Salwico

Gas Detection System

Installation Manual
Consilium Marine & Safety AB
Fire & Gas Marine Division
Phone: +46 31 710 77 00
Fax: +46 31 710 78 00
E-mail: Service: [email protected]
Spares: [email protected]
 
Consilium Marine & Safety AB
Navigation Division
Phone: +46 8 563 05 100
Fax: +46 8 563 05 199
E-mail: Service, APT: [email protected]
Spares: [email protected]
 
Consilium Marine & Safety AB
Transport Division
Phone: +46 31 710 77 00
Fax: +46 31 710 78 00
E-mail: Service: [email protected]
Spares: [email protected]
 
The contents of this document are subject to revision without notice
due to continued progress in methodology, design and manufacturing.
Consilium assumes no legal responsibility for any error or damage
resulting from the usage of this document.
 
October 2012
Document no. 5103018-00A01
Part no. 5103018

© 2012, Consilium Marine & Safety AB

 Table of contents

1 Introduction ...................................................................................... 1
1.1 About this manual ............................................................................ 1
1.2 Symbols Used in the Manual ........................................................... 2

2 Gas Detection System ....................................................................... 3

2.1 System Description ........................................................................... 3
2.2 System Block Diagram ..................................................................... 3
2.3 System Data ...................................................................................... 5

3 Installation ....................................................................................... 7
3.1 Prerequisites for Installation ........................................................... 7
3.2 Mechanical Installation ................................................................... 7
3.2.1 Installation order ............................................................................ 7
3.2.2 Control Panels ................................................................................ 7
3.2.3 Gas Detectors ................................................................................. 7
3.2.4 Mounting of modules ..................................................................... 7

3.3 Electrical Installation ...................................................................... 8

3.3.1 Cable requirements ........................................................................ 8
3.3.2 Cable lengths .................................................................................. 10
3.3.3 Connection Power Boost Loop ...................................................... 12
3.3.4 Connection Analogue M 4-20 ........................................................ 14
3.3.5 Earth connections ........................................................................... 15
3.3.6 Test the cables ................................................................................ 17
3.3.7 Setting the address ......................................................................... 21
3.3.8 Setting function or mode for modules ........................................... 21
3.3.9 Electrical installation, central equipment ....................................... 21

4 Configuration ................................................................................... 23
4.1 Uploading a configuration file to the gas detection system ............ 23
4.1.1 Uploading a configuration file from the USB memory stick ......... 23

4.2 Downloading a configuration file from the gas detection system .. 24

4.2.1 Downloading a configuration file to a USB memory stick ............ 24

5 Verification ....................................................................................... 27
5.1 Prerequisites for Verification ........................................................... 27
5.2 Verification of Power Boost loops ................................................... 27
5.3 Testing of System Parts .................................................................... 28
5.3.1 Prerequisites for Testing ................................................................ 28
5.3.2 About testing .................................................................................. 28
5.3.3 Test the control panel display ........................................................ 28

5.4 Trouble shooting .............................................................................. 29

5.4.1 Wrong number of system modules/gas detectors .......................... 29
5.4.2 Cable break .................................................................................... 29
Table of contents

5.4.3 Earth fault ....................................................................................... 30

5.4.4 Short circuit .................................................................................... 30
5.4.5 Muting faults .................................................................................. 30
5.4.6 Reset faults ..................................................................................... 30
5.4.7 Update firmware ............................................................................ 31
5.4.8 Copy the system log to a USB memory stick ................................ 31

6 Commissioning Requirements ......................................................... 33

6.1 Prerequisite ....................................................................................... 33
6.2 Loop requirements ........................................................................... 33
6.3 Part A: Power Boost loop configuration ......................................... 33
6.4 Part B: Loop status .......................................................................... 33
6.5 Part C: Central status ...................................................................... 34
6.6 Summary .......................................................................................... 34

7 Gas Detection Installation Guidelines ............................................ 35

7.1 Gas Detectors Installation ............................................................... 35
7.1.1 General comments when installing gas detectors .......................... 35
7.1.2 Location of sensors ........................................................................ 35
7.1.3 IR detectors .................................................................................... 36
7.1.4 Catalytic detectors .......................................................................... 36
7.1.5 Electrochemical detectors .............................................................. 37
7.1.6 Electrical siren ............................................................................... 37

7.2 Cabling and Electrical Installation ................................................. 37

7.2.1 Cable types ..................................................................................... 37
7.2.2 Cable protective tubes of metal ...................................................... 37
7.2.3 Cable protective tubes of plastic .................................................... 38
7.2.4 Cabling ........................................................................................... 38
7.2.5 Cable inlets to equipment ............................................................... 39
7.2.6 Fixing of cables .............................................................................. 39
7.2.7 Markings ........................................................................................ 39
7.2.8 Cable ends ...................................................................................... 40
7.2.9 Protective earthings ........................................................................ 40

8 Calibration Instruction for Salwico GD True IR ............................ 41

8.1 Preliminaries .................................................................................... 41
8.2 Calibrating the sensor (Zero calibration) ....................................... 42
8.3 Calibrating the sensor (Span calibration) ....................................... 43
8.4 Reconnecting disabled detectors ...................................................... 44

9 Calibration Instruction for Salwico GD .......................................... 45

9.1 Preliminaries .................................................................................... 45
9.2 Calibrating the sensor (Zero calibration) ....................................... 46
9.3 Calibrating the sensor (Span calibration) ....................................... 48
 Table of contents

9.4 Reconnecting disabled detectors ...................................................... 49

10 Calibration Instruction for Salwico ST200 and Salwico ST600EX

........................................................................................................... 51
10.1 Preliminaries .................................................................................... 51
10.2 Prerequisites ..................................................................................... 52
10.3 Calibrating the sensor (Zero calibration) ....................................... 53
10.4 Calibrating the sensor (Span calibration with test gas) ................. 53
10.5 Reconnecting disabled detectors ...................................................... 54

11 Calibration Instruction for Salwico ST600EX-IR and Salwico

ST700IR ............................................................................................ 57
11.1 Preliminaries .................................................................................... 57
11.2 Prerequisites ..................................................................................... 57
11.3 Calibrating the sensor (Zero calibration) ....................................... 58
11.4 Calibrating the sensor (Span calibration) ....................................... 59
11.5 Reconnecting disabled detectors ...................................................... 60

12 Calibration Instruction for Salwico ST400 H2S ............................ 61

12.1 Preliminaries .................................................................................... 61
12.2 Prerequisites ..................................................................................... 62
12.3 Calibrating the sensor (Zero calibration) ....................................... 63
12.4 Calibrating the sensor (Span calibration) ....................................... 63
12.5 Reconnecting disabled detectors ...................................................... 64

13 Calibration Instruction for Salwico ST400 O2 ............................... 65

13.1 Preliminaries .................................................................................... 65
13.2 Prerequisites ..................................................................................... 66
13.3 Calibrating the sensor (Span calibration) ....................................... 67
13.4 Calibrating the sensor (Zero calibration) ....................................... 67
13.5 Reconnecting disabled detectors ...................................................... 68

14 Appendix ........................................................................................... 69
14.1 Central Unit Terminal & Cabling Layout ....................................... 69
14.2 RS485/PB485 Termination .............................................................. 71
14.2.1 General Recommendations for Installation of RS485 ................... 71
Table of contents

14.2.2 Application Examples for Installation of RS485 ........................... 71

14.3 Fault Code List ................................................................................. 72

14.4 Definitions of Terms ......................................................................... 75

Index ................................................................................................. 79
Installation Manual 1 Introduction

1 Introduction

1.1 About this manual

This manual is intended for personnel installing a gas detection system.

NOTE!
This guide is valid for Control panel software versions beginning with version
1.0.0.

Chapter Gas Detection System, page 3 gives an overview of the system.

Chapter Installation, page 7 describes the electrical installation process of

system modules and detectors. The installation engineer does not need to have any
previous knowledge of this particular system to be able to perform an installation.

Chapter Verification, page 27 describes how to test the installed system. After
the installation is completed, the system is verified, which must be performed by a
person with good knowledge of the various functions. This chapter also includes
verification and troubleshooting.

Chapter Commissioning Requirements, page 33 describes the steps to be taken

by the installation organisation before a commissioning engineer can be sent from
the commissioning organisation.

Chapter Gas Detection Installation Guidelines, page 35 gives general

recommendations for installing a gas detection system.

Figure 1. Cabinet Compact GDS for Salwico Gas detection systems

5103018-00A01 1
1 Introduction Installation Manual

Figure 2. Cabinet LNG GDS for Salwico Gas detection systems

1.2 Symbols Used in the Manual

DANGER!
Risk of serious or fatal injury to the user, and/or severe damage to the product, if
the instructions are not followed.

WARNING!
Risk of personal injury and/or damage to the product if the instructions are not
followed.

CAUTION!
Risk of minor or moderate personal injury. Risk of equipment damage, loss of data,
extra work, or unexpected results, if the instructions are not followed.

NOTE!
Note symbols alert you to important facts and conditions.

Hint!
Tip symbols direct you to specific instructions, such as where to find additional
information and tell you how to perform a certain operation in an easier way.

2 5103018-00A01
Installation Manual 2 Gas Detection System

2 Gas Detection System

2.1 System Description

This Gas detection system is a state-of-the-art addressable detection system
designed to meet marine, industrial and transport requirements. Special care is
given to ergonomics and user-friendliness with its logical and intuitive operator
panel.

2.2 System Block Diagram

The following figures shows some typical systems with connected components, see
Definitions of Terms, page 75 in the Appendix for explanation of terms and
abbreviations.

Figure 3. An example with several Power Boost Loops in one Salwico Gas detection system

5103018-00A01 3
2 Gas Detection System Installation Manual

Figure 4. An overview of a Salwico Gas detection system

Figure 5. An overview of a distributed Salwico Gas detection system

4 5103018-00A01
Installation Manual 2 Gas Detection System

2.3 System Data

Table 1. System data for the Gas detection system.
System Data Specifications
Supply voltage Depends on PSU
Power consumption.
Depending of system configuration.
Internal system voltage 22–30 VDC
Central panel ingress protection IP55
Number of inputs per module, Analogue M 4-20 4
Number of modules in one Salwico Gas detection system max 125
Number of Control M Gas in one Salwico Gas detection
max 10
system
Number of Analogue M 4-20 in one Salwico Gas detection
max 64
system
Number of Relay M 8 in one Salwico Gas detection system max 16
Number of zones in a system max 255
Communication parameters for the external system channel RS485, 38400 Baud, Odd
parity, 8 data bits

NOTE!
System boot-time is kept to a minimum during normal operation, but it can be
extra-long after a new installation, commissioning or major maintenance work
(depending on the configuration of the data definition file).

Hint!
For detailed requirements, refer to the data sheets.

5103018-00A01 5
2 Gas Detection System Installation Manual

6 5103018-00A01
Installation Manual 3 Installation

3 Installation

3.1 Prerequisites for Installation

CAUTION!
The installation of the Gas detection system must be performed according to
SOLAS and ICS requirements.

