Download
Share
Print this page
  1. Manuals
  2. Brands
  3. International Gas Detectors Manuals
  4. Gas Detectors
  5. TOC-635
  6. Installer's manual

International Gas Detectors TOC-635 Installer's Manual

2 - wire systems gas detection
Hide thumbs

Advertisement

Quick Links

Download this manual
2-Wire Systems
Installers Guide
Document Ref: SL-016 V4.85
2 - W I R E S Y S T E M S
Gas Detection Installers Guide
Please Refer to Specific Controller
Manual and Full Version
Installers Guide.
FS646773
FS646773
EMS696504
EMS696504
International Gas Detectors
TOC-635
TOC-650
TOC-750
internationalgasdetectors.com
+44 (0)161 483 1415
@
sales@internationalgasdetectors.com
/international-gas-detectors-ltd
Triton House
Crosby Street
Stockport
SK2 6SH

Advertisement

loading
Need help?

Need help?

Do you have a question about the TOC-635 and is the answer not in the manual?

Questions and answers

Related Manuals for International Gas Detectors TOC-635

Summary of Contents for International Gas Detectors TOC-635

  • Page 1 2-Wire Systems Installers Guide Document Ref: SL-016 V4.85 International Gas Detectors 2 - W I R E S Y S T E M S Gas Detection Installers Guide Please Refer to Specific Controller Manual and Full Version Installers Guide. TOC-635...
  • Page 2 2-WIRE GAS DETECTION Display & Analogue in Sounder Detector Digital Out 2-Wire Analogue in Detector Addressable Volt Free Digital Out Relay Output Each Detector Node Has Multiple I/O WiFi Setup and Service Tools 2 Core Cable Connects Detector Nodes First Fit Cabling No Cable Polarity 350 Detector Nodes/Devices Possible IOT Options, see alarms &...
  • Page 3 INTRODUCTION This installers guide is intended for the use of system specifiers, surveyors, designers and installers. The intention of this guide is to provide information for the correct installation of IGD’s range of 2-Wire gas detection systems. This guide indicates correct cabling practice, types of cabling which can be used and options available to correctly design and install a 2-wire gas detection system.
  • Page 4 SECTION 1 MOUNTING DETAILS FOR EQUIPMENT...
  • Page 5 TOCSIN 750 PHYSICAL 360mm 56.5mm 30mm 10 off 20mm 20mm Cable Entries 48.5mm Top Face 2-Wire FRONT VIEW Addressable 120.5mm 382mm 72mm Front Face Side Face Note 150W and 24V DC Versions Can be Flush mounted into walls up to the front face flange 300W Versions have active ventilation and must be surface mounted allowing 100mm clearance all round Note that the rear case can be rotated to allow...
  • Page 6 TOCSIN 750 PHYSICAL 360mm 56.5mm 30mm 10 off 20mm 20mm Cable Entries 48.5mm Top Face 2-Wire FRONT VIEW Addressable 120.5mm 382mm 72mm Front Face Side Face Note 150W and 24V DC Versions Can be Flush mounted into walls up to the front face flange 300W Versions have active ventilation and must be surface mounted allowing 100mm clearance all round Note that the rear case can be rotated to allow...
