SC-CH4 Manual - Eng - 25 - 09 - 2012 PDF

CARBOAUTOMATYKA SA
Przedsiębiorstwo Kompletacji i MontaŜu Systemów Automatyki

43-100 Tychy, ul. Budowlanych 168
tel. centr.: (32) 323 43 00 fax: (32) 323 43 23 email: carboautomatyka@ carbo.com.pl
(32) 323 43 23 email: carboautomatyka@ carbo.com.pl (32) 323 42 62
System gas sensors

SC- * / *
System methane detector
SC-CH4/*
July 2012
TECHNICAL AND OPERATING DOCUMENTATION
IDT 107.166 A4 - 2
NUMER STRONA
TECHNICAL AND OPERATING 107.166 A4 - 2 2/29
DOCUMENTATION
Conformity
This product meets the essential requirements of safety and health protection
concerning the design and construction of protective devices and systems
intended for use in the explosive atmospheres which are specified in Annex no.
2 of the Directive 94/9/CE (the Regulation of the Minister of Economy of
22.12.2005, Journal of Laws No. 253, Item 2203) as well as the following
harmonised standards:
PN-EN 50303:2004 (EN 50303:2000);
PN-EN 60079-0:2009 (EN 60079-0:2009);
PN-EN 60079-11:2012 (EN 60079-11:2012).
This conformity is confirmed by the EC Type Examination Certificate:
OBAC 10ATEX032X
issued by The „OBAC” Institute for Research and Certification Ltd.

[Ośrodek Badań, Atestacji i Certyfikacji OBAC Sp. z o.o.],
Notified Body no. 1461
This product meets the essential requirements concerning electromagnetic

compatibility (EMC) specified in the Directive 2004/108/CE (“Law of 13th
April 2007 on electromagnetic compatibility” Journal of Laws No. 82, Item
556) as well as the following harmonised standards:
PN-EN 50270:2007 (EN 50270:2006);
PN-EN 61000-6-4:2008 (EN 61000-6-4:2007).
Manufacturer of the product – Przedsiębiorstwo Kompletacji i MontaŜu

Systemów Automatyki „Carboautomatyka” S.A. – has issued the CE
Declaration of Conformity and had marked the product with „CE” mark.

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TABLE OF CONTENTS
1. Safety instructions ................................................................................................................................... 4

2. Functional description of the device ....................................................................................................... 5
3. Technical data ......................................................................................................................................... 6
3.1 Identification of connectors, parameters connected with intrinsic safety. ...................................... 6
3.2 Other technical data......................................................................................................................... 7
4. Construction and principle of operation.................................................................................................. 8
4.1 Mechanical construction of the sensor. ........................................................................................... 8
5. Installation, start-up and calibration........................................................................................................ 9
5.1 Description of the electric signals ................................................................................................. 10
5.2 Start and configuration .................................................................................................................. 11
5.2.1 Starting of the detector ................................................................................................................... 11
5.2.2 Configuration of the detector SC-CH4/* (version n and s) ............................................................ 12
5.2.3 Configuration of the SC-CH4/W sensor (version intended for cooperation with CWx-3) ............ 14
5.2.4 Sensor switching off....................................................................................................................... 16
5.3 Calibration ..................................................................................................................................... 16
5.3.1 Preparation ..................................................................................................................................... 16
5.3.2 Calibration of methane detector SC-CH4/* (two-range chamber) ................................................. 16
5.3.3. SC-CH4/W methane detector calibration (conductometric chamber) ............................................ 23
5.4 Pin number entering....................................................................................................................... 26
5.5 Messages and additional functions................................................................................................ 27
6. Instructions and maintenance ................................................................................................................ 27
6.1 Maintenance, overhauls and repairs. ............................................................................................. 27
6.2 Charging of the accumulators........................................................................................................ 28
6.3 Procedures in emergency situations .............................................................................................. 28
7. Storage and transport............................................................................................................................. 28
8. Ordering................................................................................................................................................. 29
9. Warranty conditions .............................................................................................................................. 29
10. Acceptance by the user.......................................................................................................................... 29
10.1 Accompanying documents............................................................................................................. 29
10.2 Instructions concerning visual inspection ..................................................................................... 29
11 Special conditions for safe use.............................................................................................................. 29

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1. Safety instructions
a) This device can be assembled only by the adequately trained personnel in accordance
with the corresponding regulations (i.e. concerning electrical systems in explosive
atmospheres). These instructions are intended for the trained personnel.
b) All assembly works should be carried out in accordance with the corresponding local
(plant’s) and national standards.
c) Device should be installed strictly in accordance with this instruction.
d) Operation of the device with damaged or incomplete enclosure e.g. with damaged sight
glass, without gasket under cover, with uncovered port etc. is prohibited.
e) Before starting operation it should be checked whether external circuits are correctly
connected to the external ports, cables are choked in plug connectors and the pins are
screwed down to sockets in enclosure.
f) Connection of external circuits cannot worsen clearances between them. The required
separating clearances between the terminals (isolated parts of the conductors) of
different intrinsically safe circuits (min. 6 mm) should be maintained.
g) Device, during operation in explosive zones, can be supplied only from intrinsically safe
source of maximum parameters given in the technical data.
h) Device during battery charging outside the explosive zone can be supplied only from a
non-intrinsically safe source of maximum voltage and current given in the technical
data.
i) Inputs and outputs from the device can be connected only with intrinsically safe circuits
of parameters in accordance with these given in the Technical Data.
j) Intrinsically circuits connected with inputs (IN) should be lead in mining cables
(teletechnical line) meeting the requirements of the standard PN-EN 50394-1:
In gr
1) In groups in one cable type A or B

or
2) One by one in cables not fulfilling the requirements according to point 1)
or
3) One by one in cables not fulfilling the requirements according to point 1)
k) For installations exposed to action of atmospheric discharges it is recommended to use
external protective elements.