The different parts of the system, the control and system modules, should first be
mechanically installed. The different gas detectors are thereafter electrically
installed and set up according to the definition of the detectors and drawings.

The cables must be tested separately before the detectors are connected to the
system module. This eliminates any problem with the cables and the electrical
installation of the detectors.

The installation is completed with the electrical installation of the the control and
system modules.

3.2 Mechanical Installation

3.2.1 Installation order
Install the control panel according to the drawings. The Control M Gas is delivered
in a cabinet. Separate drawings are delivered with the system.

3.2.2 Control Panels

The external control panels are delivered in cabinets (IP55) for wall or console
mounting. Separate drawings are delivered with the system. Install the panels
indoors in areas in 0–95% RH non-condensing conditions and within a temperature
range of -5ºC to +55ºC.

3.2.3 Gas Detectors

Gas detectors are connected to Analogue M 4-20 modules.

The mechanical installation of different types of gas detectors are described in their
respective data sheets. Some guidelines on where to place detectors are given in
Location of sensors, page 35.

3.2.4 Mounting of modules

Modules are mounted on a 35 mm DIN rail inside a cabinet.

Mount the modules horizontally on the 35 mm DIN rail.

• Mount one module support on each side.

• Squeeze the whole package together and tighten the screws on the supports.

5103018-00A01 7
3 Installation Installation Manual

3.3 Electrical Installation

3.3.1 Cable requirements
Backbone Bus External (BBE), Channel 1 & 2

Figure 6. Example of connection between two cabinets

The cables connecting from the backbone bus to the control panels or stretched
central part must meet the following requirements:

• Min 2 x 2 x 0.3 mm2, twisted pair shielded

(RS485 + backup signal, one conductor)
NOTE!
The backup signal is only needed for one channel.

• Max allowed cable length is 700 m

• Optional: Power supply (24 VDC) 1 x 2 x 0.75 mm2
Refer to the system connection drawing

NOTE!
Channel 1 and Channel 2 should be routed separately for improved safety if both
channels are used.

8 5103018-00A01
Installation Manual 3 Installation

Power Boost Loops

Figure 7. Connection example for Power Boost loops

Power Boost Loop cables must meet the following minimum requirements. We
refer to current regulations for the rest of the specification.

5103018-00A01 9
3 Installation Installation Manual

• Minimum 4 x 2 x 0.75 mm2, twisted pair shielded

• Recommended 4 x 2 x 1.5 mm2, twisted pair shielded

NOTE!
Wires for communication (PB-485) must be twisted over its entire length.

Cables between Analogue M 4-20 and gas detectors

Figure 8. Connection examples of cables between Analogue M 4-20 and gas detectors

Cables between Analogue M 4-20 and gas detectors must meet the following
minimum requirements. We refer to current regulations for the rest of the
specification.

• Minimum 2 or 3 core x 0.75 mm2, shielded

• Recommended 2 or 3 core x 1.5 mm2, shielded
• Max allowed cable length is 400 m

3.3.2 Cable lengths

CAUTION!
Never exceed the recommended cable lengths.

The cable length depends on three parameters:

• cable type
• shielded or unshielded cable
• power consumption

A cable is considered shielded if the shielded part is more than 10% of the cable's
total length.

10 5103018-00A01
Installation Manual 3 Installation

Cable resistance

Figure 9. Resistance in cables with area 0,75 mm²

Figure 10. Resistance in cables with area 1 mm²

5103018-00A01 11
3 Installation Installation Manual

Figure 11. Resistance in cables with area 1,5 mm²

3.3.3 Connection Power Boost Loop

A Power Boost loop may contain max 20 gas detectors divided on max 5 Power
Boost segments.

The max load is 38 W per Power Boost loop segment.

Hint!
Please contact Consilium for advice concerning cable lengths.

12 5103018-00A01
Installation Manual 3 Installation

Figure 12. Connection example with Power Boost segments

5103018-00A01 13
3 Installation Installation Manual

3.3.4 Connection Analogue M 4-20

The information about the electrical installation of each type of gas detector is
provided in its respective data sheet and/or connection drawing.

CAUTION!
Do not remove protection cap from the gas detectors until all polluting activities
(such as construction work and painting) are finished and the area has been
cleaned.
For further information refer to Gas Detectors Installation, page 35.

Connection Examples

Figure 13. 2-wire interface

Figure 14. 3-wire interface, current source.

Figure 15. 3-wire interface, current sink.

Figure 16. 4-wire interface

14 5103018-00A01
Installation Manual 3 Installation

Figure 17. Connection example for Analogue M 4-20 and detectors

Voltage output delays

In order to avoid a massive start-up current in the system the Analogue M 4-20
module delays the voltage output (+, SG) in the transmitter interfaces upon
start-up:

• Transmitter interface 1, 0 ± 10 ms
• Transmitter interface 2, 125 ± 10 ms
• Transmitter interface 3, 250 ± 10 ms
• Transmitter interface 4, 375 ± 10 ms

The voltage outputs are delayed based on the DIP address:

• DIP 31, 500 ms

• DIP 32, 1000 ms
• DIP 33, 1500 ms
• etc

NOTE!
DIP switch addresses below 31 will NOT be delayed.

3.3.5 Earth connections

The entire length of the field cabling connected to a unit should be screened
/shielded. This screen/shield should be connected to a low noise instrument (clean)
earth at a single end. (The screen/shield can be connected to the unit’s earth in the
junction box, provided that this is isolated from all other earths/grounds.)

See the following example Figure 18.  how the cable screen should be connected to
avoid an earth loop.

= Wires marked with this symbol in the drawing must be twisted over its
entire length

5103018-00A01 15
3 Installation Installation Manual

Figure 18. The cable screen connected to avoid an earth loop.

CAUTION!
The screens/shields of field cabling should not be connected in a manner that
creates earth loops or that will result in the screens/shields carrying large currents
from the equipment.

The illustration in Figure 19.  shows an example on how the cable screens should
not be connected.

16 5103018-00A01
Installation Manual 3 Installation

Figure 19. This example shows some incorrect connections of the cable screens

The use of a single, screened/shielded cable for each field device (detector) ensures
good screening/shielding and reduces crosstalk. Cabling arrangements that use a
single cable to connect a number of field devices compromise screening and
increase the potential for crosstalk. Such arrangements should only be employed if
the electrical installation design authority is confident that this will not adversely
affect the reliability or performance of the system.

3.3.6 Test the cables

3.3.6.1 Test 1: Test for cable break
CAUTION!
When gas detectors are connected, it is not allowed to use an insulation tester with
a voltage exceeding 30 V.

Measure the resistance between the PBx terminals

Connect an ohm meter between the PBx terminals as shown in the following
figure.

5103018-00A01 17
3 Installation Installation Manual

Figure 20. Test for cable break between the PBx terminals

Measure the resistance between the - terminals

Connect an ohm meter between the - terminals as shown in the following figure.

Figure 21. Test for cable break between the - terminals

Measure the resistance between the + terminals

NOTE!
It is not possible to measure the positive side because of the short circuit isolators.
Install a temporary jumper in order to do this measurement.

The measured value

The measured value depends on the length and type of the cable. Always compare
to values provided by the manufacturer of the cable.

An infinite resistance indicates a cable break.

Locate the cable break

Hint!
The control panel indicates if modules or gas detectors are missing.

3.3.6.2 Test 2: Test for short circuits

CAUTION!

18 5103018-00A01
Installation Manual 3 Installation

When gas detectors are connected, it is not allowed to use an insulation tester with
a voltage exceeding 30 V.

Measure the resistance between the + terminal and the - terminal

Connect an ohm-meter between the two terminals, as shown in the following
figure.

Figure 22. Test for short circuit between the + terminal and the - terminal

Measure the resistance between the PBx terminal and the - terminal
Connect an ohm-meter between the two terminals, as shown in the following
figure.

Figure 23. Test for short circuit between the PBx terminal and the - terminal

Measure the resistance between the PBx terminal and the + terminal
Connect an ohm-meter between the two terminals, as shown in the following
figure.

5103018-00A01 19
3 Installation Installation Manual

Figure 24. Test for short circuit between the PBx terminal and the + terminal

The measured value

The measured value should be more than 100 kOhm.

Locate the short circuit

Hint!
The panel will report “no answer com channel A/B” for the affected units.

3.3.6.3 Test 3: Test for earth failure

CAUTION!
When gas detectors are connected, it is not allowed to use an insulation tester with
a voltage exceeding 30 V.

Measure between the + and - terminals and earth to detect an earth

fault
Connect the ohm meter between the + terminal and earth as shown in the following
figure.

NOTE!
Measure and repeat the procedure for the - terminal.

Figure 25. Test for earth failure

20 5103018-00A01
Installation Manual 3 Installation

The measured value

The measured value should be more than 50 kOhm. Values below 8 kOhm (±2
kOhm) will be indicated as earth fault.

Locate the earth fault

Hint!
The control panel reports which parts of the system that is affected by the earth
fault.

Proceed as follows when you want to locate an earth fault:

1 Divide the cable in two and locate the earth fault.

2 Divide each half in two and locate the earth fault.
3 Continue to divide the cable into halves until you have found the exact
position of the earth fault.

3.3.7 Setting the address

NOTE!
Check that the addresses are set correctly.

All Salwico Gas Detection System addressable modules must be given an unique
address in order to make it possible for the software to identify the modules. The
address is set with an 8-pole DIP switch with the exception of module Control M
Gas (there the address is set on the panel via Menu » Settings » Set CM address).
For instructions on how to set the address on DIP switch, refer to the data sheet for
each module.

Modules Control M Gas, Control M X, Relay M 8 and Analogue M 4-20 (with

connected gas detectors) has to be configured in the Configuration program, please
refer to the Configuration Manual.

3.3.8 Setting function or mode for modules

NOTE!
Check that the correct functions or modes are set for the connected modules.

On some modules (for example Power Boost M and BusCon M Gas) different
functions are set by DIP-switches.

For Relay M 8 and Analogue M 4-20 the DIP switch 8 on these modules must be
set to ON when they are used in a Gas detection system.

For instructions on how to set the DIP-switches, refer to the data sheet for each
module.

3.3.9 Electrical installation, central equipment

3.3.9.1 Terminal layout
Since most systems are designed specifically for each customer, no standard for
connecting the different modules within the system exists.

5103018-00A01 21
3 Installation Installation Manual

Refer to system connection drawings for more information.

For other electrical installations, such as printers, refer to the specific project
drawings.

3.3.9.2 Control Panels

If a Control Panel is placed outside of the Gas detection cabinet, connection to the
Central Unit is made via the external Backbone Bus channel (BBE) or the Power
Boost loop. Each cable should be routed seperately for maximum security.

22 5103018-00A01
Installation Manual 4 Configuration

4 Configuration

4.1 Uploading a configuration file to the gas

detection system
4.1.1 Uploading a configuration file from the USB
memory stick
When you have finished a configuration file it is time to upload it to the gas
detection system. The configuration file must have the file extension “.ccp”.

NOTE!
The old configuration file will be overwritten. Please save the old file before
proceeding.

