

The equipment described in this manual may be connected to remotealarms and/or shutdown systems. Ensure that local operatingprocedures are adopted before carrying out any maintenance orcalibration work.

© Crowcon Detection Instruments Ltd 2011

UK OfficeCrowcon DetectionInstruments Ltd2 Blacklands WayAbingdon Business ParkAbingdonOxfordshire OX14 1DYTel: +44 (0)1235 557700Fax :+44 (0)1235 557749Email: [email protected]: www.crowcon.com

USA OfficeCrowcon DetectionInstruments Ltd1455 Jamike AvenueSuite 100,Erlanger, KY, 41018USATel: +1 800 527 6926Fax: +1 859 957 1044Email: [email protected]: www.crowcon.com

European OfficeCrowcon DetectionInstruments LtdVlambloem 1293068JGRotterdamNetherlandsTel: +31 10 421 1232Fax: +31 10 421 0542Email: [email protected]: www.crowcon.com

Singapore OfficeCrowcon DetectionInstruments LtdBlock 194 Pandan Loop~06-20 Pantech IndustrialComplexSingapore 128383Tel: +65 6745 2936Fax: +65 6745 0467Email: [email protected]: www.crowcon.com

Crowcon reserves the right to change the design or specification of this product without notice.



TABLEOFCONTENTS1. INTRODUCTION......................................................................................................................... 31.1 CONTROL PANEL DESCRIPTION...................................................................................................... 31.2 SYSTEM CONFIGURATION .............................................................................................................. 31.3 TECHNICAL SPECIFICATION............................................................................................................ 4

2. INSTALLATION .......................................................................................................................... 52.1 CONTROL PANEL ........................................................................................................................... 52.2 SYSTEM WIRING ............................................................................................................................ 72.3 SERIAL CONNECTION TO A PERSONAL COMPUTER........................................................................... 92.4 DETECTOR ADDRESSES................................................................................................................. 9

3. SYSTEM FEATURES ............................................................................................................... 103.1 FRONT PANEL CONTROLS............................................................................................................ 103.2 START-UP OPERATION OF THE CONTROL PANEL ............................................................................ 123.3 SYSTEM OPERATING MODES ....................................................................................................... 133.4 SYSTEM STATUS ......................................................................................................................... 133.4.1 Normal Operation................................................................................................................ 133.4.2 System Alarm...................................................................................................................... 133.4.3 System Fault ....................................................................................................................... 133.4.4 Acknowledge....................................................................................................................... 133.4.5 Reset................................................................................................................................... 13

3.5 SYSTEM STATUS ......................................................................................................................... 143.6 SYSTEM SET ............................................................................................................................... 153.7 SYSTEM UNSET........................................................................................................................... 153.8 ALARM STATUS ........................................................................................................................... 163.9 EVENT LOG................................................................................................................................. 163.10 PROGRAMMING MENU .................................................................................................................. 163.11 PROGRAMMING BY THE CONTROL PANEL KEYPAD AND DISPLAY ...................................................... 173.12 PROGRAMMING BY PC................................................................................................................. 19

4. APPENDIX A – DETECTOR INSTRUCTIONS......................................................................... 204.1 INSTALLATION NOTES .................................................................................................................. 204.2 INTRODUCTION ............................................................................................................................ 204.3 HYDRA2 DETECTOR CONFIGURATION ........................................................................................... 214.4 CALIBRATION AND MAINTENANCE ................................................................................................. 22

5. APPENDIX B – OUTPUT & RELAY MODULE INSTRUCTIONS............................................ 24

6. APPENDIX C – CALIBRATION KEYPAD INSTRUCTIONS.................................................... 276.1 CONNECTING THE KEYPAD........................................................................................................... 276.2 ADJUSTING SETTINGS.................................................................................................................. 27Detector Calibration........................................................................................................................... 27

7. APPENDIX E – CONFIGURATOR SOFTWARE INSTRUCTIONS.......................................... 307.1 INTRODUCTION ............................................................................................................................ 307.2 STARTING THE PROGRAM............................................................................................................. 307.3 PARAMETERS PRE-SETTING ......................................................................................................... 317.4 CREATING A NEW CONFIGURATION FILE ........................................................................................ 317.5 GENERAL .................................................................................................................................... 327.6 PROFILES.................................................................................................................................... 337.7 CHANNELS .................................................................................................................................. 357.8 OUTPUTS .................................................................................................................................... 367.9 SEND CONFIGURATION (DOWNLOAD) ........................................................................................... 387.10 RECEIVE CONFIGURATION (UPLOAD) ............................................................................................ 387.11 TEST MENU................................................................................................................................ 387.12 STATE......................................................................................................................................... 397.13 EVENT LOG ................................................................................................................................. 40

8. APPENDIX F – WARRANTY .................................................................................................... 41



1. INTRODUCTION1.1 CONTROL PANEL DESCRIPTIONThe Crowcon Hydra32 gas detection control system has been designed to enable simpleinstallation and expandability with minimum cost and installation time. Detectors areconnected to the control panel via an RS-485 addressable loop with up to 32 gas detectors.

The control panel is also able to control up to 32 remote outputs (open-collector type), all ofwhich are programmable. These outputs, combined with the five built-in relays (3 alarm, 1fault and 1 watch dog) can be used to indicate the system status remotely or provide controlof auxiliary equipment.

The high brightness front panel display provides an ongoing reading of the gasconcentration being measured and, in case of an alarm, the alarm threshold attained for therespective channel. It can be controlled and programmed from the front panel using theAcknowledge, Reset and Set push buttons.

The panel enclosure is Ingress Protection rated IP65 and comes complete with 24Vdc, 3Apower supply. The control unit can also house 2 optional back-up batteries (each rated 12V7Ah) for use in the event of power failure.

An RS485 serial port is provided for connection to a Personal Computer for fast and easyprogramming of the control panel. The system can be connected to a site managementsystem via the same serial port which, when using appropriate software, can create graphicmaps and permit the remote control of the system.

1.2 SYSTEM CONFIGURATION

Figure 1 – System Block Diagram

2 x Addressable output moduleswith 16 x open-collectorsemiconductor outputs.

