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PL4

TECHNICAL HANDBOOK
Gas detection control unit

SENSITRON S.r.l. Via A. Manzoni, 19 20010 Pogliano Milanese MI - Italy Tel: 02/93548155 Fax: 02/93548089 http://www.sensitron.it E-mail: sales@sensitron.it

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TECHNICAL HANDBOOK INDEX

ST.PL4E REV.4

INTRODUCTION .................................................................................................................3 1-1 Central unit technical specifications...............................................................................3 1-2 Fuses .............................................................................................................................3 2 INSTALLATION ...................................................................................................................4 2-1 Mechanical fixing ...........................................................................................................4 2-2 Circuit layout ..................................................................................................................5 2-3 Expansion module .........................................................................................................7 3 Cables and connections ......................................................................................................8 3-1 Mains power supply (220Vac)........................................................................................8 3-2 Detectors connection .....................................................................................................9 3-3 Proportional 4-20 mA SMART 2 gas detectors connection (code S261_ and S260_)...9 3-4 Proportional 4-20 mA SMART 3 gas detectors connection (code S1096_ and S1097_). 3-5 Connection to detectors with output relay....................................................................10 4 CENTRAL UNIT TECHNICAL CHARACTERISTICS ........................................................11 4-1 Front panel..................................................................................................................11 4-2 Connection to Battery and First switching on...............................................................12 4-3 SET Mode....................................................................................................................12 4-3.1 Alarm condition ......................................................................................................12 4-3.2 Fault condition .......................................................................................................13 4-4 UNSET Mode...............................................................................................................13 4-5 Programming Mode .....................................................................................................13 4-6 Backup Battery Low.....................................................................................................13 4-7 Over-Range alarm .......................................................................................................13 5 SYSTEM PROGRAMMING MENU...................................................................................15 5-1 Example of input channel programming. .....................................................................16 5-2 Programming the input channel for Oxygen detectors.................................................18 5-3 The TIMES menu for output channel relays (software version 3.0)...........................19 5-4 RESET to default conditions (software version 3.0) ....................................................20 6 WARRANTY FORM FOR REPAIR....................................................................................23

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TECHNICAL HANDBOOK
1 INTRODUCTION

ST.PL4E REV.4

The PL4 is a built-in 4 analogue 4-20mA input control unit that can be extended to 8 by using an on-board 4 zone expander module, easily connectable directly into the control unit. PL4 accepts also Oxygen detectors and manages both its excess and deficiency. For manage Oxygen and other type of gas detectors use sepately PL4 control unit. On the front panel a backlit LC display shows the values being measured. Any single input configuration requires setting both the type of detector being used, the measuring range and the alarm thresholds. Functions programming is easily performed through the push buttons on the front panel. The control panel is equipped with 5 relays and precisely, one for each alarm threshold (AL1, AL2, AL3), 1 for fault (FLT) and an auxiliary one (AUX). The 4-zone expander is provided with 16 Open-Collector negative safety outputs that can be associated to AL2 AL3 alarms of each of the 8 inputs. 1-1 Central unit technical specifications 220 V ac +/- 10 % 60mA typical in no alarm state 4 inputs (Analog Twin Oxygen ). 4 inputs (Analog Twin Oxygen ). 5 relays (Aux, AL1, AL2, AL3, Fault) 1A 24Vdc or 0,5A 120Vdc, 1A at 24Vdc or 0.5A at 120Vdc (relay AUX: 10A at 125 Vac or 5A at 24Vdc) 16 Open collectors (AL2 AL 3 for all of the 8 zones) Main power supply, battery supply Auxiliary output Pre-alarm 1 pre-alarm, 2, Alarm 3, Fault Back lit LCD 16x2 characters 12V 6A/h optional battery 0-40 C 15-85% non condensing Metal cabinet. Dimensions 360x225x110 mm New dimensions since January 2004 360x225x150 mm

Power supply Power consumption Inputs (base version) Input extension Outputs (base version) Contacts rating Extended Outputs LED indications Display Backup battery Operating temperature Humidity Housing

1-2 F1 F2 FU4

Fuses Main supply fuse Battery fuse Main supply fuse fast 2 A fast 2 A 630mA delayed.