  • Page 7 TOCSIN 750 PHYSICAL 2-Wire Addressable TOCSIN 635 MICRO AND PLUS PHYSICAL 210mm Bottom Face 80mm 75mm 42mm 19mm 5 off 20mm 185mm Cable Entries Front Face Weight: 2.7kg Side Face Installation Cables Supported Installation Cables 2 Core 1.5mmSQ or 2.5mmSQ See IGD Cable System Calculator Typically SWA, FP200, CY, screened or Similar...
  • Page 8 ATEX MOUNTING DETAILS & DIMENSIONS COVER SECURING SCREW 145.0 M20 x 1.5 128.5 126.0 25.0 40.0 128.0 Ø7.0 Ø110 EXTERNAL EARTH 40.0 MKIII FLAMMABLE GAS DETECTOR SHOWN The ATEX version uses IGD’s JB3 series ATEX EXD terminal enclosure. Please note that cable glanding and sealing must conform to ATEX requirements which is more fully described in the ATEX JB3 manual Mounting Details and Dimensions Safe Area Versions 20mm Entries Top, Bottom &...
  • Page 9 BATTERY BACKUP MODULES TOC-750-BAT1 7AH Battery Backup with 150W PSU 120.5mm 382mm 72mm Front Face Side Face 360mm 56.5mm 30mm 10 off 20mm 20mm Cable Entries 48.5mm Bottom Face FRONT VIEW TOC-750-BAT2 17AH Battery Backup with 300W PSU 115mm 460mm Front Face Side Face 95mm...
  • Page 10 SECTION 2 SITING GAS DETECTORS...
  • Page 11 SITING GAS DETECTORS Gas detectors usually fall into two groups for placement 1. Plant Protection. Typically flammable gas detectors fall into this category. Aside from asphyxiation flammable gases are typically not directly toxic and so detectors are placed strategically where the gas is expected to accumulate based on its relative density to air (lighter or heavier) 2.
  • Page 13 CRYOGENIC GAS DETECTION Applications involving Cryogenically cooled gases such as liquid Nitrogen or Helium need careful consideration for gas detection. On initial release as cryogenically cooled gases can typically be at lower temperature and high density than their surroundings they will behave differently than when in their gaseous state.
  • Page 14 GENERAL MOUNTING POSITIONS ATEX (BS EN 60079-29-1) Detectors should be mounted vertically with the sensor face facing downwards to protect from contamination. GENERAL MOUNTING POSITIONS SAFE AREA (BS EN 50194) Sensor Facing Down Sensor Mounted to Vertical Wall in Various Orientations Do NOT Mount With The Sensor Facing Upwards...
  • Page 15 Detectors in Airflows Mounting Positions Atex (BS EN 60079-29-1) Air Flows up to 6M/S Are Allowable Without Any Performance Issue Across the front of The Sensor Face Do NOT mount Detectors Where Airflows Are Likely to be Directed either onto or Away From the Sensor Face.
  • Page 16 SITING SYSTEM COMPONENTS Control Panels These should be located outside of the area protected by its connected gas detectors. The control panel should be accessible such that in the event of an alarm the area can be evacuated and gas levels viewed from the controller.

