passive shutdown system (pss) -...
TRANSCRIPT
Passive ShutdownSystem (PSS) for CFR 173.315Instruction Manual
In the U.S., to contact your nearest stocking location, dial toll-free 1-800-MSA-INSTTo contact MSA International, dial 1-412-967-3354
© MINE SAFETY APPLIANCES COMPANY 2004 - All Rights Reserved
This manual is available on the internet at www.msanet.com
Manufactured by
MSA INSTRUMENT DIVISIONP.O. Box 427, Pittsburgh, Pennsylvania 15230
(L) Rev 1 10045304
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THIS MANUAL MUST BE CAREFULLY READ BY ALL INDIVIDUALS WHO HAVE OR WILLHAVE THE RESPONSIBILITY FOR USING OR SERVICING THE PRODUCT. Like any piece ofcomplex equipment, this instrument will perform as designed only if it is used and servicedin accordance with the manufacturer’s instructions. OTHERWISE, IT COULD FAIL TO PER-FORM AS DESIGNED AND PERSONS WHO RELY ON THIS PRODUCT FOR THEIR SAFETYCOULD SUSTAIN SEVERE PERSONAL INJURY OR DEATH.
The warranties made by Mine Safety Appliances Company with respect to the product arevoided if the product is not used and serviced in accordance with the instructions in his man-ual. Please protect yourself and others by following them. We encourage our customers towrite or call regarding this equipment prior to use or for any additional information relative touse or service.
"! WARNING
MSA Permanent Instrument Warranty1 Warranty - Seller warrants that this product will be free from mechanical defect or faulty workmanship
for a period of eighteen (18) months from date of shipment or one (1) year from installation, whicheveroccurs first, provided it is maintained and used in accordance with Seller's instructions and / orrecommendations. This warranty does not apply to expendable or consumable parts whose normallife expectancy is less than one (1) year such as, but not limited to, non-rechargeable batteries,filament units, filter, lamps, fuses etc. The Seller shall be released from all obligations under thiswarranty in the event repairs or modifications are made by persons other than its own or authorizedservice personnel or if the warranty claim results from physical abuse or misuse of the product. Noagent, employee or representative of the Seller has any authority to bind the Seller to any affirmation,representation or warranty concerning the product. Seller makes no warranty concerningcomponents or accessories not manufactured by the Seller, but will pass on to the Purchaser allwarranties of manufacturers of such components. THIS WARRANTY IS IN LIEU OF ALL OTHERWARRANTIES, EXPRESSED, IMPLIED OR STATUTORY, AND IS STRICTLY LIMITED TO THETERMS HEREOF. SELLER SPECIFICALLY DISCLAIMS ANY WARRANTY OFMERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE.
2. Exclusive Remedy - It is expressly agreed that Purchaser's sole and exclusive remedy for breach ofthe above warranty, for any tortious conduct of Seller, or for any other cause of action, shall be therepair and / or replacement at Seller's option, of any equipment or parts thereof, which afterexamination by Seller is proven to be defective. Replacement equipment and /or parts will beprovided at no cost to Purchaser, F.O.B. Seller's Plant. Failure of Seller to successfully repair anynonconforming product shall not cause the remedy established hereby to fail of its essential purpose.
3. Exclusion of Consequential Damage - Purchaser specifically understands and agrees that underno circumstances will Seller be liable to Purchaser for economic, special, incidental or consequentialdamages or losses of any kind whatsoever, including but not limited to, loss of anticipated profits andany other loss caused by reason of nonoperation of the goods. This exclusion is applicable to claimsfor breach of warranty, tortious conduct or any other cause of action against seller.
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Table of Contents
Chapter 1, Introduction, Installation and Start-up . . . . . . . . . . . . . . .1-1
" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Four PSS Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1Dual Module or Stand-Alone Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Figure 1-1a. PSS (Passive Shutdown System), Dual Module . . . . . . . . . . . . . . .1-2Figure 1-1b. PSS (Passive Shutdown System), Stand Alone . . . . . . . . . . . . . . . .1-3
Installation and Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4PSS Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Table 1-1 PSS Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4Figure 1-2. PSS Pneumatic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5Figure 1-3 Cable-Operated Remote Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6Figure 1-4. Air-Operated Remote Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7Figure 1-5. Cable-Operated Stand-Alone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8Figure 1-6. Air-Operated Stand-Alone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Identify PSS Components: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10Installation Requirements: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10mounting location Selection for the Dual Module Remote Sensor Module or the Stand-Alone Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10Figure 1-7. PSS Sensor Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Mount the Dual Module Remote Sensor Assembly or the Stand-Alone PSS . . . . .1-12" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Mounting Location Selection for the Dual Module Display Module Assembly . . . .1-13Mounting the Dual Module Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13Connecting Customer Connection (Power) Cable . . . . . . . . . . . . . . . . . . . . . . . . .1-13" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
Mount and Install the Air Power Actuator (Cable Systems) . . . . . . . . . . . . . . . . . . . .1-14Install the pneumatic Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14Initial Start-up for Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14Figure 1-8. LCD Gas Concentration Display . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14Table 1-2. Instrument Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
Function Test the PSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15Expected Actuator Operation During Function Testing . . . . . . . . . . . . . . . . . . . . . .1-15" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15Figure 1-9. Aerosol Spray Can . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16
Chapter 2, Calibration Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1Figure 2-1. Calibrator (P/N 809997) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Calibration Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1Non-combustible Chemicals that Reduce Catalytic Sensor Sensitivity . . . . . . . . . .2-1
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Calibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1Calibration Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
PSS Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1Initial Calibration (ICal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2Regular Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Zeroing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2Figure 2-2. Apply Zero Gas Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Spanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3Figure 2-3. Apply Span Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3Figure 2-4. Calibration End Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Chapter 3, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
PSS Operation Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1System Check Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
System Check using a PSS System Check Kit (Aerosol Spray Can) . . . . . . . . . . .3-2System Check and Calibration Check Using a Calibration Kit (Gas Cylinder) . . . . .3-2
Figure 3-1. Aerosol Spray Can . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3Power Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
LED Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Chapter 4, Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Table 4-1 Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Chapter 5, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Figure 5-1. CHANGE SENSOR Scrolls Across the Display . . . . . . . . . . . . . . . . .5-1Figure 5-2. Sensor and SensorGard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1Replacing a PSS Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Table 5-1 Operational Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1Table 5-2 Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Obtaining Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3TABLE 5-3. PSS Replacement Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Figure 5-3. PSS Component Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . .5-5
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IntroductionThe Passive Shutdown System (PSS) forCompressed Gas Cargo Tanks:
• is designed to meet emergency dischargecontrol for MC330 and MC331 Cargo Tankvehicle requirements of 49CFR 173.315
• is assigned DOT Registration No. CT-8111
• provides passive shutdown capability
• automatically shut OFF flow of productwithout human intervention within 20seconds of unintentional release causedby a complete separation of a liquiddelivery hose
• uses a catalytic combustible sensor which,upon hose separation, detects a Cargo Tankproduct gas leak and shuts down the MainDischarge Valve
• can only be used for the detection of butane,propane, anhydrous ammonia ordimethylether.
