WatchGas TOX Point 2000/3000 User Manual

1. GENERAL

The Tox Point 2000/3000 toxic gas detector is designed to detect gas leaks from industrial sites and various toxic gases generated in factories, gas storages, and manufacturing processes. It helps prevent accidents by providing early detection. The detector is installed in areas with gas leak hazards and continuously monitors for leaks. It displays measurements on an LCD and transmits data as a DC 4~20 mA standard output signal. For the DC 4~20 mA output, the transmission length between the detector and receiver can be up to 2,500 meters when using Cable CVVS or CVVSB 1.5sq or thicker.

2. CONFIGURATION

The body of the Tox Point 2000/3000 is constructed from Aluminum alloy, while the gas sensor module is made of stainless steel. It features a complete explosion-proof enclosure (Ex d IIC T6), making it suitable for installation in areas with combustible gas leaks and explosion hazards. The detector includes a built-in LCD to display gas leak status at the installation site. It comprises a display part for measurements, a terminal part for external output (DC 4~20 mA), and a PCB board. The external configuration includes the detector part for gas leak monitoring and cable inlets.

Figure 1. Tox Point 2000/3000 Overview: A block diagram illustrating the system architecture. It shows the "Gas Sensor Module (GSA860TX)" connected to the "Transmitter enclosure (GDH-1000)", which contains the "Display Board (User Interface)" and "Main Board (Transmitter)". The transmitter enclosure has a "VIN & 4-20mA Analog Signal Output". The system is depicted as being in a "Hazardous Area (Filed)" and connected to a "Safety Controller (PLC or DCS)" in a "Safe Area".

3. SPECIFICATIONS

3.1. BASIC SPECIFICATIONS

Note1: Refer to the measured gas list for measured gases and their ranges. Contact us for special gas.

3.2. MECHANICAL SPECIFICATIONS

3.3. ELECTRICAL SPECIFICATIONS (STANDARD TYPE)

3.4. ENVIRONMENTAL SPECIFICATIONS

4. NAME AND DESCRIPTION OF EACH PART

4.1. COMPONENTS

Figure 2. Tox Point 2000/3000 Components: A detailed illustration showing the physical layout of the detector's internal components. It includes numbered callouts pointing to parts like the detector housing body, cover, various PCBs (AMP PCB, Display PCB), connectors (CN1-CN6), potentiometers (VR1, VR2), DIP switches (SW1, SW2), sensor, and mounting holes.

5. INSTALLATION

Warning - It is prohibited for an individual, other than an approved user or a technician responsible for installation and repair from the head office, to install a gas leak detector on site or open the cover of the installed gas leak detector and manipulate it. This may cause serious loss of life and property from fire, explosion, and etc. In addition, please check whether there is any remaining explosive gas or combustible material in the surroundings. Power must be turned off before performing work.

5.1. DETACHMENT OF HOUSING COVER

Warning - Do not open when electrical current is flowing

• Turn the slotted set screw (M4 x 1ea) fixing the cover part of the main body 3~4 turns counter-clockwise (ccw) using a hex wrench (M2), then turn the cover of the gas leak detector ccw to detach the cover. When the cover is detached, the LCD appears.

Figure 3. Slotted Set Screw: A close-up illustration showing the slotted set screw used to secure the housing cover, with a hex wrench (M2) indicated for removal.

After detaching the cover, disassemble the display parts as follows:

• Push in the left and right fixing rings located on the front side of the LCD at the same time.
• While pushing, pull the display parts towards the front to detach from the gas detector body.
• After detaching the display parts, the Main PCB is installed at the bottom part of the detector body.

Figure 4. Method to detach Display Part: A diagram showing the steps to detach the display part from the detector body. It involves pushing fixing rings and pulling the display assembly forward.

5.2. MAIN PCB CONFIGURATION

After detaching the cover, the Main PCB terminal layout appears as shown in the figure below.

Figure 5. Main PCB Key Layout: A detailed diagram of the Main Printed Circuit Board (PCB). It shows the layout of various connectors (CN1, CN2, CN4, CN5, CN6), potentiometers (VR1, VR2) for zero and span adjustment, DIP switches (SW1, SW2) for sensor configuration, test points (TP2, TP3, TP7, TP9), and LEDs. Terminal connections like "TO DISPLAY" and "TO SENSOR" are also indicated.