Note that old versions of the definition program may effect the upload or system
operations. Use a program version of the CCP Configuration program compatible
with the system version used in your gas detection system.

The configuration file can be uploaded using an approved USB memory stick
(available from an authorized dealer).

CAUTION!
Do not remove the USB memory stick until the upload is finished.

1 Connect the USB memory stick to the USB

port on the rear of the control panel.
2 Choose Menu » Service » Configuration »
Get from USB.

3 A list of the available “.ccp” files on the

USB memory stick will be presented.
Choose the appropriate “.ccp”
configuration file from the list and press
Continue.
4 Press Confirm to replace the systems
configuration with the selected
configuration from the USB memory.
The new configuration file is uploaded to
the gas detection system.
5 Press Close.
Disconnect the USB memory stick.

5103018-00A01 23
4 Configuration Installation Manual

6 Update the system with the new

configuration file by choosing Menu »
Service » Configuration » Apply
configuration (restart).

7 Press Confirm to start the update.

8 The system will apply the configuration.

The configuration can only be done from
the Control M Gas that is master in the
system, i.e. the Control M Gas with address
1. A Control M Gas module with address
2-10 will update its local configuration
before it restarts itself.
9 Press Restart when the distribution is
completed.

10 The Control M Gas restarts and loads the

new configuration file.

4.2 Downloading a configuration file from the

gas detection system
4.2.1 Downloading a configuration file to a USB
memory stick
When you want to view or make changes in an existing configuration file you can
download it from the gas alarm central.

Hint!
When requesting assistance on technical issues please send the configuration file
and the system log file to your local retailer.

The configuration file can be downloaded using an approved USB memory stick
(available from an authorized dealer).

CAUTION!
Do not remove the USB memory stick until the download is finished.

1 Connect the USB memory stick to the USB

port on the rear of the control panel.

24 5103018-00A01
Installation Manual 4 Configuration

2 Choose Menu » Service » Configuration »

Copy to USB.

3 Press Confirm to copy the systems

configuration to the USB memory stick.

4 The system will now download the

configuration file. Wait until this process is
complete!
Press Close.

5 Disconnect the USB memory stick and

copy the configuration file to a PC.

5103018-00A01 25
4 Configuration Installation Manual

26 5103018-00A01
Installation Manual 5 Verification

5 Verification

5.1 Prerequisites for Verification

NOTE!
The configuration of the system must be performed by a person with good
knowledge of the system. This operator must have the authority to work in access
level 4.

The system is delivered with a complete system configuration or a test

configuration.

5.2 Verification of Power Boost loops

NOTE!
Once the loop cable has been tested and is free from faults, the next step is to
connect it to the central.

The verification procedure is described below:

1 Make sure that the system is connected to Refer to chapter Installation in

an external power supply. the Installation manual and
individual project drawings
for information on the
electrical connections.
2 Connect both channels of one of the Power
Boost loops.
3 Power up the system. For more information about
The Power LED lights and a text appears the fault codes, see Fault Code
on the display to show that the system is up List, page 72.
and running.
Wait for a few minutes to let the system
perform all system checks.
If the system detects a fault during the
start-up, a fault code is displayed in the
control panel.

5103018-00A01 27
5 Verification Installation Manual

4 Verify that the correct number and type of

gas detectors are installed in the correct
place. The system will provide you with the
requested information if you use the Menu
» Observation list or the Menu » Gas
detectors.
A list of all detectors found on the Power
Boost loop will be generated (see figure to
the right).
Verify that the information for the
following is correct:
• Zone
If a unit is missing, see Wrong
• Gas type number of system
• Location modules/gas detectors, page
29.
• Address

5 Make a gas detector test of the complete CAUTION!

Gas detection system. Use appropriate test Disable all outputs
gas to test each detector. before starting the test.
Please refer to the Service and Maintenance Menu » Service » Settings »
manual. Disable all outputs

6 Use a top to bottom procedure if you have

any problem with the verification of the
Power Boost loop function.
Start by solving the problems that affect the
whole system and then continue with the
problems with each address.

5.3 Testing of System Parts

5.3.1 Prerequisites for Testing
After installation of the Gas detection system, test the different parts of the system
to assure that they function properly.

5.3.2 About testing

For additional information about testing a gas detection zone or a gas detector,
please refer to the Service and Maintenance Manual.

5.3.3 Test the control panel display

With the function Display & LED test it is possible to test:

• The display

28 5103018-00A01
Installation Manual 5 Verification

• All indications on the control panel

• The buzzer

1 To test the control panel display, use: Menu » Service » Settings » Display
& LED test.

5.4 Trouble shooting

5.4.1 Wrong number of system modules/gas detectors
If a limited number of units do not answer, the problem may depend on one of the
causes listed below.

Table 2. System modules/gas detectors troubleshooting.

Cause Remedy
Less system modules/gas detectors Install the missing system modules/gas detectors
found than configured. or change the configuration.
More system modules/gas detectors Compare the found system modules/gas
found than configured. detectors with the configuration program.
Wrong address for the system Set the correct address.
modules/gas detectors.
Two or more system modules with the Compare the found addresses with the
same address. corresponding modules and set the correct
addresses.

5.4.2 Cable break

No gas detectors are answering

1 The gas detector is not responding? The cable is broken between

the gas detector and the
Analogue M 4-20 module.

No Power Boost loop units (gas detectors) are answering

1 No answer is received? The cable is broken before the

first system module and after
the last system module.

Only some system modules are answering

1 Look for the last system modules Refer to Test 1: Test for cable
answering on each side of the loop. The break, page 17, for more
cable break is situated after or between the information.
answering modules.

5103018-00A01 29
5 Verification Installation Manual

5.4.3 Earth fault

The control panel will display which area that has the earth fault. It can be the
Power Boost loop or in cables between gas detectors and Analogue M 4-20
modules.

1 Examine the faulty cable to locate the earth Refer to Test 3: Test for earth
fault. failure, page 20 for more
details.

5.4.4 Short circuit

No answer on Power Boost loop

1 Search for the short circuits between the Refer to Test 2: Test for short
central unit and the first Power Boost circuits, page 18 for more
module. details.

If only some Power Boost loop units answer

1 The control panel displays which system Refer to Test 2: Test for short
modules are missing. Search for the short circuits, page 18 for more
circuit between the fault reported modules details.
to find the exact location of the fault.

5.4.5 Muting faults

1 Simultaneously mute all the faults by
pressing the Mute button on the Control
panel.
You can mute the faults locally on a
Repeater panel.
2 The fault indication light stops flashing and The fault is put in a fault list
change mode to steady yellow. under Menu » 2 Fault and
warnings » 1 Faults.

5.4.6 Reset faults

NOTE!
The fault alarm must be muted before it can be reset.

The faults are reset from the Fault list under Menu » 2 Fault and warnings » 1
Faults.

From the Repeater panel it is only possible to mute faults and alarms, not reset
them.

NOTE!
The cause of the problem must disappear before a fault can be reset.

The Fault is Reset

1 The fault is reset and it disappears from the fault list.

30 5103018-00A01
Installation Manual 5 Verification

The Fault is not Reset

1 The fault is not reset and the reason for this

is displayed.
2 Check the problem and try to solve it. See Fault Code List, page
72 for more information.
3 Attempt to reset the fault. For further information refer
to the Service & Maintenance
manual.

5.4.7 Update firmware

This instruction describes how to update firmware in a Salwico Gas detection
system.

NOTE!
Access Level 4 is required to upgrade firmware in the system. You may be required
to login with correct credentials during the firmware upgrade process.

NOTE!
The system will only update the modules that have software that differs from what
is in the service package stored locally in the control module.

1 Choose Menu » Service » Update firmware.

2 Press Confirm to start the update.

NOTE!
The Gas Detection system will not
be operational for the duration of
the update.
3 The system starts the update process.
CAUTION!
Wait until this process is complete!

4 Press Restart to restart the system.

5.4.8 Copy the system log to a USB memory stick

If you want to control the information saved in the system log you can download it
from the gas alarm central.

Hint!
When requesting assistance on technical issues please send the system log file and
the systems configuration file to your local retailer.

5103018-00A01 31
5 Verification Installation Manual

The system log file can be downloaded using an approved USB memory stick
(available from an authorized dealer).

CAUTION!
Do not remove the USB memory stick until the download is finished.

1 Connect the USB memory stick to the USB

port on the rear of the control panel.
2 Choose Menu » Service » System
information » Copy system log to USB.

3 Press Copy to copy the systems log to the

USB memory stick.

4 The system will now download the system

log file. Wait until this process is complete!
Press Close.

5 Disconnect the USB memory stick and File name example:

copy the system log file to a PC. YYYY-MM-
DD_xxxxxx_syslog.txt

32 5103018-00A01
Installation Manual 6 Commissioning Requirements

6 Commissioning Requirements

6.1 Prerequisite
The procedure described below in Loop requirements is to be followed by the
installation team.

If nothing else is agreed, no commissioning engineer will be sent before the steps
below are confirmed and the appropriate papers are signed and sent to your local
Consilium office or authorized representative.

6.2 Loop requirements

The following specification is a checklist of requirements for the system loops. The
specification shall be used by the installation organisation of Power Boost loop
units/detectors and cabling. Start with Part A: Power Boost loop configuration,
continue with Part B: Loop status and then Part C: Central status.

The list in Part A: Power Boost loop configuration includes all data you need when
configuring the loops.

Part B: Loop status is more like a checklist - follow it point by point. When you
have completed this part you should have filled in, signed and faxed a test report
containing each Power Boost loop unit/detector in the system.

Part C: Central status is also a checklist, but it deals with the status of the central
unit.

6.3 Part A: Power Boost loop configuration

Refer to Cable requirements, page 8 and Cable lengths, page 10 for
requirements and limitations.

6.4 Part B: Loop status

1 All units shall be located at the proper place according to the project
drawings.
2 Each system module shall be given a unique address, refer to Setting the
address, page 21.
3 Connect cables to Power Boost loop units/detectors according to the project
drawing for that unit. Follow the requirements in chapter Electrical
Installation, page 8
CAUTION!
Do not remove any protective covers from the gas detectors before
the function test.

5103018-00A01 33
6 Commissioning Requirements Installation Manual

4 A test report must be filled in for each Power Boost loop unit/detector.
The test report must contain at least the following information for each
unit/detector:
• Type of unit/detector
• Location
• Address
• Installation date

5 Send one copy of the signed test protocol to your local Consilium office or
authorized representative.
6 When all protocols are signed, your local Consilium office or authorized
representative will make the final control and adjustment of the system.

6.5 Part C: Central status

CAUTION!
The presence of an authorised engineer is required before power is connected to
the central unit to minimise the start-up costs for the yard and/or owner during
commissioning.

• All control and indication functions must be connected to relay outputs.

Connect all outputs and inputs according to the project drawings.
• Connect finalized Power Boost loops to the central according to the project
drawings.

NOTE!
Deviations from the above criteria may cause time delays. These time delays will
be invoiced.