  • Page 17: Cable Types

    SECTION 3 GENERAL CABLING PRINCIPLES CABLE TYPES CABLE SIZING...
  • Page 18 CABLE TYPE GUIDANCE IGD’s 2-Wire gas detection systems operate using screened cabling of appropriate cross sectional area. There are no specific requirements and our typical advised cable types are indicated below. Cable screens, either foil and drain wire, braid or armouring must be continuous between devices and grounded for effective operation.
  • Page 19 MAIN BASE PCB CONNECTORS When unplugging detectors from the main PCB DO NOT lever them off. This will potentially cause damage to the PCB and/or connector mating parts and invalidate any warranty. If it is necessary to remove the PCB connectors use long nose pliers. Note that connectors can be plugged either vertically or Horizontally to the PCB...

  • Page 20: System Example

    SYSTEM EXAMPLE 2-Core 1.5mmSQ Screened Cable, eg: FP,CY 3-Core 1.5mmSQ Screened Cable, eg: FP,CY 3-Core 1.5mmSQ Screened Cable, eg: FP,CY or Security Cable Typical Belden 450 FE Flammable Gas Detector Biomass Area Running From H2S Detector 0-100%LEL GAS DETECTOR SN:20235-1-1 ADD:4110 0-100%LEL GAS DETECTOR SN:20235-1-1 ADD:4110...
  • Page 21 INTERFACING REMOTE MODBUS PORT The Tocsin 750 series controllers have an in-built memory map allowing access to alarm status, panel status, readings etc using Modbus RTU protocol. Wiring between units is as follows: RS485 Modbus Comms Port Master DCS/BMS Note only the A,B and 0V DC Connections are Used.
  • Page 22 INTERCONNECTING MODULES ON A DATA HIGHWAY Tocsin 750 Series Annunciator Modules are interconnected as follows using two core cable. The system is designed to operate using screened cable. In some circumstances, for instance in ATEX Zone 1 areas a protective armour may be desirable to provide mechanical protection. The system provides both power and digital communication over the single pair of wires.
  • Page 23 Cable Sizing The total number of devices that can be supported on a cable highway will be limited by the reset fuse on the PCB, the cable length and size fitted and the power requirement for each module. The controller reset fuse is set to 2A. The following table is intended as a guide to show the number of devices that can be run taking into account the volt drop for differing cable sizes before boosters need to be employed.
  • Page 24 SECTION 4 MAKING DEVICE CONNECTIONS TO DETECTOR NODES...
  • Page 25 MAINS POWER & CONTROLLER OVERVIEW Display Option 1 (750) Display Option 2 (650/635) 7” Colour Touch Screen HMI 2 x 8 RGB LCD and Jog Wheel Hub Card PCB Common to All Assemblies. Note entry level 635 version is a part populated PCB supporting fewer detectors.
  • Page 26 MAINS POWER CONNECTION 650/750 Controllers with mains power supplies must be fed via a unique unswitched fused spur fused at 3A with double pole circuit disconnect. Use ferrules or 4mm fork crimps to prevent stray wire strands and potential shorting Note incoming Earth connection Note the backbox can be mounted 650 and 750 Series Controllers...
  • Page 27 MAINS POWER CONNECTION 635 Note the backbox can be mounted so cable entries face either UP or DOWN the wall to suit the installation PSU is 100 to 240V AC 50/60Hz Incoming Panel Earth Battery Backup Battery Connection Point Cable Screens...