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2. Functional description of the device
System methane sensor (methane detector) SC-CH4/* is a device intended for continuous
measurement of methane concentrations within the range 0÷100 % CH4 underground and
on the surface of mining enterprises in methane and/or coal dust explosion hazard zones.
In case of version SC-CH4/W in connection with methane high concentration sensor
CWx-3 it is a measuring point for percentage content in demethanation pipelines.
Output signal from the methane detector can be, depending on the version, digital signal,
voltage signal or frequency coded.
In voltage version it can be used for cooperation with analogue control units which are
equipped with voltage input 0,4 ÷ 2 V.
In digital or frequency version it can be used for cooperation with methanometric systems
which allows receiving and conversion of signal in the convention assumed for the
system.
CAUTION! During carrying out of the measurements the sensor can operate only in one selected
system that is transmission standard.
System methane detector SC-CH4/* operates in stationary device mode and can be
supplied from intrinsically safe power unit or intrinsically safe supply-transmission line of
the methanometric system. Correct operation is signalled by greed LED diode. System
methane detector can also realize function of two-threshold switching off device enabling
control of external devices using two bi-state outputs (galvanically isolated). Two alarm
thresholds can be set on any value within the range 0÷2 % CH4 for version SC-CH4/*
and/or 30÷80 % CH4 for version SC-CH4/W. Exceeding or decrease of a given alarm
threshold results in activation of alarm that is pulsation of red diode and change of state
of the given detector’s output (or outputs).
CAUTION! Signalling with red diode LED depends on configuration of AWP and KCL function and
whether switching on is controlled by control unit or methane detector and can occur in the
following cases:
- if SC-CH4/* (KCL function active) cooperates with control unit or power unit and
interruption of telemetrical or supplying line occurs;
- if exceeding of internal alarm threshold will occur (AWP function switched on) regardless
of system methane detector cooperation with control unit or power unit;
- if on telemetric line, where the SC-CH4/* sensor is installed the alarm impulses will occur
alarm thresholds will be exceeded on telemetric control unit on a given measuring line where
the detector is located or on other line and through sending (switching off) matrix the alarm
will be forwarded to the second line);
- operation in the high concentrations range regardless of alarm thresholds.
During service-inspection works (calibration of the methane detector, periodic control of
operation) the device communicates bi-directionally with methanometric control unit
what results in rationalization and shortening of time required for these operations.
Version Signal Description of version Measuring range
SC-CH4/n Basic version

Frequency 5÷12 kHz
Special version Measurement
SC-CH4/s Digital FSK (modified soft) 0÷100 % CH4
Voltage 0,4 ÷ 2 V or 1 ÷ 5 V Version for connection of high
SC-CH4/W concentrations of methane detector
CWx-3

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3. Technical data
3.1 Identification of connectors, parameters connected with intrinsic safety.
Supply (1 x WE)……….………...…. - from intrinsically safe telemetric line:
connector A, contact no. 1 (+), 2 (-)
for Gr. I Ui = 60V, Ii = 0,15A, Pi = 2,5W, Uo = 0, Io = 0,
Ci = 0, Li ≤ 300µH
for Gr. II Ui = 30V, Ii = 0.2A, Pi = 1.3W
or - with non-intrinsically safe source only for charging
of accumulators’ battery outside explosion hazard
zone)
Um = 45V, Imax = 40mA
Measuring signal (3 x WY)…………. - frequency 5÷12 kHz or digital 2÷5 kHz
Ui = 60V, Ii = 0,15A, Pi = 2,5W, Uo = 0, Io = 0,
Li ≤ 300µH
- voltage 0,4 ÷ 2 V or 1 ÷ 5 V (0÷5 % CH4)
Uo = 5,88V, Io = 20,2mA, Po = 96,1mW,
Li ≤ 300µH, Ci = 0, Co = 15µF, Lo/Ro=5mH/Ω,
Lo = 5mH
- voltage 0,4 ÷ 2 V or 1 ÷ 5 V (0÷100 % CH4)
Uo = 5,88V, Io = 20,2mA, Po = 96,1mW,
Co = 15µF, Lo = 5mH, Lo/Ro=5 mH/Ω,
Ci = 0, Li ≤ 300µH
Alarm signal (2 x WY)....………....- bi-state output type OC
connector B, contact no. 1 (+), 2 (-) (AL1) and
contact no. 3 (+), 4 (-) (AL2) and
Ui = 30V, Ii = 100mA, Pi = 500mW,
Uo = 0, Io = 0, Ci = 0, Li = 0
Control signal (1 x WE)…………….- bi-state input

connector B, contact no. 5 (+), 6(-)
Uo = 5,88 V, Io = 4 mA, Po = 13,6 mW,
Ui = 0, Ii = 0, Co = 15µF, Lo = 5mH,
Lo/Ro = 5mH / Ω, Ci = 0, Li = 0
Supply (1 x WY, only SC-CH4/W)....- supplying of external measuring chamber

connector C, contact no. 1 (+), 2 (-)
Uo = 5,88V, Io = 1,266A, Po ≤ 0,62W,
Lo = 200µH, Co = 15µF, Ci = 24µF,
Li =26,5µH
Signal (1 x WE, only SC-CH4/W)…....- signal from external measuring chamber

