HB Products HBGS Gas Leakage Sensor for NH3 and CO2 Instruction Manual

HB Products HBGS Gas Leakage Sensor for NH3 and CO2

Product Information

The HBGS sensor is designed for leakage measurement in and around industrial refrigeration systems. It detects NH3 (R717) in ranges from 0-100 ppm up to 0-15% and CO2 (R744) in a range of 0-10000 and 020000 ppm. The sensor is an independent unit that must be supplied with 24 V DC. It has 3 built-in digital alarm outputs and one analog 4-20 mA output. The alarm can be configured using a PC with the HB Configuration Tool and a special USB cable and adapter.

Safety Instructions

• Only qualified personnel should work with the product.
• The technician must be aware of the consequences of an improperly installed sensor and must be committed to adhering to the applicable local legislation.
• The person responsible for operation must commit to adhering to all the legislative requirements, prevent accidents, and do everything to avoid damage to people and materials.
• Make sure that qualified personnel assess any faults and take necessary precautions before attempting to make replacements or repairs, so as to avoid collateral damage.
• The product’s input and output, as well as its accessories, may only be connected as shown in the guide. HB Products assumes no responsibility for damages resulting from not adhering to the above.

CAUTION! Always read the instruction manual before commencing work! Read all warnings to the letter! Installation of the sensor requires technical knowledge of both refrigeration and electronics. Only qualified personnel should work with the product. The technician must be aware of the consequences of an improperly installed sensor and must be committed to adhering to the applicable local legislation.
If changes are made to type-approved equipment, this type approval becomes void. The product’s input and output, as well as its accessories, may only be connected as shown in this guide. HB Products assumes no responsibility for damages resulting from not adhering to the above.
Explanation of the symbol for safety instructions. In this guide, the symbol below is used to point out important safety instructions for the user. It will always be found in places in the chapters where the information is relevant. The safety instructions, and the warnings, must always be read and adhered to.

CAUTION! Refers to a possible limitation of functionality or risk in usage.
NOTE! Contains important information about the product and provides further tips.
The person responsible for operation must commit to adhering to all the legislative requirements, prevent accidents, and do everything to avoid damage to people and materials.

Intended use, terms of use. The leakage sensor is designed for leakage measurement in and around industrial refrigeration systems. If the sensor is to be used in a different way and if the operation of the product in this function is determined to be problematic, prior approval must be obtained from HB Products.
Prevention of collateral damage Make sure that qualified personnel assess any faults and take necessary precautions before attempting to make replacements or repairs, so as to avoid collateral damage.
Disposal instructions: The sensor is constructed so that the modules can easily be removed and sorted for disposal.

Design and Function

The HBGS sensor is designed to fulfill the requirements for gas leakage measurement in accordance with F-GAS regulation EU/517/2014. It is constructed so that the modules can easily be removed and sorted for disposal.
The NH3 sensor versions up to 5000 ppm uses a sensor head which has a lifetime of two years in severe conditions and longer if no NH3 is present during normal operation. The CO2 sensor versions and the NH3 15 % has a lifetime of more than 5 years. All sensor elements can easily be replaced and does not require a new calibration. On the front, you can find 4 integrated LEDs for display of the supply (green) as well as 3 alarm levels (red, orange, and yellow). There is a R button used for resetting after an alarm and putting the sensor in service mode used when doing maintenance with a controlled gas leakage. The sensor is factory calibrated and does only require additional calibration in special applications. The sensor is optimized for use in machine rooms and similar environments. Built-in heating element ensures operation in ambient temperatures down to -30 ° C. The sensor comes with a calibration certificate as well as with pre-configured alarm limits.

Technical Data

• Supply voltage: 24 V DC – Power consumption max 3watt
• Connection: Screw terminals
• Cable glands: 2 x PG7
• Alarm: Can be configured with HB-tool and an USB cable and an adapter
• Measurement accuracy NH3 Repeatability +/-10%
• Measurement accuracy CO2 Repeatability +/-2%

Standard alarm configuration:
Factory settings – alarms according to EN378 and other relevant standards

Gas| Measuring range| Alarm A (main alarm)| Alarm B (pre-alarm)| Alarm C (pre- alarm)
---|---|---|---|---
NH3| 0-100 ppm| 75 ppm| 50 ppm| 25 ppm
NH3| 0-300 ppm| 225 ppm| 150 ppm| 60 ppm
NH3| 0-1000 ppm| 750 ppm| 500 ppm| 250 ppm
NH3| 0-5000 ppm| 4000 ppm| 2500 ppm| 1000 ppm
NH3| 0-15%| 0.3 %| 0.75 %| 1.12 %
CO2| 0-10000 ppm| 7500 ppm| 5000 ppm| 2000 ppm
CO2| 1-20000 ppm| 15000 ppm| 10000 ppm| 4000 ppm
Output:

Analog output:                              4-20 mA

Max load:                                       500 ohm

Alarm output:                                3 x SPDT, 0,5A

| Installation conditions:

Ambient temperature:                  -30…+50°C

Waterproof rating:                         IP20, box IP65

---|---
Certifications:

EMC Emission:                              EN61000-6-4

EMC Immunity:                            EN61000-6-2

| Mechanical specifications:

Dimension:                                     82 x 59 x 126 mm

Material:                                         Plastic

Mounting:                                       On walls with screws

Intended Use, Terms of Use
The HBGS sensor is designed for leakage measurement in and around industrial refrigeration systems. If the sensor is to be used in a different way and if the operation of the product in this function is determined to be problematic, prior approval must be obtained from HB Products.