Each module capable of driving2 x 8 relay modules (optional)

2 x Output modulesUp to 32 HydraЇ Gas Detectors

5 Alarm/fault relay outputs(3 Alarm levels, 1 Fault and1 Watch Dog

RS485Interface

Requires USBor 232 converterfor PC connection

PC for control panel set upSupplied by customer

ST.G/OUTST.G/OUT

2 wires for RS485 communication (Belden 9841 cable)plus 2 wires for the power supply

Control panel



1.3 TECHNICAL SPECIFICATIONAddressable Control Panel SpecificationSize: 486mm x 288mm x148mm (width x height x depth).Inputs: Maximum 32 HydraЇ detectors connected on one RS485 bus.

Detector maximum cable length 1km*Outputs: 5 relays. Mounted in the control panel

Optional 16-way output modules (up to 2 can be connected on theRS485 bus). Each module has 16 open-collector semiconductoroutputs each capable of sinking 50mA.RS485 port for local system configuration, log upload and Modbusinterface for transfer to BMS/DCS/SCADA systems

Relay contact rating 1A 24Vdc 60VAPower Supply: 230V AC +/- 10% 50Hz (battery back-up available as an option)(Specified when ordering) Or 110V AC +/- 10% 50Hz (battery back-up available as an option)Power consumption: Max 6 VABackup battery 2 x 12V 7Ah max (optional).Panel containing: OLED Pictiva 96 x 64 display

Status LEDs organized as double row LED pairs - 3 Red pairs for Alarmthresholds, 1 Yellow pair for Fault, 1 Green pair for Unit power.Panel sounder can be de-activatedSoft-keys for system configuration

Temperature: Operational 0-55°C Storage -20 / +70 C°Relative humidity: Operational 15-85% Storage 5-85% (non condensing)EMC compliance: EN 50270: Electromagnetic compatibility-Electrical apparatus for the

detection and measurement of combustible gases, toxic gases oroxygen.EN 61000-6-3 (2001)+A11 (2004): Electromagnetic compatibility – Part6-3 Generic standard. Emission standard for residential, commercialand light industry.CFR 47 Part 15 B Non-intentional Radiators & ICES-003: 2004

Detector Specification

Construction: AlloySize: 100mm (w) x 180mm (h) x 65mm (d)Certification: Not hazardous area certified; safe area use onlyOperating Temperature: -10 to +55°CHumidity: 20-90% RH non-condensing (@40°C)Ingress Protection: IP55Voltage: 12-27V DC, 90mA max. (CO/NO2 version 40mA)Outputs: RS-485 addressable communicationsCalibration: Requires hand-held keypadGases and Ranges: 0-300ppm CO (electrochemical sensor)

0-20ppm NO2 (electrochemical sensor)0-100% LEL LPG/Propane (catalytic bead)

Sensor Life: 4-years typicalT90 Response Time: <60 secs*Accuracy: 5% of range or 10% of displayAccessories: Hand-held calibration keypad

Calibration adaptor



2. INSTALLATION2.1 CONTROL PANELBefore installing the control panel, read and strictly follow these instructions.Unlock the control panel front door and open it. Unplug the terminal block that connects thepower supply wires from the main PCB to the transformer on the back side of the box. Closethe front door and lock it again.Unscrew the four screws placed close to the front door corners and remove the front part. Itis now possible to drill the rear part of the enclosure for the cable entry glands.We would recommend all cables enter from the lower face of the enclosure. Make sure youare using IP65 rated cable entry glands to assure the box ingress protection is notcompromised.The rear part of the enclosure can now be wall fixed using the mounting brackets detailed inthe picture below.

Mount the control unit shown in Fig. 2.

Figure 2 – Control Panel Mounting Arrangement

The mains supply should be connected via either a suitably rated circuit breaker or fuse.Connect the three core mains supply cable to the power supply terminals (1.5 mm2 per coreminimum) and secure it with the appropriate cable grip.Connect the 24V dc power supply and the RS485 lines for the detectors and the outputmodules (optional) to the CN3 terminal block on the main board (See Fig. 4), following thewiring diagrams shown in Fig. 5, before powering up the control panel.Where the installation requires back-up batteries, place them in the upper side of theenclosure just above the DIN rail. After powering up the control panel, connect the red and

353mm

1,00

444 mm

It is not required to make anyFixing holes in the enclosure

Hole in the box

223mm



black power supply cables fitted with Faston connectors to the 2 x sealed lead acid batteries(12 Vdc / 7 Ah max.) as detailed in Fig.3. Please make sure the battery connectors arefacing the inside of the enclosure. As is shown in the photograph belowBecause of the vast range of batteries available, it has not been possible to create auniversal fixing system. It is therefore recommended that either double sided adhesive tapeor tie wraps with an adhesive base be used to anchor the battery.

Figure 3 – Battery Connection and Mounting Arrangements

Battery

12 V / 7 Ah

Battery

12 V / 7 Ah

27.4 Vdc/ 5A power supply230Vac



All connections of the Hydra32 are made on the main board connectors shown in Fig. 4.

Figure 4 – Hydra32 Main Board Connector Arrangement

2.2 SYSTEM WIRINGCommunication between the Hydra32 and the detectors is by RS485 bus. The control panelconstantly monitors the detectors and the remote modules connected. A break in thecommunication from any one of the detectors or modules generates a Fault status on thecontrol panel.

Gas Detector ConnectionRS485 Cable specificationWiring between the detectors, output modules and the control panel should be made byusing EIA RS485: 2 pair cable, one pair is used for the RS485 and the other pair un-used,with section 0.22 / 0.35 mm2 and shield (twisted pair). Nominal capacity between the wires< 50pF/m, nominal impedance 120 ohm. Crimp-type connectors should be used to ensurecables do not oxidise or loosen.

These features can be found in BELDEN 9842 cable or similar (data transmission cable inEIA RS485). Using this cable, the detector total line length should not exceed 1000 m.

Detectors and output modules are to be wired in ‘daisy chain’ mode (or Linear topology). Werecommend avoiding star or tree mode connection as interference immunity would bereduced.