connector C, contact no. 3 (+), 4 (-)
Uo = 5,88 V, Io – negligibly small

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3.2 Other technical data.
Output signal…………………………. - frequency 5 ÷ 12 kHz
- digital FSK
- voltage 0,4÷2 V or 1÷5 V
Accuracy ....................................................... for version SC-CH4/* (version n and s)
± 0,1 % CH4 within the range 0÷2,5 % CH4
± 0,3 % CH4 within the range 2,5 ÷ 5 % CH4
± 3 % CH4 within the range 5 ÷ 100 % CH4
for version SC-CH4/W
± 3 % CH4 within the range 0 ÷ 60 % CH4
or ± 5 % of value of indication within the
range 60 ÷ 100 % CH4
Principle of operation................................... Methane concentrations within the low
concentrations range 0÷5 % as well as
conductometric measurement of methane
concentrations within the high range
5÷100 % (for SC-CH4/*)
conductometric measurement of methane
concentrations 0÷100 % (for SC-CH4/W)
Measuring range ........................................... 0 ÷ 100 % CH4
Measuring method ....................................... continuous
Response time T90 ......................................... ≤ 3,5 sec.
Execution ..................................................... I M1 Ex ia I
II 2G Ex ia II (CH4) T4
Ambient temperature and
measured gas mixture ................................. -20 ÷ 40 °C
Resolution .................................................... within the low concentrations range 0,01% CH4
within the high concentrations range 0,1% CH4
Protection degree of enclosure and head …. IP 54
Humidity....................................................... < 95 % without condensation
Penetration of mixture .................................. by diffusion
Air flow rate ................................................. to 10 m/s
Air dustiness ................................................ max. 1000 mg/m3
Mechanical hazard ........................................ impacts and vibrations are not allowed
Operation position ........................................ measuring sensor directed downwards
or backwards to air stream
external dimensions ...................................... 160 x 90 x 55 mm
weight ........................................................... ~ 1 kg
setting of alarm thresholds............................ in methane detector or from control unit
……………………………………………….KSP-3 for digital transmission
time of activation of alarm thresholds
AL1, AL2 .....................................................below 1 sec.
loading of executory elements of switching
off outputs......................................................intrinsically safe circuit of current
max. 100 mA and voltage 30 V
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4. Construction and principle of operation
Methane detector SC-CH4/* is a modern device where special-purpose microcontrollers
and sensors were used what allowed to achieve high utility and metrological values.
The methane detector is supplied from external accumulator which is connected in buffer
way to the telemetrical line from which it is charged. Intrinsically safe power unit can be
used as an alternative source of supply.
This methane detector enables carrying out continuous measurement of methane
concentrations within the range of 0 ÷ 100 % CH4. Two-range measuring chamber type
SG-1/NW is used as a standard. The measurement is carried out in two sub-ranges:
a) range I: 0 ÷ 5 % CH4 – by catalytic method;
b) range II: 5 ÷ 100 % CH4 – by conductometric method;
Ranges are automatically switched over depending on methane concentration.
Measurement results appear on the display and on sensors’ outputs - on port of the
telemetrical line and on ports of voltage outputs. Methane detector is equipped with
function allowing setting two so-called alarm thresholds. Increase/decrease of methane
concentration over/below set threshold value results in switching on/switching off light
signalling (red diode on the enclosure) as well as change of bi-state output’s (outputs’)
state controlling the external circuit. Information about exceeding of alarm threshold
(thresholds) is additionally displayed on the display and line’s port. Detector is equipped
also with one bi-state output which can be used to confirm emergency shutdown of the
external device.
CAUTION! Signalling by red diode LED depends on the way how the AWP and KCL functions are
configured and whether switching off is controlled by the control unit or methane detector and
can occur in the following cases:
- SC-CH4/* (KCL function active) cooperates with control unit or
interruption of telemetrical or supplying line will occur;
- if exceeding of the external alarm thresholds will occur (AWP function switched on)
regardless whether system methane detector cooperates with central unit or power unit;
- If on the telemetrical line, where the SC-CH4/* detector is installed the alarm impulses
will occur (exceeding of the alarm thresholds on telemetrical control unit on a given
measuring line, where the detector is located or on the other line, and through sending
(switching off) matrix the alarm is forwarder to the given line);
- operation within the range of high concentration regardless of alarm thresholds.
4.1 Mechanical construction of the sensor.

Basic components:
- measuring chamber of the detector (version SC-CH4/*) [1];
- basic printed circuit;
- measuring circuit;
- socket 7-fold. (ZŁ A) intended for connection of supply-transmission line or power
unit as well as 2 voltage outputs [3];
- socket 7-fold. (ZŁ B) outputs of alarm thresholds and bi-state input [4];
- in version SC-CH4/W socket 4-fold. (ZŁ C) intended for connection of high
methane concentrations detector CWx-3 [5];
- enclosure Ex made of plastics [2];
- keyboard [7]
- shield (doors).

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1 7 2 7 2
R R
Y KA Y KA
AT AT
TOM
TOM
AU
AU
CA C
RB O A RB O
1 ,67 O 1O (K4 26 ,7 O 1O (K4

CZUJNIK CZUJNIK
SC-CH4 SC-CH4
3 4 3 4 5
Fig. 1 Version type SC-CH4/* Fig. 2 Version type SC-CH4/W
Two 7-fold plug sockets are lead out through holes in the bottom part of the body (on
the longer edge). One of the sockets (ZŁ A) is intended for connection of supply-
transmission line or intrinsically safe power unit as well as 2 voltage outputs. The
second connector (ZŁ B) is intended for leading out bi-state outputs switching off of
Alarm 1 and Alarm 2 as well as bi-state voltage-free input allowing control of
contacts’ state and lines which are connected to the devices.
There is a third socket ZŁ C, to which high methane concentrations sensor CWx-3 is
connected, lead out in case of SC-CH4/W version. In such case the measuring chamber
is moved from SC-CH4 sensor to CWx-3 sensor.
Metal shield is installed on the sensor’s enclosure cover which additionally protects
sight glass and keyboard against the impact.
5. Installation, start-up and calibration

SC-CH4/* type detectors are installed in location in mine selected by the supervision.
CAUTION!
It should be remembered to operate sensors in locations where there is no direct influence of
noxious chemical compounds such as: silicone, paints, foams, chlorine compounds, lead and
cadmium compounds, sulphur and freon vapours.
The above listed compounds influence toxically the measuring chamber resulting in reduction
of its sensitivity and life and even in permanent damage.
In SC-CH4/n and/or SC-CH4/s version the device should operate with measuring sensor
directed downwards or backwards to the air stream
Methane detector should be installed in the highest point of the heading, according to
the obligatory regulations.
Ventilating air flow rate should be lower than 10 m/s (in place of methane detector’s
installation).
Electric parameters of the methane detector allow cooperation with the following systems
of automatic methanometry:
- for FSK transmission (digital signal) with KSP-3 control unit;
- for frequency signal with control units KSP-2c, KSP-2, CST-40, CMC series equipped
with frequency modules;
- for voltage signal 0,4÷2,0 V with control units:
• CMC-3xx through analogue control units CCD, CCD-1, MCCD-01;
• CST-40 through analogue control unit CSA-1;
•
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• Venturon through underground local stations VAL;
• MICON-3 through local stations MIC1003;
or for voltage signal 1÷5 V with other control units.
CAUTION!
5.1
Selection of the transmission standard is realized through proper configuration of
the supply-transmission connector.
The sensor can operate only in one selected system that is transmission standards
during carrying out of the measurements.
5.1 Description of the electric signals