  • Page 28: Connection Possibilities

    CONNECTION POSSIBILITIES The 750 Series Module PCB Operates as an Interface ‘Hub’ on the Addressable 2-Wire Highway. The Diagram Below Shows a Typical Set of Connection Possabilities Device Address Table Option Type Device Device Address Input Gas DetectorPellistor Input Toxic Gas Detector Input TOC-10 I/O Port 1...
  • Page 29 Module PCB Features The following diagram indicates features available on the TOC-750 ‘module’ PCB. Please note that failure to observe and make correct connections or exceed ratings may result in damage to the PCB. Pellistor (Catalytic) Flammable Gas Detector Interface Suitable for IGD Types MK3, MK6, MK7 Ribbon Cable Connection For TOC-750...
  • Page 30 DETECTOR NODE CONCEPTS Internal to each detector is a detector node module PCB (see illustration). This is common to both ATEX and safe area detectors. The module is a common connection point onto the system for gas detectors and also other inputs and outputs.
  • Page 31 DETECTOR NODE CONCEPTS The LED’s on the bottom edge of the PCB indicate the PCB setup and status at a glance. Detector Node Module Base Address 5 1s 10s LED 1: Pellistor LED 1: Toxic/O2 LED 1: I/O Port 1 LED 1: I/O Port 2 LED 1: Relay In addition there are two push buttons that can be used to view and/or change the module address.
  • Page 32 DEFAULT ALARM SETUP When the controller is first powered the option is displayed for 10s to run the FIND Fault Any fault wizard. Select by pressing the jog wheel and Monitoring the controller will find connected devices, set Station Any Alarm Level 1 up detector channels and alarms.
  • Page 33 SETUP NOTES & CONTROLLER ACCESS All 2-Wire addressable controllers have additional inputs available on their control cards and these all have addresses. If the I/O port is on the control card then these are treated as being on CABLE 0. You can connect to the controllers via WiFi for service and setup.
  • Page 34 Gas Detector Connection The most commonly supplied detector node comes pre-fitted with a gas detector. The detector front assembly simply plugs onto the indicated connector. Note that all detector front assemblies have a common system address. The detector node module is designed to read the data from this address and report it back to the control panel using its own ‘unique’...
  • Page 35 Relay Output The Detector Node relay output can be used as an alarm interface to external systems, run additional audio visual alarms or directly control other devices. Typical applications could be gas solenoid valves, boiler shut down interfaces or similar. When switching external loads it is important to consider the nature of the load being switched.
  • Page 36 Solid State Output Each Detector Node has 2 multi-function input - output ports. These can be configured independently as either 4-20mA inputs, Digital Inputs or solid state outputs. The solid state outputs are typically intended to switch small loads such as LED beacon sounder modules or small signal interface relays as indicated below.
  • Page 37 Solid State Output Cont.. Alternative Banshee Excel Version Beacon Sounder PN 5083101 Strobe - Ve Strobe - Ve Sounder - Ve Sounder - Ve Sounder + Ve 4-20mA Sounder + Ve I/O Port 2 Strobe + Ve I/O Port 1 Strobe + Ve Screen cabling interfaced to I-O port 1 or 2.Typical Belden Style Security Cable 4502 FE, Foil Screen...
  • Page 38 Digital Input Each Detector Node has 2 multi-finction input - output ports. These can be configured independently as either 4-20mA inputs or solid state outputs. The digital inputs are typically intended to totalise pulse counts, mainly from gas meters, or use for slam switch/ E-Stop ansd non illuminated call point applications I/O Port 2 I/O Port 1...
