Fixedgas Microsafe500600 FP 624d Usermanual English

INSTRUCTION MANUAL
Detcon Model FP-624D
PGM 1
MODEL HOUSTON, TEXAS FP-624D
MicroSafeTM LEL Gas Sensor

ALM ALM
FLT 1 2 CAL
PGM 2
FP-624D Combustible Gas Sensor

(0-100% LEL)
DETCON, Inc.
4055 Technology Forest Blvd, Suite 100,
The Woodlands, Texas 77381
Ph.281.367.4100 / Fax 281.298.2868
www.detcon.com
June 05, 2018 • Document #3598 • Revision 1.5

Model FP-624D
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FP-624D Instruction Manual ii

Model FP-624D
Table of Contents
1. Introduction ..................................................................................................................................................1
1.1 Description .......................................................................................................................................... 1
1.2 Modular Mechanical Design ............................................................................................................... 3
1.3 Relay Outputs...................................................................................................................................... 5
2. Installation ....................................................................................................................................................6
2.1 Operational Guidelines for Safe Use .................................................................................................. 6
2.2 Sensor Placement ................................................................................................................................ 6
2.3 Sensor Contaminants and Interference ............................................................................................... 7
2.4 Mounting Installation .......................................................................................................................... 8
2.5 Electrical Installation .......................................................................................................................... 9
2.6 Field Wiring ...................................................................................................................................... 10
2.7 Remote Mounting Installation .......................................................................................................... 11
2.7.1 Bridge Voltage Adjustment .......................................................................................................... 12
2.8 Initial Start Up................................................................................................................................... 12
3. Operation .................................................................................................................................................... 14
3.1 Programming Magnet Operating Instructions................................................................................... 14
3.2 Operator Interface ............................................................................................................................. 15
3.3 Normal Operation ............................................................................................................................. 17
3.4 Calibration Mode (AutoSpan)........................................................................................................... 17
3.4.1 AutoZero....................................................................................................................................... 17
3.4.2 AutoSpan ...................................................................................................................................... 18
3.5 Program Mode .................................................................................................................................. 20
3.5.1 View Sensor Status ....................................................................................................................... 20
3.5.2 Set AutoSpan Level ...................................................................................................................... 22
3.5.3 Set Gas Factor............................................................................................................................... 23
3.5.4 Set Cal Factor ............................................................................................................................... 24
3.5.5 Set Bridge Voltage........................................................................................................................ 25
3.5.6 Signal Output Check ..................................................................................................................... 26
3.5.7 Restore Factory Defaults .............................................................................................................. 26
3.5.8 Set Serial ID ................................................................................................................................. 27
3.5.9 Alarm 1 and 2 Settings ................................................................................................................. 27
3.5.10 Fault Settings ............................................................................................................................ 28
3.6 Program Features .............................................................................................................................. 29
3.6.1 Operational Features ..................................................................................................................... 29
3.6.2 Fault Diagnostic/Failsafe Features ............................................................................................... 29
4. RS-485 ModbusTM Protocol ....................................................................................................................... 32
5. Service and Maintenance ............................................................................................................................ 34
6. Troubleshooting Guide ............................................................................................................................... 36
7. Customer Support and Service Policy ........................................................................................................ 39
8. FP-624D Sensor Warranty.......................................................................................................................... 40
9. Appendix .................................................................................................................................................... 41
9.1 Specifications .................................................................................................................................... 41
9.2 Spare Parts, Sensor Accessories, Calibration Equipment ................................................................. 43
9.3 Revision Log ..................................................................................................................................... 44
FP-624D Instruction Manual iii

Model FP-624D
List of Figures
Figure 1 Sensor Assembly Front View ................................................................................................................ 1
Figure 2 Sensor Cell Construction ....................................................................................................................... 2
Figure 3 Wheatstone Bridge ................................................................................................................................. 2
Figure 4 Response Curves .................................................................................................................................... 3
Figure 5 Circuit Functional Block Diagram ......................................................................................................... 3
Figure 6 Transmitter Module ............................................................................................................................... 4
Figure 7 Field Replaceable Combustible Gas Sensor .......................................................................................... 4
Figure 8 Base Connector Board ........................................................................................................................... 5
Figure 9 Typical Outline and Mounting Dimensions ........................................................................................... 8
Figure 10 Typical Installation .............................................................................................................................. 9
Figure 11 Sensor Connector PCB....................................................................................................................... 11
Figure 12 Remote Sensor Wiring Diagram ........................................................................................................ 12
Figure 13 Magnetic Programming Tool ............................................................................................................. 14
Figure 14 Magnetic Programming Switches ...................................................................................................... 14
Figure 15 FP-624D Software Flowchart ............................................................................................................ 16
Figure 16 Replaceable Combustible Gas Sensor............................................................................................... 36
Figure 17 Plug-in Sensor (Bottom View) ........................................................................................................... 36
List of Tables
Table 1 Wire Gauge vs. Distance ....................................................................................................................... 10
Table 2 Gas/Cal Factors ..................................................................................................................................... 24
Table 3 Modbus Registers .................................................................................................................................. 32
Table 4 Notation Text String Description .......................................................................................................... 33
Shipping Address: 4055 Technology Forest Blvd, Suite 100, The Woodlands Texas 77381
Mailing Address: P.O. Box 8067, The Woodlands Texas 77387-8067
Phone: 888.367.4286, 281.367.4100 • Fax: 281.292.2860 • www.detcon.com • [email protected]
FP-624D Instruction Manual iv

Model FP-624D
1. Introduction
1.1 Description
Detcon Model FP-624D combustible gas sensors are non-intrusive “Smart” sensors designed to detect and
monitor combustible gases in air. Range of detection is 0-100% LEL (Lower Explosive Limit). The sensor
features an LED display of current reading, fault, and calibration status. The sensor is equipped with standard
analog 4-20mA, ModbusTM RTU output, and 3 relay contact outputs. A primary feature of the sensor is its
method of automatic calibration, which guides the user through each step via fully scripted instructions displayed
on the LED display.
The microprocessor-supervised electronics are packaged as a plug-in replaceable Transmitter Module that is
housed in an explosion proof junction box. The Transmitter Module includes a four character alpha/numeric
LED used to display sensor readings, and the sensor’s menu driven features when the hand-held programming
magnet is used.
PGM 1

ALM ALM
FLT 1 2 CAL
PGM 2
Figure 1 Sensor Assembly Front View
Catalytic Bead (Pellistor) Sensor Technology

The sensor technology is a poison-resistant catalytic bead type. Catalytic bead sensors show a strong response
to a long list of combustible gases. The sensor is supplied as a matched-pair of detector elements mounted in a
plug-in replaceable module. One bead is a catalytically active detector and the other is a non-active reference
detector. Each detector consists of a fine platinum wire coil embedded in aluminum oxide. A catalytic mixture
is applied to the active detector while the reference detector is treated so that oxidation of the gas does not occur.
The technique is referred to as non-selective and may be used to monitor most any combustible gas. Detcon
catalytic bead sensors are specifically designed to be resistant to poisons such as sulfides, chlorides, and
silicones. The sensors are characteristically stable and capable of providing reliable performance for periods
exceeding 5 years in most industrial environments.
FP-624D Instruction Manual Rev. 1.5 Page 1 of 44

Model FP-624D
Alumina Bead
Platinum Wire Catalytic Beads
Main Housing Insert
Printed Circuit Board

Catalyst Construction
of Detector Gold Plated Pins
Bead
Figure 2 Sensor Cell Construction
Principle of Operation
Method of detection is by diffusion/adsorption. Air and combustible gases pass through a sintered stainless steel
filter and contact the heated surface of both the active and reference detectors. The surface of the active detector
promotes oxidation of the combustible gas molecules while the reference detector has been treated not to support
this oxidation. The reference detector serves as a means to maintain zero stability over a wide range of
temperature and humidity.
When combustible gas molecules oxidize on the surface of the active detector, heat is generated, and the
resistance of the detector changes. Electronically, the detectors form part of a balanced bridge circuit. As the
active detector changes in resistance, the bridge circuit unbalances. This change in output is conditioned by the
amplifier circuitry, which is an integral part of the sensor design. The response and clearing characteristics of
the sensor are rapid and provide for the continuous and accurate monitoring of ambient air conditions.
Sensor
Cell Compensator /
Reference Bead
Input
Zero
Voltage
Adjust
Detector /
Active Bead
Output
Figure 3 Wheatstone Bridge
Performance Characteristics
The detector elements maintain good sensitivity to combustible gas concentrations in the Lower Explosive Limit
(LEL) range, as shown in the response curves in Figure 4. However, for gas concentrations significantly above
the LEL range (100% LEL = 5% by volume Methane), the bridge output begins to decrease. Ambiguous
readings above the LEL range dictate that alarm control logic be of the latching type, wherein alarms are held
in the “ON” position until reset by operations personnel.

Model FP-624D
Figure 4 Response Curves
1.2 Modular Mechanical Design

The Model FP-624D Sensor Assembly is completely modular and is made up of four parts:
1) FP-624D Plug-in Transmitter

2) Field Replaceable Combustible Gas Sensor
3) Connector PCB
4) Splash Guard
FP-624D Plug-in Transmitter

The Plug-in Transmitter Module is a microprocessor-based package that plugs into the connector board located
in the explosion proof junction box. Circuit functions include extensive I/O circuit protection, sensor pre-
amplifier, sensor temperature control, on-board power supplies, microprocessor, LED display, magnetic
programming switches, a linear 4-20mA DC output, and a Modbus RTU output. Magnetic program switches
located above and below the LED Display are activated via a hand-held magnetic programming tool, thus
allowing non-intrusive operator interface with the Transmitter Module. Calibration can be accomplished without
declassifying the area. Electrical classifications are Class I, Division 1, Groups B C D.
Pre-Amp Display Analog 4-20mA Out

Micro-
Plug-In Processor I/O Relays Out
Sensor Temperature RS-485 Circuit
Element Control Protection Modbus RTU
4-20mA
Power In
Power Supply
Figure 5 Circuit Functional Block Diagram

Model FP-624D
PGM 1

ALM ALM
FLT 1 2 CAL
PGM 2
Figure 6 Transmitter Module
The transmitter module includes four LED status indicators (see Figure 3). These indicators are labeled FLT,
ALM1, ALM2 and CAL. The ALM1 and ALM2 LEDs are illuminated when the sensor is above the
corresponding alarm threshold. The FLT LED is illuminated when the sensor is in fault. The CAL LED is
illuminated solid when the sensor is completing an AutoZero or AutoSpan calibration. If the sensor is not being
calibrated, the CAL LED will flash each time the sensor answers a poll request from a ModbusTM master.
Field Replaceable Sensor

The Detcon combustible gas sensor is a field proven, replaceable type sensor. It can be accessed and replaced
in the field by removing the threaded insert from the lower housing and unplugging the replaceable sensor. The
Detcon combustible gas sensor has an infinite shelf life and is supported by a 2 year warranty.
Replaceable Sensor
Threaded Insert O-ring Main Housing
Figure 7 Field Replaceable Combustible Gas Sensor
NOTE: The Field Replaceable Combustible Gas Sensor housing is constructed from 316 Stainless Steel in order
to maximize corrosion resistance in harsh environments.
Base Connector PCB
The base connector board is mounted in the junction box. The connector board includes lug-less terminal
connections for incoming power, Modbus, and mA output, and connections for the Combustible Gas
Replaceable Sensor. Terminals for the 3 common and normally open/normally closed relay outputs are also
located on the base connector board.