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TECHNICAL HANDBOOK
2 2-1 INSTALLATION Mechanical fixing

ST.PL4E REV.4

Open the central unit front door and disconnect the power supply cables from the CN10 connector, the one that connects the board on the rear side of the door to the transformer on the bottom of the box. Also disconnect the GND cable placed on the column near CN10 terminal. It is then possible to remove the door from the hinges to work easily. Wall fix the central unit through the fixing holes described here below:

358 179 5 mm 179


26 220 168

5 mm 26 153 153

5 mm
26

26

Replace the front door on the housing once steadily wall fixed and reconnect the wires previously disconnected to the CN10 connector, terminals 1 and 3, and the GND to the column nearby. Proceed with the gas detectors connection as described on chapter 3.3 and following, on page 9.

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TECHNICAL HANDBOOK
2-2 Circuit layout

ST.PL4E REV.4

TERMINAL BLOCK FOR THE EXPANSION 8 INPUTS MODULE

The above figure shows the board mounted on the rear side of the front door, on which gas detectors are to be connected.

CN1, CN2, CN3, CN4 represent the detectors connecting terminal blocks, and more precisely: CN1 (zone1), CN2 (zone 2), CN3 (zone 3), CN4 (zone 4). TERMINALS 1 2 3 4 DESCRIPTION
NOT to be used

4-20mA signal Positive (+12Vdc) Negative (-12Vdc)

CN5 is the output terminal block of the 4 relays to be found on the card, and more precisely:

TERMINALS 1-2 3-4 5-6 7-8

RELAY OUTPUTS (CHANGEOVER CONTACTS) Alarm 1 (AL1) Alarm 2 (AL2) Alarm 3 (AL3) Fault (FLT)

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TECHNICAL HANDBOOK

ST.PL4E REV.4

The choice of a normally open relay (NA) or a normally closed one (NC) is carried out by four jumpers (jp1 to jp4) according to the relay (JP1 corresponds to RL1) as shown in the picture..
CN7 represents the auxiliary relay exit (the AUX lamp on the control unit front panel)

1 2 3

NA NC C

CN7 terminal Normally Open Normally Closed Common

CN10 represents the AC supplying terminal board from the transformer. The protection fuse is F1. CN8A-CN8B indicate the connectors for the expansion module of the 4 zones + 16 additional outputs. Be careful while introducing the module, check that all the pins are properly introduced, that is to say not folded outside the connector; verify that the CN8A connector coincide with the CN16A (expansion module), and that the CN8B coincide with the CN16B (expansion module).

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TECHNICAL HANDBOOK
2-3 Expansion module

ST.PL4E REV.4

CN12, CN13, CN14, CN15 represent the additional detector connecting terminal boards. More precisely: CN12 (zone 5), CN13 (zone 6), CN14 (zone 7), CN15 (zone 8).

On CN17 connector 16 open collector outputs are programmed as follows: Connector CN17

Pin 3 5 7 9 11 13 15 17 1-2 NB.

Level2 Zone 1 Alarm 2 Zone 2 Alarm 2 Zone 3 Alarm 2 Zone 4 Alarm 2 Zone 5 Alarm 2 Zone 6 Alarm 2 Zone 7 Alarm 2 Zone 8 Alarm 2 Connect to + V supplier

Pin 4 6 8 10 12 14 16 18 19-20

Level3 Zone 1 Alarm 3 Zone 2 Alarm 3 Zone 3 Alarm 3 Zone 4 Alarm 3 Zone 5 Alarm 3 Zone 6 Alarm 3 Zone 7 Alarm 3 Zone 8 Alarm 3 -V Common supply

The output current for each open collector is up to 20mA MAX The load to be supplied requires a voltage between 12 and 24 Volt dc Pins 19 and 20 represent the common supply (-V) and are to be connected to the negative of the external power supply, employed to supply O/C loads. Pins 1 and 2 must be connected to the positive of the external power supply. To these pins inductive loads protection diodes are connected.

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TECHNICAL HANDBOOK
3 Cables and connections

ST.PL4E REV.4

3-1

Mains power supply (220Vac)

Connect a three-wire cable (1.5 mm2 minimum for each pole) to the main supply terminal board and fix it by using the suitable cable fastener. Before supplying the system, connect all detectors to the main card and to the expansion interface, if any.