6.6 Summary
For each gas detector, a test report as described in Part B: Loop status, page 33
must be filled in and sent to your local Consilium office or authorized
representative before commissioning of the system starts.

34 5103018-00A01
Installation Manual 7 Gas Detection Installation Guidelines

7 Gas Detection Installation Guidelines

CAUTION!
Always refer to and act according to current local rules and regulations.

7.1 Gas Detectors Installation

7.1.1 General comments when installing gas detectors
This chapter provides important information for installing gas detection equipment.

• We strongly recommend protecting the gas detector sensor cell when doing
painting work to avoid the high amount of silicones that exists in paint. In order
to protect the sensor cell Consilium has installed a protection cover that is
mounted on the detector cell from delivery. Keep the covers mounted as long as
possible, recommendable is to keep them on until first sea-trial. It’s also a
benefit to keep the gas detectors without power. When the gas detector is
currentless it’s less affected by paint.
• To help maintain the correct IP class, plug any unused cable glands.
• Keep the detectors protection caps on as long as possible. The protection caps
should be removed after commissioning is completed and the system is handed
over.

NOTE!
For detailed connection and installation information, refer to the data sheet for each
unit.

7.1.2 Location of sensors

Considerable guidance is available from standards such as EN50073 Guide for
selection, installation, use and maintenance of apparatus for the detection and
measurement of combustible gases or Oxygen. Similar international codes of
practice may be used where applicable. In addition certain regulatory bodies
publish specifications giving minimum gas detection requirements for specific
applications. These references are useful, but tend to be either very generic and
therefore too general in detail, or application specific and therefore irrelevant in
most applications.

The placement of detectors should be determined following the advice of experts

having specialist knowledge of gas dispersion and equipment involved. The
agreement reached on the location of detectors should also be recorded.

There are a number of simple and quite often obvious considerations that help to
determine detector location:

• To detect gases that are lighter than air (e.g. Methane and Ammonia), detectors
should be mounted at high level and preferably use a collecting cone.
• To detect heavier than air gases (e.g. Butane, Sulphur Dioxide and Propane),
detectors should be mounted at a low level.

5103018-00A01 35
7 Gas Detection Installation Guidelines Installation Manual

• Consider how escaping gas may behave due to natural or forced air currents.
Mount detectors in ventilation ducts if appropriate.
• Detectors should be positioned a little way back form high pressure parts to
allow gas clouds to form. Otherwise any leak of gas is likely to pass by in a
high speed jet and not be detected.
• Consider ease of access for functional testing and servicing.
• Detectors should be installed at the designated location with the detector
pointing downwards. This ensures that dust or water will not collect on the front
of the sensor and stop the gas entering the detector.

7.1.3 IR detectors
There are two main types of IR Detectors, open-path or single point. Open-path
detectors are mainly used in outdoor situations and Single point detectors in indoor
situations.

Many combustible gases have absorption bands in the infrared region of the
electromagnetic spectrum of light and the principle of infrared absorption is used to
detect the gas concentration.

IR Detectors has a very fast response (typically less than 10 seconds). They can
also be designed to be unaffected by any known ‘poisons’, they are failsafe and
they will operate successfully in inert atmospheres, and under a wide range of
ambient temperature, pressure and humidity conditions. The technique operates on
the principle of dual wavelength IR absorption, whereby light passes through the
sample mixture at two wavelengths, one of which is set at the absorption peak of
the gas to be detected, whilst the other is not. A detector compares the signal
strengths of sample and reference beams and, by subtraction, can give a measure of
the gas concentration.

7.1.4 Catalytic detectors

Catalytic sensors consists of a very small sensing element sometimes called a
"bead". It is made of an electrically heated platinum wire coil, covered first with a
ceramic base such as Alumina and then with a final outer coating of Palladium or
Rhodium catalyst dispersed in a substrate of Thoria. This type of sensor operates
on the principle that when a combustible gas/air mixture passes over the hot
catalyst surface, combustion occurs and the heat evolved increases the temperature
of the "bead". This in turn alters the resistance of the platinum coil and can be
measured by using the coil as a temperature thermometer in a standard electrical
bridge circuit. The resistance change is then directly related to the gas
concentration in the surrounding atmosphere and can be displayed on an indicating
device.

The response time for catalytic sensors are typically between 20 and 30 seconds.

These detectors have the following properties:

• Presence of oxygen is not required during equipment life time.

• Immunity to poisoning from H2S, silicone and other agents.
• No saturation effects from high gas concentrations.

36 5103018-00A01
Installation Manual 7 Gas Detection Installation Guidelines

• The gas flow rate has no influence on accuracy.

• Proven high reliability and long term stability results in low test frequency and
lower calibration cost.
• Can be used in duct installations.

7.1.5 Electrochemical detectors

There are many different designs of electrochemical detectors but the common
features are described below:

Three active gas diffusion electrodes are immersed in a common electrolyte for
efficient conduction of ions between the working and counter electrodes.
Depending on the specific cell the target gas is either oxidised or reduced at the
surface of the working electrode. This reaction alters the potential of the working
electrode relative to the reference electrode. The primary function of the associated
electronic driver circuit connected to the cell is to minimise this potential
difference by passing current between the working and counter electrodes, the
measured current being proportional to the target gas concentration. Gas enters the
cell through an external diffusion barrier that is porous to gas but impermeable to
liquid.

Gas specific electrochemical sensors can be used to detect the majority of common
toxic gases, including CO, H2S, Cl2, O2, SO2 etc. Electrochemical sensors are
compact, require very little power, have excellent linearity and repeatability and
generally have a long life span, typically one to three years. Response times are
typically 30-60 seconds.

These detectors have the following properties:

• Sensitive to poisoning from H2S, silicone and other agents.

• Can detect a wide almost all hydro carbon based gases.

7.1.6 Electrical siren

• Make sure to programme the siren to the correct sound and intermittence using
the DIP switch inside the siren. More information about how to set the DIP
switch is found in the siren’s data sheet.
• Turn the volume control to max.
• Clearly label the siren with the alarm’s category (e.g., GAS ALARM).

7.2 Cabling and Electrical Installation

7.2.1 Cable types
All cables must be approved. Refer to Cable requirements, page 8.

7.2.2 Cable protective tubes of metal

When installing cable protective tubes – take into account that the cable easily can
be pulled through the tube and afterwards easily be changed or removed.

5103018-00A01 37
7 Gas Detection Installation Guidelines Installation Manual

When installing metal cable tubes – following must be taken into account:

• If there is more than one cable in the same tube, the cross section (counted of
mutual external diameters) may be max 40% of the inner cross section of the
tube.
• If the tube is more than 10 m long, drafting holes has to be done.
• Tubes must be installed on support so that the background may be painted.
• Tube installation must be done by welding or by tube joints. Fastening distances
are located 100 mm from the tube end and afterwards every 1.5 m.
• Bending radius must be at least 6 times the external diameter of the tube.
• The upper tube end in open decks must be sealed up, this to prevent water from
coming in.

7.2.3 Cable protective tubes of plastic

Plastic tubes will be used inside the wall linings and also in the ceiling, where
attachment directly to the supporting construction is not possible.

When installing plastic cable tubes – following must be taken into account:

• Bending radius must be at least six times external diameter of the tube.
• Installation must be done onto the warm side of a thermal insulation and at least
100 mm from a hot surface, preferably below it. Piping is not allowed inside a
thermal insulation.
• The tubes are tied with galvanized wire clips. The first clip is located
approximately 100 mm from the tube end and afterwards every 1 m.

7.2.4 Cabling
When installing the cables – take into account the minimum internal bending
radius, that has nominal value of six times the external diameter of the cable.

• If two separate routes for the cables are required – all supplies and involved
control cables must be passed by separate routes according to the drawings and
cable passing list.
• Do not bundle low voltage cables together with power cables, they have to be
separated from each other.
• When cable bundles are mounted on trays this can be done as follows:
• On the trays along the ship – the power cables on the left side (Port-side)
and the low voltage cables on the right side (Starboard-side) of the tray.
• On the trays across the ship – the power cables to the fore side and the low
voltage cables in the stern side of the tray.
• On the fore or stem bulkhead trays in vertical shaft – the power cables to the
Port-side or the Starboard-side bulkhead trays, the power cables to the fore
side and the low voltage cables to the stern side of the tray.

38 5103018-00A01
Installation Manual 7 Gas Detection Installation Guidelines

• In cable junctions and when exiting the cable trays bridges with fastening bolts
have to be used – low voltage cables for alarm, communication, navigational
and measuring equipment have to be installed in their own bundles.
• Each gas detector installed in engine room areas shall have two (2) meters extra
cables, this to make it possible to relocate the detector position when
performing “real” gas tests with fans etc. running.

7.2.5 Cable inlets to equipment

When installing – the following must be taken into account.

• Wet spaces:
• Cables are penetrated from the bellow or from the side with diaphragm
seals.
• Let the cables enter the sealing at a right angle (or as near a right angle as
possible).

• Dry spaces:
• Free entering

No cables are to be installed below 50 mm distance from bottom or fuel oil tank,
except cables ending in these spaces.

7.2.6 Fixing of cables

When fixing the cables – the following must be taken into account.

• When cable bundles are mounted on trays the fixing is as follow:

• Cables above a tray:
- a few small cables with a normal bundle tie
- bigger bundles with wide bundle ties
• Cables under a tray, vertical trays and tray installed in their angle side:
- plastic bundle ties can be used, however every fourth tie shall be of metal

• Outdoor cables shall be mounted with stainless steel band or bundle-ties of

steel.
• Cable fixing is to be done at every ladder rung, max 400 mm.
• Cable fixing in device penetrations/switchboards/desks etc. are to be fixed so
that possible mechanical strain do not pass over to penetrations or connection
points.
• Cable fixing shall be fixed so that possible mechanical strain do not pass over to
penetrations or connection points.
• When installing cables without plastic tube inside the lining, the cables are
fastened to supporting construction of the ceiling with plastic bundle-ties.

7.2.7 Markings
• Cables entering terminal boxes and equals shall be marked with identification
markings.

5103018-00A01 39
7 Gas Detection Installation Guidelines Installation Manual

• The cable identification is to be done with a metal dymo-tape – on open decks

the dymo-tape must be of stainless steel.
• Cable markings are the same as the identification marks in the drawings.

7.2.8 Cable ends

When terminating the cables – the following must be taken into account:

• The cable is passed in switchboards, decks and terminals unpeeled as near the
connection place as possible.
• Mark extra wires (not used) and do not cut them.
• Earthing wire is marked with yellow/green sleeve.
• Cable wire ends of 0.5–2.5 mm2 shall be equipped with compression-type
collar, if the contact screw presses direct wires.
• A cable eye shall be installed at the end of a conductor, connected by means of
a screw or a bolt.
• No more than two conductors shall be connected onto one side of the same
terminal.