  • Page 39 Interfacing Call Points Illuminated Call Point Wiring Diagram Call Point Node I/O Port Connections Connections Call Point I/O Port 2 12-24V DC Call Point Relay O/P I/O Port 1 Call Point Connections Call Point 12-24V DC N.O -1 Call Point Relay O/P N.C -1 COM -1...
  • Page 40 Digital Input..Gas Meters To be able to read a digital pulse train from a gas meter volt free contact or similar it is necessary to use adaptor cable part number TOC-750-GMA. The following diagram indicates fitting the cable and field wiring to a volt free contact. Accessory Port I/O Port 2 I/O Port 1...
  • Page 41 4-20 mA Inputs Each Detector Node has 2 multi-finction input - output ports. These can be configured independently as either 4-20mA inputs or solid state outputs. When used as 4-20mA inputs any standard 4-20mA loop powered can be read in as an analogue signal. Using the setup routine the signal can be scaled and then read back addressably onto the system controller.
  • Page 42 PELLISTOR (CATALYTIC) FLAMMABLE GAS DETECTOR INTERFACE The Detector Node PCB is equipped with a Pellistor or Catalytic flammable gas detector interface. This supports all IGD manufactured pellistors as indicated below. Note that the correct pellistor option must be selected in the setup software routine for the pellistor to operate correctly.
  • Page 43 SECTION 5 Control Panel Interfaces and Connections...
  • Page 44 4 port card Tocsin 650 and 750 Control Panel & New 2 Wire Hub PCB Features for Rs485 Remote Ethernet (Modbus etc) Bluetooth Display Battery Connection Colour HMI For Battery Backup Display TOC-650 (2x8 LCD) Fault Relay Alarm Relay 1 Alarm Relay 2 Alarm Relay 3 Power in...
  • Page 45 6 port card Tocsin 650 and 750 Control Panel & New 2 Wire Hub PCB Features for Rs485 Remote (Modbus etc) Display Colour HMI Battery Connection Cable Cable For Battery Backup Highway 5 Highway 6 Display TOC-650 (2x8 LCD) WiFi Fault Relay Alarm Relay 1 Alarm Relay 2...
  • Page 46 T635 PLUS Control Panel & 2 Wire Hub Controller PCB Features & I/O Addresses Fitted to Controller PN TOC-635-PLUS Note that addressable inputs and outputs on Battery Backup Display TOC-650/635 (2x8 LCD) the hub card and display are on Highway 0...
  • Page 47 Gateway Product Versions, General Requirements Distance Should be as short as possible. 635 Gateway version shown Under 300mm. Use External 24V DC Cable Provided Note Position of Filter L N E 0V 24V Ensure PSU is dedicated to the gas detection system and that earth and 0V is linked at the PSU.
  • Page 48 TOC-650 or 750 switched inputs 1 and 2, volt free contacts Normally Closed Loops Opening on Alarm TOC-635 Use Screened Cable Note these inputs typically used for call points / input from Fire Systems etc...
  • Page 49 Alarm and Fault Relays 24V DC All Relay FOR DC LOADS NO COM NC DO NOT EXCEED COMM 30V DC 5A Fault Normally Open Relay 0V DC Example fit protection diodes when switching Relay external DC loads. 1N4004 Diodes are provided with each module.
  • Page 50 Panel Displays Two display option are available. A 2 x 8 RGB LCD, supplied as standard on the 650 model and a colour HMI touchscreen supplied as standard on the 750 model. Both run from different ports on the same hub card. TOC-650 Style display connects TOC-750 Style display connects through an using an RS485 connection via...
  • Page 51 TOCSIN 650/750 ADDRESSABLE RELAY CARD In all Cases: Relay contact ratings. 5A @ 250V AC Non-Inductive 5A @ 30V DC Non-Inductive Power out for 0V DC use in Spike suppression must be fitted conjunction 24V DC Note that FAULT relays are normally with relays energised on power up.
  • Page 52 Tocsin 650/750 Addressable Relay Card Input Ports Relay cards also have analogue and digital inputs that can be used to read data onto the system from external devices. Setup of the inputs, type, range, addressing etc is controlled via IGD’s Android Apps.