This system can be used to detectbutane, propane, anhydrous ammoniaor dimethylether gas only.Failure to follow all warnings andinstructions can result in serious per-sonal injury or death.
Four PSS Models
There are four PSS models (see FIGURES 1-1aand 1-1b). Each PSS is identified by the methodused to control the Cargo Tank Main DischargeValve (belly valve).
• Two PSS models (designated Cable System)are for Cargo Tanks with cables:
• attached to manual levers on the MainDischarge Valve
• used to open and close the MainDischarge Valve.
• Two additional PSS models (designated AirSystem) are for a Cargo Tank with a
pneumatic actuator:
• an integral part of Cargo Tank Main Valve
• used to open and close the MainDischarge Valve.
Dual Module or Stand-Alone AssemblyPSS models are further defined by their physicalassembly as Dual Module or Stand-Alone:
• Dual Module includes a Remote CombustibleGas Sensor Module, which can be mountedup to seven feet from the Display Module.
• Stand-Alone System has an IntegralCombustible Gas Sensor and is a completeassembly mounted on one stainless steelmounting plate.
PSS MODEL P/N
(Cable System), Dual Module System for Cable Controlled Cargo Tank Main Valve 10045559
(Air System), Dual Module System for Air Controlled Cargo Tank Main Valve 10045570
(Cable System), Stand Alone System for Cable Controlled Cargo Tank Main Valve 10045557
(Air System), Stand Alone System for Air Controlled Cargo Tank Main Valve 10045558
All systems use air-controlled actuators to operatethe Cargo Tank Main Valve (belly valve). However,the actuators operate in different modes.
See FIGURE 1-2 and TABLE 1-1 for a descriptionof PSS Modes and air-controlled actuator func-tions. The actuator for the:
• Cargo Tank with cables attached to the MainDischarge Valve is supplied with the PSS.
• other PSS models used with the Cargo Tankwith pneumatically controlled Main Valve, is an integral part of the Cargo Tank MainDischarge Valve.
See FIGURES 1-1a and 1-1b.
• The Display Module enclosure and mountingplates are stainless steel.
" WARNING
1-1
Chapter 1, Introduction, Installation and Start-up
1-2
Figure 1-1a. PSS (Passive Shutdown System), Dual Module
1-3
Figure 1-1b. PSS (Passive Shutdown System), Stand Alone
The Sensor Module Housing:• includes the gas detection elements (sensor)
• is installed as close to the source of leaks aspossible.
• monitors for gas discharge from the CargoTank Valve(s)
• must be within five feet of all points ofdischarge during the off-loading process.
The Display Module:• controls power to the PSS
• includes the Control Switch and Air ControlSolenoid Valve
• provides measurement data, status LEDs,alarm and control circuits
• is mounted on the Cargo Tank in a positionwhere the:
• display is easily monitored by theoperator
• POWER/RESET switch is readilyaccessible.
PSS Control Switch (POWER/RESET Switch) isa momentary pushbutton switch that:
• initiates PSS Power up
• resets Alarm indicators
• resets Fault indicators.
A PSS Control Solenoid Valve:• operates an air powered actuator controlling
the Cargo Tank Main Discharge Valve.
PSS Shut Down:• occurs when the Cargo Tank Transport
brakes are applied.
Installation and Start-upA PSS must be installed, tested, calibrated andmaintained by a DOT-registered inspector asrequired by 49CFR 173.315.
Install the PSS according toNational Electrical Code and DOTprocedural codes. Failure to do socan result in an unsafe condition.
PSS Component Identification
Before installation see FIGURES:
• 1-1a and 1-1b
• 1-3 through 1-6 (Installation Drawings).
Become familiar with the PSS model selected foryour Cargo Tank, system components andcomponent locations:
• Dual Module, Cable System, FIGURE 1-3
• Dual Module, Air System, FIGURE 1-4
• Stand-Alone, Cable System, FIGURE 1-5
• Stand-Alone, Air System, FIGURE 1-6
" WARNING
1-4
Table 1-1 PSS Modes
PSS MODES CARGO TANK CABLE CONTROLLED MAIN VALVE AIR CONTROLLED MAIN VALVE MAIN VALVE ACTUATOR (CABLE SYSTEM) ACTUATOR (AIR SYSTEM)
POSITION
Initial Start- Closed Air Pressure Applied to the actuator, Air Pressure Removed from the manual control toggle valve andup period cable taut, Main Valve closed air actuator, internal actuator spring closes the Main Valve
Normal Open *Air Pressure Removed from actuator, **Air Pressure Applied to the actuator, air pressure suppliedOperation cable slack created through the manual control toggle valve to the actuator
Alarm Closed Air Pressure Applied to the actuator, Air Pressure Removed from the manual control toggle valvecable taut, Main Valve closed and air actuator, internal actuator spring closes the Main Valve
Fault Closed Air Pressure Applied to the actuator, Air Pressure Removed from the manual control toggle valve cable taut, Main Valve closed and actuator, internal actuator spring closes the Main Valve
*Requires manual action to open the Cargo Tank Main Discharge Valve**Requires manual operation of the Control Toggle Valve to open the Cargo Tank Main Discharge Valve.
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Identify PSS Components:• Stand-Alone PSS
• Dual Module PSS
• Remote Sensor Assembly (Dual Module)
• Sensor
• SensorGard
• Calibration Gas Inlet Fitting
• Display Module
• Display Module LCD
• POWER/RESET Switch
• Remote Sensor Cable (Dual Module PSS)
• Customer Connection Cable (Power Cable)
• Air Controlled Actuator (Cable System)
• Air Control Toggle Valve (Air System)
• Discharge Valve(s) and Sensor Relationship
Installation Requirements:• Select a mounting location on the Cargo Tank
to mount the PSS Remote Sensor Assembly(Dual Module) or Stand-Alone Assembly
• Mount the PSS Remote Sensor Assembly(Dual Module) or Stand-Alone Assembly
• Select a mounting location on the Cargo Tankto mount the Display Module Assembly (Dual Module)
• Mount the Display Module (Dual Module)
• Connect the customer-connection cable(power cable)
• Mount and Install the Air Power Actuator(Cable System)
• Install the pneumatic tubing
• Perform an Initial Start-up
• Function test the PSS
• Calibrate the PSS sensor
Do not install or use the PSS in anarea classified as a "HazardousLocation". Although the enclosurehas been sealed to prevent an opensource of ignition, this system isdesigned for General Purpose useonly. Disconnect all power sourcesbefore opening the cover. Do notdefeat or remove any sealing devicesattached to the enclosure. Failure tofollow this warning can result in per-sonal injury or death.