Installation

The installation of the sensor requires technical knowledge of both refrigeration and electronics, and only qualified personnel should work with the product. Follow the installation instructions carefully and adhere to all safety instructions and warnings.

Application Examples
The sensor is designed for leakage measurement of refrigerant in industrial refrigeration systems. It can be installed where the gas potentially can leak, typically in the machine room or where you have the evaporators or condensers inside.

General Installation Instructions
The following applies to system design:

1. The sensor may be installed and supplied with a standard unshielded cable. If the EMC is higher than described in EN 61326, a shielded cable must be used.
2. If the sensor is mounted in dusty conditions or where water is used for cleaning the sensor head should be pointing downwards as the sensor might be block or damaged by the water. A protection of the head is recommended during cleaning using water. Remember to remove the protection after cleaning
3. It is recommended to install the sensor in stairways and other places where gas pockets can form.
4. If a ventilation system is installed, it would make sense to place a sensor at the inlet.

Special Instructions for NH3
Ammonia is lighter than air so the sensor should be installed above the potentially leaking components or at least 1.5 m from the ground.

1. The sensor must be mounted at a distance of at least 150 cm from the floor.
2. By safety valves, the sensor must be placed 1-2 m above the outlet to secure fast reaction.

Special Instructions for CO2
CO2 is heavier than air so the sensor should be installed below the potentially leaking components and maximum 0.5 m from the ground.

1. The sensor must be mounted maximum 50 cm above the lowest point in the room.
2. If there is a basement in open connection which the machine room, it should be placed there
3. By safety valves, the sensor must be placed below the outlet to secure fast reaction.

For refrigeration systems, HB Products recommends sensor installation at the following locations:

• A. At the safety valve and valve stations
• B. In the machine room
• C. At the pump separator
• D. At the evaporators
• E. At condensers when mounted indoor

Electrical Connection

The sensor is supplied with 24 VDC.

The sensor can be connected directly to a siren using the Alarm A, Alarm B, Alarm C and ground. At the same time the mA signal can be send to a PLC
Analog output signal is linear with the gas content.

NH3 0-100 ppm| NH3 0-300 ppm| NH3 0-1000 ppm| NH3 0-5000 ppm| NH3 0-15 %| CO2 0-10000 ppm| CO2 0-20000 ppm| Outp ut mA
---|---|---|---|---|---|---|---
0| 0| 0| 0| 0| 0| 0| 4
20| 60| 200| 1000| 0.3| 2000| 4000| 7,2
50| 150| 500| 2500| 0.75| 5000| 10000| 12
80| 240| 800| 4000| 1.2| 8000| 16000| 16,8
100| 300| 1000| 5000| 1.5| 10000| 20000| 20

Functionality

LED Indication
On the front of the sensor, LED indication is integrated for power supply ON and alarm indication A, B, & C.

Service mode
The sensor can be put in service mode, which means it is not reacting on gas for 60 minutes or until switched off again. Service mode is activated by pressing the “R” button for minimum 15 seconds until the “Power ON” LED starts to flash fast. Going back to normal mode is done by pressing the “R” button for minimum 15 seconds until the “Power ON” LED show constant light for more than 5 seconds.

minutes
All LED flashing| Error – sensor head missing or other error

Lifetime and verification

The NH3 sensor head measuring up to 500 ppm has an expected lifetime of two years and then the entire head is replaced. The sensor output can slide up to 2% per month and it is affected by the gas level content in the area – it is these two factors which set the lifetime to two years. The CO2 sensor heads and the 15% NH3 has a lifetime of at least 5 years. The sensor verification must follow the local requirements and it can be verified using a suited test gas and a test kit. Test gases must be purchased locally as they are subject to shipment restrictions.

Accessory for test and HB tool

The service kit can be used for both NH3 and CO2

• Part no. Service kit: HBGS -ServiceKit
• HBGS- ServiceKit includes:
  • Cup and tube
  • HBxC-USB (Cable)
  • HBGS Adaptor

Configuring the sensor

The HB Products PC-Tool can be found at: https://www.hbproducts.dk/en/hb- tool.
Use a PC with the HB Configuration Tool and a special USB cable and adapter to configure the alarm settings. Follow the configuration instructions carefully.

Unscrew the two Philips screws on the top and connect the HBxC-USB to the HBGS-USB-ADAPTOR. Connect the HBGS-USB-ADAPTOR to the M12 circular connector of the main unit. Supply the sensor with 24VDC. The alarm settings can be typed in and saved to the sensor. All alarms can be configured both as NO (normally open) and NC (normally closed) which refers to the contactor, so NO means the contactor will be closed when an alarm occur, and the siren will start if connected. NC can be used to make the installation safer and detect a broken wire, but it requires siren with a similar function, which means it makes alarm when the signal is removed.

Maintenance

Regularly assess the sensor for faults and take necessary precautions before attempting to make replacements or repairs, so as to avoid collateral damage. Dispose of the sensor and its modules in accordance with the disposal instructions provided in the manual.

Sensor Repair

A new sensor head can be ordered with product no. HBGS-NH3-UNIT or HBGS- CO2-UNIT The sensor head can be replaced directly and requires no calibration. If you have questions to the product, please contact HB Products’ dealers/distributors. Please consider their complaint procedures before returning the sensor.

Further Information
For further information, please visit our website, www.hbproducts.dk, or send an email to: support@hbproducts.dk. HB Products A/S – Bøgekildevej 21 – DK8361 Hasselager – support@hbproducts.dk – www.hbproducts.dk.

Using the Sounder Beacon (Klaxon Nexus 105)

References

• Optimal solutions for level measurement and control of oil and refrigerants
• Optimal solutions for level measurement and control of oil and refrigerants
• HB Tool

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