Consilium PG11 User manual

Operating Manual PG11 / PGE11 Page 1

Operating Manual PG11 / PGE11 Page 2

Warnings

It is important that the manual is carefully read in its entirety. The manual shall be read and

understood by those having the responsibility for the Operation and Maintenance of the product. If

the product is not used and maintained in accordance with the manufacturer’s instructions, the

product may not perform as intended.

Warranties with respect to the product are voided if the product is not used and maintained as

described in this manual. Warranties are also voided if product is used outside temperature and

vibration certified ranges. Please read the general warnings in the separate chapters.

Please see the

Abbreviations

chapter for a description of abbreviations and foreign words.

 
 
 
 
 
 
 
Operating Manual PG11 / PGE11 Page 3 
Table of contents 
 
Product Description and detection principle 5 
1 Technical Specifications 6 
2 Dimensions PG11 7 
3 Dimensions PGE11 8 
4 Detection principle of PG11 and PGE11 10 
Safety and Warnings PG11 11 
Installation 11 
1 Installation checklist 11 
2 Preparations and Positioning considerations 12 
3 Mounting the detector 13 
3.1 Pole mounting 14 
3.2 Duct or pipe mounting 14 
4 Electrical connections and Earthing 16 
4.1 Booting up the Gas Detector 17 
4.2 Performing loop test 18 
5 Environment Shield for PG11 18 
6 Sunshade 19 
7 Mosquito net 20 
Commissioning the Gas Detector 20 
Operation 21 
1 Function test 21 
1.1 PG11 function check with the “Gas Test kit” 22 
1.2 PG11 Function check with the “Gas Test kit” 23 
1.3 PG11 Function check using the “Gas nozzle” 23 
1.4 PG11 Function check with the “Remote Gas Test kit” 24 
1.5 PGE11 short and medium Function check 26 
2 Perform a check of the Gas Detector accuracy 27 
Maintenance 28 
1 Cleaning of optics - lens and mirror 28 
2 Inspecting detector for damage 28 
3 Keeping a stable Zeroing of the Detector 29 
3.1 The OptoBAS™ function 29 
3.2 Manual zero adjustment 29 
4 Self Diagnostics 29 

Operating Manual PG11 / PGE11 Page 4

6.4.1 Downloading Self diagnostics datalog 30

6.5 The Blocking kit - Protection during site Maintenance 30

7 Signal outputs 31

7.1 Detector status flags 31

7.2 Light indicator 32

7.3 Analog Safety output 33

7.4 HART® 34

7.4.1 HART® electrical connection 34

8 Warranty 34

9 Certifications and standards 34

9.1 Directives and standards 34

9.2 Approvals and Certificates 35

9.3 Marking 35

9.3.1 Certification 35

9.3.2 Vendor information 35

9.3.1 Serial number and year of manufacturing 35

9.4 Specific conditions of use 36

10 Troubleshooting 36

11 Accessories and Spare Parts 38

12 Product coding and Ordering information 40

13 The OptoCom™ module 42

14 Abbreviations 43

15 Safety Manual 43

16 Support and Contact details 43

Operating Manual PG11 / PGE11 Page 5

1 Product Description and detection principle

PG11 is an explosion proof rugged Optical Gas Detector for the detection of flammable gases and CO2. The

detector comes calibrated for life from the factory and requires very little effort to install and maintain.

The PG11 is built for long maintenance intervals in very demanding environments such as extreme

temperatures and tough vibrations. It has built in condition monitoring that enables better maintenance

planning and less risk of unplanned shutdowns.

In the figure below, the PG11 Optical Gas Detector has the following parts:

A. Multicolour indicator light.

B. Sapphire lens

C. Sapphire mirror with heating

D. Mounting leg.

E. Two entries for cable glands M20. On request 1/2”NPT, 3/4"NPT, and M25.

F. Cover terminal compartment.

G. Sign plates with certification details.

Operating Manual PG11 / PGE11 Page 6

1.1 Technical Specifications

Detection

technology

Gas Detection by Dual band Optical absorption in target gases.