Mounting Location Selection for theDual Module Remote Sensor Module orthe Stand-Alone Assembly
Sensor Housing in this section refers to either the:
• Dual Module Remote Sensor Sensor Housingor the
• Stand-Alone Sensor Housing:
Select a mounting location the mounting place forthe Sensor Housing with the following restrictionsdictating placement of the Sensor Housing on theCargo Tank.
• The Sensor must be mounted within five feetof all points of discharge during the off-loading process.s
• See FIGURE 1-7 for guidelines whenselecting a location on the Cargo Tank tomount the PSS Sensor.
To Aid in Selecting a Suitable Site:• FIGURE 1-7 identifies the volume
surrounding the points of discharge when off-loading.
• Observe these limitations when selecting aSensor Housing location.
" WARNING
1-10
1-11
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• FIGURE 1-7 identifies the common volume,considering all points of discharge during off-loading. The shaded volume:
• is five feet from all points of discharge[Cargo Tank Main Valve and ExternalProduct Discharge Valve(s)].
• represents the installation sites toconsider when selecting a mountinglocation for the Sensor HousingAssembly.
• Dual Module PSS:
• see FIGURE 1-1a.
• A seven-foot cable connects the modulesof the Dual Module PSS together.
• Keep the location of the Display Modulein mind when selecting the site for theRemote Sensor Assembly.
• Although shown to the left of thedischarge valve manifold, the SensorHousing can be positioned on either sideof the manifold or its cage if the five footmaximum distance from any dischargevalve limitation is met.
Mount the Dual Module Remote SensorAssembly or the Stand-Alone PSS
Sensor Housing in this section refers to eitherSensor Housing of the PSS:
• Dual Module Remote Sensor Assembly or the
• Stand-Alone Sensor Housing.
See the respective PSS Installation Drawing foryour Cargo Tank for component details:
• Dual Module, Cable System (FIGURE 1-3)
• Dual Module, Air System (FIGURE 1-4)
• Stand-Alone, Cable System (FIGURE 1-5)
• Stand-Alone, Air System (FIGURE 1-6).
1. Observe information given under MountingLocation Selection for the Dual ModuleRemote Sensor Module or the Stand-AloneAssembly concerning location andorientation.
2. Fasten the Mounting plate for the SensorHousing to a solid structure of the Cargo Tankusing the bolt holes provided.
• i.e., the valve cage structure can be usedto mount the Sensor Housing Assembly.
3. To secure the bolts and nuts, apply threadlock to the bolt threads before assembly.
Alternate method:
• The Sensor Housing Assembly mountingplate can be welded in place. When weldingthe mounting plate to the Cargo Tankstructure, do not apply excessive heat to theSensor Housing Assembly.
Applying excessive heat to the elec-tronic circuits in the Sensor Housingmay prevent the PSS from operatingproperly. Damage of this nature is notcovered in the product warranty.
Mount the Sensor Housing:
• with the sensor positioned below thedischarge valves of the Cargo Tank
• where it is protected from road debris
• above the undercarriage of the Cargo Tank
• by using the cage of the Cargo Tank valve(s)and other Cargo Tank structures to protectthe Sensor and Sensor Housing Assemblyfrom road hazards.
Mount the PSS Sensing Housingwith the sensor inlet fitting point-ed downward (FIGURE 1-1a); oth-erwise, the inlet may becomeclogged with particulate matter orliquids. Do not paint the PSS. If painting isdone in an area where a sensor islocated, exercise caution toensure paint is not deposited onthe sensor inlet fitting. Such paintdeposits would interfere with thediffusion process, in which a sam-ple of the monitored atmospherediffuses into the sensor. Also, sol-vents in the paint may cause analarm condition to occur.
• in a location not blocking or restricting air flowto the sensor, sensor grill, or SensorGard.
• in a location providing access to theCalibration Gas Inlet fitting at the bottom ofthe SensorGard, since this entry is requiredfor regular calibrations.
" CAUTION
" CAUTION
1-12
Mounting Location Selection for theDual Module Display Module Assembly
Once the Sensor Housing Assembly mountinglocation is selected, the Display Module Assemblylocation can now be selected.
When selecting a location to mount the DisplayModule Assembly, ensure that:
• A seven-foot cable connects the PSS DisplayModule to the Sensor Housing Assembly(FIGURE 1-1a). This cable is of a shieldedconstruction and must not be altered.
• The LCD is easily seen
• The POWER/RESET switch is accessible.
One suggested site is:
• at the valve cage
• with the Display Module LCD facing outward,to allow the LCD to be easily read
• with the POWER/RESET switch accessible
• with the Cargo Tank structure used to protectthe Display Module from road hazards.
A second suggested site is:
• on the forward face of the Cargo Tank
• where the LCD is easily read
• where the POWER/RESET switch isaccessible.
Mounting the Dual Module DisplayModule
See the respective PSS Installation Drawing foryour Cargo Tank for component details:
• PSS Installation Drawing, Dual Module, CableSystem (FIGURE 1-3)
• PSS Installation Drawing, Dual Module, AirSystem (FIGURE 1-4)
Following directions given under MountingLocation for the Dual Module Display ModuleAssembly:
• Use provided bolt holes to fasten Mountingplate to a solid structure of the Cargo Tank
• Before assembly, apply thread lock to the boltthreads to secure the bolts and nuts .
Alternate method:
• Weld the Display Module mounting plate intoplace.
• When welding the mounting plate to theCargo Tank structure, use caution not toapply excessive heat to the DisplayModule Assembly.
Applying excessive heat to the elec-tronic circuits inside the DisplayModule Housing may prevent the PSSfrom operating properly. Damage ofthis nature is not covered in the prod-uct warranty.
Connecting Customer Connection (Power)CableThe customer connection (power) cable is:
• a six-foot, three-conductor cable
Connect the un-terminated end of the power cableto a suitable junction box.
This six-foot customer-connection power cable:
• can be shortened but not replaced
• can be spliced to a similar type of cable (type SOOW, #16-3C)
Provide a connector:
• compatible with the junction box
• that provides a water-tight seal.
• Cable overall O.D. is 0.39 inches
The customer-connection (power) cable connectsto two distinct power sources. See FIGURE 5-3and the respective FIGURE for power cable wiringdetails:
• Dual Module, Cable System (FIGURE 1-3)
• Dual Module, Air System (FIGURE 1-4)
• Stand-Alone, Cable System (FIGURE 1-5)
• Stand-Alone, Air System(FIGURE 1-6).