Model FP-624D
Relays
Customer
Wiring
Wiring to
Figure 8 Base Connector Board
1.3 Relay Outputs

The FP-624D includes three 5A Form C relay outputs. Two of these relays are dedicated to alarm outputs, and
the third is used to indicate when the sensor is in fault. The common and normally closed contacts on the alarm
relays are connected when the gas concentration is below the alarm threshold. If the concentration exceeds the
alarm threshold for more than five seconds, then the common and normally open contacts will be connected.
The common and normally closed contacts on the fault relay are connected when the sensor is not in fault. If the
sensor experiences a fault condition for more than five seconds, then the common and normally open contacts
will be connected.
The common and either the normally open or the normally closed contacts from the alarm and fault relays are
connected to terminals on the base connector board. A jumper near each relay is used to select whether the
normally open or normally closed contact is connected to the terminal on the base connector board.
The relays can be configured to operate in Energized Mode. In this mode, the common and normally open
contacts are connected when the gas is below the alarm threshold (alarm relays) or is not in fault (fault relay).
This mode allows for fail-safe operation of the sensor. If the power to the sensor fails or the cable to the sensor
I/O is disconnected, then the common and normally open contacts will no longer be connected.
The alarm and fault relays can be configured as either latching or non-latching. In non-latching mode, the relay
is deactivated as soon as the sensor alarm or fault condition is cleared. In latching mode, the relay remains active
even after the alarm or fault condition has cleared. Once activated, the relay can only be deactivated by swiping
a magnetic programming tool above the PGM1 or PGM2 mark on the FP-624D face plate.
The alarm relays can be configured for ascending or descending mode. In ascending mode the relay will be
activated when the concentration is above the alarm threshold. This is the most common mode of operation for
the FP-624D. The alarm relays can also be activated in descending mode. In this mode, the alarm relays will
activate when the concentration is below the alarm threshold.
NOTE: The relay outputs will not activate during the first 60 seconds after sensor power up.
This allows the sensor cell to stabilize and begin outputting an accurate reading.

Model FP-624D
2. Installation
2.1 Operational Guidelines for Safe Use
1. Ensure that the sensor is properly mounted in a vertical orientation with the sensor facing down. When
applying Teflon tape, do not apply to all threads - only use enough to make a good seal (covering about
½ the threads is sufficient). A metal to metal connection is required to ensure earth ground continuity
for electrical safety.
2. Ensure that the sensor is properly mounted in a vertical orientation with sensor facing down. Avoid
use of excessive Teflon Tape, or any type of non-conductive pipe thread coating on the NPT threaded
connection. All NPT connections should remain grounded to the junction box.
3. Use ¾” NPT plugs properly rated for hazardous locations to block any unused connections.
4. Removal of the Junction box cover or threaded sensor housing (612-820000-000) violates the Ex Proof
protection method and hence power must be removed from the sensor prior to its safe removal.
5. Ensure that the threaded insert and plug-in sensor are installed during operation. The threaded insert
should be secured tightly to the sensor housing. Removal of the threaded insert violates the Ex Proof
protection method and hence power must be removed from the sensor prior to its safe removal.
6. Proper precautions should be taken during installation and maintenance to avoid the build-up of static
charge on the plastic components of the sensor. These include the splashguard and splashguard adapter.
7. Do not operate the sensor outside of the stated operating temperature limits.
8. Do not operate the sensor outside the stated operating limits for voltage supply.
2.2 Sensor Placement

Selection of sensor location is critical to the overall safe performance of the product. Six factors play an
important role in selection of sensor locations:
(1) Density of the gas to be detected

(2) Most probable leak sources within the industrial process
(3) Ventilation or prevailing wind conditions
(4) Personnel exposure
(5) Maintenance access
(6) Additional Placement Considerations
Density
Placement of sensors relative to the density of the target gas is such that sensors for the detection of heavier than
air gases should be located within 4 feet of grade as these heavy gases will tend to settle in low lying areas. For
gases lighter than air, sensor placement should be 4-8 feet above grade in open areas or in pitched areas of
enclosed spaces.
NOTE: Methane and Hydrogen are lighter than air. Most other combustible gases are heavier
than air. Compare the molecular weight, density, or specific gravity of the target gas(es) with
that of air to determine appropriate placement.
Model FP-624D
Leak Sources
The most probable leak sources within an industrial process include flanges, valves, and tubing connections of
the sealed type where seals may either fail or wear. Other leak sources are best determined by facility engineers
with experience in similar processes.
Ventilation
Normal ventilation or prevailing wind conditions can dictate efficient location of gas sensors in a manner where
the migration of gas clouds is quickly detected.
Personnel Exposure
The undetected migration of gas clouds should not be allowed to approach concentrated personnel areas such as
control rooms, maintenance or warehouse buildings. A more general approach toward selecting sensor location
is combining leak source and perimeter protection in the best possible configuration.
Maintenance Access
Consideration should be given to providing easy access for maintenance personnel. Consideration should also
be given to the consequences of close proximity to contaminants that may foul the sensor prematurely.
NOTE: In all installations the gas sensor should point straight down (refer to Figure 10).
Improper sensor orientation may result in false readings and permanent sensor damage.
Additional Placement Considerations

The sensor should not be positioned where it may be sprayed or coated with surface contaminating substances.
Painting sensor assemblies is prohibited.
Although the sensor is designed to be RFI resistant, it should not be mounted in close proximity to high-powered
radio transmitters or similar RFI generating equipment.
When possible mount in an area void of high wind, accumulating dust, rain, or splashing from hose spray, direct
steam releases, and continuous vibration. If the sensor cannot be mounted away from these conditions then
make sure the Detcon Harsh Location Dust Guard accessory is used.
Do not mount in locations where temperatures will exceed the operating temperature limits of the sensor. Where
direct sunlight leads to exceeding the high temperature-operating limit, use a sunshade to help reduce
temperature.
2.3 Sensor Contaminants and Interference

Detcon combustible gas sensors may be adversely affected by exposure to certain airborne substances. Loss of
sensitivity or corrosion may be gradual if such materials are present in sufficient concentrations.
The performance of the detector elements may be temporarily impaired during operation in the presence of
substances described as inhibitors. Inhibitors are usually volatile substances containing halogen compounds.
Inhibitors include halide compounds such as Cl2, ClO2, F2, HF, HCl, Br2, vinyl chloride, and methyl chloride.
Inhibition is typically a temporary effect and the detectors generally recover after short periods of operation back
in clean air.

Model FP-624D
Some background gases may act as poisoning agents and have a more damaging effect on the sensor. Although
the sensor is designed to be poison resistant, it does have physical limits. Poisoning gases deactivate the active
detector’s catalytic ability and cause a permanent reduction in the span sensitivity. Examples of typical poisons
are: silicone oils and greases, siloxanes (HMDS), H2S, anti-knock petrol additives, and phosphate esters.
Activated carbon filters can be used to provide additional protection from poisoning in most cases.
The presence of such inhibitors and poisons in an area does not preclude the use of this sensor technology,
although it is likely that the sensor lifetime will be shorter as a result. Use of this sensor in these environments
may require more frequent calibration checks to ensure safe system performance.
2.4 Mounting Installation

The FP-624D should be vertically oriented so that the sensor points straight downward. The explosion-proof
enclosure or junction box would then typically be mounted on a wall or pole (See Figure 9). Detcon provides a
selection of standard junction boxes in both Aluminum and Stainless Steel.
NOTE: Do not use Teflon Tape or any other type of Pipe Thread material on the ¾” threads
unless the unit is mounted in a severe or harsh environment. Metal-on-metal contact must be
maintained to provide a solid electrical ground path. If Teflon Tape is used the Sensor must be
externally grounded using a ground strap.
When mounting on a pole, secure the Junction Box to a suitable mounting plate and attach the mounting plate
to the pole using U-Bolts. (Pole-Mounting brackets for Detcon Junction Box’s are available separately.)
6.125"
5.5" 3
NPT Ports 4.6"
4
5.25"
6.985"
8-32 tapped
ground point
mounting surface)
Wall (or other
1
4" mounting holes
LEL Sensor
2.1"
Splash Guard
2"
0.5"
Figure 9 Typical Outline and Mounting Dimensions

Model FP-624D
2.5 Electrical Installation

The Sensor Assembly should be installed in accordance with local electrical codes. The sensor assemblies are
CSA/NRTL approved (US and Canada) for Class I, Division 1, Groups B C D area classifications.
Proper electrical installation of the gas sensor is critical for conformance to Electrical Codes and to avoid damage
due to water leakage. Refer to Figure 10 and Figure 11 for proper electrical installation.
NOTE: If a conduit run exits the secondary port, repeat the installation technique shown in
Figure 10.
In Figure 10, the drain allows H2O condensation inside the conduit run to safely drain away from the sensor
assembly. The electrical seal fitting is required to meet the National Electrical Code per NEC Article 500-3d
(or Canadian Electrical Code Handbook Part 1 Section 18-154). Requirements for locations of electrical seals
are covered under NEC Article 501-5. Electrical seals also act as a secondary seal to prevent water from entering
the wiring terminal enclosure. However, they are not designed to provide an absolute watertight seal, especially
when used in the vertical orientation.
NOTE: For products utilizing the aluminum junction box option, the conduit seal shall be placed
at the entry to the junction box (see Figure 10 as an example). For products utilizing the stainless
steel junction box option, the conduit seal shall be placed within 18" of the enclosure. Crouse
Hinds type EYS2, EYD2 or equivalent are suitable for this purpose.
NOTE: The Detcon Warranty does not cover water damage resulting from water leaking into
the enclosure.
Conduit
"T" EYS Seal Fitting
PGM 1
MODEL HOUSTON, TEXAS TP-624D
MicroSafeTM H2S Gas Sensor
Drain FLT
ALM ALM
1 2 CAL
PGM 2
Figure 10 Typical Installation
NOTE: Any unused ports should be blocked with suitable ¾” male NPT plugs. Detcon Supplies
one ¾” NPT male plug with each J-box enclosure. If connections are other than ¾” NPT, use
an appropriate male plug of like construction material.
Model FP-624D
2.6 Field Wiring

Detcon Model FP-624D combustible gas sensor assemblies require up to five conductor connections between
power supplies and host electronic controller. Wiring designations are DC+, DC-, MA (sensor signal), Modbus
A and Modbus B. If the MA signal is not needed, a 250 ohm load resistor should be connected between the 4-
20mA and the Power ‘-‘ terminals to properly terminate the signal. The maximum wire length between the
sensor and 24VDC source is shown in the Table below. The maximum wire size for termination in the Junction
Box is 14 AWG.
Table 1 Wire Gauge vs. Distance

Over-Current
AWG Wire Dia. Meters Feet
Protection
22 0.723mm 700 2080 3A
20 0.812mm 1120 3350 5A
18 1.024mm 1750 5250 7A
16 1.291mm 2800 8400 10A
14 1.628mm 4480 13,440 20A
NOTE 1: Wiring table is based on stranded tinned copper wire and is designed to serve as a
reference only.
NOTE 2: Shielded cable is required for installations where cable trays or conduit runs include
high voltage lines or other possible sources of induced interference. Separate conduit runs are
highly recommended in these cases.
NOTE 3: The supply of power should be from an isolated source with over-current protection
as stipulated in Table 1 Wire Gauge vs. Distance.
NOTE 4: A 250 ohm load resistor is needed between the 4-20 mA and the Power ‘-‘ terminals
when the 4-20mA signal is not being used.
Terminal Connections
CAUTION: Do not apply System power to the sensor until all wiring is properly terminated. Refer to
Section 2.8 Initial Start Up

Model FP-624D
Alarm 2
Alarm 1
Fault
Customer
Wiring
Power (+ -)
4-20 mA
RS-485 (A,B)
Yellow
White
Black
Blue
Wiring to
LEL Sensor
Figure 11 Sensor Connector PCB
a) Remove the junction box cover and unplug the Transmitter Module. Identify the terminal blocks for
customer wire connections.
b) Observing correct polarity, terminate the field wiring (DC+, DC-, MA, A, and B) to the sensor assembly
wiring in accordance with the detail shown in Figure 11.
c) Trim all exposed wire leads if they are not permanently landed in the terminal block.
d) Plug the Transmitter Module into the connector PCB and replace the junction box cover.
NOTE: A 6-32 or 8-32 threaded exterior ground point is provided on most junction boxes for an
external ground. If the Sensor Assembly is not mechanically grounded, an external ground strap
must be used to ensure that the sensor is electrically grounded.
2.7 Remote Mounting Installation

Some sensor mounting applications require that the gas sensor head be remotely mounted away from the sensor
transmitter. This is usually true in instances where the gas sensor head must be mounted in a location that is
difficult to access. Such a location creates problems for maintenance and calibration activities. Detcon provides
the FP-624D sensor in a remote-mount configuration in which the sensor (Model FP-624D-RS) and the
transmitter (Model FP-624D-RT) are provided in their own condulet housing and are interfaced together with a
three conductor cable. There is a limit 0.5 ohm maximum resistance drop per wire over the separation distance.
AWG Maximum Separation (feet)

20 50
18 75
16 125
14 175
Reference Figure 12 for wiring diagram. Also note the jumper that is required on the remote sensor connector
board. Failure to install this jumper will cause a sensor fault condition.