5.3. POWER AND SIGNAL TERMINAL CONFIGURATION

Warning - Turn off power before connecting power terminal

• After disassembling display parts, there is a terminal block in the Main PCB as shown in the figure below. Holding it with hands and pulling towards ceiling detaches it from the Main PCB.
• Loosen 5 terminal fixing screws located at the top part of the detached terminal block CN8 (VIS, +, mA, -, ETH) Connector by turning counter-clockwise (ccw) using a driver. Connect DC 18~24 V power to +, and - then connect signal cable to mA. Tighten 5 terminal fixing screws clockwise (cw) so that the terminal does not leave the track, then insert the Main PCB in the same condition as before disassembly.

Use CVVS or CVVSB 2.0sq Shield Cable for terminal configuration.

Figure 6. CN1 Terminal Configuration: A diagram illustrating the terminal configuration for the CN1 connector, which is the Power & Output Signal Terminal. It shows the pin assignments: Pin 1 for "+V" (Power), Pin 2 for "-V" (4-20mA Source Out), and Pin 3 for "ET" (Earth). It also shows the input voltage range (DC 18-31V) and the 4-20mA signal output.

5.4. METHOD TO CONNECT TO EXTERNAL CONTROL UNIT

Connect 18 V~31 V DC operation power to CN1 (+, mA, -, ET) Connection Terminal of the gas detector, then connect a device that can receive 4~20 mA signals to mA.

Figure 6. Method to connect External Control Unit: A system diagram showing how the Gas Detector connects to an external control unit. The detector's CN1 terminal (+V, -V, ET) receives power (18-31V DC) from a power supply in a non-hazardous area. The detector's 4-20mA output signal is sent to an input module of the control unit. The diagram also shows the toxic sensor within the detector.

5.5. INSTALLATION CABLE LENGTH

The maximum length between the TOX Point 2000/3000 and the power supply is determined by the wire specification. The formula for maximum installation length is: Max. Installation Length = VMAXDROP ÷ IMAX ÷ WIRER/m ÷ 2, where:

• VMAXDROP: Maximum Power Loop Voltage Drop (= Power Supply voltage - min operating voltage)
• IMAX: Max. Current of TOX Point 2000/3000
• WIRER/m: The resistance of the wire (ohms/meter value available in wire manufacturer's specification data sheet)

Example of installation lengths using 24 V power supply and 16 AWG wire:

• Tox Point 2000/3000 minimum operating voltage = 16 V DC
• VMAXDROP = 24 - 16 - 5.5 = 2.5V
• IMAX = 0.022A (22mA)
• Calculation: 2.5 ÷ 0.022 ÷ 0.01318 ÷ 2 = 4,310.9 m (approximately 4310 m)

Figure 7. Calculation of TOX Point 2000/3000 Installation Cable Length: A diagram illustrating the calculation of maximum cable length based on voltage drop and wire resistance. It shows a simplified loop with power supply, detector, and voltage drops.

6. DETECTOR OPERATION FLOW

6.1. INITIAL OPERATION STATUS (POWER ON)

After wiring to the power terminal at the top of the Main PCB board and supplying power, the following contents are displayed on the LCD. Approximately 30 minutes of stabilization time is needed from the initial supply of operation power, and it starts to operate normally after sufficient stabilization.

• The display shows the Program Version.
• After running "SELF TEST" for 30 seconds, it converts to Measuring Mode.
• During "SELF TEST", the status LED blinks on the Main Board. After completion of "SELF TEST", the status LED lights on.
• However, when Membrapor O₂ is used, "SELF TEST" persists until the sensor stabilizes. Contacting the "RESET" key returns to Measuring Mode.

6.2. MEASURING MODE

After power on, if there is no error from "SELF TEST", the detector automatically enters Measuring Mode. The current measurement is displayed.

• When a value equal to or greater than 10% of the High Scale value is inputted, "OUr(over)" is displayed on the LCD.
• When the %LEL value is below zero and equal to or less than -10%, "Und(under)" is displayed on the LCD. (Optional - Refer to Page 20)

6.3. OPERATION FLOW

After power on, the detector passes its self-diagnostic process and then enters Measuring Mode. From here, by operating the front keys, you can access the internal System Mode. The timeout for Level1 and Level2 is 10 seconds. It is set to 1 hour for Level2 Calibration and Test Mode. When the "RESET" key is contacted at the Program Mode Screen, it returns to Measuring Mode. When the "RESET" key contacts at each Program Setting Screen, it returns to the parent step.