" CAUTION
1-13
Wire Color Identifications are:
• Black wire, positive (+), from 12 VDC @ 1 AMP, continuous power source
• Green wire, positive (+), from 12 VDC @ 0.02 AMPS, intermittent, brake power
• Wire wire, negative (-), from 12 VDCcommon of both power sources, connected toCargo Tank chassis ground.
Select two 12-VDC power sources for the PSS.
• A continuous power source must provide 1 AMP available at all times during the off-loading process.
• A second power source must provide 0.02 AMPs available only when the CargoTank Transport brake pedal is pressed(i.e., connected to the brake light circuits).
The negative (-) wire:
• must be common to both power sources.
• also serves as the PSS chassis ground
• must connect to the Cargo Tank chassisground.
Use caution when making theconnections.
The PCB PSS interface includes fuses for both power sources.Reversing the polarity of the con-ductors of the power sources willcause the fuses to open. Thesefuses are soldered in place.Inoperative fuses require replace-ment of the PCB PSS Interface.
Mount and Install the Air PowerActuator (Cable Systems)See the respective FIGURES:
• Dual Module, Cable System (FIGURE 1-3)
• Stand-Alone, Cable System (FIGURE 1-5)
Mount the Air-powered Actuator in a position toallow connection to the existing cable system forthe product discharge valves. This location shouldenable smooth operation of all cables. Connect acable to the Clevis (provided with the actuator)and the existing discharge valve cable system.
NOTE: Test the operation of the Actuator at thelowest operating air pressure specified forthe Cargo Tank. When the Actuator is acti-vated, the cable should be taut and thelocking pin for the Main Discharge Valveshould be fully withdrawn.
Install the Pneumatic Tubing• See FIGURES 1-1a , 1-1b, and 1-2.
• Use 3/8 O.D. DOT approved tubing.
• PSS Fittings are push-in tube fittings.
Initial Start-up for Display Module• The PSS is factory-calibrated and requires
only a System Check.
• Once power is applied to the unit, the:
• LCD shows a test of all display words
• software version number displays
• 30-second (self-check) countdown forsensor stability begins.
• The red Alert LED is ON during the30-second countdown.
• Gas type and gas concentration (% LEL)alternately flash (FIGURE 1-8)
• The Normal green LED is ON after the 30-second countdown.
• After an additional 30 seconds, the controlsolenoid valve allows the Cargo Tank MainDischarge Valve to open.
• During normal operation, the PSS displaysthe gas concentration of the surroundingenvironment.
NOTE: The PSS catalytic combustible sensor candetect concentrations of certain com-bustible gases above 100% LEL. Whenexposed to these concentrations, the PSSdisplays one of two modes:
Figure 1-8. LCD Gas Concentration Display
" CAUTION
1-14
• PSS was exposed to a high gasconcentration (above the LEL) and theover-range condition
• may still exist.
• definitely still exists.
Correct the condition causing theexcessive gas level and vent or purgearea before attempting the following.
• In the +LOC % LEL mode, the PSS must beunlocked by performing a manual reset withthe PSS POWER/RESET Switch.
• The PSS will not revert to a normalcondition until a POWER/RESET Switchreset is performed. This is an exclusivePSS safety feature to prevent ambiguousreadings when the sensor is exposed togas concentrations above 100% LEL.
• In the OVER % LEL mode, the combustiblegas is over the 100% LEL range.
• The PSS returns to normal operationwhen the gas concentration level fallsbelow 100% LEL.
Table 1-2. Instrument Operation
OPERA- GREEN RED FAULT ALARMTION LED LED RELAY RELAY NO. 3
LATCHING LATCHING
NORMAL, NO ALARMS ON steady OFF Energized Energized
*ALARM-ING OFF Flashing Energized De-energized
*FAULT, NO ALARM-ING OFF ON Steady De-energized Energized
POWER UP/INITIALCOUNT-DOWN OFF ON Steady De-Energized De-energized
*SENSOR MISSING/INITIALCOUNT-DOWN OFF ON Steady De-Energized De-energized
*SENSOR CAL OFF ON Steady De-energize Energized
*CALFAULT OFF ON Steady De-energized Energized
*UNDER RANGE OFF ON Steady De-energized Energized
*OVER RANGE/ LOC OFF FLASHING Energized De-energized
*NOTE:In order to return the relay to the energized state, all Fault and AlarmNo. 3 Relay functions noted by * and identified as de-energized requiremanual RESET after the initiating condition is corrected.
Function Test the PSSDuring the function test, leak test all fittings andtubing connections. See FIGURES 1-1a, 1-1b, and1-2 for location of tube fittings.
• Turn OFF the product discharge pump.
• Close all Cargo Tank external dischargevalves.
• On Air System, close the Air Control ToggleValve.
Expected Actuator Operation DuringFunction Testing
• Cargo Tank Main Valve operation is describedand shown in TABLE 1-1 and FIGURE 1-2.
• Both the Cable System and the Air Systeminclude an Air Actuator.
• Air Actuator operation for the two systemsdiffers:
• Cable System Air ActuatorAir is applied to the Air Actuator to closethe Cargo Tank Main Discharge Valve.
• Air System Air Actuator Air is applied to the Integral Air Actuatorto open the Cargo Tank Main DischargeValve.
• Initially, the power to the PSS is OFF and theMain Discharge Valve cannot be opened.
1. Press the PSS POWER/RESET switch.
• A 30-second warm up interval follows.
• A 30- to 0-second countdown appears onthe PSS Display Module LCD.
• A solid Red alert LED is ON.
• At the end of the 30-second interval, the:
• Red LED turns OFF and
• Green LED is ON.
• After an additional 30 seconds, thesystem activates the PSS controlsolenoid valve to allow opening the CargoTank Main Discharge Valve.
2. Open the Main Discharge Valve on the CargoTank.
3. Use the aerosol spray can of test gas fromthe System Check Kit (Calibration Kit GasCylinder can also be used).
" CAUTION
1-15
4. Remove and discard the Flat Locking Tabfrom the top of a new Aerosol Spray Can(labeled on the tab).
5. Remove the short red tube from the top of theaerosol spray can and insert it in the frontspray port of the aerosol spray can.
6. Hold the cylinder horizontally with the redtube facing up ( FIGURE1-9).
7. Insert the red tube into the calibration port onthe PSS Sensor SensorGard.
8. Apply three to four short bursts of test gasfrom the Aerosol Spray Can by quicklypressing and releasing the Aerosol Spray CanTrigger.
NOTE: Do not hold the trigger down toproduce a continuous flow. Althoughthis will function test the system, it isnot the proper method to test thePSS Sensor and may force the PSSinto the +LOC % LEL mode.