Model FP-624D
Figure 12 Remote Sensor Wiring Diagram
2.7.1 Bridge Voltage Adjustment

When a sensor is remote mounted, consideration must be given to the lengths of cable used and how it affects
the sensor bridge voltage. Differing lengths of cables will have varying amounts of resistance which will shift
the sensor bridge voltage. Because of this, the bridge voltage will need to be adjusted after initial power up.
This adjustment is only required after initial installation and will not be necessary thereafter, except in the
event of replacement of the plug-in sensor. Refer to section 3.5.5 to perform this adjustment.
NOTE: Refer to section 3.5.5 to set the sensor bridge voltage.
2.8 Initial Start Up

Upon completion of all mechanical mounting and termination of all field wiring, apply system power in the
range of 12-28VDC (24VDC typical) and observe the following normal conditions:
a) FP-624D display reads “0”, and no fault messages are flashing.
b) A temporary upscale reading may occur as the sensor heats up. This upscale reading will decrease to “0” %
within 1-2 minutes of power-up, assuming there is no gas in the area of the sensor.
NOTE: The 4-20mA signal is held constant at 4mA for the first two minutes after power up.
Initial Operational Tests

After a warm up period of 1 hour, the sensor should be checked to verify sensitivity to combustible gas.
Material Requirements
-Detcon PN 600-610000-000 Splash Guard with integral Cal Port -OR-
-Detcon PN 943-000006-038 Threaded Calibration Adapter
- Detcon PN 942-520124-050 Span Gas; 50% LEL methane/balance Air at fixed flow rate of 200-500cc/min.
NOTE: Do not use calibration gases in Nitrogen background gas mixtures. This will cause
significant reading inaccuracies.

Model FP-624D
a) Attach the calibration adapter to the threaded sensor housing. Apply the test gas at a controlled flow rate of
200 - 500cc/min (200cc/min is the recommended flow). Allow 1-2 minutes for the reading to stabilize.
Observe that during the 1-2 minutes the display increases to a level near that of the applied calibration gas
value.
b) Remove test gas and observe that the display decreases to “0”.
Initial operational tests are complete. Detcon combustible gas sensors are factory calibrated prior to shipment,
and should not require significant adjustment on start up. However, it is recommended that a complete
calibration test and adjustment be performed 16 to 24 hours after power-up. Refer to span calibration instructions
in Section 3.4.

Model FP-624D
3. Operation
3.1 Programming Magnet Operating Instructions
The Operator Interface of the FP-624D gas sensors is accomplished via two internal magnetic switches located
above and below the LED display (Figure 14). The two switches, labeled “PGM1” and “PGM2”, allow for
complete calibration and configuration, thereby eliminating the need for area de-classification or the use of hot
permits.
Figure 13 Magnetic Programming Tool
The magnetic programming tool (Figure 13) is used to operate the magnetic switches. Switch action is defined
as momentary contact, 3-second hold, and 10-second hold. (Hold times are defined as the time from the point
when the arrow prompt “▼” appears.) For momentary contact use, the programming magnet is briefly held
over a switch location. For 3-second hold, the programming magnet is held in place over the switch location for
three seconds. For 10-second hold, the programming magnet is held in place over the switch location for 10
seconds. The 3 and 10 second holds are generally used to enter calibration/program menus and save new data.
The momentary contact is generally used to move between menu items and to modify set-point values. Arrows
(“▼” and “▲”) are used on the LED display to indicate when the magnetic switches are activated. The location
of “PGM1” and “PGM2” are shown in Figure 14.
Program 1
PGM 1

ALM ALM
FLT 1 2 CAL
PGM 2
Program 2
Figure 14 Magnetic Programming Switches
NOTE: While in the Program Mode, if there is no magnetic switch interaction after 4 consecutive
menu scrolls, the sensor will automatically revert to normal operating condition. While changing
values inside menu items, if there is no magnet activity after 3-4 seconds the sensor will
revert to the menu scroll. (Exception to this is with “Signal Output Check” mode.)

Model FP-624D
3.2 Operator Interface

The operating interface is menu-driven via the two magnetic program switches located under the target marks
of the sensor housing. The two switches are referred to as “PGM1” and “PGM2”. The menu list consists of
three major items that include sub-menus as indicated below. (Refer to the complete Software Flow Chart.)
Normal Operation
Current Reading and Fault Status
Calibration Mode
AutoZero
AutoSpan
Program Mode
View Sensor Status

Sensor Model Type
Current Software Version
Range of Detection
AutoSpan Level
Days Since Last AutoSpan
Remaining Sensor Life
Sensor Bridge Current
Sensor Bridge Voltage
Gas Factor
Cal Factor
mA Output
Input Voltage Supply
Sensor Temperature
Serial ID
Alarm 1 Level
Alarm 1 Ascending
Alarm 1 Latching
Alarm 1 Energized
Alarm 2 Level
Alarm 2 Ascending
Alarm 2 Latching
Alarm 2 Energized
Fault Latching
Fault Energized
Set AutoSpan Level
Set Gas Factor
Set Cal Factor
Set Bridge Voltage
Signal Output Check
Restore Default Settings
Set Serial ID
Alarm 1 Settings
Alarm 2 Settings
Fault Settings
Model FP-624D
Software Flowchart
Normal Operation Calibration Mode

PGM1 (3)
PGM1 (3) (Auto Zero)
PGM2 (3)
PGM2 (3)
Calibration Mode
(Auto Span)
View Sensor Status
Auto Time-Out
PGM1/2 (M) Set AutoSpan Level Set Gas Factor Set Cal Factor Set Bridge Voltage
PGM1/2 (3) AutoTime-out Auto Time-Out Auto Time-Out Auto Time-Out
PGM1/2 (M) PGM1/2 (M) PGM1/2 (M) PGM1/2 (M)
PGM1/2 (3) PGM1/2 (3) PGM1/2 (3) PGM1/2 (3)
Model Type
## ## ## ##
Version X.XX
inc PGM1 (S) inc PGM1 (S) inc PGM1 (S) inc PGM1 (S)
PGM2 (S) dec PGM2 (S) dec PGM2 (S) dec PGM2 (S) dec
PGM1/2 (3) PGM1/2 (3) PGM1/2 (3) PGM1/2 (3)
Range XXX ppm
AutoSpan @ XX
Signal Output Check Restore Defaults Set Serial ID

Last Cal XX Days Auto Time-Out Auto Time-Out Auto Time-Out
PGM1/2 (M) PGM1/2 (M) PGM1/2 (M)
PGM2 (10) PGM1/2 (10) PGM1/2 (3)
Sensor Life XXX%
Simulation Defaults Restored ##

Bridge Current
PGM1/2 (3) inc PGM1 (S)
PGM2 (S) dec
PGM1/2 (3) LEGEND:
Bridge Voltage
PGM1 - Program Switch Location #1
PGM2 - Program Switch Location #2
Gas Factor
(S) - Momentary Swipe
Alarm 1 Settings Alarm 2 Settings Fault Settings (M) - Momentary hold of Magnet during text
Cal Factor AutoTime-out AutoTime-out AutoTime-out scroll until the ">" appears, then release
PGM1/2 (M) PGM1/2 (M) PGM1/2 (M) (3) - 3 second hold from ">" prompt
PGM1/2 (3) PGM1/2 (3) PGM1/2 (3) (10) - 10 second hold from ">" prompt
mA Output XX.XX Auto Time-out - 5 seconds
Alarm 1 Level Alarm 2 Level Fault Latching inc - Increase

Voltage XX.X VDC dec - Decrease
## ## Y/N
inc PGM1 (S) inc PGM1 (S) AutoTime-out #, ##, ### - numeric values
PGM2 (S) dec PGM2 (S) dec inc PGM1/2 (M)
Sensor Temp XX C
PGM1/2 (3) PGM1/2 (3) PGM1/2 (3)
Serial ID
Alarm 1 Level
Alarm 1 Ascending
Alarm 1 Ascending Alarm 2 Ascending Fault Energized
Y/N Y/N Y/N
AutoTime-out AutoTime-out AutoTime-out
Alarm 1 Latching
inc PGM1/2 (M) inc PGM1/2 (M) inc PGM1/2 (M)
PGM1/2 (3) PGM1/2 (3) PGM1/2 (3)
Alarm 1 Energized
Alarm 2 Level
Alarm 2 Ascending
Alarm 1Latching Alarm 2 Latching

Y/N Y/N
Alarm 2 Latching
AutoTime-out AutoTime-out
inc PGM1/2 (M) inc PGM1/2 (M)
PGM1/2 (3) PGM1/2 (3)
Alarm 2 Energized
Fault Latching
Fault Energized
Alarm 1 Energized Alarm 2 Energized

Y/N Y/N
AutoTime-out AutoTime-out
inc PGM1/2 (M) inc PGM1/2 (M)
PGM1/2 (3) PGM1/2 (3)
Figure 15 FP-624D Software Flowchart

Model FP-624D
3.3 Normal Operation

In normal operation, the display continuously shows the current sensor reading, which will normally appear as
“0”. Once every minute, the LED display will flash the sensor’s units of measure and the gas type (i.e. % LEL).
If the sensor is actively experiencing any diagnostic faults, a “Fault Detected” message will scroll across the
display once every minute instead of the units of measure and the gas type. At any time, while the sensor is in
“Fault Detected” mode, PGM1 or PGM2 can be swiped to prompt the sensor to display a list of the active faults.
In normal operation, the 4-20mA current output linearly corresponds with the full-scale range.
3.4 Calibration Mode (AutoSpan)

Calibration Mode allows for sensor span calibration. Span calibration should be performed on a routine basis
(quarterly minimum) to ensure reliable performance. If a sensor has been exposed to any de-sensitizing gases
or to very high over-range combustible gas levels, then a re-calibration should be considered. Unless otherwise
specified, span adjustment is recommended at 50% LEL. This function is called “AUTO SPAN.”
3.4.1 AutoZero
The AutoZero function is used to zero the sensor. Local ambient air can be used to zero calibrate the sensor as
long as it can be confirmed that it contains no combustible gases. If this cannot be confirmed then a zero air
cylinder should be used.
Material Requirements:
-Detcon PN 327-000000-000 MicroSafe™ Programming Magnet
-Detcon PN 613-120000-000 Splash Guard with integral Cal Port -OR-
-Detcon PN 942-001123-000 Zero Air cal gas or use ambient air if no combustible gas is present.
NOTE: The zero gas source should have a normal background concentration of 20.9% O2. Pure
Nitrogen gas standards should not be used or errors may result.
a) If the ambient air is known to contain no combustible gas content, then it can be used to zero calibrate. If a
zero gas cal cylinder is going to be used then attach the calibration adapter and set flow rate of 200-
500cc/min and let sensor purge for 1-2 minutes before executing the AutoZero.
b) From Normal Operation, enter Calibration Mode by holding the programming magnet over PGM1 for 3-4
seconds. Note, the “▲” prompt will show that the magnetic switch is activated during the 3 second hold
period. The display will then scroll “PGM1=Zero …PGM2=Span”. Hold the programming magnet over
PGM1 for 3-4 seconds once the “▲” prompt appears to execute AutoZero (or allow to timeout in 10 seconds
if AutoZero is not desired).
NOTE: Upon entering Calibration Mode, the 4-20mA signal drops to 2mA and is held at this
level until the program returns to normal operation. The “In Calibration” bit in the ModbusTM
Fault Status register will be set until the calibration is complete.