7.2.9 Protective earthings

• All metal casings of electrical equipment over 24 V are to be earthed to the
ships hull. When the earthing is done with cable conductors – yellow/green
conductors are to be used or last conductor wire of the cable covered along the
whole length with yellow/green hose. Yellow/green is used only for earthings.
• A separate earthing conductor is connected to the earthing point on the external
enclosure of the equipment and on the ships hull by means of a screw
connection.
• Devices shall not be earthed by means of a separate earthing conductor through
another installation (serial earthing).
• The door of a metal casing containing electrical equipment (voltage over 24 V)
must be earthed to the casings body with one earthing conductor. The earthing
fastening screw shall have a diameter of at least 6 mm with the exception of the
screws mounted by the manufacturer. The earthing screw shall not be used for
any other purpose than earthing.
• Electrical equipment is to be earthed by S-conductor (yellow/green) of supply
cable with a cross section area of 1.5–16 mm2.

Other equipment earthings - see table below.

Table 3. Protective earthings for other equipment.

Cross section of supply
1.5 2.5 4 6 10 16 25 35 50
cable (mm2)
S-conductur (mm2)
6 6 6 6 6 10 16 25 35
(yellow/green)

40 5103018-00A01
Installation Manual 8 Calibration Instruction for Salwico GD True IR

8 Calibration Instruction for Salwico GD

True IR

8.1 Preliminaries
This instructions applies to the following products: 5200138-00A, 5200138-01A,
5200204-00A, 5200204-01A and 5200204-02A.

Figure 26. Salwico GD FH TRUE IR

It is recommended to periodically carry out a gas response check on the gas

detector to ensure correct operation.

CAUTION!
Before initial calibration allow the detector to stabilize for 30 minutes after
applying power. When in zero and span calibration mode the current output from
the detector is inhibited (default 2mA) to avoid false alarms. For Flammable gas
calibration use a calibration gas concentration of between 25%LEL and 75%LEL
to ensure that the required accuracy can be attained.

Considerations:
• To calibrate the detector, use an appropriate span gas cylinder, constant flow
regulator.
• A compressed air cylinder (20.9%Vol oxygen) should be used to perform the
zero calibration, if the area where the detector is located contains any residual
amount of the target gas. If no residual gas is present then the background air
can be used to perform the zero calibration.

To calibrate the detector follow the procedures below.

5103018-00A01 41
8 Calibration Instruction for Salwico GD True IR Installation Manual

8.2 Calibrating the sensor (Zero calibration)

1 Use the arrow keys on the control panel to
manoeuvre through the different menus.
Press the right arrow key to access the
menu tree.

2 Scroll to 4 Gas Detectors and press

Continue.

3 Scroll to the detector that should be

calibrated and press Options.

4 Scroll to 2 Calibrate Zero and choose

Continue.
NOTE!
There will be a padlock on this
menu if you are not in access level
3 or above. You will be prompted to
enter the access code for level 3
before you can continue.
5 You have to confirm your selection before
you can proceed.
NOTE!
The detector will be disabled
during the whole calibration
process and 15 minutes after to
prevent unwanted alarms.
Press Continue to proceed.
6 Now you will be in the zero calibration
menu and able to see the real time value of
the detector.
Use the and keys to zero calibrate
the gas detector.
Press Continue to proceed.
7 If the ambient air is NOT considered
reliable to use to set the zero, apply a clean
source of zero gas or compressed air to the
gas detector.
Wait for a minimum of two minutes to
ensure that the gas reading is stabile.

42 5103018-00A01
Installation Manual 8 Calibration Instruction for Salwico GD True IR

8 After the gas detector reading has stabilized

press Calibrate.

9 You will get a confirmation message that

the detector has been successfully
calibrated.
Press Close to get back to menu Gas
Detectors.
10 CAUTION!
If a zero gas or compressed air has
been used during calibration make
sure to close all valves and
disconnect it from the detector.

8.3 Calibrating the sensor (Span calibration)

1 Use the arrow keys on the control panel to
manoeuvre through the different menus.
Press the right arrow key to access the
menu tree.

2 Scroll to 4 Gas Detectors and press

Continue.

3 Scroll to the detector that should be

calibrated and press Options.

4 Scroll to 1 Calibrate Span and choose

Continue.
There will be a padlock on this menu if you
are not in access level 3 or above. You will
be prompted to enter the access code for
level 3 before you can continue.
5 You have to confirm your selection before
you can proceed.
NOTE!
The detector will be disabled
during the whole calibration
process and 15 minutes after to
prevent unwanted alarms.
Press Continue to proceed.

5103018-00A01 43
8 Calibration Instruction for Salwico GD True IR Installation Manual

6 Use the and keys to enter

calibration gas concentration that will be
used during the span calibration; the default
value will be half of the detector range.
Press Continue to proceed.
7 In the Span calibration menu you will be
able to see the real time value of the
detector.

8 Apply calibration gas to the detector.

Wait for a minimum of two minutes to
ensure that the gas reading is stabile.

9 After the gas detector reading has stabilized

press Calibrate.

10 You will get a confirmation message that

the detector has been successfully
calibrated.
Press Close to get back to menu Gas
Detectors.
11 Close all valves on the calibration test gas The detector has now been
and disconnect it from the detector. calibrated from the control
panel.

8.4 Reconnecting disabled detectors

All disablements in the Salwico Gas Detection System are presented in the
disablements list. Any enablement is made from this list.

1 Scroll to Menu » Disablements.

2 Choose the detector you just disabled and press Options.
3 Select Reconnect and press Continue.

44 5103018-00A01
Installation Manual 9 Calibration Instruction for Salwico GD

9 Calibration Instruction for Salwico GD

9.1 Preliminaries
This instructions applies to the following products: 5200260-01A, 5200260-02A,
5200260-03A, 5200260-04A, 5200261-01A, 5200262-01A, 5200262-02A and
5200262-03A.

Figure 27. Salwico GD

It is recommended to periodically carry out a gas response check on the gas

detector to ensure correct operation.

CAUTION!
Before initial calibration allow the detector to stabilize for 30 minutes after
applying power. When in zero and span calibration mode the current output from
the detector is inhibited (default 2mA) to avoid false alarms. For Flammable gas
calibration use a calibration gas concentration of between 25%LEL and 75%LEL
to ensure that the required accuracy can be attained.

Considerations:
• To calibrate the detector, use an appropriate span gas cylinder, constant flow
regulator.
• A compressed air cylinder (20.9%Vol oxygen) should be used to perform the
zero calibration, if the area where the detector is located contains any residual
amount of the target gas. If no residual gas is present then the background air
can be used to perform the zero calibration.

To calibrate the detector follow the procedures below.

NOTE!
The Oxygen sensor does not require a zeroing procedure. Background air
(20.9%Vol oxygen) can be used to span the oxygen sensor in place of a compressed
air cylinder (20.9%Vol oxygen).

5103018-00A01 45
9 Calibration Instruction for Salwico GD Installation Manual

9.2 Calibrating the sensor (Zero calibration)

1 Use the arrow keys on the control panel to
manoeuvre through the different menus.
Press the right arrow key to access the
menu tree.

2 Scroll to 4 Gas Detectors and press

Continue.

3 Scroll to the detector that should be

calibrated and press Options.

4 Scroll to 3 Disable and choose Continue.

5 You have to confirm the disablement before

you can proceed.
Press Disable to continue.

6 You will get a confirmation message that

the detector has been disabled.
Press Close to continue.

7 If the ambient air is NOT considered

reliable to use to set the ZERO, apply a
clean source of zero gas or compressed air.
8 NOTE!
For the following steps in the zero
calibration instruction proceed to
the Salwico GD detector.
9 To access the calibration menu, hold the
end of the magnet over the switch
located at the top center of the detector
display for at least 3 seconds and then
remove.

46 5103018-00A01
Installation Manual 9 Calibration Instruction for Salwico GD

10 The display will indicate the first

configuration mode menu ‘SEt CAL’.

11 Put the magnet over the switch again

and remove it to enter the Calibration
menu.
12 The display will show the current gas
reading, and the icon flashes.

13 When the zero gas reading is stable use

to confirm zero calibration.
14

If successful the display shows ‘ZEro (If not successful, the display
PASS’. shows ‘Zero FAIL’ and
(If not successful, the display shows ‘Zero returns to configuration
FAIL’ and returns to configuration mode). mode.)
15 The display shows ‘SPAn’ with ‘YES’
flashing.

16 If span calibration is required?

• Use to proceed to the span
calibration menu.
Follow the separate instructions in
section Calibrating the sensor (Span
calibration), page 48.
If span calibration is not required?
• Perform the following steps to quit.

17 Use or to select ‘No’.

Use to return to configuration mode.

18 The instrument returns to the ‘Set CAL’

menu.

5103018-00A01 47
9 Calibration Instruction for Salwico GD Installation Manual

19 Use or to select ‘QuIT’ to return to

normal monitoring mode.

9.3 Calibrating the sensor (Span calibration)

1 The display shows the current calibration
span gas concentration while flashing the
icon.
Use or to change the calibration
span gas concentration, and when
required span calibration level is set.
2 The display will show the current gas
reading, and the icon flashes.

3 Connect the regulator to the span gas

cylinder.
4 Apply the span gas to the sensor using the
Salwico GD weather house.
The live gas reading is displayed.
• When the reading is stable, use to
confirm the span calibration.

If the sensor has been replaced a display

with ‘YES’ or ‘No’ may be shown.
6 If the sensor has been replaced?
• Use or to select ‘YES.
If the sensor has not been replaced?
• Use or to select ‘No.

48 5103018-00A01
Installation Manual 9 Calibration Instruction for Salwico GD

If the span calibration is successful the (If the span calibration fails
instrument will briefly display ‘SPAn the instrument will briefly
PASS’. display ‘SPAN FAIL’ and
return to configuration mode.)
8 The display alternates between “Purg gAS”
and the gas reading to indicate that the unit
is expecting the span gas to be removed
from the sensor.

9 Promptly switch off the calibration span

gas.
Remove the hose from the sensor weather
house.
Allow the gas to disperse.
10 When the reading falls below 50% of the
calibration gas level the display indicates a
countdown (up to 180 seconds dependant
on gas type).

11 When the countdown is finished, the

calibration procedure is complete.
12 The instrument returns to the ‘Set CAL’
menu.

13 Activate the or switch to select

another menu or select ‘QuIT’ to return to
normal monitoring mode.

14 Calibration of the sensor has now been

performed.

9.4 Reconnecting disabled detectors

All disablements in the Salwico Gas Detection System are presented in the
disablements list. Any enablement is made from this list.

1 Scroll to Menu » Disablements.

2 Choose the detector you just disabled and press Options.
3 Select Reconnect and press Continue.

5103018-00A01 49
9 Calibration Instruction for Salwico GD Installation Manual

50 5103018-00A01
 10 Calibration Instruction for Salwico ST200 and
Installation Manual Salwico ST600EX

10 Calibration Instruction for Salwico

ST200 and Salwico ST600EX

10.1 Preliminaries
This instructions applies to the following products:

Figure 28. Salwico ST200. Part No. 4470

Figure 29. Salwico ST600EX. Part No. 4460.

NOTE!
It is recommended to periodically carry out a gas response check on the gas
detector to ensure correct operation.