Should any cable junctions be necessary please make sure there is no interruption in thecable shield (screen). Please remember that the shield should be connected to ground atthe control panel end only; never connect the shield to the detectors.

Cn3

Cn2

1

8

+-

BA

NONC

C

NONC

C

NONCC

Circuit layout and electrical connections

Relay alarm outputs

24 Vdc from the PowerSupply unit

500 mAFUSE+

-AB

Fault relay output

NO

NO

Detector connections(bus RS485 + power supply)

Hydra32 CONTROL PANEL

PC RS485 serial line

Detectors RS485 comm. boardPC RS485 comm. board

Al1

Al2

Al3

(Rl1)

(Rl2)

(Rl3)

(Rl5)

(Rl4)

WD relay output



Ensure that each 2 pair detector bus cable wire includes just one RS485 (i.e. is notconnected to another RS485 network).

Also ensure that a 120 Ohm end of line resistor is placed between the ‘A’ and ‘B’ terminalsat the beginning and the end (on the last detector or output module) of each bus line.

Detector Power WiresAn appropriate cross-sectional area (csa) must be selected, suitable for transmission of thepower to the detector loop. The following should be used as a guide for selectingappropriate cable:

A Hydra CO detector requires a DC supply of 12-27 volts, at up to 40mA, with up to 32detectors available on a single cable. It is essential there is a minimum of 12V at eachdetector (or output module), taking into account the voltage drop caused by the cableresistance.

Example: a nominal 24Vdc detector power supply has a guaranteed minimum supply of 22volts. The maximum voltage drop allowable is therefore 10V. Each Hydra CO detector candemand up to 40mA, and so for a 32 detector loop the maximum acceptable loop resistanceis 7.81 ohms.

A 1.5 mm2 cable will typically allow cable runs up to 300 metres. The table below showsmaximum cable distances given typical cable parameters.

C.S.A. Resistance Maximum(Ohms per km) Distance

mm2 Awg Cable Loop (metres)1.0 17 18.1 36.2 2151.5 15 12.1 24.2 3202.5 13 7.4 14.8 525

Note: power cable distances can be increased by using power supplies local to detectors.

Once the installation has been completed and the system is powered-on, check that eachdetector receives at least 12V dc.



Collegamento rilevatori SMART3NC / Connection of SMART3NC detectors

Make sure that a 120 ohm end of line resistance is placed at the beginning and at the end (on the l ast detectoror output module) of the bus line

* *

*

120 ohm

Powersupply

12 / 24 Vdc

1 = +2 = A3 = B4 = -

-V

+V

SERIAL “B”SERIAL “A”

Schermo a terra da un solo lato(earth at only one end)

CENTRALE(CONTROLUNIT)

120 ohm

Figure 5 – Detector and Output Module Wiring

2.3 SERIAL CONNECTION TO A PERSONAL COMPUTERThe control panel can be connected to a Personal Computer using the RS485 serial port, topermit initial programming or system management with the appropriate managementsoftware. Fig. 6 shows the connection to a Personal Computer.

Figure 6 – Personal Computer Wiring

2.4 DETECTOR ADDRESSESThe serial loop can have up to 32 detectors and 2 remote 16-output modules. The detectoraddress must be between 02 and 33 (addresses 0 and 1 are reserved for output modules).

Hydra32ControlPanel

Cn3

Cn2

1

8

+-

BA

NONCC

NONCC

NONCC

500 mAFUSE+

-

AB

NO

NO

Hydra32 Circuit Layout

RS485 serial line for the PC

PC RS485 comm. board

PCRS485 to USB interfaceor RS232

4= 0V3= B2= A1= +V

4= 0V3= B2= A1= +V



Each detector must have a unique address set using the Calibration Keypad. Refer tosection 4.3 for more detail. It is strongly recommended that the detector address is noted oneach detector or cable-tag for future reference.

NB: The detector addressed as 2 on the loop is the identified as No. 1 on the control paneland address 3 as No.2 and so on until address 33 which is No. 32 on the control panel.Every detector connected to the control panel is identified through a code that enablescommunication and programming. The 4-digit code shown on the control panel displaycontains all the base specifications for physical identification.

Example:

DETECTORS

DetectorAddress

Always 01

Ch02.01

3. SYSTEM FEATURES3.1 FRONT PANEL CONTROLSOn the Hydra32 front panel, a display provides an ongoing reading of the gas concentrationmeasured by each detector and, in case of an alarm, the alarm threshold attained for therespective channel. Each threshold or function is also indicated by a double row LED forAlarm, Warning and Caution. Three push buttons for the Acknowledge, Reset, and Setfunctions are available for front panel control and programming.

NB: after two minutes of inactivity, the display intensity progressively reduces. Thedisplay intensity is restored when a function key is pressed or when an alarmcondition occurs.



M. 0 SET

OK



3.2 START-UP OPERATION OF THE CONTROL PANELAt start-up the Hydra32 control panel will enter a warm-up phase during which the indicationHydra32 is shown on the display and all LED's turn off except for FAULT and POWER. Oncethe warm-up phase is over and the start-up procedure is correct, the first detector status willbe displayed.

Should the buzzer sound after start up, mute it by pressing ACK and check the FAULT,CAUTION (Alarm1), WARNING(Alarm2) or ALARM(Alarm3) LEDs or the display (FT(Fault) or L1, L2 or L3 depending on alarm level) to determine the cause. After confirmingwhether the system is in a Fault or Alarm condition; take the following action:

System in FaultEnter the Unset (UNS) mode by keeping SET pushed for 3 seconds then push ACK. AFault condition may either be caused by one or more gas detectors in Fault or faulty ormissing RS485 communications. Rectify the fault condition and then return the system tothe SET mode by pressing and holding the SET button again for 3 seconds followed byACK.

System in Alarm:Press ACK key to mute the audible Alarm. Once the gas has been dispersed and thereading is normal press RST to clear the alarm status and return to normal operation.

Note: Crowcon Hydra systems are supplied un-configured; a new configuration filemust be created before commissioning and operating the system (refer to Appx E).