• Once the gas reading exceeds 10% LEL:
• the unit goes into Alarm (indicated bya blinking red Alert LED at the PSSDisplay Module)
• the Main Discharge Valve closes.
9. Allow the gas to dissipate and the sensorreading to return to normal.
• The PSS LCD reading returns to zero(or < 10% LEL).
• The Main Discharge Valve remainsclosed.
10.On an Air System, close the Air ControlToggle Valve.
11.Press the POWER/RESET switch.
• The PSS activates the control solenoidvalve to allow opening the Cargo TankMain Discharge Valve.
• The Red alert LED is OFF.
• The Green LED is ON.
NOTE: The PSS Fault Mode produces thesame results as the Alarm Modedescribed above but will not be testedduring this procedure.
12.Press the Cargo Tank brake pedal; the:
• PSS turns OFF
• Display Module LCD is blank
• LEDs are OFF
• Main Discharge Valve cannot be opened.
13. If unable to accomplish any of the aboveoperations:
• see TABLE 5-2 for troubleshootingguidance
• make any needed repairs
• repeat this function test until alloperations are accomplished.
NOTE: Verify operation of the Air Actuator andMain Discharge Valve at the lowest oper-ating air pressure specified for the CargoTank.
• Cable System: when the Air Actuator is activated:
• the cable should be taut
• the locking pin for the MainDischarge Valve should be fully withdrawn.
Figure 1-9. Aerosol Spray Can
1-16
• Air System:• with air pressure:
• available and the Air ControlToggle Valve open, the Main Discharge Valveshould be open.
• removed by closing the AirControl Toggle Valve, the Main Discharge Valveshould close.
14.Calibrate the PSS sensor
• Follow the procedure given in Chapter 2,Initial Calibration (ICAL).
1-17
Calibration BasicsWhile the PSS is factory-calibrated, it is goodpractice to calibrate the unit after installation.
• As with any type of gas monitor, the only truecheck of its performance is to apply gasdirectly to the sensor.
• Calibration checks must be included as partof the routine inspection of the system.
• The frequency of the calibration checksdepends on the operating time and chemicalexposures of the sensors.
• New sensors should be calibrated moreoften until the calibration records provesensor stability. The calibration frequencycan then be reduced to the schedule setby the safety officer.
• Before calibrating, the PSS must be poweredON for at least one hour to allow the sensorto settle into its new environment.
Before attempting calibration, powerON the unit for at least one full hour.To ensure a fully functional sensor,perform a calibration check andadjustments at initial start-up and atregular intervals.
Non-combustible Chemicals thatReduce Catalytic Sensor Sensitivity
Catalytic combustible sensors located in areaswhere non-combustible chemicals may leak(particularly ones known to reduce sensitivity; see the following list), should be calibrated aftersuch exposures:
• Silanes
• Silicates
• Silicones
• Halides, which are compounds containing:
• Fluorine
• Chlorine
• Iodine
• Bromine.
When calibration is determined to be required, thePSS provides a one-person, non-intrusive methodof adjustment at the unit.
Calibrator
The Calibrator (P/N 809997; FIGURE 2-1):
• is required to calibrate the unit
• allows the following functions:
• zero
• calibration (zero and span)
• ADDRESS button is not used in thisapplication.
Calibration Kit• Calibration Kit (P/N 10045985) is available for
use with the PSS.
PSS Calibration Procedure• Read all calibration instructions before
attempting an actual calibration.
• Identify and become familiar with all of thecalibration components.
• During calibration, it is necessary to quicklyapply the span gas to the unit.
Figure 2-1. Calibrator (P/N 809997)
" CAUTION
2-1
Chapter 2, Calibration Basics
• Prior connection of the calibrationcomponents enables easy unit calibration.
• The only true check of any gas monitorperformance is to apply gas directly to thesensor.
• The calibration procedure must be performedregularly.
• A System Check Aerosol Cylinder cannot beused to perform a Calibration; a SystemCheck is not a substitution for a RegularCalibration.
INITIAL Calibration (ICal)INITIAL Calibration:
• is recommended when:
• the unit is powered ON for the first time
• a new sensor module is placed in theunit.
• enables the unit to gather sensor data andaccurately enable the following functions:
• CHANGE SENSOR
• CAL FAULT.
• is not performed during normal use unless aregular calibration will not clear a faultcondition (due to the use of incorrectcalibration gas or a similar situation).
1. Simultaneously press the Calibrator’s ZERObutton and CALIBRATE button.
• Display shows APPLY ZERO GAS
• ICAL on display distinguishes an INITIALCalibration from a Regular Calibration.
• If ICAL does not appear, stop thecalibration and retry this procedure.
NOTE: The zero or calibration process canbe stopped at any time by pressingany CALIBRATOR button whileaiming it at the unit during the 30-second countdown.
2. The remainder of this procedure is identical tothe following Regular Calibration procedure.
Regular Calibration• Regular calibration includes the following
“zero” and “span” procedures.
• If user chooses to perform just a “zero”
procedure, press the Calibrator ZERO buttoninstead of the CALIBRATE button.
Zeroing1. If the ambient air is suitable (without traces of
the Cargo Tank product or other combustiblegas), place the Calibration Kit zero cap overthe SensorGard inlet, and hold it in place fortwo minutes.
2. Point the Calibrator at the PSS display andpress the CALIBRATE button.
NOTE: The zero or calibration process canbe aborted at any time during the 30-second countdown interval bypressing any Calibrator button whileaiming it at the unit.
• Display shows:
• 30 to 0 second countdown
• APPLY ZERO GAS (FIGURE 2-2)
NOTE: Use the zero cap.
After the 30-second countdown:
• Display alternates between CAL and avalue which is the actual gasconcentration reading detected by thesensor.
• Once the gas value on the display isstable:
• Alternating display stops
• END displays if the calibration issuccessful.
3. Remove the zero cap
Remove the zero cap or gas monitor-ing will be permanently suspended.
" CAUTION
Figure 2-2. Apply Zero Gas Flag
2-2
• If CAL FAULT appears:
• Sensor was not successfully zeroedor calibrated.
• PSS is operating with the calibrationparameters defined before thiscalibration attempt.
• See Chapter 5, TroubleshootingGuidelines.
• CAL FAULT can be removed fromthe display by performing a complete,successful calibration.
The PSS allows automatic zero adjustmentonly within a pre-defined range. It cannotmake corrections outside of this range (such as when an empty or wrong gascylinder is applied or gas flow was not startedwithin the allotted 30-second countdown).
4. If only a ZERO is being performed, theprocedure is complete; return the calibrationequipment to the cal kit.
If a CAL was performed, the gas monitorcontinues to the “span” sequence as follows:
SpanningDuring Regular Calibration, the PSSautomatically begins the span countdownafter a successful zeroing of the unit. Spancountdown is 30 seconds (FIGURE 2-3).