The ST200 and ST600EX detectors for 0-100% LEL Hydrocarbon can be
calibrated and the out-signal adjusted.

Hint!
Reading at 0% is 4.0 mA, and full range 100% LEL is 20 mA.

Tools
Tools required for this operation are:

5103018-00A01 51
10 Calibration Instruction for Salwico ST200 and
Salwico ST600EX Installation Manual

• A small terminal screw driver, with thin straight tip.

• A multimeter with mA (milliampere) capacity.

10.2 Prerequisites
1 Use the arrow keys on the control panel to
manoeuvre through the different menus.
Press the right arrow key to access the
menu tree.

2 Scroll to 4 Gas Detectors and press

Continue.

3 Scroll to the detector that should be

calibrated and press Options.

4 Scroll to 3 Disable and choose Continue.

5 You have to confirm the disablement before

you can proceed.
Press Disable to continue.

6 You will get a confirmation message that

the detector has been disabled.
Press Close to continue.

7 If the ambient air is NOT considered

reliable to use to set the ZERO, apply a
clean source of zero gas or compressed air.
8 NOTE!
For the following steps in the zero
calibration instruction proceed to
the Salwico ST200 or ST600EX
detector.

52 5103018-00A01
 10 Calibration Instruction for Salwico ST200 and
Installation Manual Salwico ST600EX

9 Connect the Flowcap to the sensor head as

shown in the picture.
Connect the measuring tips of the
multimeter to the test points in the detector.
Plus is red, minus is black.
Hint!
Picture shows a ST200. The
ST600EX has identical connections
and calibration, only fitted in an EX
proof housing.

10.3 Calibrating the sensor (Zero calibration)

Before gas Calibration is made, a Zero-adjustment should be made.

1 Connect the multimeter to the two test

points as shown in the picture.

2 The multimeter readout should be 4.0 mA

with normal air / zero gas exposed to the
sensor.
Adjust to this reading with the ‘Zero’
potentiometer, marked in red. (See where
the screwdriver is placed in the picture.)

10.4 Calibrating the sensor (Span calibration

with test gas)
NOTE!
For the ST600EX the procedure is identical as below, but note that the EX-Seal is
void if the unit is open, so necessary precautions in the working area may be
required.
Check on site what is applicable before the unit is opened up.

5103018-00A01 53
10 Calibration Instruction for Salwico ST200 and
Salwico ST600EX Installation Manual

1 Connect the suitable test-gas for the Recommendations:

detector, normally a 50% LEL mixture. The ST200 and ST600EX can
only respond to gas in normal
Air. This means that
Calibration gas in N2 /
Nitrogen are not suited for
these detectors.
On LNG vessels a 50% LEL
gas of CH4 Methane in air is
to be used.
For LPGs and Tankers we
normally recommend a 50%
LEL C3H8 Propane gas in air.
2 Adjust the reading to 12.0 mA using the
‘SPAN’ pot. See picture.

Figure 30. Detector ST200

Figure 31. Detector ST600EX

3 If the readout of 12.0 mA cannot be Catalytic detectors have a
reached even with the “SPAN” pot in the limited lifespan of up to 5
bottom position, the sensor cell must be years, but can be ‘poisoned’
replaced to a new one. Consilium by silicones, salt air, very
Replacement article number for ST200 and humid air, etc. and their output
ST600EX detectors is 004460-S. will be reduced.
NOTE!
When a new sensor is fitted, a new
Zero adjustment as well as span
calibration should be made.

10.5 Reconnecting disabled detectors

All disablements in the Salwico Gas Detection System are presented in the
disablements list. Any enablement is made from this list.

54 5103018-00A01
 10 Calibration Instruction for Salwico ST200 and
Installation Manual Salwico ST600EX

1 Scroll to Menu » Disablements.

2 Choose the detector you just disabled and press Options.
3 Select Reconnect and press Continue.

5103018-00A01 55
10 Calibration Instruction for Salwico ST200 and
Salwico ST600EX Installation Manual

56 5103018-00A01
 11 Calibration Instruction for Salwico ST600EX-IR
Installation Manual and Salwico ST700IR

11 Calibration Instruction for Salwico

ST600EX-IR and Salwico ST700IR

11.1 Preliminaries
This instructions applies to the following products:

Figure 32. Salwico ST600EX-IR. Part No. 4483 and 4484.

Figure 33. Salwico ST700IR. Part No. 4482.

Consilium Replacement Sensor 004483 is suitable for ST600EX-IR and ST700IR.

11.2 Prerequisites
1 Use the arrow keys on the control panel to
manoeuvre through the different menus.
Press the right arrow key to access the
menu tree.

5103018-00A01 57
11 Calibration Instruction for Salwico ST600EX-IR
and Salwico ST700IR Installation Manual

2 Scroll to 4 Gas Detectors and press

Continue.

3 Scroll to the detector that should be

calibrated and press Options.

4 Scroll to 3 Disable and choose Continue.

5 You have to confirm the disablement before

you can proceed.
Press Disable to continue.

6 You will get a confirmation message that

the detector has been disabled.
Press Close to continue.

7 If the ambient air is NOT considered

reliable to use to set the ZERO, apply a
clean source of zero gas or compressed air.
8 NOTE!
For the following steps in the zero
calibration instruction proceed to
the Salwico ST600EX-IR or
ST700IR detector.
9 Remove the cover from the detector.
The calibration push buttons is situated at
the PCB below the display.
Hint!
In this type of detector no
multimeter is required, the mA
signal is adjusted by pressing the
keys.

11.3 Calibrating the sensor (Zero calibration)

1 Push SW4 on the detector calibration push
buttons to access the user menus.
The display shows PASS.

58 5103018-00A01
 11 Calibration Instruction for Salwico ST600EX-IR
Installation Manual and Salwico ST700IR

2 Push once (SW3) and twice (SW2) to

insert the USER password and access the
user menus.
3 Push again on PASS (SW4). To change menu number,
The display shows E1, the first calibration press SW1 or SW2. E2 will
menu. be used later for Span
calibration.
4 Apply Zero gas (or simply clean air). NOTE!
If clean air is used,
make sure there is no
LEL content in the
area before work
starts) to the sensor.
5 Press SW3 (ENTER) to activate the ZERO
menu.
6 Press SW3 (ENTER) to perform the ZERO Reading should now stabilize
calibration. to zero. One can press SW3
several times and wait a little
to make sure the reading is
stable, for half a minute or so.
7 Press SW4 (MENU). The display will return to its
standard mode operation after
displaying some numbers for
the calibration factor.

11.4 Calibrating the sensor (Span calibration)

1 Push SW4 on the detector calibration push
buttons to access the user menus.
The display shows PASS.
2 Push once (SW3) and twice (SW2) to
insert the USER password and access the
user menus.
3 Push again on PASS (SW4). To change menu number,
The display shows E1, the first calibration press SW1 or SW2.
menu.
4 Select the menu E2 for span calibration by
pressing SW1 (DOWN).
5 Press SW3 (ENTER) to activate the menu.
6 Use the SW2 (UP) and SW1 (DOWN) 50% LEL is the standard gas
buttons to adjust the display reading in our gas bottles, if any other
according to the calibration gas bottle is used the
concentration. corresponding LEL
concentration must be chosen
in the display.

5103018-00A01 59
11 Calibration Instruction for Salwico ST600EX-IR
and Salwico ST700IR Installation Manual

7 Now apply the calibration gas to the sensor

by opening the regulator valve.

Figure 34. A ST600EX-IR detector

with a gas bottle connected to the
flowcap.
8 Wait until the display value is stable. On recently fitted sensors the
(The value will probably not correspond to reading may very well be zero
the concentration.) or much higher than 50% LEL
before the next step is done.
9 Press SW3 (ENTER) to confirm the SPAN This can be done several times
calibration. and it will take up to a minute
Now the reading should go to 50% LEL. or more for the reading to
stabilize.
10 Remove the calibration gas and wait until
the gas has disappeared and the reading is
back.
11 Press SW1 (MENU) – The display will, You can also press SW1 while
after displaying some figures gas is still flowing and reading
corresponding to sensor factor curves, is high, but the detector will
return to its standard mode operation again then immediately after restart
and the correct mA signal will be sent out. send out the high mA signal
and the central go into alarm
condition. This may or may
not be a problem, depending
on preparations before the
calibration commenced.

11.5 Reconnecting disabled detectors

All disablements in the Salwico Gas Detection System are presented in the
disablements list. Any enablement is made from this list.

1 Scroll to Menu » Disablements.

2 Choose the detector you just disabled and press Options.
3 Select Reconnect and press Continue.

60 5103018-00A01
Installation Manual 12 Calibration Instruction for Salwico ST400 H2S

12 Calibration Instruction for Salwico

ST400 H2S

12.1 Preliminaries
This instructions applies to the following products:

Figure 35. Salwico ST400 H2S, 0-30 ppm 4-20 mA. Part no. 4462

The H2S sensor is Electrochemical and measures H2S content by means of

chemical reaction.

DANGER!
H2S – Hydrogen Sulphide – is toxic and dangerous also in rather low
concentrations.

H2S is a sticky gas and smells very distinctly from rotten eggs.

Consilium Replacement article number for ST400 H2S detectors is no. 004462-S.

A new sensor is supplied without the metal housing and must be fitted in the
housing. This applies to both H2S and O2 sensors of ST400 type.

Calibration equipment
Normal measuring range is 0-30 ppm, our standard calibration bottle no.
5201005-00A contains 20 ppm of gas in air.

For SW2020 a mix-bottle is often used, with H2S 20 ppm as well as N2 99% and
C3H8 50% LEL, article no. 5201010-01A.

Test points (A) for the multi-meter as well as “SPAN” (B) and “ZERO” (C)
potentiometers are indicated below.

CAUTION!
Do not adjust the other potentiometers.

5103018-00A01 61
12 Calibration Instruction for Salwico ST400 H2S Installation Manual

A Test points
B SPAN potentiometer
C ZERO potentiometer

12.2 Prerequisites
1 Use the arrow keys on the control panel to
manoeuvre through the different menus.
Press the right arrow key to access the
menu tree.

2 Scroll to 4 Gas Detectors and press

Continue.

3 Scroll to the detector that should be

calibrated and press Options.

4 Scroll to 3 Disable and choose Continue.

5 You have to confirm the disablement before

you can proceed.
Press Disable to continue.

62 5103018-00A01
Installation Manual 12 Calibration Instruction for Salwico ST400 H2S

6 You will get a confirmation message that

the detector has been disabled.
Press Close to continue.

7 NOTE!
For the following steps in the zero
calibration instruction proceed to
the Salwico ST400 detector.

12.3 Calibrating the sensor (Zero calibration)

1 Connect the Multi-meter (set to mA) as
shown in the picture.

2 Adjust with the “ZERO” potentiometer to

4,0 mA signal output.

12.4 Calibrating the sensor (Span calibration)

Verification of detector type 0-25 ppm or 0-30 ppm
NOTE!
The ST400 for H2S is available in two types.

Type 1: 0-25 PPM. mA-signal at 20 ppm = 16.8 mA.