Hydra32



3.3 SYSTEM OPERATING MODESThe control panel can be in one of three modes:

x Set

x Unset

x Program

An operational system can be in one of three conditions:

x Normal operation (SET mode)x System alarm

x System Fault

3.4 SYSTEM STATUS3.4.1 Normal OperationDuring normal operation and with the control panel in SET mode (as shown on display) thecontrol panel continually checks the status of each detector and stores the data. The statusof detectors can be checked using the function buttons: for example the location of anydetector registering a gas alarm can be identified.

3.4.2 System AlarmWhen one or more detectors sense gas above a threshold value, the system enters thealarm condition. Three levels of alarm can be set for each detector.

3.4.3 System FaultWhen one or more detectors are in fault, or there is a line fault (eg the cable has beendisconnected), the system enters fault condition. In this condition the control panel worksnormally, with the exception that the faulty detectors or cable loop are isolated.

The system remains in this condition until the fault is corrected, or the affected detectors areUNSET from the system in programming mode (ie temporarily removed from the systemconfiguration).

3.4.4 AcknowledgeWhen there is an alarm condition, the control panel sounder can be silenced by pressing theACK button.3.4.5 ResetWith the control panel in SET mode, and in FAULT condition, the control panel sounder canbe silenced by pressing the ACK button. The system remains in this state until the faultcondition(s) have been eliminated, after which the system can be RESET, which resets thealarms and returns the control panel to a stable SET mode.



3.5 SYSTEM STATUSDuring Normal Operation (Fig. 7) with the control panel in SET mode, the system can betransitioned to the UNSET mode by pressing and holding the SET button for 3 secondsfollowed by ACK. Pressing SET for 3 seconds again followed by RST will cause the systemto enter the Program mode.

Figure 7When the panel is in SET mode, and in an alarm condition (Fig. 8), the control panelsounder can be silenced by pressing the ACK button, at which point the panel is in SET &SILenced state. The system remains in this state until all the alarm conditions (ie gas) havecleared. The operator can then perform a RESET (which resets the alarms and returns thecontrol panel to a stable SET mode), or UNSET the system (from which the Program modecan be accessed).

Figure 8

With the system in SET mode, and in fault condition (Fig. 9), the control panel sounder canbe silenced by pressing the ACK button, at which the panel is in SET & SILenced state..The system remains in this state until all the fault conditions have been eliminated. Theoperator can then perform a RESET (which resets the faults and returns the control panel toa stable SET mode). Unlike the alarm condition, even if the fault condition persists it ispossible to go from the SET & SILenced state to the PROGRAM mode, from where it ispossible to change the system configuration and if necessary isolate the faulty detector.

NORMAL OPERATION

SET UNSET PROG

ALARM CONDITION

ENDALARM

STARTALARM

SET ACK SET & SIL

RESET

UNSET PROG



Figure 9

3.6 SYSTEM SETSET is the normal operational mode of the control panel. The gas concentration beingdetected is shown on the display and the following messages are reported: Status (OK orFT fault), L1 (Caution or alarm 1), L2 (Warning or alarm 2), L3 (Alarm or alarm 3) alongwith the SET or UNSET system mode.Keep the ACK key pressed for two seconds to allow the display to scroll to the otherchannels and display their status. When the unit receives an alarm condition thecorresponding output relay activates.

Hydra32 is provided with 5 output relays with the functions below listed

RL1 (alarm threshold 1)RL2 (alarm threshold 2)RL3 (alarm threshold 3)RL4 (fault)RL5 (watch–dog).

RL1 activates when the first programmed alarm threshold of any detector is reached, RL2when the second one is reached and RL3 when the third one is reached.

RL4 activates when a Fault is present (one or more detectors in fault or an RS485communication bus failure) and RL5 deactivates if the microprocessor locks out duringnormal operation (during normal operation RL5 is always active). All the relays provide volt-free changeover contacts.

3.7 SYSTEM UNSETTo UNSET the system (UNS) keep the SET key pushed for 3 seconds and then press ACK.In this condition the control panel is monitoring the detectors but when the unit reports anAlarm or a Fault condition the relays are not activated.

To move back to the SET mode, press the SET key for 3 second and then ACK.

FAULT CONDITION

ENDFAULT

STARTFAULT

SET ACK SET & SIL UNSET PROG

RESET



3.8 ALARM STATUS

OutputsWhen a programmed alarm threshold is reached, the control unit provides a visual/acousticsignalling by activating the buzzer along with the LED and the relay corresponding to thatalarm status.The ACK key allows the audible alarm to be muted, thus deactivating the buzzer.Soon after muting, the ACK key recovers its function of channel scrolling, by keeping itpressed for about two seconds.When the alarm condition has been removed and gas is no longer present the system canbe reset, to clear current alarm conditions, by pressing the RST button.During the alarm condition, the display shows the concentration attained in real time. At thesame time, the Status indication progressively changes to L1, L2 or L3 to show the detectoralarm level.

3.9 EVENT LOGThe unit event log records date, time and type of alarm or fault. To enter the Event Logmenu follow the steps in the flowchart below:

3.10 PROGRAMMING MENUIt is necessary to program the system after the first power up and each time a systemcomponent is added or removed. It is possible to locally program the system using thekeypad on the front panel or using a Personal Computer and the dedicated configurationsoftware.



3.11 PROGRAMMING BY THE CONTROL PANEL KEYPAD AND DISPLAYIt is only possible to enter the Program mode from the UNSET (UNS) mode. First enter theprogramming mode following the flowchart on the next page. Once you have scrolled to theparameter you wish to change using the SET button, use the ACK/Ÿ�RU�RST/ź�EXWWRQV�WR�increase or decrease the setting.



FICH01.02

FLT

- - - 0%LEL

M. O UNS

Lan EnglPass1 1Pass2 0Adr 1Dt gg.mm.yyTm 24

Lan: Select language Italian or EnglishPass1 (password 1): 0-9999Pass2 (password 2): 0-9999Adr. (Address): 0-255Dt. (Date): dd.mm.yyTm (time): 12 / 24h

SET (3 SEC.) SET Press SET to scroll from one parameter to theother and ACK or RST to modify

SET ?