Solid-state Infrared SafeSource™. Temperature compensated Optical Gas detection for rugged applications

Gases and

maximum

measuring

range

Detector configured from factory for one of the following gases with 100 %vol as maximum range:

●Methane

●Propane

●Ethylene

●Butane

●CO2

●Biogas (mixture of CH4 in CO2)

Ambient

conditions

Temperature

Humidity

Vibration

Severe vibration conditions

Storage: -60 to +85°C / -76 to +185°F

Operating: -40 to +75°C / -40 to +167°F (Desert)

-40 to +65°C / -40 to +149°F (Standard)

-55 to +65°C / -76 to +149°F (Arctic)

0 - 99 %RH

Resistant to shock and vibration.

Tested for mounting on applications such as diesel engines and compressors

(vibrations up to 4G).

Electrical

Cable entry

M20 (standard), M25, 1/2" NPT or 3/4" NPT

Maximum conductor size

2.5 mm² (Stranded), 4 mm² (Solid)

Supply voltage

24 V DC, range 18 - 50 VDC

Power consumption

< 3 W average (standard configuration)

< 5 W average (arctic configuration)

Start-up current

Soft boot-up to keep rush current less than 1 A

Performance

key

characteristics

Accuracy

± 3 %FS*

Repeatability

± 1% FS*

Response time

T90 ≤2 sec, with Environment Shield

T20 ≤0.5 sec, with Environment Shield

Start-up time

Ambient above -20°C

Ambient below -20°C

< 2 minutes,

< 20 minutes

Calibration

Calibrated at the factory, no field calibration shall be done.

Signal outputs

Analog output

Current source or sink 4 - 20 mA

HART® digital communication

RS-485 serial port

Modbus RTU for OptoCom™ modules, Safety protocols or Condition monitoring.

Status indicator light

Multicolour indicator light in front of detector.

Miswiring

protection

The electronics have been designed to withstand powering up the detector with terminal wires accidentally

being swapped.

Self-test

Continuous self-verification of all important functions.

Housing

Housing material

Stainless steel 316

Weight

3.4 kg (3.9 kg with the optional steel rear lid)

Ingress Protection

IP66 and IP67

Operating Manual PG11 / PGE11 Page 7

Approvals

ATEX / IECEx

Ex db eb ib IIC T5 Gb

North America

Class I, Division 1, Groups B, C and D (Pending)

Various

MED, BV, LR, DnV GL, ABS type approvals

Safety Integrity

SIL2, and SIL3 in 1oo2 redundancy setup (Pending)

* The accuracy is specified for room temperature +25°C.

1.2 Dimensions PG11

Mount

Width

Operating Manual PG11 / PGE11 Page 8

Length

and

height

1.3 Dimensions PGE11

The PGE11 comes in three lengths with dimensions shown below.

Mount

Width

Operating Manual PG11 / PGE11 Page 9

Length

and

height

Operating Manual PG11 / PGE11 Page 10

1.4 Detection principle of PG11 and PGE11

PG11 is using an Optical Detection principle. The basic working principle is illustrated in the drawing below

and consists of the following basic parts:

A. Infrared light (2 –6 µm region) is generated at the

light source

and directed at the

sapphire lens

focusing the light so it is passing through the

gas

to be measured. The gas will absorb some wavelengths depending on the type of gas. The

higher concentration of the gas the more light is absorbed. After passing through the gas the

remaining light is

D. reflected by a

mirror

and back through the gas again reaching the lens directing the light at

E. the

light sensors

. The light sensors will measure what wavelengths that have been absorbed and how

much light has been absorbed. Based on this information the Gas Detector can decide if the target

gas is above the

alarm level

In addition to the basic principles described above there are more functions in the detector that are

compensating for changes for example by temperature and component aging over time.

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