Type 2: 0-30 PPM. mA-signal at 20 ppm = 14.6 mA.

To verify which type is in use, make a span calibration as below and verify the
display reading in the central cabinet.

• If the readout at 14.6 mA is less than 20 PPM a calibration with 16.8 mA

set-point must be done.

5103018-00A01 63
12 Calibration Instruction for Salwico ST400 H2S Installation Manual

Span calibration

1 Connect the gas bottle with flowcap to the CAUTION!

sensor head. Due to the sticky
nature of the H2S as
short hoses as possible
are to be used.
2 Open the regulator valve.
3 When the reading is stabilized, adjust the If this reading cannot be
readout to 14.6 mA (or 16.8 mA) with the reached, the sensor head
“SPAN” potentiometer. should be replaced.
NOTE!
Response can be estimated to
several minutes in some cases.

12.5 Reconnecting disabled detectors

All disablements in the Salwico Gas Detection System are presented in the
disablements list. Any enablement is made from this list.

1 Scroll to Menu » Disablements.

2 Choose the detector you just disabled and press Options.
3 Select Reconnect and press Continue.

64 5103018-00A01
Installation Manual 13 Calibration Instruction for Salwico ST400 O2

13 Calibration Instruction for Salwico

ST400 O2

13.1 Preliminaries
This instructions applies to the following products:

Figure 36. Salwico ST400 O2 0-25%. Part no. 4461

The O2 sensor is Electrochemical and measures O2 content by means of chemical

reaction.

NOTE!
The lifespan of the sensor is about one year, and it has a short shelf life – stocking
it on board is not advised and this will reduce the operational lifetime.

Consilium Replacement article for sensor only of ST400 O2 detector is no. 004472.

A new sensor is supplied without the metal housing and must be fitted in the
housing. This applies to both H2S and O2 sensors of ST400 type.

Calibration equipment
The O2 is calibrated with fresh breathing air, and is normally 20.8%.

Test points (A) for the multi-meter as well as “SPAN” (B) and “ZERO” (C)
potentiometers are indicated below.

CAUTION!
Do not adjust the other potentiometers.

5103018-00A01 65
13 Calibration Instruction for Salwico ST400 O2 Installation Manual

A Test points
B SPAN potentiometer
C ZERO potentiometer

13.2 Prerequisites
1 Use the arrow keys on the control panel to
manoeuvre through the different menus.
Press the right arrow key to access the
menu tree.

2 Scroll to 4 Gas Detectors and press

Continue.

3 Scroll to the detector that should be

calibrated and press Options.

4 Scroll to 3 Disable and choose Continue.

5 You have to confirm the disablement before

you can proceed.
Press Disable to continue.

66 5103018-00A01
Installation Manual 13 Calibration Instruction for Salwico ST400 O2

6 You will get a confirmation message that

the detector has been disabled.
Press Close to continue.

7 NOTE!
For the following steps in the zero
calibration instruction proceed to
the Salwico ST400 detector.

13.3 Calibrating the sensor (Span calibration)

Hint!
A typical sign for when lifespan of the O2 sensor is up is drifting values, instable
readings and inability to set the 17.4 mA signal even with the SPAN potentiometer
in max position.

1 Connect a Multi-meter (set to mA) to the

test points and adjust the readout on the
“SPAN” pot to 17.4 mA when normal
breathing air is present.

13.4 Calibrating the sensor (Zero calibration)

For Zero adjustment a Nitrogen mix should be used, with a pure N2/Nitrogen
concentration.

A gas bottle with Hydrocarbons in N2 can also be used, as long as the O2 content is
zero per cent.

We recommend the Consilium article no. 5201006-00A with 100% N2.

1 Connect a Multi-meter (set to mA) to the

test points.
2 Connect the gas bottle and open the
regulator valve.
3 Wait for the mA signal to drop and
stabilize.
Adjust the reading with the “ZERO”
potentiometer to 4.0 mA.

5103018-00A01 67
13 Calibration Instruction for Salwico ST400 O2 Installation Manual

13.5 Reconnecting disabled detectors

All disablements in the Salwico Gas Detection System are presented in the
disablements list. Any enablement is made from this list.

1 Scroll to Menu » Disablements.

2 Choose the detector you just disabled and press Options.
3 Select Reconnect and press Continue.

68 5103018-00A01
Installation Manual 14 Appendix

14 Appendix

14.1 Central Unit Terminal & Cabling Layout

Description of System Modules
The Gas detection system is based on standard modules. Below is a list of some
common modules:

Control M Gas internal

The Control M Gas is a control panel used to manage and supervise a gas alarm
system. Control M Gas Internal mounts in the gas alarm cabinet front.
Control M Gas External
The Control M Gas is a control panel used to manage and supervise a gas alarm
system. Control M Gas External can be mounted on any flat surface or flush
mounted, independently from a gas alarm cabinet.
Control M X
A Control Module without display that can act as bus master or slave. It is used
for providing additional communication channels in the system.
Relay M 8 Gas
A Module that provides 8 potential free contacts.
Analogue M 4-20
The Analogue M 4-20 is a transmitter module for a gas alarm system and
provides four transmitter interfaces.
BusCon M Gas
This module provides electric isolation for a gas alarm system and backbone
extension for module Control M Gas, as well as monitors the supply voltage
and the Xgas signal.
Power Boost M
The Power Boost M is designed to distribute power and supervise connections
in a gas alarm system.
Surge Prot M H
This module protects power inputs for the Backbone Bus Internal. It provides
terminal board for Backbone Bus External and electronic short circuit protected
outputs for Control panels.
Bus Isolator M
Is used for dividing the system backbone bus into segments. Can provide power
to Control Panel M 4.3 and Control M 2.2.
PSU M AC/DC 5A
A 5 ampere 115/230 VAC/VDC Power Supply.
PSU units can be used in pairs to supply 5+5 A.

For complete information, see the data sheet for each module.

An example of a central unit terminal layout with cabling

Since all Gas detection systems are tailored to each customer installation, no
standard exists for how the different modules are to be connected in the system.
However, in the figure below you will find an example with one module of each
type showing the connection terminals.

5103018-00A01 69
14 Appendix Installation Manual

Figure 37. An example of a central unit terminal layout with cabling

70 5103018-00A01
Installation Manual 14 Appendix

14.2 RS485/PB485 Termination

14.2.1 General Recommendations for Installation of
RS485
General recommendations for RS485 installation:

• Twisted pair wire should be used

• Shielded cables
• Star networks are not permitted
• Termination shall be made at each end of the bus with a 120 ohm resistor
• Max 700 m cable in one communications segment
• Two-wire connection shall be used when nodes have a common ground (-)
• Three-wire connection shall be used when nodes have a different ground (-), for
example between Isolator M.

14.2.2 Application Examples for Installation of RS485

14.2.2.1 Terminating of BBE and Extensions bus

* Activate the built-in terminator (120 ohm).

See datasheet for location of the DIP switch.
** Terminator 120 ohm.

5103018-00A01 71
14 Appendix Installation Manual

14.3 Fault Code List

Listed in the table below are all fault codes, their causes, and how an operator with
knowledge of the system can solve the problem.

72 5103018-00A01
Installation Manual 14 Appendix

Table 4. Fault Code List

Fault Code Cause Remedy
The text generated for fault 1-6
Corresponds to a fault interval Check the details view for the gas
is configurable via the
generated by the gas detector, the detector to obtain the current
configuration program for
1-6 configurable text gives the fault generated information from the 4-20
individual Gas Detectors, e.g.
description. See the gas detectors mA interface and check the gas
“DETECTOR FAULT” or “IR
documentation for details. detectors documentation for details.
PATH OBSCURED”.
Verify that the detector connected to
The current on the Analogue M 4-20 this interface is working properly.
7 Overcurrent
interface is above 25mA Refer to the Service & Maintenance
manual:
Verify that the PSU is supplying the
The voltage has dropped below 22
8 Low voltage system with the correct voltage.
VDC
Nominal 24 VDC.
The Control M Gas reporting the error
has been configured to be connected
to a BusCon M Gas:
1. Check that the unit is connected to
a BusCon M Gas and that there is
The Control M Gas reporting the fault no break on the cable.
9 BCM communication has lost communicate with the
BusCon M Gas 2. If the connection is OK there is
something wrong with the
communication interface on the
Control M Gas or the BusCon M
Gas - try exchanging modules to
identify the faulty module.

Wrong type of unit Switch to the correct unit

Two units have the same address (a
No answer Check address of the units.
secondary fault appears)
Replace the unit.
128 Explanation: Lost
Defect unit Refer to the Installation manual or
communication. The system has
Service & Maintenance manual:
recognized a unit but lost
contact. Locate the cable break or short circuit.
Cable break or short circuit in a loop
Refer to the Installation manual or
(a secondary fault appears)
Service & Maintenance manual:
Check the unit addresses.
Two units have the same address Refer to the Installation manual or
Communication problem Service & Maintenance manual:
Replace the unit.
143 Explanation: The Faulty unit Refer to the Installation manual or
communication with a unit is Service & Maintenance manual:
deficient Locate interference source.
Interference from external source If not possible to solve the problem,
contact an authorized service office
Locate the short circuit and restore
149 Short circuit Short circuit detected
operation
Verify if unit address is correct.
152 Present not configured Unit present but not configured Verify there is power to the module.
Contact an authorized service office.

5103018-00A01 73
14 Appendix Installation Manual

Fault Code Cause Remedy

Locate the earth fault.
155 Earth fault positive Earth fault on the positive conductor Refer to the Installation manual or
Service & Maintenance manual:
Locate the earth fault.
156 Earth fault negative Earth fault on the negative conductor Refer to the Installation manual or
Service & Maintenance manual:
159 Open circuit A cable break has been detected Restore the cable
167 Checksum eep Incorrect EPROM checksum Contact an authorized service office
If restarts happen repeatedly, contact
168 Restarted A module has restarted
an authorized service office
The configuration file is corrupt
176 System configuration An error has occurred during Contact an authorized service office
downloading of the configuration file
Fault code generated when a module
183 No answer ch 1 backbone stops answering on channel 1 on the Contact an authorized service office
Backbone Bus
Fault code generated when a module
184 No answer ch 2 backbone stops answering on channel 2 on the Contact an authorized service office
Backbone Bus
Verify that the Control M Gas panel is
Communication has been lost with the
operational.
185 No poll from master controller of the system (Control M
Verify that all cables are connected
Gas with address 1)
properly.
210 Cause/Effect error Fault detected in the configuration Contact an authorized service office
The configuration file’s in the system Synchronise the configuration files
are not the same everywhere between all panels
213 Config not synchronized Central X Module Y settings in
configuration file compared to Check configuration and DIP-settings.
DIP-settings are not OK.
The firmware in a module does not
comply with the modules hardware
216 Incompatible firmware Contact an authorized service office
version. (Fault code generated by the
faulty module.)
The voltage from PSU 1 is too high.
217 High voltage psu 1 (Fault code generated by the Charger Adjust the voltage from the PSU 1
M modules.)
The voltage from PSU 2 is too high.
218 High voltage psu 2 (Fault code generated by the Charger Adjust the voltage from the PSU 2
M modules.)
The XGas signal in the backbone is
225 xgas signal Contact an authorized service office
corrupt
Too low voltage detected on the
Backbone Bus Power Supply, channel
230 Low voltage ch 1 backbone Contact an authorized service office
1. (Fault code generated by the
Charger M modules.)
Too low voltage detected on the
Backbone Bus Power Supply, channel
231 Low voltage ch 2 backbone Contact an authorized service office
2. (Fault code generated by the
Charger M modules.)