Hour 18Min 10Day 07Mon 01Year 08W. ON 02

HourMin (Minutes)DayMon (month)YearW. ON (warm-up time) From 0 to 3minutes

RST SET Press SET to scroll from one parameter to theother and ACK or RST to modify

SETUP ?

PRF 01 % LELFS 100 UPTh1 10 BOFFTh2 20Th3 30Hys 3

PRF01 is the first out of the 32 profiles that canbe set for each channel (CH1 to CH32). Foreach one of the Profiles, it is possible to selectthe measuring range (%LEL, ppm, % Vol, O2),the three alarm thresholds and the hysteresis(Hys). Signal can be of increasing (UP) ordecreasing (DOWN) type. The audible alarmassociated to the first threshold can beactivated (BON) or deactivated (BOFF).

ACK RST Press SET to scroll from one parameter to theother and ACK or RST to modify

PASS 0

CH01TYP 01 SETWt1 100Wt2 100Wt3 100

CH01: Input channel No. 1TYPxx: profile to associate to therespective channel (from 01 to 32 orSPARE if no detector is connected toselected channel)SET: channel status SET or UNSETWt1, Wt2 e Wt3: (not to be used) alwaysto be at 100.

ACK ACK

PASS 1

CH02TYP 01 SETWt1 100Wt2 100Wt3 100

Repeat the same routine for the other 32Channels

SET RST

WAIT REMOTE

OTh1MEMODL ON 6s

HIGH

OTh1: threshold 1 programmingMEMO: relay latched until reset, REFLEX; relayunlatched, PULSE (relay pulsed).DL ON: activation delay (0-720 sec.)T OFF: deactivation delay (0-720 sec.)HIGH: relay energized, LOW: relay de-energized.

SET ACKRepeat the sameroutine to program theOTh2, OTh3 andOFLT outputs

RST and ACK to exit theprogramming mode.



Notes on Programming Menu:1. BON/BOFF indicates the buzzer is on or off for the first alarm threshold2. Output HIGH/LOW mode states for the relay being in latched or unlatched mode (coilalways energised / coil always de-energised)

3. Wt1, Wt2 & Wt3 are unused parameters and should always be set to 1004. The measurement units menu allows configuration of %LEL, %vol, ppm, %O2

5. For TYP configuration (profile) for Oxygen depletion, Th1 should be higher than Th2,which in turn should be higher than Th3. e.g.:-Th1 19

-Th2 18

-Th3 17

6. While setting OTh1, OTh2, OTh3 OFLT output options, it is possible to select threedifferent operating modes for the relays:

Reflex (Non-latched) Follows the alarm.Alarm active: output activated after any activation delayAlarm inactive: output deactivated after any deactivation delay.

Pulse (Pulsed) Produces a pulsed output. Output activated after any activationdelay and deactivated after the deactivation delay.

Memo (Latched) As Reflex, but remains active until after system reset.

The above three operating modes allow configuration of the activation and deactivationtimers DL ON and T OFF.

3.12 PROGRAMMING BY PCThe Hydra32 control panel can be programmed by a personal computer with dedicatedconfiguration software (optional). The “PCM 602 Configuration” software has beendesigned to make the control panel programming easier and faster than using the controlpanel buttons.

Refer to Appendix E for full instructions.



4. APPENDIX A – DETECTOR INSTRUCTIONS4.1 INSTALLATION NOTESDetectors are to be installed with consideration to the gas to be detected and in accordancewith all National rules in force.

Detectors must be mounted close to any possible source of gas leaks or where any eventualgas accumulation can be foreseen.

To measure explosive gas with a specific weight heavier than air (e.g. petrol vapour orLPG), the detectors must be installed approximately 30-50cm. from floor. To measure toxicgas (e.g. CO or NO2, we recommend to mount the detector at “nose height” approximately150-160 cm. from floor.

Consideration should be given to the security of detectors installed in public areas such ascar parks. It is advisable that a coarse-mesh cover be fitted over the whole of the detector toprevent deliberate damage. It is imperative that any cover fitted does not prevent gas fromreaching the sensor.

As a guide, one detector can cover approximately 80-100 m2 when considering a squarearea without obstacles. Application specific standards must be referred to when deciding onthe quantity and coverage of detectors.

Ventilation patterns must be considered when locating gas detectors. Consideration must begiven to the likely movement of a gas cloud due to draughts (doors, windows, ventilation,etc.). Avoid installing gas detectors close to air intakes or fans causing strong air currents.

Ensure detectors are attached to a firm base to prevent damage or spurious functionalitydue to vibration.

Although the electronics comply with EC electromagnetic compatibility rules, it is advised tokeep the detectors at a distance from any radio frequency transmitters (such as radio linksor similar).

The detector must always be mounted with the sensing element pointing downwards. Thedetector enclosure must not be drilled; wall-mount the detectors using the mounting lugsprovided. Detectors must be protected from direct contact water contact or immersion inwater.

Detectors must be accessible for maintenance and calibration after installation. Maintenancemust be regularly performed in compliance with these instructions.

There are some substances that, when present in the atmosphere being analysed, canconsiderably change the response of the sensor and even cause irrevocable damage. Inparticular silicones, silicon halides, tetraethyl lead, hydrogen sulphide, carbon tetrachloride,trichloroethylene. In applications where these compounds may be present it isrecommended to check the detector's sensitivity (using test gas) at regular intervals, andalways after an alarm occurrence.

Detectors are factory calibrated. Future calibration must be carried out by the ST.CKDcalibration keypad (see Appendix C).

4.2 INTRODUCTIONThe Crowcon Hydra2 gas detector has been designed for operation in commercialapplications e.g. non-classified areas. The detector is dust and water protected to IP55.Hydra has been designed to detect gas concentrations in an atmosphere mainly composedof air. Versions are available to detect explosive vapours (%LEL), Carbon Monoxide (CO) orNitrogen Dioxide (NO2), with a concentration expressed in ppm (parts per million).



The type of catalytic sensor employed in flammable detectors, and the electrochemical cellemployed in CO and NO2 detectors both offer superior precision and selectivity, thusavoiding false alarms and assuring an excellent reliability over time.