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TECHNICAL HANDBOOK
3-2 Detectors connection

ST.PL4E REV.4

This system is able to support 8 detectors 4-20mA (1 for each inputs) in its maximum expansion. It is possible to connect various double level detectors (Twin) to each input, even though, for a maximum current absorption reasons, it is not allowed to have more than 12 gas detectors supplied by the PL4 power supply.

3-3

Proportional 4-20 mA SMART 2 gas detectors connection (code S261_ and S260_)

Gas detector is to be connected to the central unit by means of a 3x0.75 mm2 shielded cable (the shield must be grounded only on the central unit side). The max. distance between the detector and the system or the expansion module must not exceed 100 mt. Once the system has been switched on, check that every detector is supplied at least with 12 Vdc. On the figure here below, connector CNxx corresponds to one of the 4+4 connectors present on the main board or on the expansion board of PL4 control unit.

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TECHNICAL HANDBOOK
3-4

ST.PL4E REV.4

Proportional 4-20 mA SMART 3 gas detectors connection (code S1096_ and S1097_)

3-5

Connection to detectors with output relay.

R1=1650 OHM (2 x 3300) R2=470 OHM R3=820 OHM

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TECHNICAL HANDBOOK

ST.PL4E REV.4

4 4-1

CENTRAL UNIT TECHNICAL CHARACTERISTICS Front panel

On the front panel LEDs are present to indicate:


(AL 1) (AL 2) (AL 3) (FLT) (AUX) (BATT) (AC)

Alarm 1 Alarm 2 Alarm 3 Fault Auxiliary relay activation Battery operation 220 V~ operation

Two push buttons are also available and their functions changes according to the operational mode the central unit has been set to: Acknowledge (ACK) (RST) System reset PL4 central unit offers three operational modes defined by the key switch positioning:

(ON) (OFF) (PGM)

System ON System OFF System in programming mode

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TECHNICAL HANDBOOK
4-2 Connection to Battery and First switching on

ST.PL4E REV.4

Turn the key on the OFF position and power the Control unit. Connect to the red and black faston wires of the power supply unit, a 12V 7Ah max LD buffer battery and place it in the central unit paying attention to fix it steadily. The main power supply LED (AC) will illuminate while the central unit will enter a stand-by mode for nearly one minute to allow the connected detectors to finish their pre-heating phase. Once this stand by period is over the FAULT LED will illuminate (without activating the corresponding relay), the buzzer will sound and the display will show the state of the first two channels. The button ACK will allow turning the buzzer sound off. The central unit is now ready to be programmed according to the users needs. Warning: As a standard configuration all four channels are activated. If less than 4 detectors are connected, after the stand-by period the central unit will signal a FAULT condition and the first relay will activate. It is necessary to enter the program mode to disable the non-used channels. On the other side if, when switching on, more than 4 detectors are connected by employing the extension module, being the central unit programmed to be connected to 4, you will need entering the program mode to activate the corresponding channels. 4-3 SET Mode

KEY SWITCH in ON position. This is the normal operating mode: input signals are coming from the detectors and relay outputs are managed. The display shows the status of two detectors, one each line. It will appear Chn1: and Chn2: followed by the readout concentration, the set full-scale and the channel status (OK, A1, A2, A3, FT). Pushing and holding for a couple of seconds the ACK push button, allows the scrolling of the other channels being used. 4-3.1 Alarm condition

When one or more detectors exceed the present thresholds, the central unit emits an acoustic warning while the LED corresponding to that alarm threshold illuminates and the associated relay activates. Press ACK push button to silence the buzzer. Any time a threshold has been exceeded, the buzzer activates and a manual resent will always be necessary to silencing it. Once the buzzer has been silenced, the ACK button can be used again to get the channels scrolling again. When the alarm condition has been removed and gas presence is no longer detected, it is possible to reset both alarms and light indications showing the highest concentration attained. To reset the system turn the Key on OFF position than press RST. Always remember to turn the key switch in ON position to restart the unit.