74 5103018-00A01
Installation Manual 14 Appendix

Fault Code Cause Remedy

232 Invalid application Corrupt firmware Contact an authorized service office
The type of module found is different Change the module or the system
236 Wrong type of module found
from the type configured configuration

14.4 Definitions of Terms

Alarm Condition The state of the system when a gas alarm is detected.
Device that is activated in case of a gas alarm, for example audible and optical alarms
Alarm Device
like bells, sirens and flashlights.
Analogue M 4-20 The Analogue M 4-20 is a transmitter module for a gas alarm system.
The main bus outside a Central cabinet used for communication between Modules and
Backbone Bus External
stretched central parts. It consists of two redundant RS485 channels, two 24 VDC
(BBE)
power lines and the Basic Backup (BBU) signal.
The main bus inside a Central Cabinet used for communication between Modules. It
Backbone Bus Internal (BBI) consists of two redundant RS-485 channels, two 24 VDC power lines and the Basic
Backup (BBU) signal.
A Backbone Bus may be split in several Segments. Power feeding can be separate for
Backbone Segment each segment by using one BusCon M Gas per segment. Communication can be
isolated between segments by using Isolator Modules.
A signal in the Backbone Bus that is used for transmitting the Central's alarm status.
Basic Backup Signal (BBU) The signal is only used when a module in Managed mode loses communication with
its Controller Module.
BusCon M Gas The BusCon M Gas is a connection modul for a gas alarm system.
The Cause/Effect program defines how the inputs and outputs of the system should
Cause/Effect
react.
An umbrella name for all the Modules and Devices that can be connected together, e.g.
CCP Platform
“the Control M Gas module is a member of the CCP Platform”.
A Central is a complete system that can operate autonomously; monitor its detectors
Central and inputs, activate its outputs and display its faults and alarms.
A central can only have one Backbone Bus.
Central Cabinet Enclosure to contain a complete or part of a central.
The Control M Gas and the Control M X can all act as Controller Modules, i.e. be in
Control Module
Controller Mode.
The Control M Gas can act as a Control Panel, i.e. it has an HMI and the rights to
Control Panel
manipulate and supervise the System.
Control Modules can run in Controller Mode within a central. Control Modules can
Controller Mode also be in managed mode, that is being a module that is managed by the master. All
other modules are always running in managed mode.
Controller Module A Control Module that is in Controller Mode in a Central or System.
DCS Distributed Central System (see also Stretched Central).
Detector A device capable of detecting gas alarms.
This mode is used for inhibit the detectors from generating the Alarm Condition but
Disable all outputs the alarms are displayed on the Control Panels to prove that the tested Detectors are
operational.
Disablement of devices such as a Zones or Detectors. Alarms from disabled devices
Disablement
will be inhibited.

5103018-00A01 75
14 Appendix Installation Manual

Communication to external entities is called external communication, using for

External Communication
example MODBUS or NMEA protocols.
External Control Outputs used to control external equipment, for example ventilation.
Fault Condition The state of the system when a fault is detected.
A module with inputs and/or outputs. I/O modules always run in Managed Mode, that
I/O Module
is they must be managed by a Controller Module.
I/O Pin or I/O Signal An I/O Pin or an I/O Signal is a logical signal, compare to terminal.
Inter-central Communication Communication between centrals is called inter-central communication.
A communication channel used to interface the systems with external devices.
Interface Channel
Interface channels can be configured to communicate on different protocols.
The opposite of Controller Mode. All modules that are managed by a Controller
Managed Mode
Module are in Managed Mode.
Modules in the System can take on different roles. Connected to the Backbone Bus
they can be in:
• Central Controller Mode (Master)
• Central Managed Mode
Mode of operation
Modules connected to the System Bus can be in:
• System Controller Mode (Master)
• System Managed Mode

A module that is a part of the Platform, that is can be used to build Centrals. Modules
Module within the platform generally supply a Backbone Bus interface. Controller Modules
also have an Interface.
Module Address Module Addresses are set via DIP switches on the Modules.
Mute Acknowledge and silence the local buzzer and in some cases the alarm devices.
PA Public Addressing.
Power Boost Loop The Power Boost Loop is a subsystem in the CCP Gas system.
The Power Boost M is designed to distribute power and supervise connections in a gas
Power Boost M
alarm system.
System function for transfer of xGas status between the Power Boost modules on a
Power Boost xGas (Pbx) Power Boost Loop (Signal name PbxGas) and the modules connected to the Power
Boost module on the internal Backbone Bus (BBI).
Power Output Output providing power supply, normally used to power external devices.
A condition preceding the Alarm Condition to give early warning for potentially
Pre-Alarm Condition
dangerous situations.
Programmable Output Output which signal behaviour is configurable via the Configuration Program.
PSU Power Supply Unit.
Refers to the quality or state of being redundant, that is exceeding what is necessary or
Redundancy normal. In the System the term is used to describe backup functionality like in
Controller Modules.
Electrically operated switch output, normally providing C/NO/NC contacts for
Relay
connection of signal receiver.
Modules enter 'safe state' when they detect system faults. Modules in Safe State put
Safe State their I/O in a predefined state and stop all communication in order to avoid disturbing
system integrity.
SCS Single Central System.

76 5103018-00A01
Installation Manual 14 Appendix

A central that is physically distributed to two or more physical locations. One location
Stretched central (DCS) may or may not supply power to another location (segmented) and two locations may
or may not have isolated communication lines.
Terminal A Terminal is a physical point of connection, compare I/O pin.
Universal Serial Bus, a communications bus that may be used to connect flash
USB
memories, keyboards, mice or other devices.
The state of the system when a warning is detected. Warnings are not as serious as
Warning Condition faults and only of informative nature, for example that a Gas Detector is in need of
calibration.
The Backbone Bus contains a signal, xGas, which will be activated by any module that
xGas
detects a gas alarm.
Zone A group of detectors located in a geographical area.

5103018-00A01 77
14 Appendix Installation Manual

78 5103018-00A01
 Index

Index
A I
About testing.......................................................... 28 Installation guidelines, Cabling and electrical
Analogue M 4-20 ................................................... 69 installation.............................................................. 37
Analogue M 4-20, Cable requirements.................. 10 Installation order, Mechanical installation............. 7
Analogue M 4-20, Connection example ................ 14 IR detectors ............................................................ 36
   
B L
Backbone Bus External (BBE), Cable LED test ................................................................. 28
requirements........................................................... 8 Location of sensors ................................................ 35
Backbone Bus External (BBE), Electrical  
installation.............................................................. 8
Bus Isolator M........................................................ 69
M
Muting faults, Trouble shooting............................. 30
BusCon M Gas....................................................... 69
 
 
C P
Power Boost loop, Connection example................ 12
Cable break, Trouble shooting ............................... 29
Power Boost Loops, Cable requirements............... 9
Cable lengths, Electrical installation...................... 10
Power Boost loops, Verification of ........................ 27
Cable markings ...................................................... 39
Power Boost M ...................................................... 69
Cable requirements, Electrical installation ............ 8
Procedure for installation commissioning ............. 33
Cabling, Installation guidelines ............................. 37
Protective earthings................................................ 40
Catalytic detectors.................................................. 36
PSU M AC/DC 5A ................................................ 69
Central unit terminal layout with cabling .............. 69
Channel 1 & 2, Cable requirements....................... 8
 
Commissioning requirements ................................ 33 R
Control M Gas External ......................................... 69 Reconnecting disabled detectors............................ 44
Control M Gas Internal .......................................... 69 Reconnecting disabled detectors............................ 49
Control M X........................................................... 69 Reconnecting disabled detectors............................ 54
Control panel display, Testing................................ 28 Reconnecting disabled detectors............................ 60
Control panels, Mechanical installation................. 7 Reconnecting disabled detectors............................ 64
Control M Gas, Installation order .......................... 7 Reconnecting disabled detectors............................ 68
Control panels, Electrical installation .................... 22 Relay M 8 Gas ....................................................... 69
  Reset faults, Trouble shooting ............................... 30
RS485 Termination ................................................ 71
D RS485, Application examples for installation ....... 71
Download configuration file .................................. 24
Download configuration file .................................. 31
 
  S
Short circuit, Trouble shooting .............................. 30
E Span calibration, GD.............................................. 48
Earth connections................................................... 15
Span calibration, GD True IR ................................ 43
Earth fault, Trouble shooting ................................. 30
Span calibration, ST200......................................... 53
Electrical siren, Installation guidelines .................. 37
Span calibration, ST400 H2S................................. 59
Electrochemical detectors ...................................... 37
Span calibration, ST400 H2S................................. 63
  Span calibration, ST400 O2................................... 67
F Span calibration, ST600EX ................................... 53
Fault list ................................................................. 30 Span calibration, ST700IR..................................... 59
Fault list ................................................................. 30 ST200, Calibration instructions ............................. 51
  ST400 H2S, Calibration instructions ..................... 61
ST400 O2, Calibration instructions ....................... 65
G ST600EX, Calibration instructions........................ 51
Gas detection system, System data ........................ 5
ST600EX-IR, Calibration instructions................... 57
Gas detection system, System description ............. 3
ST700IR, Calibration instructions ......................... 57
GD True IR, Calibration instructions..................... 41
Surge Prot M H ...................................................... 69
GD, Calibration instructions .................................. 45
System modules, Description................................. 69
Guidelines, Gas detectors installation.................... 35
 
 

5103018-00A01 79
Index

T
Terminal layout, Electrical installation .................. 21
Test for cable break ................................................ 17
Test for earth failure............................................... 20
Test for short circuits ............................................. 18
Test the control panel display ................................ 28
 
U
Upload configuration file....................................... 23
 
W
Wrong number of gas detectors, Trouble shooting 29
Wrong number of system modules, Trouble
shooting.................................................................. 29
 
Z
Zero calibration, GD .............................................. 46
Zero calibration, GD True IR................................. 42
Zero calibration, ST200 ......................................... 53
Zero calibration, ST400 H2S ................................. 63
Zero calibration, ST400 O2 ................................... 67
Zero calibration, ST600EX.................................... 53
Zero calibration, ST600EX-IR............................... 58
Zero calibration, ST700IR ..................................... 58
 

80 5103018-00A01
 Global Service and Support

Own companies
Sales- and service representatives
 
Consilium is constantly increasing and improving its global sales and service
organisation in order to provide our customers with the most competent
service and support. Today Consilium has established own companies in
16 countries plus sales and service representatives in more than 50 countries.
You will find updated contact information on our web-site www.consilium.se.

www.consilium.se