4.3 HYDRA2 DETECTOR CONFIGURATIONEach detector must be connected on the RS-485 bus according tothe instructions shown in Figure 5, Page 8. Before applying powerensure each detector has been set a unique address as describedbelow.

SMART3NC gas detector board

RS485 Board

Hydra2 Detector Internal/PCB View

Detectors are daisy chained on one RS485 bus. In order for the system to work properly, itis very important that each detector has a unique address. The detector address is set usingthe dip switches shown on the diagram above.The Hydra32 serial bus accepts up to 32 Hydra2 detectors and 1 or 2 remote 16-way outputmodules.The addresses accepted for the detectors are from 02 to 33 included, while the addresses 0and 1 are reserved to the output modules. The table on the following page shows how thedip-switches are to be set for the address definition.

Note: The detector addressed as 2 on the loop is identified as No. 1 to the control panel; theone addressed as 3 is identified as No.2 to the panel and so on, till to address 33 that will bethe number 32 to the control panel.

DIP-switchfor settingdetectoraddress

Calibrationkeypad

connectionport



Detector 1

Detector 5 Detector 6 Detector 7









Detector 32


Detector 4

Detector 5 Detector 6 Detector 7Detector 5

Detector 2 Detector 3

Hydra2 Detector DIP-Switch Settings

4.4 CALIBRATION AND MAINTENANCEOnce power has been applied to detectors, allow a minimum of 2 minutes for sensors tostabilise. Communications between the control panel and detectors is establishedautomatically provided detector addresses have been correctly set.

It is essential that detectors are routinely tested using calibration gas. Crowconrecommends that detectors are tested every 6 months as a minimum, and calibrated asnecessary.

Detectors should also be tested after any spurious gas alarms or faults to ensure correctoperation.

Detectors must be zeroed in clean air prior to calibration.



Where a sensor fails to respond to gas, and cannot be calibrated using the instructions inAppendix C it must be replaced. Contact Crowcon for part number information.

Accessories required for calibration:x Calibration Adaptor (part number: C02125)x Calibration Keypad (part number: C02124)x Calibration gas (contact Crowcon for part numbers)x Calibration gas regulator (contact Crowcon for part numbers)

See Appendix C for calibration instructions.

If fitted, the back-up battery in the control panel and/or detector loop power supply should bechecked regularly. Lead-acid type batteries should be replaced every 2-3 years on average.

All functions of the control panel, detectors, output modules, alarm devices and controlsystem interfaces must be checked and verified at the commissioning stage, and regularlyafterwards during the operating life of the system



5. APPENDIX B – OUTPUT & RELAY MODULE INSTRUCTIONS

The optional output module has 16 open-collector type outputs rated at 50mA maximum.The outputs are designed for driving relay coils, which in turn are used for signalling oractivating alarm devices.

Each module must be secured using the four 3mm holes located at the corners of the PCB.The module can be installed anywhere on a detector bus within a suitable weather protectedenclosure.

One or two output modules can be connected in serial mode (RS-485). Each output modulemust have a unique address on the communications bus (either ‘0’ or ‘1’). If the module isWKH� ODVW� HOHPHQW�RQ�D� ORRS�� D��ȍ� WHUPLQDWLQJ� UHVLVWRU�PXVW� EH� ILWWHG�DFURVV� WKH�56��wires.

Connector for optional relaymodules

Output connections

Connection from controlpanel/detector bus

Rotary switches for settingmodule address

+V A B -V

+v O1

O2

O3

O4

O5

O6

O7

O8 -v +v O9

O10

O11

O13

O14

O15

O16 -vO12

012310

CN2

CN1

JP3

120 mm105 mm

75mm

90mm

Output Module Layout



The Hydra32 can accept up to two output modules with the following addresses:

Output module connection details; it is recommended that power required for drivingaudible/visual alarms etc is supplied from a separate source.

Switch settings for address 0 Switch settings for address 1

Output Module Connections



Each output module can optionally be connected to one or two relay modules. Each relaymodule contains eight single-pole change-over contacts rated 16A 230Vac.

Out 1 Out 2 Out 3 Out 4Out 1 Out 9 Out 10 Out 11 Out 12

Out 8 Out 7 Out 6 Out 5 Out 16 Out 13Out 15 Out 14

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16Open Collector outputs

NC C NO

NO C NCNO C NC

NC C NO

ST.G/OUT16 ModuleOutput Module

Relay Module Connections



6. APPENDIX C – CALIBRATION KEYPAD INSTRUCTIONS

The calibration keypad enables the detector zero and calibration to be performed, and faultsto be reset.

6.1 CONNECTING THE KEYPADThe keypad should be connected to the appropriate port inside the Hydra2 detector (seeAppendix A) using the ribbon cable which is stored in the keypad battery compartment. Thekeypad may be connected when the detector is switched on.

Once connected, the keypad will display the gas concentration being measured by thedetector (which should be 0 in clean air).

6.2 ADJUSTING SETTINGS

Detector Calibration

Note: During routine calibration always put the control panel into UNSET mode to avoidcausing alarms.

These instructions describe the method required to zero and calibrate a Hydra2 gasdetector.Calibration is required whenever either Fault or unjustified Alarms due to environmentalconditions occur (Zero adjustment) or where detectors are due for routine calibration.Calibration requires a calibration gas cylinder, either filled with the same gas the detectorhas been calibrated for, or a reference gas advised by the manufacturer (e.g. Propane foran LPG detector, or Pentane for a Petrol Vapour detector).A calibration cap is necessary to let the gas flow to the sensor head.

Essential requirements to perform correct Zero and Span adjustments are as follows:

x Gas detectors are to be in fresh air (without any gas or interfering compounds)and powered on for a minimum of 8 hours where practical.

x Once the calibration routine is complete, a test with gas (i.e. ‘bump test’) must bemade to verify the detector and control panel are operating correctly.

The following diagrams show the calibration keypad menu sequence.







7. APPENDIX E – CONFIGURATOR SOFTWARE INSTRUCTIONS

7.1 INTRODUCTIONThe configurator software has been designed to make the control panel programming easierand faster. Although the control panel can be fully programmed using the keypad, systemconfiguration can be completed quickly and easily using the software interface.