Electric signals of the methane detector in SC-CH4/* version are lead out to two
sockets located next to each other and marked with “ZŁ A” and “ZŁ B”.
In case of SC-CH4/* version the electric signals are lead out to three sockets located
next to each other “ZŁ A”, “ZŁ B” and “ZŁ C”.
Socket ZŁ “A” (male) - supplying, transmission, voltage signals; 7-fold socket type
C16-1 ecomate C016 30C006 200 12.
Socket ZŁ “B” (female) - switching off outputs AL1 and AL2 as well as bi-state 7-fold
socket type eco-mate C016 30C006 200 12.
Socket ZŁ “C” (female) - 4-fold socket type eco-mage C016 20C006 200 12, where
high methane concentrations sensor is connected by Pitot-Prandtl tube type CWx-3
(only version SC-CH4/W).
Plugs type C16-1 eco-mate, which are intended for connection to the individual
sensor’s sockets.
ZŁ A - Female plug on straight cable 6+PE C016 30D006 210 10
ZŁ B - Male plug on straight cable 6+PE C016 30H006 210 10
ZŁ C - Male plug on straight cable 3+PE C016 20H003 210 10 (only version SC-CH4/W).
SOCKET ZŁ A
No. of
Function of contact
contact
1 Telemetric line L+ (supply, signal to/from control unit)
2 Telemetric line L- (supply, signal to/from control unit)
3 Voltage output 0,4÷2,0 V or 1÷5 V 0÷5 % CH4 (+)
6 Voltage output 0,4÷2,0 V or 1÷5 V 0÷100 % CH4 (-)
7 NC
SOCKET ZŁ B
No. of
Function of contact
contact
1 AL 1 (+) (bi-state output; alarm threshold no. 1)
2 AL 1 (-) (bi-state output; alarm threshold no. 1)
3 AL 2 (+) (bi-state output; alarm threshold no. 2)
4 AL 2 (-) (bi-state output; alarm threshold no. 2)
5 Bi-state control (+) (bi-state input)
6 Bi-state control (-) (bi-state input)
7 NC

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SOCKET ZŁ C only SC-CH4/W
No. of
Function of contact
contact
1 Supply output (+) (measuring chamber supply)
2 Supply output (-) (external chamber supply)
3 Measuring signal output 0÷100 % CH4 (+)
4 Measuring signal output 0÷100 % CH4 (-)
CAUTION: Sockets and plugs are differs between each other and it is not possible to
connect it to the other socket than required.
5.2 Start and configuration
5.2.1 Starting of the detector

Starting of the methane detector is made by pressing and holding the E button
or by connecting a supply-transmission line until the „ SC-CH4 „ will appear
on the display.
Software will be started after switching on the methane detector and the
messages will appear in turn every 2 seconds which inform about current
settings of the detector.
SC-CH4/* Name of the methane detector
nr xxxx Serial number
ver. xxx Software version
Digital control unit

KSP-3
or
KSP-2 Control units where signal is frequency coded
or Operations with intrinsically safe power unit or with

BRAK analogue control units
Automatic switching off alarm 1 and alarm 2 thresholds from
KSP-2C, KSP-2 control units or without participation of control
AWP xxx units where “xxx”: ZAŁ - control switched on
WYŁ - control switched off
if “ZAŁ” is set then the information about set alarm thresholds AL1 and AL2 is
displayed.
AL1 x.xx Alarm threshold 1 set where x.xx – alarm value
AL2 x.xx Alarm threshold 2 set where x.xx – alarm value
if “WYŁ” is set then the following message will be displayed:

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setting of lines continuity control where “xxx”:
KCL xxx ZAŁ - control switched on
WYŁ - control switched off
setting of voltage output control where “xxx”:

WY-U xxx ZAŁ - voltage output switched on
WYŁ - voltage output switched off
setting of information displayed on the LCD where “xxx”:
WY-U xxx TIME - switching off measurement displaying after the time
ON - continuous display
AKU = xx.x Accumulator voltage
ŁAD=xx.x value of charging current in mA
burning-in of catalytic bead sensors and possibility

CZEKAJ of entering to complete configuration of the methane
detector (simultaneous
pressing of [+] and [-] buttons)
normal operation mode, where x.xx - measurement
x.xx % CH4 value
After a while the methane detector will start to send its identification number to
methanometric control unit (KSP-2C, KSP-2 control units) while in case of
digital signal will send such information as type of detector, identification
number, alarm thresholds set as well as any other information connected with
state of its operation (KSP-3 control units).
Information about normal measurement will be displayed on the methane
detector’s display at the same time.
x.xx % CH4
In case of KSP-2 and/or KSP-2C control units the identification number of the
sensor is received during fourfold polling the device. Proper entries concerning
number of the sensor will be displayed on the control unit’s display at this time.
If given line will be switched off on the KSP-2C control unit (control unit will
not poll the sensor) then methane detector SC-CH4/* will switch to carrying out
the measurements and the identification number will be sent just after
switching on the control unit on a given line to the registration mode.
5.2.2 Configuration of the detector SC-CH4/* (version n and s)

Entering to setting of the complete sensor’s configuration is possible only after
switching on the sensor. When the following message is displayed
KONFIG?
You should press buttons [+] and [-] on the keyboard simultaneously
The message will be displayed
KONFIG

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This will allow entering to the methane detector’s settings mode.
The following message will be displayed after 2 seconds:
SET [ - / + ]
KSP-2 or KSP-3 or BRAK
Buttons [+] or [-] are used to select option as describe above.

Confirmation with [E] button. Then another message will be displayed:
it concerns operation of internal switching off devices
AWP xxx In place of xxx we set:
ZAŁ - alarm thresholds set switched on
WYŁ - alarm thresholds set switched off
Buttons [+] or [-] are used to select ZAŁ or WYŁ.
Selected option is confirmed with “E” button.
Then the message will be displayed:
in place of x.xx we enter value of alarm threshold
AL1 = x.xx from 0 ÷ 2 % CH4
Button “+” or “-” is used to select the value of alarm threshold value.
After entering of correct value press “E” to confirm.
in place of x.xx we enter value of alarm threshold
AL2 = x.xx from 0 ÷ 2 % CH4
CAUTION! Value of AL2 threshold cannot be lower than value of AL1 threshold.
The message will be displayed:
it concerns control of lines continuity In place of xxx we set:
KCL xxx ZAŁ - line continuity control
WYŁ - lack of line continuity control
setting of action of voltage output