Model FP-624D
c) The transmitter will display the following sequence of text messages as it proceeds through the AutoZero
sequence:
Zero Cal . . . Setting Zero . . . Zero Saved (each will scroll twice)
d) Remove the zero gas and calibration adapter, if applicable.
3.4.2 AutoSpan
Material Requirements:
-Detcon PN 327-000000-000 MicroSafe™ Programming Magnet
- Detcon PN 613-120000-000 Splash Guard with integral Cal Port -OR-
-Detcon PN 942-520124-050 50% LEL Methane in balance air (recommended) or other suitable span gas
containing a certified level of % LEL concentration of combustible gas in air balance. A flow fixed rate of 200-
500cc/min is recommended.
NOTE 1: Before performing AutoSpan Calibration, verify that the AutoSpan level matches the
span calibration gas concentration as described in Section 3.5.2 Set AutoSpan Level.
NOTE 2: The span gas source must have a normal background concentration of 20.9% O2. Pure
Nitrogen background mixtures are not acceptable! Significant span calibration inaccuracies will
result.
NOTE 3: If the target gas is other than methane, use the appropriate Gas Factor as described in
Section 3.5.3 Set Gas Factor
NOTE 5: To maintain the CSA certification, it must be calibrated on methane.
CAUTION: Verification that the calibration gas level setting matches the calibration span gas
concentration is required before executing “AutoSpan” calibration. These two numbers must be equal.
AutoSpan consists of entering Calibration Mode and following the menu-displayed instructions. The display
will ask for the application of span gas in a specific concentration. This concentration must be equal to the
calibration gas level setting. The factory default setting and recommendation for span gas concentration is 50%
LEL. If a span gas containing the recommended concentration is not available, other concentrations may be
used as long as they fall between 5% and 95% LEL. However, any alternate span gas concentration value must
be programmed via the “Set AutoSpan Level” menu before proceeding with AutoSpan calibration. Follow the
instructions “a” through “e” below for AutoSpan calibration.
a) Verify that the AutoSpan Level is equal to the calibration span gas concentration. (Refer to View Sensor
Status in Section 3.5.1.) If the AutoSpan Level is not equal to the calibration span gas concentration, adjust
the AutoSpan Level as instructed in Section 3.5.2 Set AutoSpan Level.
b) From Normal Operation, enter Calibration Mode by holding the programming magnet over PGM1 for 3-4
seconds. Note, the “▲” prompt will show that the magnetic switch is activated during the 3-4 second hold
period. The display will then scroll “PGM1=Zero…PGM2=Span”. Hold the programming magnet over
PGM2 for 3-4 seconds once the “▼” prompt appears, until the display starts to scroll “Span Cal” to execute
AutoSpan (or allow to timeout in 5 seconds if AutoSpan is not desired). The display will then scroll “Apply
XX % LEL” (where XX is the AutoSpan Level).

Model FP-624D
NOTE: Upon entering Calibration Mode, the 4-20mA signal drops to 2mA and is held at this
level until the program returns to normal operation. The “In Calibration” bit in the ModbusTM
Fault Status register will be set until the calibration is complete.
c) Apply the span calibration test gas at a flow rate of 200-500cc/min (200cc/min is the recommended flow
rate). As the sensor signal begins to increase, the display will switch to reporting a flashing “XX” reading
as the display shows the sensor’s “as found” response to the span gas presented. If it fails to meet the
minimum in-range signal change criteria within 2½ minutes, the display will report “Range Fault” twice and
the sensor will return to normal operation, aborting the AutoSpan sequence. The sensor continues to report
a “Range Fault” and will not clear the fault until a successful AutoSpan is completed.
Assuming acceptable sensor signal change, after 1 minute the reading will auto-adjust to the programmed
AutoSpan level. During the next 30 seconds, the AutoSpan sequence checks the sensor for acceptable reading
stability. If the sensor fails the stability check, the reading is re-adjusted back to the AutoSpan level and the
cycle repeats until the stability check is passed. Up to three additional 30-second stability check periods are
allowed before the unit reports a “Stability Fault” twice and the sensor will return to normal operation, aborting
the AutoSpan sequence. The sensor will continue to report a “Stability Fault” and will not clear the fault until a
successful AutoSpan is completed.
If the sensor passes the stability check, the sensor display reports a series of messages:
“AutoSpan Complete”
“Sensor Life XXX%”
“Remove Span Gas”
d) Remove the span gas and calibration adapter. The sensor will report a live reading as it clears toward “0”.
When the reading clears below 5 % LEL, the sensor will display “Span Complete” and will revert to normal
operation. If the sensor fails to clear to less than 5% LEL within 5 minutes, a “Clearing Fault” will be
reported twice and the sensor will return to normal operation, aborting the AutoSpan sequence. The sensor
will continue to report a “Clearing Fault” and will not clear the fault until a successful AutoSpan is
completed.
NOTE 1: If the sensor fails the minimum signal change criteria, a “Range Fault” will be
declared and a “Fault Detected” message will be displayed alternately with the sensor’s current
reading. The 4-20mA output will be taken to 0mA and the “Range Fault” bit in the Modbus
Fault Status register will be set.
NOTE 2: If the sensor fails the stability criteria, a “Stability Fault” will be declared and a “Fault
Detected” message will be displayed alternately with the sensor’s current reading. The 4-20mA
output will be taken to 0mA and the “Stability Fault” bit in the Modbus Fault Status register will
be set.
NOTE 3: If the sensor fails the clearing time criteria, a “Clearing Fault” will be declared and a
“Fault Detected” message will be displayed alternately with the sensor’s current reading. The 4-
20mA output will be taken to 0mA and the “Clearing Fault” bit in the Modbus Fault Status
register will be set.

Model FP-624D
3.5 Program Mode

Program Mode provides a “View Sensor Status” menu to check operational and configuration parameters.
Program Mode provides for adjustment of the AutoSpan Level, Bridge Voltage, Gas Factor, Cal Factor, Serial
ID, Alarm and Fault Settings. Additionally, Program Mode includes the diagnostic functions “Signal Output
Check” and “Restore Factory Defaults”.
The Program Mode menu items appear in the order presented below:
View Sensor Status

Set AutoSpan Level
Set Gas Factor
Set Cal Factor
Set Bridge Voltage
Signal Output Check
Restore Default Settings
Set Serial ID
Alarm 1 Settings
Alarm 2 Settings
Fault Settings
Navigating Program Mode

From Normal Operation, enter Program Mode by holding the magnet over PGM2 for 4 seconds (until the
displays starts to scroll “View Sensor Status”). Note, the “▼” prompt will show that the magnetic switch is
activated during the 4 second hold period. The sensor will enter Program Mode and the display will display the
first menu item “View Sensor Status”. To advance to the next menu item, hold the magnet over PGM1 or PGM2
while the current menu item’s text is scrolling. At the conclusion of the text scroll the arrow prompt (“▼” for
PGM2 or “▲” for PGM1) will appear, immediately remove the magnet. The display will advance to the next
menu item. Repeat this process until the desired menu item is displayed. Note, PGM1 moves the menu items
from right to left and PGM2 moves the menu items from left to right.
To enter a menu item, hold the magnet over PGM1 or PGM2 while the menu item is scrolling. At the conclusion
of the text scroll the “▼”prompt (“▼” for PGM2 or “▲” for PGM1) will appear, continue to hold the magnet
over PGM1 or PGM2 for an additional 3-4 seconds to enter the selected menu item. If there is no magnet activity
while the menu item text is scrolling (typically 4 repeated text scrolls), the sensor will automatically revert to
Normal Operation.
3.5.1 View Sensor Status
View Sensor Status displays all current configuration and operational parameters including: sensor type,
software version number, detection range, AutoSpan level, days since last AutoSpan, estimated remaining sensor
life, bridge current, bridge voltage, gas factor, cal factor, mA output, input voltage, sensor ambient temperature,
serial ID, alarm and fault settings.
From the View Sensor Status text scroll, hold the magnet over PGM1 or PGM2 until the “▼” prompt appears
and continue to hold the magnet in place for an additional 3-4 seconds (until the display starts to scroll “Status
Is”). The display will scroll the complete list of sensor status parameters sequentially:

Model FP-624D
Sensor Model Type

The menu item appears as: “FP-624D”
Current Software Version

The menu item appears as: “V X.XXZ6”
Range of Detection
The menu item appears as: “Range XXX”
AutoSpan Level
The menu item appears as: “Auto Span Level XX”
Days Since Last AutoSpan

The menu items appears as: “Last Cal XX days”
Remaining Sensor Life

The menu item appears as: “Sensor Life XXX%”
Sensor Bridge Current

The menu item appears as: “Bridge XXXmA”
Sensor Bridge Voltage

The menu item appears as: “Bridge X.XXVDC
Gas Factor
The menu item appears as: “Gas Factor X.XX”
Cal Factor
The menu item appears as: “Cal Factor X.XX”
mA Output
The menu item appears as: “mA Output XX.XX mA”
Input Voltage Supply

The menu item appears as: “Voltage XX.X VDC”
Operating Temperature
The menu item appears as: “Temp XX C”
Serial ID
The menu item appears as: “Serial ID XX”
Alarm 1 Level
The menu item appears as: “Alarm 1 Level XX”
Model FP-624D
Alarm 1 Ascending
The menu item appears as: “Alarm 1 Ascending or Descending”
Alarm 1 Latching
The menu item appears as: “Alarm 1 Latching or Non-Latching”
Alarm 1 Energized
The menu item appears as: “Alarm 1 Energized or Non-Energized”
Alarm 2 Level
The menu item appears as: “Alarm 2 Level XX”
Alarm 2 Ascending
The menu item appears as: “Alarm 2 Ascending or Descending”
Alarm 2 Latching
The menu item appears as: “Alarm 2 Latching or Non-Latching”
Alarm 2 Energized
The menu item appears as: “Alarm 2 Energized or Non-Energized”
Fault Latching
The menu item appears as: “Fault Latching or Non-Latching”
Fault Energized
The menu item appears as: “Fault Energized or Non-Energized”
When the status list sequence is complete, the display will revert to the “View Sensor Status” text scroll. The
user can either: 1) review list again by executing another 3-4 second hold, 2) move to another menu item by
executing a momentary hold over PGM1 or PGM2, or 3) return to Normal Operation via automatic timeout of
about 15 seconds (the display will scroll “View Sensor Status” 4 times and then return to Normal Operation).
3.5.2 Set AutoSpan Level
Set AutoSpan Level is used to set the span gas concentration level that is being used to calibrate the sensor.
This level is adjustable from 5% to 95% of selected full-scale range. The current setting can be viewed in View
Program Status.
The menu item appears as: “Set AutoSpan Level”.
From the Set AutoSpan Level text scroll, hold the magnet over PGM1 or PGM2 until the “▼” prompt appears
and continue to hold the magnet in place for an additional 3-4 seconds (until the display starts to scroll “Set
Level”). The display will switch to “XX“(where XX is the current span level). Swipe the magnet momentarily
over PGM1 to increase or PGM2 to decrease the AutoSpan Level until the correct level is displayed. When the
correct level is achieved, hold the magnet over PGM1 or PGM2 for 3-4 seconds to accept the new value. The
display will scroll “Level Saved”, and revert to “Set AutoSpan Level” text scroll.