MINIMUM PC HARDWARE REQUIREMENTSMicroprocessor: 486 SXRAM Memory: 4MBClock frequency: 33Mhz

The software has been designed to operate on Windows 98/ME/2000/XP platforms.

Insert the “PCM 602 configuration” CD-Rom into the computer’s drive, start “FileManager” and run the executable file UP.EXE from the CD-Rom. Follow the instructionswhich appear in the monitor screen until the software installation is finished.

Refer to section 3.2 of this manual for details on connecting a PC to the control panel.

7.2 STARTING THE PROGRAMFrom the Programs menu select the “Pcm602EV V. 2.01” group and then select“Pcm602EV V. 2.01”

The following window will appear:

The programming software window offers the following menus:

x Filex Actionx Test



7.3 PARAMETERS PRE-SETTINGBy choosing “File” and clicking on the submenu “Parameters” the window below appearswhere it is possible to select the language used by the program, the password for theconnection to the control panel (for Up-load and Down-load), the serial communicationport for the PC, and the path for saving the configuration files.

7.4 CREATING A NEW CONFIGURATION FILESelect New from the File menu and, between the three options Analogic, ISA and IDI, choseIDI for the Hydra32 control unit. The window below appears

About the menu:

General: is for setting the general options of the Hydra32 control panel. See section 8.5.Profiles: this option specifies up to 32 operational channel functions that can be customizedfor the user’s requirements. e.g. the % LEL monitoring, the alarm levels and so on. Seesection 8.6.

Channels: sets the operating condition of each channel. See section 8.7.Outputs: sets the behaviour for each relay output. See section 8.8.



7.5 GENERAL

Model: Sets the control panel nameStart up Delay: Sets the Warm Up time of the control panel, after power up (0-999minutes). It is suggested that 2 minutes is used.

Serial number: is the serial number of the control panel. It appears after the first data Up-load or Down-load from the control panel.

Test date: factory test date of the control panel. It appears after the first data Up-load orDown-load from the control panel.

Language: is the language used for the control panel displayDate format: the date format: dd/mm/yy or mm/dd/yy or yy/mm/dd.Time format: 24 h or am/pmControl panel address: is the address of the control panel (fixed to 1)Firmware version: firmware version of the control panel. It appears after the first data Up-load or Down-load from the control panel.



7.6 PROFILES

Up to 32 Profiles are available for programming. The “Profile” specifies all the configurableparameters for each gas to be detected and the detection tasks required, e.g. measuringunit, full scale range, alarm levels etc.

Measure Unit: can be % LEL (Lower Explosive Limit) for flammable gas detectors, ppm(Part Per Million) for Toxic gas detectors, % Vol. for CO2 and % O2 for Oxygen detectors.Signal direction: Down for Oxygen detectors or Up for every other kind of gas detector.Full Scale: is the measuring range of each gas detector. Usually this corresponds to 100 forflammable gas detectors but can be different from type to type for Toxic gas detectors.Threshold 1: the first Alarm level of this ProfileThreshold 2: the second Alarm level of this ProfileThreshold 3: the third Alarm level of this ProfileHysteresis: This value indicates how variations in the signal will be ignored when in closeproximity to the alarm threshold. The value is expressed the same as for the measure unit(% or ppm).Copy Profile: This command allows copying of the settings of one Profile to another.

In the Channel menu (section 8.7) one of the programmed Profiles will need to beassociated to each detector.



Below are some example Profiles.

Flammable gas detector(Methane, LPG, Hydrogen etc.)

Carbon Monoxide (CO) gas detector(range 300 ppm)



7.7 CHANNELS

Setting the Channel parameters require the association of the appropriate Profile foreach detector and defining of the Channel status (Set or Unset).

Select the channel (detector) from 1 to 32.

Associated type: choose a Profile from those previously programmed in the Profiles menu.If the Channel is not used (detector not connected) the option Spare should be chosen.Channel status: Choose SET for a normal channel (detector) operational. If in SET modethe input channel is monitored and in the event of an alarm all the associated outputs areactivated.Choose UNSET for a channel (detector) in test mode. In UNSET, the input channel ismonitored but, in the event of an alarm the associated outputs will not activate.

Weight Threshold 1: not used (forced to 100)Weight Threshold 2: not used (forced to 100)Weight Threshold 3: not used (forced to 100)

Copy Channel: This command allows the settings of a particular channel to be copied toanother channel.



7.8 OUTPUTSProgramming the output parameters defines how the system outputs will operate.

Select the output to be programmed. All system outputs are listed below:

Threshold 1: control panel relay Alarm level 1.Threshold 2: control panel relay Alarm level 2.Threshold 3: control panel relay Alarm level 3.Fault: control panel relay Fault condition.External Output 1 to 16 (optional): Open collector outputs of address 0 output module (ifconnected).

External Output 17 to 32 (optional): Open collector outputs of address 1 output module (ifconnected).

Output type: the Output can have three different operating modes:Reflex (Non-latched) Follows the alarm.

Alarm active: output activated after any activation delayAlarm inactive: output deactivated after any deactivation delay.

Pulse (Pulsed) Produces a pulsed output. Output activated after any activationdelay and deactivated after the deactivation delay.


Activation delay: Delays output activation from 1 to 720 secondsDeactivation delay Delays output deactivation, in Reflex mode only, from 1 to 999 secondsafter the alarm event.

Pulse duration: Sets the duration of output activation in Pulse mode only.Output level: Sets whether the relay output is activate high or active low.



Open Collector output on the output module configuration.

When the output modules are connected on the RS485 loop, it is possible to program theexternal outputs from 1 to 16 (module address 0) and from 17 to 32 (module is address 1).

Choose the external output.

Output type: the Output can have three different operation modes:Reflex (Non-latched) Follows the alarm.

Alarm active: output activated after any activation delayAlarm inactive: output deactivated after any deactivation delay.


Not used The output is not used (if the output is not connected to thecontrol panel loop, the option must be Not used).