7. SYSTEM MODE

7.1. PROGRAM MODE

• PASSWORD [**]: Contacting the "FUNC" key with the Magnet-bar for 2 seconds or longer in Measuring Mode enters Password mode. After setting the password using the "[Up Arrow Key]" or "[Down Arrow Key]", contact the "FUNC" key.
• PROGRAM MODE: If the password is correct, it enters Program mode. By contacting the "[Up Arrow Key]" or "[Down Arrow Key]", modes change in the defined order: (PROGRAM -> CALIBRATION -> ALARM -> SENSOR -> MAINTENANCE -> DEVICE -> VERSION -> TEST).
• GAS TYPE [DEFIN.]: This mode sets the gas name type. Contacting the "[Up Arrow Key]" or "[Down Arrow Key]" changes the gas type (DEFIN. / USER). "DEFIN." is an acronym for Define and is selected when using the built-in setting of the gas name. "USER" is selected when the user directly sets a gas name. When the desired gas type is displayed, contact the "FUNC" key to set the gas name and enter Program Mode.
• GAS SEL [COMB.]: This mode sets the gas name. Contacting the "[Up Arrow Key]" or "[Up Arrow Key]" changes the gas name. When the gas type is set to DEFIN., built-in gas names can be selected. When it is set to USER, the user must set the gas name using up to 5 characters. Allowed characters include numbers, capital alphabet, space, and period. When the position is moved by setting characters, a cursor in a black box shape appears.
• USER GAS [SER]: This mode sets the gas measuring unit. Contacting the "[Up Arrow Key]" or "[Down Arrow Key]" changes the gas measuring unit (% / %LEL / PPM / PPB). When the desired gas measuring unit is displayed, contact the "FUNC" key to set the unit and enter Program Mode.
• UNIT SEL [%LEL]: This mode changes the decimal place. Contacting the "[Up Arrow Key]" or "[Up Arrow Key]" changes the decimal place (0.100/1.00/10.0/100). When the desired decimal place is displayed, contact the "FUNC" key to set the decimal place and enter the next Program Mode.
• D-POINT [100]: This mode sets the high scale value that should be displayed for the full range. Contacting the "[Up Arrow Key]" or "[Down Arrow Key]" increases or decreases the scale value (1 ~ 10000). When the desired high scale is displayed, contact the "FUNC" key to set the high scale value and enter the next Program Mode.
• HIGH SCL [100]: This mode sets the high scale value that should be displayed for the full range. Contacting the "[Up Arrow Key]" or "[Down Arrow Key]" increases or decreases the scale value (1 ~ 10000). When the desired high scale is displayed, contact the "FUNC" key to set the high scale value and enter the next Program Mode.
• PASSWORD [00]: This is the password setting mode. This password is checked when entering Program Mode. Set using the "[Up Arrow Key]" or "[Down Arrow Key]" then contact the "FUNC" key to set the password and enter the next Program Mode.

7.2. CALIBRATION MODE

Due to the characteristics of the gas detector, a minimum of 30 minutes of stabilization time is required, and maintenance conditions may change depending on site conditions.

• Contacting the "FUNC" key with the Magnet-bar for 2 seconds or longer in Measuring Mode enters Password mode.
• Enter a 2-digit password using the "[Up Arrow Key]" or "[Down Arrow Key]" then contact the "FUNC" key to enter Program Mode.
• Contact the "[Up Arrow Key]" or "[Down Arrow Key]" to select "Calibration Mode".
• Contact the "FUNC" key when "CAL" is displayed to enter Calibration Mode. Contact the "RESET" key to return to Measuring Mode.
• Contact the "[Up Arrow Key]" or "[Down Arrow Key]" to achieve Z-C (Zero-Calibration) then contact the "FUNC" key to enter the next step.
• Contact the "[Up Arrow Key]" or "[Down Arrow Key]" to achieve [YES] then contact the "FUNC" key to enter Zero Calibration. (Default "no")
• This mode performs Zero Calibration and measurement is displayed. Using a calibration tool, inject clean air or 100% nitrogen into the sensor at a flow rate of 500 mL/min for 1 minute. Contact the "FUNC" key when measurement is stabilized to automatically perform Zero Calibration.
• When zero calibration is successful, "god (good)" is displayed on the LCD for 2 seconds.
• When zero calibration is not successful, "FAI (Fail)" is displayed for 2 seconds and it changes to "Calibration Data". Contact the "RESET" key to return to "Calibration".
• This mode displays measurement after calibration and checks whether calibration was successful after performing auto calibration. Contacting the "FUNC" key returns to "Calibration Mode".
• Contact the "[Up Arrow Key]" or "[Down Arrow Key]" to achieve S-C (Span-Calibration) then contact the "FUNC" key to enter the next step.
• Contact the "[Up Arrow Key]" or "[Down Arrow Key]" to achieve [YES] then contact the "FUNC" key to enter Span Calibration. (Default "no")
• Using a calibration tool, inject standard gas to the sensor. When it is stabilized, contact the "FUNC" key.
• Using the "[Up Arrow Key]" or "[Up Arrow Key]", set the standard gas value then contact the "FUNC" key.
• When span calibration is successful, "god (good)" is displayed on the LCD for 2 seconds.
• When span calibration is not successful, "FAI (Fail)" is displayed for 2 seconds and it changes to "Calibration Data Mode". Contact the "RESET" key to return to "Calibration Mode".
• This mode displays measurement after calibration and checks whether calibration is successful after performing auto calibration. Contacting the "FUNC" key returns to "Calibration Mode".