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TECHNICAL HANDBOOK

ST.PL4E REV.4

During the alarm condition the display keeps on modifying the readout of the gas concentration coming form the detector, updating it each second. Contemporaneously the OK message changes into A1, A2 and A3 or back to OK in case the alarm is over. In any case LEDs and relays are to be manually reset as explained above. 4-3.2 Fault condition

When one or more channels enter a Fault condition (sensor damaged or open circuit due to a line interruption) the buzzer activates and the FLT LED on the front panel illuminates; contemporaneously the relay associated to the fault status activates also. To silence the buzzer press ACK. Once the buzzer has been silenced, the ACK button can be used to get the channels scrolling again. When the Fault condition has been removed it is possible to resent both alarm and light indications. To reset the system turn the Key on OFF position than press RST. Always remember to turn the key switch in ON position to restart the unit. 4-4 UNSET Mode

KEY SWITCH in OFF position. This is the UNSET mode. The signals from the detectors are managed but the relay outputs are not activated. The display shows the status of two detectors, one each line. It will appear Chn1: and Chn2: followed by the readout concentration, the set full-scale and the channel status (OK, A1, A2, A3, FT). When one or more detectors exceed the present thresholds, the central unit emits an acoustic warning while the LED corresponding to that alarm threshold illuminates but the relay outputs are not activated. Press ACK push button to silence the buzzer. Once the buzzer has been silenced, the ACK button can be used to get the channels scrolling again. 4-5 Programming Mode

KEY SWITCH in PGM position and FLT LED on. The control unit doesnt manage inputs or outputs but allows all parameters configuration, as described in the next chapter. 4-6 Backup Battery Low

When the central unit is battery operated and the battery' voltage decreases below the safety s limit, the central unit shows this status by the BATT and FLT LED illumination and the corresponding relay activation. On the display the message BATTERY LOW will appear. Once the correct working conditions have been restored, ACK and RST will reset the unit. 4-7 Over-Range alarm

When an input signal is over range (input >20mA), the control unit, besides the usual activations corresponding to the 3rd thresholds attainment, will signal a Fault condition with the corresponding relay activation, and block the over-range channel readout at 099.
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TECHNICAL HANDBOOK

ST.PL4E REV.4

Once the buzzer has been silenced, to reset that condition, turn the key in PGM position, the message INPUT OVER RANGE - RST will be displayed, than pushing the RST push button the situation will be reset and a message RESTORED will be shown. Than turn the keyswitch in ON position and the control unit becomes operative again, showing the real concentration being measured.

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TECHNICAL HANDBOOK
5 SYSTEM PROGRAMMING MENU

ST.PL4E REV.4

Turn the key on the PGM position and follow the block diagram below.

SOLO SE LA FUNZIONE 4/8 CANALI E ABILIT TA A (JUST IF THE 4/8 CHANNEL FUNCTION IS ABLED)

Come sopra per CHN. 1 (As above for the CHN. 1)

MENU Pl4 VERS. 3.04 OTT. 2004

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TECHNICAL HANDBOOK
5-1 Example of input channel programming. Example of programming for one explosive gas detector (0-100% LEL).

ST.PL4E REV.4

N.B. The following programming steps are applicable to explosive gas detectors with 0-20mA output signal and full scale of 100% LEL. The reported alarm thresholds may change as requested by the local Authorities or by the plant requirements. Entering the programming menu (key on PGM), the display shows:

SETUP CHN.: 1
By pressing RST the other programming steps will be available while by pressing ACK the programming of the first input (detector) is enabled. Select NORMAL to choose a SENSITRON SMART2 explosive gas detector.

CHN.: 1 NORMAL
By pressing ACK the measurement unit may be selected: for explosive mixtures will be %LE.

CHN.: 1 RANGE 100% LE


Press ACK again to see the full scale value. It must be left equal to 100% skipping, by pressing RST, to the next programming step that will display the alarm threshold 1.

CHN.: 1 ALL.: 1

010% LE

10% LEL is a reasonable value for the first threshold (other values may be set, if necessary, up to the 60% of LEL): press the ACK button until the arrow is on the left of the threshold value and then push RST to set the 10% value.