Output level: Sets whether the output is activate high or active lowType (Profile) and Threshold: Type (Profile) associates a channel to an output. Channelsand Outputs with the same Type (Profile) are linked so that the output is triggered by anevent on the channel. Threshold sets the channel threshold level that triggers the output.Example 1

x Channel (detector) 4 is set to Profile 1

x External output 3 is set to Profile 1

x and the Threshold is set to Threshold 3Outcome: whenever Channel 4 (detector 4) reaches the 3rd alarm Threshold, theExternal output No. 3 will activate.

Example 2

x 32 detectors each with an output associated to the 2nd alarm threshold

x Requires 32 Profiles to be created and associated with each of the 32 channels(detectors) and associated with 32 outputs with their Thresholds set to 2.



7.9 SEND CONFIGURATION (DOWNLOAD)Once the parameter programming has been completed, it is possible to download (Send)the set-up to the control panel. It is advisable to save the programming file beforedownloading data to the Hydra32 control panel using the Save option from the File menu. Byusing the Parameters option in the File menu, check that the configuration of the port towhich the control panel has been connected is correct.Select ”Send” from the “Action” menu, enter the password (default 000001) and enter theControl panel address “1” but do NOT press OK at this point.

In the control panel, enter the Programming mode (please refer to the control panelprogramming part of this manual)

Now click OK to start downloading. The downloading bar will be immediately displayed. Onthe control panel display the message “Remote prog.” will appear. During download it is notpossible to carry out any other operation or monitor the inputs.

Once the data download is over, disconnect the cable between the control panel and thePC. The control panel is still in PROGRAM mode at this point and it is necessary to exit thismode to return to normal operation.

7.10 RECEIVE CONFIGURATION (UPLOAD)Whenever the data stored in the panel needs updating or revising, connect the panel to thePC and upload the old parameters.In the control panel, enter the PROGRAM mode (please refer to the control panelprogramming part of this manual). Select the Receive option in the Action menu of theconfiguration software.

Enter the control panel address “1” then click OK. The downloading bar will be immediatelydisplayed. During upload it is not possible to carry out any other operation or monitor theinputs.

Once the data up-load has ended, disconnect the cable between the control panel and thePC. The control panel is still in PROGRAM mode at this point and it is necessary to exit thismode to return to normal operation. Data can now be modified on the PC.

7.11 TEST MENU

The “TEST” menu offers the following options:x Statex Event log



7.12 STATE

This option gives users the ability to view graphically the state of the control panel and ofall the 32 channels.

To launch this option click on State in the TEST drop down menu. To Log On to thepanel, the user must enter the control panel address “1” as prompted by the windowdisplayed below:

Then press OK. The uploading bar will be immediately displayed.

Once the State function has been accessed, the user is presented with a graphicalrepresentation of the Hydra32 control panel currently on-line. The window gives a generaloverview of the Hydra32 system. All the 32 channels are displayed with details below:

Indication of thesystem statusSET or UN-SET

Alarm level 1

Alarm level 2

Alarm level 3 Fault status

Communication Fault output module “0”

Communication Fault output module “1”

ChannelstatusSET or UNSETor SPARE

ChannelProfile

Gas concentrationmeasured.In real time

Channelnumber



7.13 EVENT LOGThis option displays the system event log. The log records all events that occurred in thesystem. To launch this option click on Event log in the TEST drop down menu. To Log Onto the panel, the user must enter the control panel address “1” as prompted by the windowdisplayed below:

Then click OK. The uploading bar will be displayed immediately.

On entering this option, the most recent events displayed in the following format:

x Using the Export command you can save the event list to the computer as a .csvfile. A .csv file can be opened by other programs as Microsoft Excel.

x Using the Print command all the events can be printed.x Using the Update command the event list can be up-dated with the latest events.



8. APPENDIX F – WARRANTY

This equipment leaves our works fully tested and calibrated. If within a period of one year,the equipment is proved to be defective by reason of faulty workmanship or material, weundertake at our discretion either to repair or replace it free of charge, subject to theconditions below.

Warranty Procedure

To facilitate efficient processing of any claim, contact our customer support team on 01235557711 with the following information:

Your contact name, phone number, fax number and email address.Description and quantity of goods being returned, including any accessories.Instrument serial number(s).Reason for return.

Obtain a Returns form for identification and traceability purpose. This form may bedownloaded from our website ‘crowconsupport.com’, along with a returns label; alternativelywe can ‘email’ you a copy.Instruments will not be accepted for warranty without a Crowcon Returns Number (“CRN”). Itis essential that the address label is securely attached to the outer packaging of thereturned goods.Units returned to Crowcon as faulty, and are subsequently found to be ‘fault free’ orrequiring service, may be subject to a handling and carriage charge.

Warranty DisclaimerThe guarantee will be rendered invalid if the instrument is found to have been altered,modified, dismantled, or tampered with. The warranty does not cover misuse or abuse of theunit.Any warranty on batteries may be rendered invalid if an unreasonable charging regime isproven.Sensor types have individually defined warranty periods which can differ from the hardwarewarranty period. Crowcon reserve the right to amend warranty periods for particularapplications. Sensor warranty is rendered invalid if the sensors have been exposed toexcessive concentrations of gas, extended periods of exposure to gas or have beenexposed to ‘poisons’ that can damage the sensor, such as those emitted by aerosol spraysCrowcon accept no liability for consequential or indirect loss or damage howsoever arising(including any loss or damage arising out of the use of the instrument) and all liability inrespect of any third party is expressly excluded.The warranty and guarantee does not cover the accuracy of the calibration of the unit or thecosmetic finish of the product. The unit must be maintained in accordance with theOperating and Maintenance Instructions.Our liability in respect of defective equipment shall be limited to the obligations set out in theguarantee and any extended warranty, condition or statement, express or implied statutoryor otherwise as to the merchantable quality of our equipment or its fitness for any particularpurpose is excluded except as prohibited by statute. This guarantee shall not affect acustomer’s statutory rights.

For warranty and technical support enquiries please contact::Customer SupportTel +44 (0) 1235 557711Fax +44 (0) 1235 557722Email ‘[email protected]’

Crowcon Hydra Addressable Gas Detection System · 2019. 7. 17. · Addressable Gas Detection System Manual Hydra32 System Manual 1 Issue 2, February 2013 INTRODUCTION The Crowcon

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