8. DRAWINGS AND DIMENSIONS

Figure 8. TOX Point 2000/3000 Drawing: Technical drawings showing the mechanical dimensions and layout of the TOX Point 2000/3000 detector from different views (top, side). Dimensions are provided in millimeters.

9. PRECAUTIONS BEFORE INSTALLATION

9.1. SELECTING A PLACE FOR INSTALLATION (OCCUPATIONAL HEALTH & SAFETY ACT DATA)

A gas leak detector alarm shall be installed in the following places:

• Around chemical equipment and accessories that have concerns of gas leak. This includes compressors, valves, reactors, pipe joints, etc., installed inside and outside of a building that handle combustible and toxic materials.
• Places that are easier for gases to stay, such as areas around manufacturing facilities with ignition sources like heating furnaces, etc.
• Areas around equipment for filling combustible and toxic materials.
• Substations, panel rooms, control rooms, and etc., located within an explosive area.
• Other areas that are easier for gases to stay.

9.2. SELECTING A SITE FOR INSTALLATION (HIGH-PRESSURE GAS SAFETY CONTROL ACT DATA)

The gas leak detector alarm must be installed as close to the areas with concerns of gas leakage as possible. However, for areas where direct gas leakage is not expected but are easier for leaked gas to stay, the detector must be installed at point 1 of the following:

• Gas leak detector alarms installed outside a building shall be installed at points where gas is likely to stay, considering wind direction, wind speed, specific gravity of gas, etc.
• Gas leak detector alarms installed inside a building shall be installed near the floor when the specific gravity of gas is heavier than air, and near ventilation of the ceiling when it is lighter than air.
• Alarms for gas leak detector alarms must be installed at sites where the gas detector is installed and workers are present.

9.3. PRECAUTIONS DURING INSTALLATION

Avoid areas with electrical barriers such as rain water, etc. It is recommended to be installed in areas that are easier to work in, as regular maintenance is needed. Avoid areas with vibration or shock, as they can affect output values. The sensor part must be installed towards the direction of gravity.

• This equipment has explosion-proof construction for internal pressure and belongs to GROUP II for gas and vapor in general work sites and chemical plants. It can be used in ZONE 1 (ONE) and ZONE 2 (TWO) hazardous sites.
• Allowable temperature is 85 °C or below, which corresponds to T6.
• Surrounding temperature shall be in a range of -40 to 80 °C (for the Main body. For the sensor, refer to each sensor manual.)
• Installation Height: 1,000 M below sea level
• Relative Humidity: 5% ~ 99% (Non-condensing)
• Installation Site: Indoor and Outdoor
• Explosion Ignition Group for Target Gas or Vapor: Ex d IIC T6
• During wiring work, use an explosion-proof cable gland at the cable inlet or tightly seal the cable conduit during metal cable wiring construction to prevent the spread of flames in case of explosion or movement of gas, etc., through the cable conduit within 50 mm. All materials, including materials used for sealing of unused inlets, must have safety certificates!
• When connecting the equipment with cable, the screw thread must be tightened 5 threads or more.
• Work in conditions satisfying other [Standards for Selection, Installation, and Maintenance, etc. of Explosion-proof Electric Machine and Equipment Wiring, etc. at Work Site].
• All materials used for cable inlet, such as cable gland and sealing fitting, etc., and used for sealing unused inlets must pass verification!

Figure 9. High-Pressure Packing Type: A diagram illustrating the proper method for connecting cables using a high-pressure packing type, showing the arrangement of sealing rings, connectors, and cable-fixing devices.

Figure 10. Y Sealing Compound: A diagram illustrating the use of Y sealing compound for cable connections, showing the placement of the compound and cable-fixing devices.

10. REVISION HISTORY