CHN.: 1 ALL.: 1 >010% LE


Push ACK to confirm and then RST to move to the 2nd threshold value:

CHN.: 1 ALL.: 2 020% LE


Use the ACK and RST buttons as before to set the 2nd threshold value to 20% of LEL. In the same way set the 3rd threshold value to 30%.

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TECHNICAL HANDBOOK

ST.PL4E REV.4

CAUTION - in programming the threshold values of a 100% LEL explosive gas detector, as in this example, the threshold values must be in a growing sequence like 10%, 20% and 30%: values for threshold 2 lower than that of threshold 1 are not accepted (the same applies to threshold 3).

CHN.: 1 ALL.: 3 030% LE

After the setting of the three threshold values and their confirmation with ACK, by pressing the RST button the ISTERESI (hysteresis) programming appears. As hysteresis value select 1 that is applicable to all of the most common gas detectors.

CHN.: 1 ISTERESI 01% LE


Confirm with ACK any possible change and then push RST to reach the END message. The programming of the input channel 1 is now complete. Push ACK to see the channel available for programming, the display is now reporting 1:

SETUP CHN.: 1
Use RST to achieve the indication of channel 2 (CHN.2) and execute the programming of the input channel 2 as previously described for channel 1.

SETUP CHN.: 2
Once completed the programming for all the 4 available input, the next programming step will concern with the AUXILIARY RELAY. By means of the ACK and RST buttons it will be possible to relate the RELE AUX with any one of the displayed functions (i.e. NOT USED, FAULT, ALARM 1, ALARM 2, ALARM 3 or RESET). The programming of the auxiliary relay can be skipped if this relay is not needed for the system functionality.

SETUP RELE AUX.

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TECHNICAL HANDBOOK

ST.PL4E REV.4

The next programming step will allow enable, if present and needed, the optional expansion board for 4 more gas detectors. The added input channels can be programmed in the same way as the first 4 previously described.

SETUP 4/8 CHN.

At this point the input channels programming is complete. Before exiting the programming it is mandatory to reach the channel 1 set-up on the display:

SETUP CHN.: 1

Exit the programming by turning the key to the OFF position (and then back to ON if needed). BEWARE: the control unit CANNOT operate when in programming mode.

5-2

Programming the input channel for Oxygen detectors

The following are the details to program the PL4 control unit when connected to SENSITRON SMART2 DEFICIENCY/EXCESS Oxygen detectors. The mentioned detectors provide 420mA of current proportional to 0-30% of the O2 in air. The normal O2 concentration is close to 20.8% that produces a current of about 15.9mA. The input channel to be used for the O2 must be set as follows: use the RST button in programming mode (with the key switched on PGM) to select the input channel to be programmed then confirm it with ACK. With RST select O2.

CHN.1 O2
Press ACK to display the full scale value to be set: by using ACK and RST set it to 30%.

CHN.1 RANGE

0030%02

Press RST to confirm and then to set the 3 alarm thresholds. The thresholds must be defined in the following way: one in Excess (increase) and two in Deficiency (decrease).

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TECHNICAL HANDBOOK
The following is an example: AL3 AL2 AL1 only INCREASING (therefore a value grater than 21%: e.g. 25%) it is the 1 threshold while DECREASING (e.g. 18%) it is the 2
nd st

ST.PL4E REV.4

threshold while DECREASING (e.g. 10%)

In this programming mode, the TIMES menu described in the next paragraph must be left as the default preset, i.e. with the output channels in latched mode.

5-3

The TIMES menu for output channel relays (software version 3.0)

The TIMES mode of the PL4 control unit allows the output relays operation to be custom programmed. In particular, with TIMES it is possible to set automatic cycles for actuators. For example, it allows alarm cycles to be delayed from the activation event and/or to automatically shut-off after a certain other period. The above are useful features to protect unattended sites (car parking, small depots etc.) avoiding the need of operators for the reset procedure of triggered alarms. When the control unit is switched on, the 3 output relays (present within the control unit) related to the 3 alarm thresholds are by default set in latched mode so the output remains active until the reset procedure is executed. By programming the output mode of operation it is possible to modify the relay behaviour selecting it from the following: LATCHED (default), DIRECT or DELAYED from 1 to 30 minutes from the activation event (alarm ON), DIRECT or DELAYED from 1 to 30 minutes from the deactivation event (alarm OFF). To program these 3 different operations, in programming mode (the key switched on PGM), press the RST button until the last menu TIMES is reached:

TIMES
Press ACK:

TIMES ON : S1 000
The first TIMES parameter concerning the activation delay related to the first threshold will appear. Modify it by pressing ACK first and then by pressing RST to increment the value. The delay with respect to the activation may range from 1 to 31 minutes (+/- 10%) while 000 means instantaneous activation.