  • Page 53: Power Supply

    Adding Power Terminals to the Controller In some cases it may be necessary to add additional 0V and 24V DC terminals to the controller to allow easier interfacing to accessories. PN TOC-AUX-PSU This part number adds a cable loom and Wago style screwless terminal blocks to the controller. The additional terminals can then be used to provide power to external devices.
  • Page 54 External Battery Backup and Power Booster Modules Both the 650 and 750 series 2-Wire control panels can accommodate 5AH internal batteries for battery backup. If battery backup is required for longer time periods than the internal batteries allow then external battery backup units can be employed. Two external battery back options are available.
  • Page 55 Max Power Watts TOC 750 Controller TOC-750-150 13.00 TOC 650 Controller TOC-650-150 8.00 TOC 635 Controller TOC-635-PLUS 4.20 I-O Card TOC-750-IO1 or 2 8.50 IGD Beacon Sounder (Typically 25mA@24V DC) 5083101 0.63 NODE With IGD Beacon Sounder & Relay TOC-750(X)-NDE 1.40...
  • Page 56 Calculate the corrected run time as: Uncorrected Run Time x Aging Factor x Temp De-rating Factor Design Margin The following worked example is provided Example Calculation TOC-635-PLUS Controller with 10 Flammable Gas Detectors Load in Watts Total Load in Item Description (In alarm...
  • Page 57 BOOSTER MODULES 0-100%LEL GAS DETECTOR SN:20235-1-1 ADD:4110 2-Wire Addressable Mains Power Controller in Supervisors Office Laboratory ATEX Zoned Area 0-100%LEL GAS DETECTOR SN:20235-1-1 ADD:4110 Gas Bottle Store Power Booster Cable Highway Mains Power Power boosters are used where the control panel cannot supply enough power for the installed cable system.
  • Page 58 CABLE INSTALLATION STANDARDS IGD Installations are undertaken to the requirements of BS7671:2018 and subsequent ammendements, in particular Annexe A444. Note that this is not concerned with placement of gas detectors but relates to the installation cabling requirements. In Addition to BS7671 there are other relevant standards relating to cable segregation to minimise electrical interference.
  • Page 59 TYPICAL INDUSTRIAL INSTALLATION SCHEME A Standard Safe Area Gas Detectors Internal Installation Preferred Cable Type 2 Core FP200 Min Ceiling Height Basket Tray 1.5mmSQ, Check Cable Typically 50mm Sizing to IGD Guide Accessory Cables Typically Belden Style Security Cable 4502 FE, Foil Screen, 4 Core and Drain Wire 0.75mmSQ...
  • Page 60 TYPICAL INSTALLATION SCHEME B Standard Safe Area Gas Detectors Internal Installation Ceiling Height Cable Tray Note Segregation Requirement Primary Containment Preferred Cable Type 2 Core CY Cable Min 1.5mmSQ, Check Cable Sizing to IGD Guide Secondary Containment 20mm White Plastic Conduit DO NOT Attempt to Enlarge Mounted Using Metal 20mm Entries, This Will...
  • Page 61 TYPICAL INSTALLATION SCHEME D Room Status IndicatorsSystems Ceiling Height Cable Tray Primary Containment Note Segregation Requirement Secondary Containment DO NOT Attempt to Enlarge 20mm Entries, This Will Preferred Cable Type 2 Invalidate Warranty and Core CY Cable Min Damage Enclosure Sealing. 1.5mmSQ, Check Cable Sizing to IGD Guide Onto Dado Trunking Systems...
  • Page 62 TYPICAL INSTALLATION SCHEME E Beacon Sounders Ceiling Height Cable Tray Note Segregation Requirement Primary Containment Accessory Cables Typically Belden Style Security Cable 4502 FE, Foil Secondary Containment Screen, 4 Core and Drain Wire 0.75mmSQ Beacon Sounder PN 5083101 20mm White Plastic Conduit Mounted With Labelling Mounted Using Metal Provided Such That it Has...
  • Page 63 TYPICAL ROOM INSTALLATION SCHEME F Typical of Laboratories and Similar Preferred Cable Type 2 Core FP200 Min 1.5mmSQ, Check Cable Sizing to IGD Guide Gas Detection Cabling Mounted to Existing Containment For Fire/Security System Accessory Cables Cabling Fitted to Tray Typically Belden Style Using Stainless Steel Security Cable 4502...
  • Page 64 TYPICAL ROOM INSTALLATION SCHEME G Onto Dado Trunking Systems 20mm Plastic Conduit Mounted Using Metal Saddles and Fixings as Required to be Compliant With BS7671 amendment 3 Reg 521.11.201 Note Conduit Size Large Enough For two 1.5mmSQ CY Cable Runs DO NOT Attempt to Enlarge 20mm Entries, This Will Invalidate Warranty and...
  • Page 65 INSTALLATION REQUIREMENTS FOR SAMPLERS Connect screens as indicated to ensure screen continuity Interconnecting Highway Cabling For 2-Wire Addressable Systems: For Safe Area Detectors Use 2 Core Cable 1.0 to 2.5mmSQ Cable Depending on Distance. TOCSIN Ensure Cable Screens are 650 OR 750 Series Correctly Terminated and cables Controller...
  • Page 66 INSTALLATION REQUIREMENTS FOR NO-VOLT RELEASE MODULES No Volt-Release modules are fitted in situations where user intervention is required after resetting a gas alarm before a signal is re-instated. An example of its use would be where an output from the gas detection system is being used to control a gas supply to a process.
  • Page 67 Notes...
  • Page 68 International Gas Detectors 2 - W I R E S Y S T E M S Gas Detection Installers Guide International Gas Detectors Ltd Triton House Crosby Street Stockport SK2 6SH internationalgasdetectors.com +44 (0)161 483 1415 sales@internationalgasdetectors.com /international-gas-detectors-ltd...

This manual is also suitable for:

Toc-650Toc-750