WY-U xxx where “xxx”: ZAŁ - voltage output switched on
Another message will be displayed:
setting of information displayed on the LCD where “xxx”:
WY-U xxx TIME - switching off measurement’s displaying after the time
ON - continuous display

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Another message will be displayed:
ZAPISANE Information about saving of changes in processor’s memory
After 2 seconds sensor will return to item:
SC-CH4/*
and messages (every 2 sec.) will be displayed automatically, with information
about current settings of the sensor. If the configuration is correct then it
switches to normal operation mode and the following message will be
displayed:
where in place of x.xx the measured value will be
x.xx % CH4 displayed
If NO then there is a possibility of repeated entering to configuration mode by
pressing [+] and [-] buttons on the keyboard simultaneously.
5.2.3 Configuration of the SC-CH4/W sensor (version intended for

cooperation with CWx-3)
Entering to setting of the complete sensor’s configuration is possible just after

switching on the sensor. When the following message is displayed
KONFIG?
You should press buttons [+] and [-] on the keyboard simultaneously
The message will be displayed
KONFIG
This will allow entering to the methane detector’s settings mode.
SET [ - / + ]
KSP-2 or KSP-3 or BRAK
Buttons [+] or [-] are used to select option as describe above.

Confirmation with [E] button. Then another message will be displayed:
it concerns operation of internal switching off devices
AWP xxx In place of xxx we set:
ZAŁ -alarm thresholds set switched on
WYŁ - alarm thresholds set switched off
Selected option is confirmed with “E” button and the following message will
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be displayed:
in place of x.xx we enter value of alarm threshold for
AL1 = xx.x high concentrations
Button “+” or “-” is used to select the value of alarm threshold value.
in place of x.xx we enter value of alarm threshold for
AL2 = xx.x high concentrations
CAUTION! Value of AL1 threshold cannot be lower than value of AL2

threshold.
it concerns control of line’s continuity In place of xxx we set:
KCL xxx ZAŁ - line continuity control
WYŁ - lack of line continuity control

Selected option is confirmed with “E” button. The message will be displayed:
setting of voltage output control
WY-U xxx where “xxx” : ZAŁ - voltage output switched on

setting of information displayed on the LCD where
WY-U xxx “xxx”: TIME - switching off measurement’s displaying
after the time
ZAPISANE Information about saving of changes in processor’s memory
After 2 seconds sensor will return to item:
SC-CH4/*
and messages (every 2 sec.) will be displayed automatically, with information
about current settings of the sensor. If the configuration is correct then it
switches to normal operation mode and the following message will be
displayed:
x.xx % CH4 displayed
methane content
If NO then there is a possibility of repeated entering to configuration mode by
pressing [+] and [-] buttons on the keyboard simultaneously.

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5.2.4 Sensor switching off
Sensor is switched off after simultaneous pressing of the “E” and “-”
buttons. The message will be displayed:
WYŁ? Question whether the sensor should be switched

off
If we want to switch off then press [+]. The message will be displayed:
WYŁACZAM Sensor is switching off
If we abandon switching off the sensor now, we do not have to press any button
but it will switch to normal operation mode on its own after approx. 5 sec.
x.xx %CH4 displayed
methane content
5.3 Calibration
5.3.1 Preparation
In order to equal temperature of the devices with ambient temperature in
working place you should carry out calibration after min. 30 minutes:
- from switching off the methane detector;
- in case of temperature difference exceeding 10°C between storage location
and installation location.
To check calibration you will need:
- cylinder with clean air;
- cylinder with reference mixture of concentration 2%CH4 ±0,3%CH4(SC-CH4/*);
- cylinder with reference mixture of concentration 30 ÷ 45 % CH4 (SC-CH4/*);
- cylinder with reference mixture of concentration 50 ÷ 80 % CH4 (SC-CH4/W);
- calibration cap;
- special key;
- soft brush.
Cylinders should be equipped with valve and pressure reducer with reduced
pressure gauge enabling setting of gas flow with rate of 20 ÷ 30 l/h.
Rubber hose should be connected to the reducer’s end where cap, adapted to
feeding of reference mixture for a given type of chamber, is fixed.
CAUTION: Flow rate of reference mixture fed should be equal to 20 ÷ 30 l/h.
CAUTION: Do not use the same reducer for different mixtures or blow through it earlier in
order to get rid of methane residues in the reducer.
5.3.2 Calibration of methane detector SC-CH4/* (two-range chamber)

Before calibration you should unscrew a special screw and uncover access to
the buttons and chamber by opening the door. Clean chamber filter, buttons and
window with display using brush, if necessary.
In order to enter calibration mode you should press button “E” and “+”
simultaneously and wait until the following message will be displayed:
CZEKAJ or PIN XXXX

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“CZEKAJ” message will be displayed when the sensor is cooperating with
methanometric control unit (option KSP-2 or KSP-3 selected).
“PIN XXXX” message will be displayed when the sensor is operating self-
contained, without methanometric system (option BRAK selected).
In case when the methane detector cooperates with methanometric control unit
KSP-3, KSP-2C, KSP-2 then the methane detector sends signal to the control
unit with query about permission for calibration. If message confirming
permission will be sent from control unit within 1.5 min from sending a query,
then the methane detector will switch to calibration mode and the following
message will be displayed on the display:
information about permission to carry out
ZEZWALAM calibration by the methanometry dispatcher
In case when the methane detector operates self-contained, after displaying of

“PIN XXXX” message user will enter four-digit number. If the pin number is
correct then the following message will be displayed on the screen:
ZEZWALAM information about permission to carry out calibration
If during 1.5 min from sending a query the sensor will not receive permitting
signal or entered pin is incorrect then the following information will be
displayed:
BRAK ZEZWOLEN
and will switch to normal operation mode
x.xx % CH4
In such case calibration procedure beginning with sending a signal with query
for calibration permission can be repeated.
When the permitting message is displayed, then after 2 seconds the following
message will be displayed:
ST. WYS. information about entering to high concentration range
Using [+] [-] buttons user can select between four windows
ST. WYS. ST. NIS. UST.FAB. WYJSCIE
It is so-called MAIN MENU [MENU GŁÓWNE].

CAUTION: If, from any reasons, calibration of the methane detector will not be continues then
after approx. 2 min the calibration procedure will be interrupted, the methane detector will
switch to normal operation mode and will send information to the control unit about
calibration process stop.
It high concentrations calibration is not required, then user should press “+”
button and the methane detector will switch to low concentrations calibration.