Model FP-624D
Move to another menu item by executing a momentary hold, or return to Normal Operation via automatic timeout
of about 15 seconds (the display will scroll “Set AutoSpan Level” 4 times and then return to Normal Operation).
3.5.3 Set Gas Factor
Because of the catalytic bead sensor’s almost universal response to combustible gases, the FP-624D sensor can
be configured to specifically detect any of the combustible gases listed in Table 2. This gas is referred to as the
“target gas”. In addition, the sensor can also be configured so that it can be calibrated with any of the listed
gases regardless of which target gas is selected. This gas is referred to as the “cal gas”. These two features, Set
Gas Factor and Set Cal Factor, allow a significant degree of flexibility in the detection and span calibration
process.
NOTE: The default value for gas factor is 1.0. This would be used when methane is the target
gas. Values other than 1.0 would be used when the target gas is not methane.
Set Gas Factor is used to make the appropriate signal sensitivity adjustment when the target gas is a gas other
than methane. This is necessary because the catalytic bead sensor has different signal strengths for each
combustible gas and all reading calculations are made based on a reference to methane. The gas factor value is
adjustable from 0.2 to 5.0. It represents the translation between the target gas and methane gas, where methane
has a normalized gas factor = 1.0. For example, the gas factor for butane is 1.71, because the signal strength of
butane is 1.71 times lower than methane. The current setting can be viewed in View Program Status – Gas
Factor.
The following table shows the gas factors of most combustible gases that can be measured. Find the target gas
and enter the corresponding value as the gas factor. For example, if butane were the target gas, the correct gas
factor would be 1.71. If there is a mixture of target gases, use a weighted approach to determine the correct gas
factor. For example, if the target gas was 50% butane and 50% methane, the correct gas factor would be
calculated and entered as 0.5(1.71) + 0.5 (1.0) = 1.35.

Model FP-624D
Table 2 Gas/Cal Factors

Gas Factor Gas Factor Gas Factor
Acetaldehyde 1.66 Decane 3.05 Dimethyl Ether 1.60
Acetic Acid 1.84 Diethylamine 2.05 Methylethyl Ether 2.27
Acetic Anhydride 2.17 Dimethylamine 1.73 Methylethyl Ketone 2.42
Acetone 1.93 2,3-Dimethylpentane 2.51 Methyl Formate 1.49
Acetylene 1.76 2,2-Dimethylpropane 2.52 Methyl Mercaptan 1.64
Alkyl Alcohol 1.96 Dimethyl sulfide 2.30 Methyl propionate 1.95
Ammonia 0.79 1,4-Dioxane 2.24 Methyl n-propyl Ketone 2.46
n-Amyl Alcohol 3.06 Ethane 1.47 Naphtha 3.03
Aniline 2.54 Ethyl Acetate 1.95 Naphthalene 2.94
Benzene 2.45 Ethyl Alcohol 1.37 Nitromethane 1.72
Biphenyl 4.00 Ethylamine 1.90 n-Nonane 3.18
1,3-Butadiene 1.79 Ethyl Benzene 2.80 n-Octane 2.67
Butane 1.71 Ethylcyclopentane 2.52 n-Pentane 2.18
iso-Butane 1.93 Ethylene 1.41 iso-Pentane 2.15
Butene-1 2.20 Ethylene Oxide 1.93 Propane 1.81
cis-Butene-2 2.06 Diethyl Ether 2.16 n-Propyl Alcohol 2.12
trans-Butene-2 1.97 Ethyl Formate 2.26 n-Propylamine 2.07
n-Butyl Alcohol 2.91 Ethyl Mercaptan 1.78 Propylene 1.95
iso-Butyl Alcohol 1.89 n-Heptane 2.59 Propylene Oxide 2.18
tert-Butyl-Alcohol 1.34 n-Hexane 2.71 iso-Propyl Ether 2.29
n-Butyl Benzene 3.18 Hydrazine 2.22 Propyne 2.40
iso-Butyl Benzene 3.12 Hydrogen Cyanide 2.09 Toluene 2.47
n-Butyric Acid 2.63 Hydrogen 1.30 Triethylamine 2.51
Carbon Disulphide 5.65 Hydrogen Sulphide 2.54 Trimethylamine 2.06
Carbon Monoxide 1.32 Methane 1.00 Vinyl Chloride 2.32
Carbon Oxysulphide 1.07 Methyl Acetate 2.01 Vinyl Ethyl Ether 2.38
Cyanogen 1.12 Methyl Alcohol 1.16 o-Xylene 2.79
Cyclohexane 2.43 Methylamine 1.29 m-Xylene 2.55
Cyclopropane 1.60 Methylcyclohexane 2.26 p-Xylene 2.55
The menu item appears as: “Set Gas Factor”.
From the Set Gas Factor text scroll, hold the magnet over PGM1 or PGM2 until the “▼” prompt appears and
continue to hold the magnet in place for an additional 3-4 seconds (until the display starts to scroll “Set Factor”).
The display will then switch to “X.XX“(where X.XX is the current gas factor). Swipe the magnet momentarily
over PGM1 to increase or PGM2 to decrease the gas factor level until the correct value is displayed. Hold the
magnet over PGM1 or PGM2 for 3 seconds to accept the new value. The display will scroll “Factor Saved”,
and revert to “Set Gas Factor” text scroll.
Move to another menu item by executing a momentary hold, or, return to Normal Operation via automatic
timeout of about 15 seconds (the display will scroll “Set Gas Factor” 4 times and then return to Normal
Operation).
3.5.4 Set Cal Factor
Because of the catalytic bead sensor’s almost universal response to combustible gases, the FP-624D sensor can
be span calibrated with any of the combustible gases listed in Table 2 above. This specific gas is referred to as
the “cal gas”.
NOTE: The default value for cal factor is 1.0. This would be used when methane is the cal gas.
Values other than 1.0 would be used when the span cal gas is not methane.

Model FP-624D
Set Cal Factor is used to make the appropriate signal sensitivity adjustment when the cal gas is a gas other than
methane. This is necessary because the catalytic bead sensor has different signal strengths for each combustible
gas and all reading calculations are made based on a reference to methane. The cal factor value is adjustable
from 0.2 to 5.0. It represents the translation between the cal gas and methane gas, where methane has a
normalized cal factor = 1.0. For example, the cal factor for butane is 1.71 because the signal strength of butane
is 1.71 times lower than methane. The current setting can be viewed in View Program Status.
Table 2 shows the cal factors of most combustible gases that will be used as span calibration sources. Find the
gas of interest and enter that value the cal factor. For example, if propane were used as the cal gas, the correct
cal factor would be 1.81.
The menu item appears as: “Set Cal Factor”.
From the Set Gas Factor text scroll, hold the magnet over PGM1 or PGM2 until the “▼” prompt appears and
continue to hold the magnet in place for an additional 3-4 seconds (until the display starts to scroll “Set Factor”).
The display will then switch to “X.XX“(where X.XX is the current cal factor). Swipe the magnet momentarily
over PGM2 to decrease or PGM1 to increase the gas factor level until the correct value is displayed. Hold the
magnet over PGM1 or PGM2 for 3-4 seconds to accept the new value. The display will scroll “Factor Saved”,
and revert to “Set Cal Factor” text scroll.
timeout of about 15 seconds (the display will scroll “Set Cal Factor” 4 times and then return to Normal
Operation).
3.5.5 Set Bridge Voltage
Each Detcon plug-in combustible gas sensor requires a one-time setting for optimal bridge voltage. This is set
automatically during the “Set Bridge Voltage” sequence. The “Set Bridge Voltage” sequence determines the
required bridge voltage such that every plug-in sensor operates at exactly 200mA current. This technique
provides for tremendous uniformity in sensor-to-sensor operational performance, and it is notably better than
sensors that are operated on a common fixed bridge voltage platform. The range of bridge voltages required for
Detcon sensors is generally between 2.5 – 2.9VDC.
NOTE: The “Set Bridge Voltage” function is executed during factory calibration of every FP-
624D sensor. In the field, this menu item is only needed when a replacement plug-in sensor is
being installed, when mating a new FP-624D transmitter with an existing plug-in sensor or when
remote mounting the sensor away from the transmitter.
The menu item appears as: “Set Bridge Voltage”.
From the Set Bridge Voltage text scroll, hold the magnet over PGM1 or PGM2 until the “▼” prompt appears
and continue to hold the magnet in place for an additional 7-8 seconds (until the display starts to scroll “Setting
Bridge”). The transmitter will then display “WAIT”. During the 1-minute sequence, the transmitter will display
the three-digit number that corresponds to the bridge current as it is being adjusted. At conclusion, the display
will scroll “Set Bridge Voltage”. The new bridge voltage can be viewed in the “View Sensor Status” menu.
timeout of about 15 seconds (the display will scroll “Set Bridge Voltage” 4 times and then return to Normal
Operation).

Model FP-624D
3.5.6 Signal Output Check
Signal Output Check provides a simulated 4-20mA and Modbus output. This simulation allows the user to
conveniently perform a functional system check of their entire safety system. This signal output simulation also
aids the user in performing troubleshooting of signal wiring problems.
The menu item appears as: “Signal Output Check”.
From the “Signal Output Check” text scroll, hold the magnet over PGM1 or PGM2 until the “▼” prompt appears
and then hold continuously for an additional 10 seconds. Once initiated, the display will scroll “Simulation
Active” until the function is stopped. During simulation mode, the 4-20mA value will be increased from 4.0mA
to 20.0mA (in 1% of range increments at about a 1 second update rate) and then decreased from 20.0mA to
4.0mA. The value of the Modbus concentration register (40002) will also be increased and decreased in the same
manner.
NOTE: Signal Output Check stays active indefinitely until the user stops the function. There is
no automatic timeout for this feature.
To end simulation mode, hold magnet over PGM1 or PGM2 for 3 seconds. The display will either move to the
prior menu item or move to the next menu item respectively.
timeout of about 15 seconds.
3.5.7 Restore Factory Defaults
Restore Factory Defaults is used to clear current user configuration and calibration data from memory and
revert to factory default values. This may be required if the settings have been configured improperly and a
known reference point needs to be re-established to correct the problem.
This menu item appears as: “Restore Defaults”.
NOTE: “Restoring Factory Defaults” should only be used when absolutely necessary. All
previously existing configuration inputs will have to be re-entered if this function is executed.
A full 10-second magnet hold on PGM 1 is required to execute this function.
From the “Restore Defaults” text scroll, hold the programming magnet over PGM1 until the “▲” prompt appears
and continue to hold 10 seconds. The display will scroll “Restoring Defaults”, and then will revert to the
“Restore Defaults” text scroll.
timeout of about 15 seconds (the display will scroll “Restore Defaults” 4 times and then return to Normal
Operation).
Following the execution of “Restore Defaults”, power to the FP-624D needs to be cycled before the FP-624D
will revert to its factory default settings. The default settings are:
NOTE: The user must remove and then reapply power to the sensor before the factory default
settings will be restored.
NOTE: The following must be performed in order before the sensor can be placed back into
operation.