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TECHNICAL HANDBOOK
Confirm with ACK and then press RST to go to the 2nd parameter:

ST.PL4E REV.4

TIMES OFF : S1 031


The 2nd TIMES parameter acts on the deactivation time delay of the threshold 1 output measured from the alarm off condition (the detector signal returns below the 1st threshold value). The value 031 is the default and indicates that the relay remains active until the RST button is pressed. Modify it by pressing ACK first and then by pressing RST to change the value. The delay with respect to the deactivation event may range from 1 to 30 minutes (+/- 10%) while 000 means no delay, i.e. the output will be disabled immediately after the signal from the detector goes below the defined threshold value. Acts in the same way as above to set the ON and OFF times of the 2nd and 3rd threshold relays. The display will show:

TIMES ON : S2 000

TIMES OFF : S2 031

TIMES ON : S3 000

TIMES OFF : S3 031

5-4

RESET to default conditions (software version 3.0)

To simplify the programming operations of the PL4 control unit it is possible to reset all the parameter values to the latest default defined by the producer immediately before the delivery of the control unit. Because it erases all the previously programmed values, without the possibility of any recover, this operation should only be performed by the Technical having the system responsibility. After the reset the control unit must be reprogrammed. The reset is executed when the key is turned on the PGM position while the RST button is contemporary pressed. After few seconds the display will report:

PL4 Ver. xx PLEASE WAIT

Note: the control unit will restart as the startup after a line power loss and some output relay may temporarily activate. The control unit then restarts with all the default parameters as for the following table:

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TECHNICAL HANDBOOK

ST.PL4E REV.4

DEFAULT PARAMETERS VALUES


Menu CHN.1 Default value NORMAL RANGE 100 ALL.1 010 ALL.2 015 ALL.3 020 ISTERESI 003 Come CHN.1 Come CHN.1 Come CHN.1 NOT USED Menu CHN.7 Default value NOT USED

CHN.2 CHN.3 CHN.4 CHN.5

%LEL %LEL % LEL %LEL %LEL

CHN.8 RELE AUX (auxiliary relay) 4/8 CHN TIMES (RELAY exit mode)

CHN.6

NOT USED

NOT USED NOT USED 4 (CHN.5-8 DISABILITATI) ON : S1 = 000 OFF : S1 = 031 ON : S1 = 000 OFF : S1 = 031 ON : S1 = 000 OFF : S1 = 031

In order to improve its products, the Sensitron S.r.l. and his suppliers reserve the rights to modify the technical and/or aesthetic characteristics in any moment and without notice.

For further information contact:

Sensitron S.r.l.
(Milan) ITALY

Tel: 00 39 (0) 2 935.48.155 Fax: 00 39 (0)2 935.48.089 e-mail: sales@sensitron.it

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TECHNICAL HANDBOOK

ST.PL4E REV.4

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TECHNICAL HANDBOOK
6 WARRANTY FORM FOR REPAIR

ST.PL4E REV.4

The warranty on the Sensitron products is valid one year from the manufacturing date recorded on the product. It is however intended as valid for one year from the date of installation, provided that the same one happens within the twelve months following the date of manufacturing. They do faith the stamp and the date set from the technician on the present form that the user will have to preserve duly and to return to the same in case of functional verifications and repairs.

Installation date *

Model/s

Serial number/s

______________ ______________ ______________ ______________ ______________ ______________

Technician stamp

Technician signature

* Use a single form for each installation date NOTE: it is intended that for installed perishable components on the products (sensors, backup battery etc.) the above warranty is bound and limited to the terms of warranty declared by the respective producers.

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