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5.3.2.1. Calibration within the high concentrations range
If high concentrations calibration is required then user should press “E” button
until the following message will be displayed:
POD. POW.
Clean air is fed through a cap. Measurement is taken and after 5 seconds the
measured value will be displayed.
x.xx % CH4
CAUTION! Measurement result should be stabilized but it does not have to show 0,0%
Checking whether “high zero” is contained within adjustment range takes place
after confirmation of the mixture with “E” button.
If NO - then the following message will be displayed after approx. 5 seconds:
SERWIS Z methane detector should be sent do the service
And then it will move to item
ST. NIS.
If YES the following message will be displayed:
UST 00.0 %
After next 2 seconds the following message will be displayed:
ZAPIS!
After mentioned time the methane detector will send 1 control measurement
with record of calibration with clean air to the control unit.
CAUTION! If, from any reasons, calibration of the methane detector will not be continued then
after approx. 5 min the calibration procedure will be interrupted, the methane
detector will switch to normal operation mode and will send information to the
control unit about calibration process stop.
After 2 seconds the following message will be displayed:
UST. GAZ
And then
GAZ xx.x %
Using “+” or “-” buttons we set on the display value of high reference mixture
concentrations. Confirmation with [E] button. The message will be displayed:
POD. GAZ

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We feed reference gas through a cap (approx. 30 ÷ 45 % CH4).
Measurement result will be displayed after 10 seconds.
x.xx % CH4
CAUTION! Measurement result should be stabilized but it does not have to show
accurately concentration of the reference gas.
Calibration is confirmed by pressing [E] button. Checking whether “high
concentration” is contained within adjustment range takes place.
SERWIS C methane detector should be sent do the service
UST.FAB.
If YES (condition is met) then after 2 sec. the following message will be
displayed:
ZAPIS ! Gas feeding is about to be stopped.
And then
CZEKAJ
It will be displayed until gas concentration will not decrease below 4 % CH4
and then it will be switched to calibration of “low range”.
with record of high concentrations after correction. The message will be
displayed:
ST. NIS.
5.3.2.2. Calibration within the range of low concentrations

“E” button should be pressed until the following message will be displayed if
calibration of low concentrations is required:
POD. POW.
x.xx % CH4
CAUTION! Measurement result should be stabilized but it does not have to show 0.00%
Checking whether “low zero” is contained within adjustment range takes place
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And then
WYJSCIE
UST 0.00 %
ZAPIS!
CAUTION! If, from any reasons, calibration of the methane detector will not be continued then after
approx. 5 min the calibration procedure will be interrupted, the methane detector will
switch to normal operation mode and will send information to the control unit about
calibration process stop.
UST. GAZ
After another 2 seconds message:
GAZ xx.x %
Using “+” or “-” buttons we set on the display value of low reference mixture
concentrations. Confirmation with [E] button. The message will be displayed:
POD. GAZ
We feed reference gas through a cap (2 % CH4 ±0,3 % CH4).

Measurement result will be displayed after 10 seconds
x.xx % CH4
CAUTION! Measurement result should be stabilized but it does not have to show accurate
concentration of the reference gas.
Calibration is confirmed by pressing [E] button. Check whether “low
concentration” is between adjustment ranges.
If YES (condition is met) then after 2 seconds the following message will be
displayed:
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At this time the methane detector will send 1 control measurement with record
of low concentrations after correction. After 2 seconds the following message
will be displayed:
WYJSCIE
Selected option is confirmed with “E” button and the following message will
be displayed:
NIE
Buttons [+] or [-] are used to select NO or YES.
YES NIE
Selected option is confirmed with [E] button.

If we select NO then we go to the beginning of the calibration that is
KALIBR.
and the calibration is started again. If YES is selected then we exit the calibration
mode and CH4 sensor switches to normal operation, that is
x.xx % CH4
5.3.2.3. Factory settings

If despite correctly carried out calibration procedure or from any other reasons it
will be impossible to calibrate device correctly, user can try to recover so-called
FACTORY SETTINGS.
UST.FAB. Calibration settings made by the manufacturer.
After confirmation with “E” button the message will be displayed:
ZAPIS
After another 2 seconds message
WYJSCIE
It is necessary to calibrate the device once again according to the manual in order
to ensure correct operation.
CAUTION! IF entering of factory setting did not allow calibrating the device it should
be sent to the manufacturer’s service.

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KALIBR
2 sec.
OR
CZEKAJ PIN XXXX

to 1.5 min.
YES NIE 2 sec.
Permission
ZEZWALAM BRAK ZEZWOLEN

from
dispatcher
?
2 sec.
- + - + - +
ST. WYS. ST. NIS. UST.FAB. WYJSCIE

E E E E
POD.POW. POD.POW. ZAPIS
5 sec. 5 sec. 2 sec.
X.X%CH4 X.XX%CH4
E 2 sec. S E S
E NIE
E
KOMORA
NIE R KOMORA
SPRAWNA
R NIE
SPRAWNA
?
W ? W -
I I
YES S S +
YES
YES
UST00.0% Z UST0.00% Z
2 sec. 2 sec. E
ZAPIS! ZAPIS! XX.X%CH4

2 sec. 2 sec. E
UST. GAZ UST. GAZ UST.FAB.

- + - +
GAZXX.X% GAZX.XX%
E E
POD.GAZ POD.GAZ
10 sec. 10 sec.
XX.X%CH4 X.XX%CH4
S S
E E E E
R NIE
R NIE
W WARUNEK W WARUNEK
I I
S S
YE YE
C C
ZAPIS! ZAPIS!
2 sec. 2 sec. 2 sec.
STĘśENIE
<4%
Fig. 3 SC-CH4/*methane detector calibration (block diagram)

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5.3.3. SC-CH4/W methane detector calibration (conductometric chamber)
After obtaining permission for carrying out calibration the following window
will be displayed:
ST. WYS.
“E” button should be pressed until the following message will be displayed if
calibration is required:
POD. POW.
x.xx % CH4
CAUTION! Measurement result should be stabilized but it does not have to show 0.0 %
Checking whether “high zero” is contained within adjustment range takes place
UST.FAB.
UST 00.0 %
ZAPIS!
CAUTION! If, from any reasons, calibration of the detector will not be continued then after approx. 5 min
the calibration procedure will be interrupted, the methane detector will switch to normal
operation mode and will send information to the control unit about calibration process stop.
UST. GAZ
And then
GAZ xx.x %
Using “+” or “-” buttons we set on the display the value of high reference
mixture concentrations. Confirmation with [E] button.
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POD. GAZ
Feed reference gas through a cap (50 ÷ 80 % CH4). Measurement result will be
displayed after 10 seconds
xx.x % CH4
CAUTION! Measurement result should be stabilized but it does not have to show accurate concentration
of the reference gas.
Calibration is confirmed by pressing [E] button. Checking whether “high
concentration” is contained within adjustment range takes place.