NOTE: The span process can be aborted at anytime during the countdown by simplypressing any Calibrator button while aim-ing it at the unit.
5. Locate the span gas cylinder and theCalibration Kit Flow Controller.
6. Screw the Flow Controller onto the top of thespan gas cylinder.
7. Locate the Tube Assembly from the cal kit.
8. Push the smaller end of the Tube Assemblyover the Flow Controller gas outlet andensure that tubing completely covers the gasoutlet.
9. Connect the other end of the tubing over theSensorGard inlet fitting.
10.Turn ON the gas flow by turning the flowcontroller knob.
• It is good practice to have all calibrationcomponents previously assembled.
• Ensure that any calibration gases areapplied during the 30-second countdownperiod.
• If a CAL FAULT display appears beforethe user is able to apply the gas:
• a steady state gas condition wasreached, causing the unit to use awrong reading as a span indication.
• It is necessary to restart thecalibration process to clear thiscondition.
After the 30-second countdown:
• The display alternates between CAL andthe actual gas concentration readingdetected by the sensor.
• Once the gas value on the display isstable, the alternating display stops.
• If the calibration is successful, ENDdisplays for approximately two seconds(FIGURE 2-4).
• No user adjustments are necessary.
• The display shows the span gas valuewhile the span gas is flowing to the unit.
11.Turn OFF the gas flow by turning the flowcontroller knob.
• When the span gas is removed from the
Figure 2-4. Calibration End Display
Figure 2-3. Apply Span Gas
2-3
sensor, the sensor reading should changeto show an ambient condition.
• If CAL FAULT appears on the display,this indicates:
• An unsuccessful attempt to calibratethe PSS
• The PSS is operating with thecalibration parameters defined beforethis calibration was attempted.
• To extinguish the CAL FAULT flag, acomplete calibration procedure must beperformed.
• The PSS allows automatic zero and spanadjustments only within a pre-definedrange. It cannot make corrections outsideof this range (such as when an empty orwrong gas cylinder is applied or gas flowwas not started within the allotted 30-second countdown).
12.After a successful calibration:
a. Remove tubing from the Flow Controller.
b. Remove the Flow Controller from thecylinder.
c. Return all items to their appropriatelocation in the Calibration Kit.
2-4
For basic Display Module operation, see Chapter1, Initial Start up for Display Module.
PSS Operation Steps1. Inspect the components.
2. Perform a System Check
3. Operate the PSS.
4. Off-load the Product.
• For optimum gas monitoring during off-loading, spot the Cargo Tank with the PSSSensor as close as practical to the receivingtank fill port.
• Before each off-loading, inspect all systemcomponents and cables for physical damage.
• If any damage is detected, do not off-load.
• Repair all damage at an MSA Factory-Authorized service center.
• Before each off-loading, perform the followingsystem check.
System Check Guide
Operation• The PSS gas monitor must be powered ON
and in operating mode to allow material off-loading.
• A visual inspection and system check must beperformed to ensure:
• unit was not damaged during transit
• PSS SensorGard is free of debris andcapable of sensing gas.
Before starting this procedure:
1. turn OFF the Cargo Tank product dischargepump.
2. Close all Cargo Tank Discharge Valves [mainvalve and external discharge valve(s)].
3. On Air System, close the Air Control ToggleValve.
• For optimum gas monitoring during off-loading, spot the Cargo Tank with the PSSSensor as close as practical to the receivingtank fill port.
Power ON
The PSS is powered ON by pressing the DisplayModule POWER/RESET button.
• The unit performs a 30-second self check toensure proper operation
• A self-check is indicated by a solid redalert LED at the PSS Display Module.
• Once successfully completed:
• The red LED turns OFF
• The green normal LED turns ON.
• After an additional 30 seconds, the systemallows the Cargo Tank Main Discharge Valveto open.
System Check
Perform this system check before off-loading. The unit must operate prop-erly to detect hose separation.
This system can be used to detectbutane, propane, anhydrous ammoniaor dimethylether gas only.
Failure to follow all warnings andinstructions can prevent the systemfrom detecting hose separation,which risks ignition of tank contentsand serious personal injury or death.
NOTES:
• This System Check Method:
• is a quick test to ensure functional PSSoperation
• is not a substitution for a RegularCalibration Check.
• For additional Calibration information, seeChapter 2.
" WARNING
3-1
Chapter 3, Operation
• When testing the system, use only the testgas provided in the PSS System Check Kits.
• Use of other simulation gases or gasmixes (% propane or % LEL) mayactivate the PSS +LOC % LEL mode,which requires:
• cancelling the check procedure
• resetting the PSS.
• For example:Do not use gas from a cigarette lighter, a cylinder used for soldering, a cylinderused for welding, etc.
System Check Using a PSS SystemCheck Kit (Aerosol Spray Can)
Use the System Check Kit with Aerosol Spray Can(Kit P/N 10045987) for this procedure.
1. Locate the aerosol spray can provided in theSystem Check Kit.
2. Remove and discard the Flat Locking Tabfrom the top of a new Aerosol Spray Can.
3. Remove the short red tube from the top of theaerosol spray can and insert it in the frontspray port of the aerosol spray can (FIGURE 3-1).
4. Open the Cargo Tank Main Discharge Valve.
5. Hold the cylinder in a horizontal position (withthe red tube facing upward) and insert the redtube into the PSS SensorGard calibrationport.
6. Quickly press and release the Aerosol SprayCan Trigger to apply three to four short burstsof test gas.
NOTE: Do not hold the trigger down toproduce a continuous flow. Althoughthis will function test the system, it isnot the proper method to test thePSS Sensor and may force the PSSinto the +LOC mode.
• Once the gas reading exceeds 10% LEL:
• the unit goes into Alarm (indicated bya blinking red Alert LED at the PSSDisplay Module)
• the Cargo Tank Main Discharge Valvecloses, indicating proper operation.
7. On Air System, close the Air Control ToggleValve.
8. If the unit does not go into Alarm or the MainDischarge Valve does not close, immediately:
a. Close the Main Discharge Valve.
b. On Air System, close the Air ControlToggle Valve.
c. Do not off-load until the condition isinvestigated and the unit passes thissystem check.
9. Remove the red flow tube from the aerosolspray can and re-insert it in the aerosol spraycan top.
10.Return the aerosol spray can to the Test Kitcase.
11.Press the POWER/RESET button to clear thealarm condition.
System Check and Calibration CheckUsing a Calibration Kit (Gas Cylinder)
Use Calibration Kit (P/N 10045985) for thisprocedure and calibration.