Model FP-624D
 AutoSpan Level = 50 %LEL. AutoSpan level must be set appropriately by the operator (Section 3.5.2).
 Gas Factor = 1.0. The Gas Factor must be set appropriately by the operator (Section 3.5.3).
 Cal Factor = 1.0. The Cal Factor must be set appropriately by the operator (Section 3.5.4).
 AutoZero: AutoZero Settings are lost and user must perform new AutoZero (Section 3.4.1).
 AutoSpan: AutoSpan Settings are lost and user must perform new AutoSpan (Section 3.4.2).
 Serial ID: The Modbus address of the sensor must be set appropriately by the operator (3.5.8).
 Alarm and Fault Settings: The alarm levels and relay properties must be set appropriately by the operator
(3.5.9 and 3.5.10)
3.5.8 Set Serial ID
Detcon Model FP-624D sensors can be polled serially via RS-485 Modbus™ RTU. Refer to Section 4.0 for
details on using the Modbus™ output feature.
Set Serial ID is used to set the Modbus™ serial ID address. It is adjustable from 01 to 256 in hexadecimal
format (01-FF hex). The current serial ID can be viewed in View Sensor Status using the instruction given in
Section 3.5.1 View Sensor Status.
The menu item appears as: “Set Serial ID”.
From the “Set Serial ID” text scroll, hold the programming magnet over PGM1 or PGM2 until the “▼” prompt
appears and continue to hold the magnet in place for an additional 3-4 seconds (until the display starts to scroll
“Set ID”). The display will then switch to “XX“ (where XX is the current ID address). Swipe the magnet
momentarily over PGM2 to decrease or PGM1 to increase the hexadecimal number until the desired ID is
displayed. Hold the magnet over PGM1 or PGM2 for 3-4 seconds to accept the new value. The display will
scroll “ID Saved”, and revert to “Set Serial ID” text scroll.
timeout of about 15 seconds (the display will scroll “Set Serial ID” 5 times and then return to Normal Operation).
3.5.9 Alarm 1 and 2 Settings
The FP-624D contains two Form C alarm relay outputs. These relays can be configured to change state when
the concentration exceeds a set level. The relays can be configured to operate in either energized or non-
energized mode. In non-energized mode, the normally open contact is open if the alarm level has not been
reached. In energized mode, the normally open contact is closed if the alarm level has not been reached.
Energized mode provides for fail-safe operation since a loss of power or cable failure will cause the contact to
be open.
The alarm relays can be configured as either latching or non-latching. In non-latching mode, the relay is
deactivated as soon as the sensor alarm condition is cleared. In latching mode, the relay remains active even
after the alarm condition has cleared. Once activated, the relay can only be deactivated by swiping a magnetic
programming tool above the PGM1 or PGM2 mark on the FP-624D face plate.
The alarm relays can be configured for ascending or descending mode. In ascending mode the relay will be
activated when the concentration is above the alarm threshold. This is the most common mode of operation for
the FP-624D. The alarm relays can also be activated in descending mode. In this mode, the alarm relays will
activate when the concentration is below the alarm threshold.
The menu item appears as: “Alarm X Settings”
From the “Alarm X Settings” text scroll, hold the programming magnet over PGM1 or PGM2 until the “▼”
prompt appears and continue to hold the magnet in place for an additional 3-4 seconds (until the display starts
to scroll “Set Level”). The display will then switch to “XXX“ (where XXX is the current alarm level in % LEL).
Model FP-624D
Swipe the magnet momentarily over PGM2 to decrease or PGM1 to increase the alarm level until the desired
level is displayed. Hold the magnet over PGM1 or PGM2 for 3 seconds to accept the new value (until the display
starts to scroll “Level Saved”).
The display will scroll “Set Ascending”, and then switch to “Yes” or “No”. “Yes” indicates the relay is in
ascending mode and “No” indicates the relay is in descending mode. Swipe the magnet momentarily over PGM2
or PGM1 until the correct value is displayed. Hold the magnet over PGM2 for three seconds to save the setting.
The display will scroll “Set Latching”, and then switch to “Yes” or “No”. “No” indicates the relay is non-
latching and “Yes” indicates the relay is latching. Swipe the magnet momentarily over PGM2 or PGM1 until
the correct value is displayed. Hold the magnet over PGM2 for three seconds to save the setting.
The display will scroll “Set Energized”, and then switch to “Yes” or “No”. “No” indicates the relay is normally
non-energized and “Yes” indicates the relay is normally energized. Swipe the magnet momentarily over PGM2
timeout of about 15 seconds (the display will scroll “Alarm X Settings” 4 times and then return to Normal
Operation).
3.5.10 Fault Settings
The FP-624D contains a single Form C fault relay output. This relay can be configured to change state when the
sensor experiences a fault condition. This relay can be configured to operate in either energized or non-energized
mode. In non-energized mode, the normally open contact is open if the sensor is not in fault. In energized mode,
the normally open contact is closed if the sensor is not in fault. Energized mode provides for fail-safe operation
since a loss of power or cable failure will cause the contact to be open.
The fault relay can be configured as either latching or non-latching. In non-latching mode, the relay is deactivated
as soon as the fault condition is cleared. In latching mode, the relay remains active even after the fault condition
has cleared. Once activated, the relay can only be deactivated by swiping a magnetic programming tool above
the PGM1 or PGM2 mark on the FP-624D face plate.
The menu item appears as: “Fault Settings”
From the “Fault Settings” text scroll, hold the programming magnet over PGM1 or PGM2 until the “▼” prompt
appears and continue to hold the magnet in place for an additional 3-4 seconds. The display will scroll “Set
Latching”, and then switch to “Yes” or “No”. “No” indicates the relay is non-latching and “Yes” indicates the
relay is latching. Swipe the magnet momentarily over PGM2 or PGM1 until the correct value is displayed. Hold
the magnet over PGM2 for three seconds to save the setting.
The display will scroll “Set Energized”, and then switch to “Yes” or “No”. “No” indicates the relay is normally
non-energized and “Yes” indicates the relay is normally energized. Swipe the magnet momentarily over PGM2
timeout of about 15 seconds (the display will scroll “Fault Settings” 4 times and then return to Normal
Operation).

Model FP-624D
3.6 Program Features

Detcon FP-624D combustible gas sensors incorporate a comprehensive set of diagnostic features to achieve Fail-
Safe Operation. These Operational features and Failsafe Diagnostic features are detailed below.
3.6.1 Operational Features
Over-Range
When gas greater than the full-scale range is detected, the sensor display will continuously flash the full-scale
reading of 100. This designates an over-range condition. The 4-20mA signal will report a 22mA output during
this time. The Modbus concentration register will report the measured concentration (up to full scale + 10%).
In-Calibration Status
When the sensor is engaged in AutoZero or AutoSpan calibration, the 4-20mA output signal is taken to 2.0mA.
This alerts the user that the sensor is not in an active measurement mode. This feature also allows the user to
log the AutoZero and AutoSpan events via their master control system. The “In Calibration” bit in the Modbus
fault register is set while the sensor is in calibration mode.
Sensor Life
Sensor Life is calculated after each AutoSpan calibration and is reported as an indicator of remaining service
life. It is reported in the “View Sensor Status” menu and a Modbus register. Sensor Life is reported on a scale
of 0-100%. When Sensor Life falls below 25%, the sensor cell should be replaced within a reasonable
maintenance schedule.
Last AutoSpan Date

This reports the number of days that have elapsed since the last successful AutoSpan. This is reported in the
View Sensor Status menu. After 180 days, an AutoSpan Fault will be declared.
3.6.2 Fault Diagnostic/Failsafe Features
Fail-Safe/Fault Supervision
Model FP-624D MicroSafe™ sensors are designed for Fail-Safe operation. If any of the diagnostic faults listed
below are active, the sensor display will scroll the message “Fault Detected” every 60 seconds during normal
operation. At any time during “Fault Detected” mode, holding the programming magnet over PGM1 or PGM2
for 1 second will display the active fault(s). All active faults are reported sequentially.
Most fault conditions result in failed operation of the sensor. In these cases the 4-20mA signal is dropped to the
universal fault level of 0mA. The “Global Fault” bit in the Modbus fault register is also set and the fault relay
output is activated. These include the AutoZero and AutoSpan Calibration faults, Sensor Faults, Processor Fault,
Memory Fault, Loop Fault, and Input Voltage Fault. (The 0mA fault level is not employed for a Temperature
Fault, or during Calibration.)
NOTE: Refer to the Troubleshooting Guide, Section 6, for guidance on fault conditions.
Zero Fault
If the sensor drifts below –10% LEL, the “Zero Fault” will be declared. A “Zero Fault” will cause a “Fault
Detected” message to scroll once a minute on the transmitter display and drop the 4-20mA output to 0mA. The
“Zero Fault” bit in the Modbus fault register will be set. The sensor should be considered “Out-of-Service” until
a successful AutoZero calibration is performed.
Model FP-624D
Range Fault – AutoSpan

If the sensor fails the minimum signal change criteria during AutoSpan sequence (Section 3.4), the “Range
Fault” will be declared. A “Range Fault” will cause a “Fault Detected” message to scroll once a minute on the
sensor display and drop the 4-20mA output to 0mA. The “Range Fault” bit in the Modbus fault register will be
set. The sensor should be considered “Out-of-Service” until a successful AutoSpan calibration is performed.
Stability Fault - AutoSpan

If the sensor fails the signal stability criteria during AutoSpan sequence (Section 3.4), the “Stability Fault” will
be declared. A “Stability Fault” will cause a “Fault Detected” message to scroll once a minute on the sensor
display and drop the mA output to 0mA. The “Stability Fault” bit in the Modbus fault register will be set. The
sensor should be considered as “Out-of-Service” until a successful AutoSpan calibration is performed.
Clearing Fault - AutoSpan

If the sensor fails the signal stability criteria during AutoSpan sequence (Section 3.4), the “Clearing Fault” will
be declared. A “Clearing Fault” will cause a “Fault Detected” message to scroll once a minute on the sensor
display and drop the mA output to 0mA. The “Clearing Fault” bit in the Modbus fault register will be set. The
sensor should be considered as “Out-of-Service” until a successful AutoSpan calibration is performed.
Sensor Current Fault

If the current through the sensor bridge (See Figure 3) drifts outside the range of 200mA ± 50mA, a “Sensor
Current Fault” will be declared. A “Sensor Current Fault” will cause a “Fault Detected” message to scroll once
a minute on the transmitter display. If a Sensor Current Fault occurs, the 4-20mA signal will be set at 0mA and
the “Sensor Current Fault” bit will be set until the fault condition is resolved.
Sensor Voltage Fault
If the voltage across the sensor bridge (See Figure 3) is greater than 3.5VDC or less than 1.8VDC, a “Sensor
Voltage Fault” will be declared. A “Sensor Voltage Fault” will cause a “Fault Detected” message to scroll once
a minute on the transmitter display. If a Sensor Voltage Fault occurs, the 4-20mA signal will be set at 0mA and
the “Sensor Voltage Fault” bit will be set until the fault condition is resolved.
Processor Fault
If the detector has any unrecoverable run-time errors, a “Processor Fault” is declared. A “Processor Fault” will
cause a “Fault Detected” message to scroll once a minute on the sensor display. If a Processor Fault occurs, the
4-20mA signal will be set at 0mA and the “Processor Fault” bit will be set until the fault condition is resolved.
Memory Fault
If the detector has a failure in saving new data to memory, a “Memory Fault” is declared. A “Memory Fault”
will cause the “Fault Detected” message to scroll once a minute on the sensor display. If a Memory Fault occurs,
the 4-20mA signal will be set at 0mA and the “Memory Fault” bit will be set until the fault condition is resolved.
4-20mA Loop Fault

If the detector measures a 4-20mA loop load resistance > 1000 ohms, a “4-20mA Fault” is declared. A “4-20mA
Fault” will cause the “Fault Detected” message to scroll once a minute on the sensor display. If a Loop Fault
occurs, the 4-20mA signal will be set at 0mA and the “4-20mA Fault” bit will be set until the fault condition is
resolved.

Model FP-624D
Input Voltage Fault

If the detector is currently receiving an input voltage that is outside of the 11.5-28VDC range, an “Input Voltage
Fault” is declared. An “Input Voltage Fault” will cause the “Fault Detected” message to scroll once a minute
on the sensor display. If an Input Voltage Fault occurs, the 4-20mA signal will be set at 0mA and the “Input
Voltage Fault” bit will be set until the fault condition is resolved.
Temperature Fault
If the detector is reporting currently an ambient temperature that is outside of the –40ºC to +75ºC range, a
“Temperature Fault” is declared. A “Temperature Fault” will cause the “Fault Detected” message to scroll once
a minute on the sensor display. If a Temperature Fault occurs, the 4-20mA signal remains operational, but the
‘Temperature Fault” bit will be set.
AutoSpan Fault
If 180 days has elapsed since the last successful AutoSpan, an AutoSpan Fault will be generated. An “AutoSpan
Fault” will cause the “Fault Detected” message to scroll once a minute on the sensor display. If an AutoSpan
Reminder Fault, the 4-20mA signal remains operational, but the “Auto Span Fault” bit will be set.