.
UST.FAB.
If YES (condition is met) then after 2 seconds the following message will be displayed:
And then
CZEKAJ
After mentioned time the methane detector will send 1 control measurement with
record of high concentrations after correction. The message will be displayed:
WYJSCIE
Selected option is confirmed with “E” button and the following message will be
displayed:
NIE
Buttons [+] or [-] are used to select NO or YES.
YES NIE
Selected option is confirmed with [E] button. If we select NO then we go to the
beginning of the calibration that is
KALIBR.
and the calibration is started again. If YES is selected then we exit the calibration
mode and CH4 sensor switches to normal operation, that is
x.xx % CH4

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KALIBR
2 sec.
OR
CZEKAJ PIN XXXX

to 1.5 min.
YES NIE 2 sec.

Permission
ZEZWALAM BRAK ZEZWOLEN

from
dispatcher
?
2 sec.
- - +
ST. WYS. UST.FAB. WYJSCIE
E E
POD.POW. ZAPIS
E
5 sec.
X.X%CH4 NIE
-
E 2 sec. S +
E
KOMORA
NIE R YES
SPRAWNA
?
W
I E
YES S
UST00.0% Z
XX.X%CH4
2 sec.
ZAPIS!
2 sec.
UST. GAZ
- +
GAZXX.X%
E
POD.GAZ
10 sec.
XX.X%CH4
S
E E
R NIE
W WARUNEK
I
S
YES
C
ZAPIS!
2 sec.
Fig. 4 SC-CH4/W with CWx-3 methane detector calibration (block diagram)

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5.3.3.1. Factory settings
If despite correctly carried out calibration procedure or from any other reasons it
will be impossible to calibrate device correctly, user can try to recover so-called
FACTORY SETTINGS.
UST.FAB. Calibration settings made by the manufacturer.
After confirmation with “E” button the message will be displayed:
ZAPIS
After another 2 seconds message
WYJSCIE
It is necessary to calibrate the device once again according to the manual in order
to ensure correct operation.
CAUTION! If entering of factory setting did not allow calibrating the device it should be
sent to the manufacturer’s service.
5.4 Pin number entering
“PIN XXXX” message will be displayed when the sensor is operating self-contained,
without methanometric system (option BRAK selected).
After displaying the message: PIN XXXX using buttons we enter proper number
(standard number is 1979).
After displaying the message PIN XXXX on the first X item “0” will be displayed and
it will start to pulsate. Then using buttons [+] or [-] user should select number from
0÷9 range. Confirmation with [E] button. In place of the number asterisk symbol *
will be displayed.
Procedure for the remaining numbers is the same.
[+]
PIN 0XXX
[-]
[E]
[+]
PIN *0XX
[E] [-]
[+]
PIN **0X [-]
[E] [+]
PIN ***0 [-]
[E] [+]
PIN ****
[-]
Correctly entered pin will allow entering detector’s calibration mode.

Further procedure is according to the point 5.3.2 or point 5.3.3.

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5.5 Messages and additional functions.
a) During normal operation pressing “+” button results in displaying of the following
messages:
ZAS = xxx - value of supply voltage from line or power unit
AKU = xxx - value of accumulator voltage
ŁAD = xxx - charging current
PEL = xxx - value of supply voltage of measuring chamber
AL1 = xxx - alarm threshold I settings
AL2 = xxx - alarm threshold II settings
b) During normal operation pressing of „−” button will result in manual switch to high
concentrations range for some time.
c) During operation of the methane detector also the following messages can be
displayed:
Aku! - low state of accumulator charging
BRAK ZAS - lack of supply or too low supply voltage.
6. Instructions and maintenance

6.1 Maintenance, overhauls and repairs.
Maintenance of SC-CH4/* methane detectors is based on periodic inspection of
calibration, cleaning with soft brush of measuring chamber’s filter, enclosure as well
as maintenance of multi-plug connectors.
CAUTION! You should pay special attention to condition of the rubber o-rings in the
connectors and sockets type C16-1 eco-mate and replace it with the new
ones if necessary.
In order to achieve and the maintain accuracy specified in the technical data the
following operations should be performed:
- Low concentrations calibration should be made each time after the installation of
the methane detector and once per 2 weeks during normal operation*;
- High concentrations calibration should be made each time after the installation of
the methane detector and once per month during normal operation;
* - in case when the methane detector is installed in the area where chemical compounds, which can
influence the measuring head in the negative way, are used then the calibration should be
performed not rarely than once per week.
In SG-1/NW type measuring head it is recommended to replace carbon filter type FW/16
every 1 month during normal operation conditions.
In other cases filter should be replaced when:
- it is contaminated in such way that is cleaning is impossible;
- is destroyed;
- elongation of response time T90 will occur;
- sudden decrease of sensitivity of the chamber occurred;
- endangering to poisoning compounds is known.
Carbon filter can be replaced by individually by trained user by removing Seger ring
or other protection using special pliers and then installation of new carbon filter
in such way that there will not be any gaps through which gas can penetrate with
omission of the filter. Carbon filters can be purchased at the manufacturer or the
service engineer of the above mentioned device.
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CAUTION! Operation of the measuring head SG-1/NW without carbon filter is
not allowed. It can lead to damage of the measuring head.
Periodic inspection of detector’s operation should be performed by the appropriate
service fulfilling the corresponding requirements.
Methane detector’s overhauls at the manufacturer’s site should be performed at
least once per 12 months.
Installation, start-up and servicing of the measuring points should be performed
according to the obligatory regulations.
Repairs of the methane detectors SC-CH4/* made by the user are not expected.
Workers designated to servicing and maintenance of underground measuring
equipment should be trained by the manufacturer of the above mentioned device.
6.2 Charging of the accumulators