1. Locate the span gas cylinder provided in thecalibration kit.
2. Screw the flow controller onto the top of thegas cylinder.
Figure 3-1. Aerosol Spray Can
3-2
3-3
3. Attach the tubing to the flow controller.
4. Attach the other end of the tubing to theSensorGard Calibration Gas Inlet Fitting.
5. Open the Cargo Tank Main Discharge Valve.
6. Turn ON the gas flow by turning the knob onthe flow controller.
7. Once the gas reading exceeds 10% LEL, theunit :
• Alarms (indicated by a blinking red AlertLED at the PSS Display Module)
• closes the Cargo Tank Main DischargeValve, indicating proper operation.
8. On Air System, close the Air Control ToggleValve.
9. Check the Display Module LCD reading:
• after 30 seconds of applying gas and
• before closing the gas cylinder flowcontrol valve.
• The reading should be between 35 and 45% LEL.
• If not, do not off-load; a sensorcalibration is required.
10.If the unit does not go into Alarm or the MainDischarge Valve does not close:
a. Immediately close the calibration gascylinder valve.
b. Close the Main Discharge Valve.
c. On Air System, close the Air ControlToggle Valve.
d. Do not off-load until the condition isinvestigated and the unit passes thissystem check.
11.Close the gas cylinder flow control knob andreturn the gas cylinder and tubing to thecalibration kit.
12.Press the POWER/RESET button to clear thealarm condition.
Reset
The PSS gas monitor requires a reset of anyalarm or fault condition.
• Once an alarm condition is cleared or a faultcondition corrected, press the POWER/RESET button to:
• unlatch the relay and
• return the PSS system to operatingmode.
Power OFF
The PSS gas monitor is powered OFF by applyingthe Cargo Transport brakes.
• This is the only mechanism to power OFF thePSS system.
LED Status
GREEN REDLED LED CONDITION ACTION
OFF OFF PSS is OFF and unit must be powered-ON To power ON, press the POWER/RESET button.to begin off-loading.
ON OFF PSS is operating in Measure mode and allows the Main Discharge Valve to open. To power OFF, apply brakes.
OFF SOLID ON PSS is in Self-check mode, Calibration mode or Once the fault condition is corrected, pressFault mode and will not allow Main Discharge POWER/RESET button to continue off-loading.Valve to open; see TABLE 4-2 for fault conditions.
OFF BLINKING ON PSS is in alarm mode (gas reading exceeds Once the alarm condition clears, press 10% LEL) and will not allow Main Discharge POWER/RESET button to continue off-loading.Valve to open.
NOTE: When the system shuts down due to an Alarm or Fault Alert, always consult the Cargo Tankemergency procedures before operating the PSS.
4-1
Chapter 4, Specifications
Table 4-1 Performance Specifications
GAS TYPE Butane, Propane, Anhydrous Ammonia and Dimethylether
CALIBRATION GAS 0.6 % by volume (29 % LEL) propane in air
TEMPERATURE RANGE -40 to +50°C (-40 to +122°F)
DRIFT, SENSOR READING ZERO DRIFT: Less than 5%/year, typically
SPAN DRIFT: Less than 10%/year, typically
NOISE RESPONSE Less than 1% FS
ACCURACY/LINEARITY <50% LEL ±3% FS; >50% LEL ±5% FS
ACCURACY/REPEATABILITY ±1% FS
STEP CHANGE, TIME TO REACH SENSOR RESPONSE 50% OF SCALE: Less Than 10 seconds
HUMIDITY 15 to 95% RH, non-condensing, 24 hours or less
35 to 95%, RH, long term
TYPICAL SENSOR LIFE 3 years
SENSOR LIFE, FULLREPLACEMENT WARRANTY 1 year (see MSA Instrument Warranty in this manual)
POWER INPUT 12 VDC @ 1 AMP continuous
12 VDC @ 0.02 AMP intermittent, follows brake operation
AIR SUPPLY PRESSURE Maximum 120 PSIG
MAXIMUM DIMENSIONS (DUAL MODULE, 12 inches H I (305 mm H)DISPLAY MODULE 16 inches W (406 mm W)ASSEMBLY) 6.25 inches D (127 mm D)
(DUAL MODULE, 15 inches H (381 mm H)REMOTE SENSOR 7 inches W (178 mm W)ASSEMBLY) 4 inches x D (102 mm D)
(STAND-ALONE 13 inches H (330 mm H)ASSEMBLY) 15 inches W (381 mm W)
6.25 inches D Inches (127 mm D)
WEIGHT PSS 21 Pounds (9.5 Kilograms)
DIAGRAMS INSTALLATION DWG. Dual Module Cable System (FIGURE 1-3)
Dual Module Air System (FIGURE 1-4)
Stand-alone Cable System (FIGURE 1-5)
Stand-alone Air System (FIGURE 1-6)
Component Connections (FIGURE 5-3)
GeneralA PSS must be installed, tested, calibrated andmaintained by a DOT-registered inspector asrequired by 49CFR 173.315.
The PSS constantly performs self-checks. When aproblem is found, it displays the appropriate errormessage (see TABLE 5-2, TroubleshootingGuidelines).
The Change Sensor message:
• is not an error indication
• does not affect the output.
NOTE: See TABLE 5-1, Operational Display Messages.
Replacing a PSS Sensor
The only routine maintenance item is the sensingelement, which has a limited lifetime.
• When the PSS readout indicates that thesensor must be changed, there is very littlesensor lifetime remaining.
• It is good practice to obtain a replacementsensing element before the existing sensingelement becomes inoperative.
• Typically, the PSS LCD display shows amaintenance message when the sensor isdue for replacement. (FIGURE 5-1).
• To obtain a replacement sensor, seeObtaining Replacement Parts.
• There is no need to open the main enclosure;simply unscrew the sensor assembly locatedon the bottom of the PSS Remote SensorAssembly (FIGURE 5-2).
Unscrew the sensor cap at least three,but no more than four, full turns fromits tightly-closed position. Wait 10seconds; then, completely remove thecap. Failure to follow this warning canresult in the ignition of a hazardousatmosphere.
• Follow a sensor replacement with an InitialCalibration (ICAL) (Chapter 2).
• All other maintenance must be performed atan MSA factory-authorized service center.
Table 5-1 Operational Display Messages
MESSAGE INDICATES
MM/DD/YY Format for date scrolling
VER Software version level will display next
TIME Time will display next
DATE Date will display next
MIN MIN value for this interval will display next
MAX MAX value for this interval will display next
AVG AVG value for this interval will display next
Adr Instrument address will display next
End End of calibration cycle
Err An Error code will display next
HR Special case indicates hours (two characters or less)
OVER Gas value is greater than the set range
" WARNING
Figure 5-2. Sensor and SensorGard
Figure 5-1. CHANGE SENSORScrolls Across the Display
5-1
Chapter 5, Maintenance
5-2
Table 5-2 Troubleshooting Guidelines
MESSAGE INDICATES ACTION
BLANK PSS will not Power ON Check fuse at Cargo Tank continuous power source.