Model FP-624D
4. RS-485 ModbusTM Protocol

Model FP-624D sensors feature Modbus™ compatible communications protocol output and are addressable via
the program mode. Communication is via a two wire, half duplex RS-485, 9600 baud, 8 data bits, 1 stop bit, no
parity, with the sensor set up as a slave device. A master controller up to 4000 feet away can poll up to 256
different FP-624D sensors. This number may not be realistic in harsh environments where noise and/or wiring
conditions would make it impractical to place so many devices on the same pair of wires. If a multi-point system
is being utilized, each sensor should be set for a different address. Typical address settings are: 01, 02, 03, 04,
05, 06, 07, 08, 09, 0A, 0B, 0C, 0D, 0E, 0F, 10, 11…etc.
Sensor Serial ID numbers are factory default to 01. These can be changed in the field via the Operator Interface
described in Section 3.5.8.
The following table explains the details of the Modbus™ protocol that the FP-624D sensor supports.
Table 3 Modbus Registers

Modbus Registers
FC REG Content Description R/W Content Definition

Value Meaning Range
03 40000 Device Type R 8 700 Sensor
03 40001 Read Detectable Range1,2 R/W 100 For 0-100 DM – 0 to 10000
06 40001 Write Detectable Range 10000 For 0-100002 FP – Read only
TP – 20, 50, 100, 200
IR – 0 to 10000
PI – 0 to 10000
03 40002 Read Concentration3,2 R 1000 Bound by range. If > range, this
value is in fault.
03 40003 Read AutoSpan Level4,2 R/W 50 Span gas at 50 DM – 1% to 95% of Range (40001)
06 40003 Write AutoSpan Level FP – 5% to 95% of Range (40001)
TP – 2% to 50% of Range (40001)
IR – 5% to 95% of Range (40001)
PI – 1% to 95% of Range (40001)
03 40004 Read Sensor Life R 85 For 85% sensor life
03 40005 Read Fault Status Bits5 R 0x0001 Global Fault
0x0002 Auto Span Fault
0x0004 Temperature Fault
0x0008 4-20mA Fault
0x0010 Input Voltage Fault
0x0020 Memory Fault
0x0040 Processor Fault
0x0080 Clearing Fault
0x0100 Stability Fault
0x0200 Range Fault
0x0400 Sensor Fault
0x0800 Zero Fault
0x1 000 Sensor Fault 2
0x2000 <reserved>
0x4000 In Calibration
0x8000 Communication Error
03 40006 Read Model # R 1, 2, 3, 4, 5 DM, FP, IR, TP, PID
respectively
03 40007 Read Days Since Cal R 29 29days
03 40008 4-20 Current Output R 400 4.00mA
03 40009 Read Input Voltage R 2400 24.00V
03 40010 Read Temperature R 28 28 °C
03/ 40011 Special #1 R/W Function Dependant on Value
FC REG Content Description R/W Content Definition
Value Meaning Range
06 of 40006 (See Special Register
Table)

Model FP-624D
03 40013 Special #3 R Function Dependant on Value

of 40006 (See Special Register
Table)
06 of 40006 (See Special Register
Table)
03 40015 Calibration Status R 0x0000 Idle
0x0001 Zero Calibration Started
0x0002 Span Calibration Started
0x0003 Span Set
0x0004 Span Calibration Unsuccessful
06 40015 Calibration Enable W 0x0001 Set Zero
0x0002 Set Span
0x0008 Signal simulation mode
0x0009 Set FP Bridge Voltage
0x000A Set TP Heater Power
0x000B Set IR Gain
03 40016 Read Text 1, first char in L R Two Char of Gas/Units String6
03 40017 Read Text 2 R Two Char of Gas/Units String6
03 40020 Read Text 5, last char in H R Two Char of Gas/Units String6
03 40021 Text null terminator in L R Two Char of Gas/Units String6
03 40022 Special #5 R/W Function Dependant on Value
of 40006 (See Special Register
Table)
03 40023 Processor Firmware Version R 0x0102 Version 01.02
1 Units are determined by “units” field in the “notation” string

2 Span Gas must be between 5% and 95% of the detectable range and is usually about 50% of it.
3 Fault status bits self-reset when fault clears
4 Text in ASCII, in order L byte, H byte, L byte… See field descriptions of notation string.
Table 4 Notation Text String Description

Character # 1 2 3 4 5 6 7 8 9 10 11
Description Units 0x20 Gas Type 0x00
Units – This field is typically ‘_ % _’ (where ‘_ ‘ is a space, 0x20).
0x20 – The units field is terminated with an ASCII space (0x20)
Gas Type – This field contains the gas type of the cell (typically “LEL _ _ _”)
0x00 – The notation string is terminated with an ASCII null character

Model FP-624D
5. Service and Maintenance

Calibration Frequency
In most applications, monthly to quarterly span calibration intervals will assure reliable detection. However,
industrial environments differ. Upon initial installation and commissioning, close frequency tests should be
performed, weekly to monthly. Test results should be recorded and reviewed to determine a suitable calibration
interval. If, after 180 days, an AutoSpan calibration is not performed, the sensor will generate an AutoSpan
fault.
Visual Inspection
The sensor should be inspected annually. Inspect for signs of corrosion, pitting, and water damage. During
visual inspection, the splash guard should be inspected to insure that it is not blocked. Examine the porous
316SS flame arrestor within the sensor’s bottom housing for signs of physical blockage or severe corrosion.
Also, inspect inside the junction box for signs of water accumulation or terminal block corrosion.
Condensation Prevention Packet

A moisture condensation packet should be installed in every explosion proof junction box. The moisture
condensation prevention packet will prevent the internal volume of the J-Box from condensing and accumulating
moisture due to day-night humidity changes. This packet provides a critical function and should be replaced
annually. Detcon’s PN is 960-202200-000.
Replacement of Combustible Gas Sensor
NOTE: It is necessary to remove power while changing the combustible gas sensor in order to
maintain area classification while the junction box cover is removed. Proper “Hot Permits” may
apply.
a) Remove the junction box cover and remove the Transmitter Module from the connector PCB.
b) Unthread the lower half of the sensor housing. The lower housing includes two recessed holes for a
spanner wrench if needed.
c) Gently pull on the combustible gas cell to unplug it from the upper housing.
d) Orient the new plug-in sensor so that it matches with the female connector pins, and insert into the upper
housing.
e) Thread the lower housing back into the upper housing and tighten using a spanner wrench.
f) Perform “Set Bridge Voltage” (Section 3.5.5) to match the new combustible gas sensor with the
Transmitter Module.
g) Perform a successful AutoZero and AutoSpan to match the new combustible gas sensor with the
Transmitter Module (Section 3.4).
Replacement of Transmitter Module

a) Remove the junction box cover and remove the Transmitter Module from the Connector PCB.
NOTE: It is necessary to remove power to the junction box while changing the Transmitter
Module in order to maintain area classification.
b) Plug the new Transmitter Module into the connector PCB, and reinstall the junction box cover.
c) Perform Set Range, Set Heater Power, and Set AutoSpan Level then perform a successful AutoSpan before
placing sensor assembly into operation.
Model FP-624D
Replacement of the Connector PCB
NOTE: It is necessary to remove power to the junction box while changing the connector PCB
in order to maintain area classification.
a) Remove the junction box cover and remove the transmitter module from the connector PCB.
b) Remove the black, white, blue, and yellow wires coming from the combustible gas sensor from the connector
PCB.
c) Remove the output wiring from the connector PCB terminals.
d) Remove the two 6-32 screws holding the connector PCB to the base of the junction box, and remove the
connector PCB.
e) Install the new connector PCB using the two 6-32 screws removed in step d).
f) Re-connect the output wiring to the terminals on the connector PCB.
g) Reconnect the black, white, blue, and yellow wires from the combustible gas sensor to the connector PCB.
h) Reinstall the transmitter module, and the junction box cover.

Model FP-624D
6. Troubleshooting Guide
Refer to the list of Failsafe Diagnostic features listed in Section 3.6.2 for additional reference in troubleshooting
activities. Listed below are some typical trouble conditions and their probable cause and resolution path.
Figure 16 Replaceable Combustible Gas Sensor
Sensor Current/Voltage Fault

Probable Cause: Plug-in sensor has failed
Remove plug-in sensor and verify resistance between PIN 5 and PIN 7 and PIN 2 and PIN 4 using an ohmmeter.
At room temperature, the normal reading range should be 2.5-3.5 ohms for both catalytic beads. Replace plug-
in sensor if either measurement is open circuit or significantly out-of range.
Figure 17 Plug-in Sensor (Bottom View)
Zero Fault
Probable Causes: Plug-in sensor has drifted
Perform AutoZero calibration per Section 3.4.1
Replace the plug-in sensor.
AutoSpan Calibration Faults – (Range, Stability, and Clearing)

To clear any AutoSpan Calibration fault, the AutoSpan process must be completed successfully (Section 3.4).
Range Fault
Probable Causes: Failed sensor, cal gas not applied or not applied at appropriate time, or problems with cal gas
and delivery
Check bridge voltage (should be 2.7 +/- 0.2VDC).
Check validity of span gas and flow rate (check MFG date on cal cylinder).

Model FP-624D
Make sure correct cal factor is set

Check for obstructions through stainless steel sinter element (including being wet).
Stability Fault
Probable Causes: Failed sensor, empty or close to empty cal gas cylinder, or problems w/ cal gas and delivery
Make sure correct cal factor is set
Clearing Fault
Probable Causes: Failed sensor, cal gas not removed at appropriate time, problems with cal gas and delivery, or
background combustible gases preventing clearing
Confirm that no combustible gasses are present in background.
Make sure correct cal factor and gas factor is set
Poor Calibration Repeatability

Probable Causes: Failed sensor, use of wrong cal gas, problems with cal gas and delivery, or poison or inhibitor
gases
Check for adequate sensor life.
Evaluate area for presence of poisoning or inhibiting gases as listed in Section 2.3.
Increase calibration frequency.
Note the sensor’s serial # and report repetitive problems to Detcon’s Repair Department.
Replace plug-in sensor.
Unstable Output/ Sudden spiking

Possible Causes: Unstable power supply, inadequate grounding, or inadequate RFI protection
Verify power source is stable.
Verify field wiring is properly shielded and grounded.
Contact Detcon to optimize shielding and grounding.
Add Detcon’s RFI Protection Circuit accessory if problem is proven RFI induced.
Nuisance Alarms
Check condulet for accumulated water and abnormal corrosion on terminal blocks.
If nuisance alarms are happening at night, suspect condensation in condulet. Add or replace Detcon’s
Condensation Prevention Packet P/N 960-202200-000.
Investigate the presence of other target gases that are causing cross-interference erroneous readings.
Determine if cause is RFI induced.

Model FP-624D
Processor and/or Memory Faults

Recycle power in attempt to clear problem
Restore factory defaults - This will clear the processor’s memory and may correct problem. Remember to re-
enter all customer settings for range and cal gas level after Restore Factory Defaults.
If problem persists, replace the plug-in transmitter module.
Unreadable Display
If due to excessive sunlight, install a sunshade to reduce glare.
Nothing Displayed – Transmitter not responding

Verify condulet has no accumulated water or abnormal corrosion.
Verify required DC power is applied to correct terminals.
Swap with a known-good transmitter module to determine if transmitter module is faulty.
Faulty 4-20mA Output

If sensor has a normal reading with no faults displayed, and the 4-20 mA signal output is 0mA….
Check that wiring is properly connected at terminal blocks and through to controller inputs.
The 4-20mA output loop must be closed (resistance of < 1000 ohms) to avoid the Loop Fault.
Perform a “Signal Output Check” sequence via Section 3.5.6 and verify 4-20mA output with current meter.
Swap with a known-good transmitter module to determine if the transmitter module’s 4-20mA output circuit is
faulty.