Charging from supply-transmission line or intrinsically safe power unit takes approx. 8
hours.
It is also possible to charge the accumulators outside the explosive zone from non-
intrinsically safe source of the following parameters:
Um = 45 V Imax = 40 mA
Rated voltage of the source Un ≥ 15 V DC
It takes ~ 8 hours to charge accumulator in this case.
In all cases charging is made by 7-fold line socket ZŁ A (contact 1 “+”; contact 1 “-”).
Pressing [+] during operation of the detector or switching off and switching on allows
to preview min. value of accumulator voltage.
6.3 Procedures in emergency situations
When the defective operation of the device is ascertained it should be disassembled
and transferred to service. Disassembly of the methane detector is made in the reverse
order than given in point 3.
Service is realized by:
„Carboautomatyka” S.A. in Tychy, ul. Budowlanych 168
Tel. (32) 32 34 346
7. Storage and transport

The methane detector should be stored in store rooms with relative humidity lower
than 80% and with temperature from 0 to 40 °C.
Rooms should be free of silicone, chlorine compounds vapours, lead and cadmium
compounds vapours, sulphur and freon.
The above listed compounds are toxic for measuring transducer causing decrease of its
sensitivity and life and can even cause its non-reversible damage.
CAUTION : Information from point 3.2, 6 applies only to domestic consignees.
In case of foreign consignees the contractual agreements are valid
in relation to warranty dates, climatic requirements as well as
authority responsible for service.
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8. Ordering
System methane detectors type SC-CH4/* can be ordered in:
PKiMSA „Carboautomatyka” S.A.
43 – 100 Tychy, ul. Budowlanych 168
tel.: (32) 323 43 42, fax: (32) 323 43 23
9. Warranty conditions
The company warrants operations of the product during 12 months from the date of
delivery. Warranty includes free of charge elimination of defects with preservation of
conditions specified in the warranty card and in this manual.
CAUTION : Information in point 6.2, 8 applies only to domestic consignees. In
case of foreign consignees the contractual agreements are valid in
relation to warranty dates, climatic requirements as well as
authority responsible for service.
10. Acceptance by the user

10.1 Accompanying documents
- Declaration of conformity CE,
- Quality Certificate,
- Service manual (DTR).
10.2 Instructions concerning visual inspection

During acceptance of the device user should check condition of the shipment and,
in case of the Reed, describe in the protocol the following:
- possible damages of the detector;

- nonconformity of detector’s serial number with this written in the warranty
card and manufacturing certificate;
- potential shortages which occurred in the shipment.
11 Special conditions for safe use

Battery charging from non-intrinsically safe supply source can be carried out only
outsider the explosion zone.

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Przedsiębiorstwo Kompletacji i MontaŜu Systemów Automatyki

System gas sensors

TECHNICAL AND OPERATING DOCUMENTATION

This conformity is confirmed by the EC Type Examination Certificate:

issued by The „OBAC” Institute for Research and Certification Ltd.

This product meets the essential requirements concerning electromagnetic

Manufacturer of the product – Przedsiębiorstwo Kompletacji i MontaŜu

Przedsiębiorstwo Kompletacji i MontaŜu Systemów Automatyki

1. Safety instructions ................................................................................................................................... 4

Przedsiębiorstwo Kompletacji i MontaŜu Systemów Automatyki

1) In groups in one cable type A or B

Przedsiębiorstwo Kompletacji i MontaŜu Systemów Automatyki

SC-CH4/n Basic version

Przedsiębiorstwo Kompletacji i MontaŜu Systemów Automatyki

Control signal (1 x WE)…………….- bi-state input

Supply (1 x WY, only SC-CH4/W)....- supplying of external measuring chamber

Signal (1 x WE, only SC-CH4/W)…....- signal from external measuring chamber

Przedsiębiorstwo Kompletacji i MontaŜu Systemów Automatyki

4.1 Mechanical construction of the sensor.

Przedsiębiorstwo Kompletacji i MontaŜu Systemów Automatyki

1 ,67 O 1O (K4 26 ,7 O 1O (K4

5. Installation, start-up and calibration

5.1 Description of the electric signals

Przedsiębiorstwo Kompletacji i MontaŜu Systemów Automatyki

5.2 Start and configuration

5.2.1 Starting of the detector

SC-CH4/* Name of the methane detector

nr xxxx Serial number

ver. xxx Software version

Digital control unit

or Operations with intrinsically safe power unit or with

AL1 x.xx Alarm threshold 1 set where x.xx – alarm value

AL2 x.xx Alarm threshold 2 set where x.xx – alarm value

if “WYŁ” is set then the following message will be displayed:

setting of voltage output control where “xxx”:

AKU = xx.x Accumulator voltage

ŁAD=xx.x value of charging current in mA

burning-in of catalytic bead sensors and possibility

5.2.2 Configuration of the detector SC-CH4/* (version n and s)

Przedsiębiorstwo Kompletacji i MontaŜu Systemów Automatyki

KSP-2 or KSP-3 or BRAK

Buttons [+] or [-] are used to select option as describe above.

setting of action of voltage output

Buttons [+] or [-] are used to select ZAŁ or WYŁ.

ZAPISANE Information about saving of changes in processor’s memory

After 2 seconds sensor will return to item:

5.2.3 Configuration of the SC-CH4/W sensor (version intended for

Entering to setting of the complete sensor’s configuration is possible just after

KSP-2 or KSP-3 or BRAK

Buttons [+] or [-] are used to select option as describe above.

CAUTION! Value of AL1 threshold cannot be lower than value of AL2

Buttons [+] or [-] are used to select ZAŁ or WYŁ.

Buttons [+] or [-] are used to select ZAŁ or WYŁ.

ZAPISANE Information about saving of changes in processor’s memory

After 2 seconds sensor will return to item:

Przedsiębiorstwo Kompletacji i MontaŜu Systemów Automatyki

WYŁ? Question whether the sensor should be switched

WYŁACZAM Sensor is switching off

5.3.2 Calibration of methane detector SC-CH4/* (two-range chamber)

CZEKAJ or PIN XXXX

In case when the methane detector operates self-contained, after displaying of

ZEZWALAM information about permission to carry out calibration