Check power wiring; tighten connections.
Check fuse F2 on PCB PSS Interface.
Check Switch wiring to the terminal strip of PCB PSS Interface.
Replace PCB PSS Interface.
VARIABLE PSS will not Turn OFF Check fuse of brake light power source.
Check power wiring; tighten connections.
Check fuse F1 on PCB PSS Interface; replace PCB PSS Interface.
CHANGE SENSOR Sensor at its end of life Replace sensor.
CAL FAULT calibration unsuccessful Repeat calibration.
Check for proper calibration gas.
Check for blockage in the calibration tubing.
SENSOR MISSING Instrument has lost communica-tion with sensor module Connect or replace sensor.
CHECK CAL Calibration should be verified Perform calibration.
SENSOR WARNING Sensor approaching its end of life Prepare to replace sensor module.
SNSR FLASH FAULT Sensor module program memory is invalid Replace sensor module.
SNSR RAM FAULT Sensor module has defective RAM location Replace sensor module.
SNSR DATA FAULT Sensor module data sheet invalid Replace sensor.
MN SUPPLY FAULT Power supply on Display Module PCB is out of range Check sensor wiring or replace Display Module PCB.
MN EEPROM FAULT EEPROM on Display Module PCB is invalid Replace Display Module PCB.
MN FLASH FAULT Program memory on DisplayModule PCB is invalid Replace Display Module PCB.
MN RAM FAULT Defective RAM memory locationon the Display Module PCB Replace Display Module PCB.
INVALID SENSOR Attached sensor module not com-patible with Display Module PCB Replace with correct sensor.
CONFIG RESET Main EEPROM memory was reset Contact service center: Reset of all configurations is required (e.g. alarm levels, calibration signals ON or OFF, etc.).
RELAY FAULT Error with internal relays Cycle power to the PSS or replace Display Module PCB.
TEMP FAULT Temperature sensor is out of range for operation Relocate unit to area within the specified temperature range.
SNSR POWER FAULT Power at sensor module is out of range Correct wiring error, replace Display Module PCB,
or replace sensor module.
und Under-range condition - quick Recalibrate or replace sensor.
Und Under-range condition - slow Recalibrate or replace sensor.
+LOC Instrument locked in over-range Press the POWER/RESET Switch button.
- SUPPLY FAULT Negative supply to sensor module is out of range Check wiring or replace sensor module.
PARAM FAULT Operational parameter out of rangeor sensor failed internal check Restart; replace, if necessary.
Obtaining Replacement PartsA PSS must be installed, tested, calibrated andmaintained by a DOT-registered inspector asrequired by 49CFR 173.315.
See TABLE 5-3 for replacement parts. To obtain areplacement part, address the order or inquiry to:
Mine Safety Appliances CompanyInstrument DivisionP.O. Box 427, Pittsburgh, PA 15230-0427
or call, toll-free, 1-800-MSA-INST.
Use only genuine MSA replacementparts when performing any mainte-nance procedures provided in thismanual. Failure to do so may serious-ly impair sensor performance. Repairor alteration of the Passive ShutdownSystem, beyond the scope of thesemaintenance instructions or by any-one other than authorized MSA serv-ice personnel, could cause the prod-uct to fail to perform as designed andpersons who rely on this product fortheir safety could sustain serious per-sonal injury or death.
• When replacing components refer to FIGURE5-3 for component connections.
" WARNING
5-3
5-4
TABLE 5-3. PSS Replacement Parts List
PART NO. DESCRIPTION
809997 CALIBRATOR
10045985 CALIBRATION KIT
10028034 CYLINDER, RP, CALIBRATION KIT, 0.6 % PROPANE IN AIR
478358 FLOW CONTROL, REGULATOR, RP, CALIBRATION KIT
710535 ZERO CAP
711112 TUBE ASSEMBLY, CALIBRATION KIT
10045987 SYSTEM CHECK KIT WITH AEROSOL SPRAY CAN
10045986 AEROSOL SPRAY CAN, 0.6 % PROPANE IN AIR
N/A DISPLAY MODULE ASSEMBLY AND MOUNTING PLATE
N/A DISPLAY MODULE
10045451 PCB ASSEMBLY, PSS INTERFACE
10018761 FUSE, 1.5 AMP, SLO-BLO, PCB ASSEMBLY, PSS INTERFACE, MAIN POWER, SOLDER IN PLACE
10018761 FUSE, 1.5 AMP, SLO-BLO, PCB ASSEMBLY, PSS INTERFACE, BRAKE POWER, SOLDER IN PLACE
N/A PCB ASSEMBLY, DISPLAY MODULE
SPECIAL ORDER PCB ASSEMBLY, DISPLAY MODULE WITH PSS INTERFACE PCB
10055171 CABLE, #16-3C, POWER, TYPE SOOW
10045554 SWITCH ASSEMBLY, MOMENTARY PUSHBUTTON
10045456 SOLENOID VALVE, NORMALLY CLOSED, AIR SYSTEM, AIR CONTROLLED CARGO TANK MAIN DISCHARGE VALVE
10045457 SOLENOID VALVE, NORMALLY OPEN, CABLE SYSTEM, CABLE CONTROLLED CARGO TANK MAIN DISCHARGE VALVE
10045496 AIR POWERED ACTUATOR, CABLE SYSTEM, CABLE CONTROLLED CARGO TANK MAIN DISCHARGE VALVE
10045497 BRACKET, PNEUMATIC ACTUATOR MOUNTING
10045874 CLEVIS
10045875 CLEVIS PIN
N/A PSS REMOTE SENSOR ASSEMBLY WITH MOUNTING PLATE
N/A PSS REMOTE SENSOR HOUSING WITH SENSOR AND SENSORGARD
A-ULTX-SENS-32-1 REMOTE SENSOR WITH SENSORGARD REPLACEMENT KIT
710346 SENSOR GARD WITH CALIBRATION FITTING
10045463 SENSOR PROTECTIVE GRILL, SHIELD
10045563 BRACKET, MOUNTING, REMOTE SENSOR
10045562 DUAL MODULE, MOUNTING PLATE, REMOTE SENSOR
10045462 DUAL MODULE, MOUNTING BRACKET, DISPLAY MODULE
10045461 STAND-ALONE ASSEMBLY, MOUNTING PLATE
10045462 STAND ALONE, MOUNTING BRACKET, DISPLAY / SENSOR MODULE
5-5
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