Model FP-624D
7. Customer Support and Service Policy

Detcon Headquarters
Phone: 888.367.4286, or 281.367.4100
Fax: 281.292.2860
• www.detcon.com
• [email protected]
• [email protected]
All Technical Service and Repair activities should be handled by the Detcon Service Department via phone, fax
or email at contact information given above. RMA numbers should be obtained from the Detcon Service
Department prior to equipment being returned. For on-line technical service, customers should have ready the
model number, part number, and serial number of product(s) in question.
All Sales activities (including spare parts purchase) should be handled by the Detcon Sales Department via
phone, fax or email at contact information given above.
Warranty Notice
Detcon Inc. warrants the Model FP-624D combustible gas sensor to be free from defects in workmanship of
material under normal use and service for two years from the date of shipment on the transmitter electronics and
for a two year conditional period on the combustible gas cell. See Warranty details in Section 8 FP-624D Sensor
Warranty.
Detcon Inc. will repair or replace without charge any such equipment found to be defective during the warranty
period. Full determination of the nature of, and responsibility for, defective or damaged equipment will be made
by Detcon Inc. personnel.
Defective or damaged equipment must be shipped to the Detcon Inc. factory or representative from which the
original shipment was made. In all cases, this warranty is limited to the cost of the equipment supplied by
Detcon Inc. The customer will assume all liability for the misuse of this equipment by its employees or other
contracted personnel.
All warranties are contingent upon the proper use in the application for which the product was intended and does
not cover products which have been modified or repaired without Detcon Inc. approval, or which have been
subjected to neglect, accident, improper installation or application, or on which the original identification marks
have been removed or altered.
Except for the express warranty stated above, Detcon Inc. disclaims all warranties with regard to the products
sold. Including all implied warranties of merchantability and fitness and the express warranties stated herein are
in lieu of all obligations or liabilities on the part of Detcon Inc. for damages including, but not limited to,
consequential damages arising out of, or in connection with, the performance of the product.

Model FP-624D
8. FP-624D Sensor Warranty

Plug-in Combustible Gas Sensor Warranty
Detcon Inc. warrants, under normal intended use, each new plug-in combustible gas sensor (PN 370-201600-
000 (Uses p/n 365-037020-160 in shipping container)). The warranty period begins on the date of shipment to
the original purchaser and ends 2 years thereafter. The sensor element is warranted free of defects in material
and workmanship. Should any sensor fail to perform in accordance with published specifications within the
warranty period, return the defective part to Detcon, Inc., 4055 Technology Forest Blvd, Suite 100, The
Woodlands, Texas 77381, for necessary repairs or replacement.
Terms & Conditions

* The original serial number must be legible on each sensor element.
* Shipping point is FOB the Detcon factory.
* Net payment is due within 30 days of invoice.
* Detcon, Inc. reserves the right to refund the original purchase price in lieu of sensor replacement.
Transmitter Module Warranty

Detcon Inc. warrants, under intended normal use, each new transmitter module to be free from defects in material
and workmanship for a period of two years from the date of shipment to the original purchaser. All warranties
and service policies are FOB the Detcon facility located in The Woodlands, Texas.
Terms & Conditions

* The original serial number must be legible on each transmitter.
* Shipping point is FOB the Detcon factory.
* Net payment is due within 30 days of invoice.
* Detcon, Inc. reserves the right to refund the original purchase price in lieu of transmitter replacement.

Model FP-624D
9. Appendix
9.1 Specifications
Sensor Type: Continuous diffusion/adsorption type
Matched-Pair Catalytic Bead type
True plug-in replaceable type
Sensor Life: 3-5 years typical
Measuring Ranges: 0-100% LEL
Accuracy/ Repeatability: ± 3% LEL in 0-50% LEL range, ± 5% LEL in 51-100% LEL range
Response Time: T50 < 10 seconds, T90 < 30 seconds
Performance Testing: Complies with CSA C22.2 No. 152-M1984, ANSI/ISA S12.13
Electrical Classification: CSAc Class I, Division 1, Groups B, C, D (Tamb= -40°C to +40°C)

Class I, Zone 1, Group IIB+H2
CSAus
Class I, Division 1, Groups B, C, D (Tamb= -25°C to +40°C)
Class I, Zone 1, Group IIB+H2
Approvals: CCSAUS (To maintain the CSA certification, it must be calibrated on methane)
Applicable Standards CSA C22.2 No. 30-M1986

CSA C22.2 No. 142-M1987
CSA C22.2 No. 152-M1984
UL Std. No. 916
UL Std. No.1203
ANSI/ISA S12.13
Warranty: Electronics – 2 years

Sensor – 2 years
Environmental Specifications
Operating Temperature: -40°C to +75°C
Storage Temperature: -40°C to +75°C
Operating Humidity: 0-100% RH (Non-condensing)
Operating Pressure: Ambient ± 10%
Electrical Specifications
Input Voltage: 12-28 VDC
Power Consumption: Normal operation = 68mA (<1.7 watt); Maximum = 87mA (2 watts)

Model FP-624D
RFI/EMI Protection: RFI Complies with ISA 92.0.01
Analog Output: Linear 4-20mA DC current

1000 ohms maximum loop load @ 24VDC
0mA All Fault Diagnostics
2mA In-Calibration
4-20mA 0-100% full-scale
22mA Over-range condition
Serial Output: RS-485 Modbus™ RTU

Baud Rate 9600 BPS (9600, N, 8, 1 Half Duplex)
Relay Outputs: Alarm 1, Alarm 2, and Fault

5A @ 250VAC
5A @ 30VDC
Status Indicators: 4-digit LED Display with gas concentration, full-script menu
Prompts for AutoSpan, AutoZero, Set-up Options, and Fault Reporting
Faults Monitored: Loop Fault, Input Voltage Fault, Zero Fault, Sensor Fault,
Processor Fault, Memory Fault, Calibration Fault(s)
4 LEDs for Alarm 1, Alarm 2, Fault, and Calibration
Cable Requirements: Power/Analog: 3-wire shielded cable

Maximum distance is 13,300 feet with 14 AWG
Serial Output: 2-wire twisted-pair shielded cable specified for RS-485 use
Maximum distance is 4,000 feet to last sensor
Mechanical Specifications
Length: 8 inches (200mm), including Splashguard
Width: 5.5 inches (140mm)
Weight: 2.7lbs (3.4Kg)
Mechanical Connection: ¾” Male NPT threaded connection
Electrical Connection: Eleven 14 gauge (maximum) wire terminal landings

Model FP-624D
9.2 Spare Parts, Sensor Accessories, Calibration Equipment
Part Number Spare Parts

926-5255D0-100 FP-624D Plug-in Transmitter Module
370-201600-000 Replacement Plug-in Sensor
(Uses p/n 365-037020-160 in shipping container)
600-02056-0 FP-P Plug-in Hsg Threaded Insert 316SS
612-820000-000 Replacement LEL sensor housing (includes threaded insert)
500-001794-004 Standard Connector PCB
960-202200-000 Condensation prevention packet (for J-Box replace annually)
Sensor Accessories
897-850800-010 NEMA 7 Aluminum Enclosure less cover – 3 port
897-850400-010 NEMA 7 Aluminum Enclosure Cover (Blank)
897-850801-316 NEMA 7 316SS Enclosure less cover – 3 port
897-850401-316 NEMA 7 316SS Enclosure Cover (Blank)
613-120000-000 Sensor Splashguard with integral Cal-Port
943-002273-000 Harsh Location Dust guard
327-000000-000 Programming Magnet
Calibration Accessories
943-000006-132 Threaded Calibration Adapter
943-020000-000 Span Gas Kit: Includes calibration adapter, In-Line Humidifying Tube,
200cc/min fixed flow regulator, and carrying case.
(Does Not include gas).
942-520124-050 Span Gas cylinder: 50% LEL Methane balance air
Contains 104 liters of gas and is good for 175 calibrations
943-090005-502 200cc/min Fixed Flow Regulator for span gas bottle
Recommend Spare Parts for 2 Years

926-5255D0-100 FP-624D Plug-in Transmitter Module
370-201600-000 Replacement Plug-in Sensor
(Uses p/n 365-037020-160 in shipping container)
600-02056-0 FP-P Plug-in Hsg Threaded Insert 316SS
612-820000-000 Replacement LEL sensor housing (includes threaded insert)
500-001794-004 Standard Connector PCB

Model FP-624D
9.3 Revision Log

Revision Date Changes made Approval
0.0 8/9/2010 Initial Release LBU
0.1 10/6/10 Updated software flowchart, revised operational guidelines for BM
safe use, references to 3 relay outputs
1.0 12/02/10 Made previous section 2.7 into 2.8 and inserted new section 2.7. BM
Added CSA note in section 3.4.2 and section 9.1. Revised note
in section 3.5.5.
1.1 06/21/11 Changed spare part 365-037020-160 to 370-201600-000 and BM
referenced that it is same part in shipping container
1.2 04/23/12 Updated section 2.6 Field Wiring, load resistor. Corrected spare parts LU
1.3 08/12/13 Updated Drawing Dimensions BM
1.4 12/06/17 Updated Electrical Classification Approval Temperatures BM
1.5 06/05/18 Updated Conduit Seal in Section 2.5 MM
Phone: 888.367.4286, 281.367.4100 • Fax: 281.292.2860 • www.detcon.com • [email protected]

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INSTRUCTION MANUAL

Detcon Model FP-624D

MODEL HOUSTON, TEXAS FP-624D

MicroSafeTM LEL Gas Sensor

FP-624D Combustible Gas Sensor

June 05, 2018 • Document #3598 • Revision 1.5

This page left intentionally blank

FP-624D Instruction Manual ii

FP-624D Instruction Manual iii

FP-624D Instruction Manual iv

MODEL HOUSTON, TEXAS FP-624D

MicroSafeTM LEL Gas Sensor

Figure 1 Sensor Assembly Front View

Catalytic Bead (Pellistor) Sensor Technology

FP-624D Instruction Manual Rev. 1.5 Page 1 of 44

Main Housing Insert

Printed Circuit Board

Figure 2 Sensor Cell Construction

FP-624D Instruction Manual Rev. 1.5 Page 2 of 44

Figure 4 Response Curves

1.2 Modular Mechanical Design

1) FP-624D Plug-in Transmitter

FP-624D Plug-in Transmitter

Pre-Amp Display Analog 4-20mA Out

Figure 5 Circuit Functional Block Diagram

FP-624D Instruction Manual Rev. 1.5 Page 3 of 44

MODEL HOUSTON, TEXAS FP-624D

MicroSafeTM LEL Gas Sensor

Figure 6 Transmitter Module

Field Replaceable Sensor

Threaded Insert O-ring Main Housing

Figure 7 Field Replaceable Combustible Gas Sensor

Base Connector PCB

FP-624D Instruction Manual Rev. 1.5 Page 4 of 44

Figure 8 Base Connector Board

1.3 Relay Outputs

FP-624D Instruction Manual Rev. 1.5 Page 5 of 44

2.2 Sensor Placement

(1) Density of the gas to be detected

Additional Placement Considerations

2.3 Sensor Contaminants and Interference

FP-624D Instruction Manual Rev. 1.5 Page 7 of 44

2.4 Mounting Installation

Figure 9 Typical Outline and Mounting Dimensions

FP-624D Instruction Manual Rev. 1.5 Page 8 of 44

2.5 Electrical Installation

"T" EYS Seal Fitting

MODEL HOUSTON, TEXAS TP-624D

MicroSafeTM H2S Gas Sensor

Figure 10 Typical Installation

2.6 Field Wiring

Table 1 Wire Gauge vs. Distance

FP-624D Instruction Manual Rev. 1.5 Page 10 of 44

Figure 11 Sensor Connector PCB

2.7 Remote Mounting Installation

AWG Maximum Separation (feet)

FP-624D Instruction Manual Rev. 1.5 Page 11 of 44

Figure 12 Remote Sensor Wiring Diagram

2.7.1 Bridge Voltage Adjustment