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Model PT500-EX

Multi-channel Gas
Monitor / Controller
Revision 2
March 2007

Operators
Manual
Pem-Tech, Inc.
Houston, Texas
www.pem-tech.com

NOTICE

PEM-TECH INCORPORATED SHALL NOT BE LIABLE FOR TECHNICAL OR


EDITORIAL ERRORS OR OMISSIONS MADE HEREIN, NOR FOR INCIDENTAL
OR CONSEQUENTIAL DAMAGES RESULTING FROM THE FURNISHING,
PERFORMANCE, OR USE OF THIS MATERIAL.

LIMITED WARRANTY
Pem-Tech, Incorporated warrants all the equipment to be free from defects in workmanship and
material. The products will operate in conformance with the published specifications when
subjected to intended and proper usage for the period of one (1) year from the date of shipment.
The warranty provides only the benefits specified and does not cover defects which result from
acts beyond the control of PEM-TECH including, but not limited to: damage by accident,
negligence, tampering, or failure to operate in accordance with the procedures outlined in the
Operations Manual. PEM-TECHs liability under no circumstances will exceed replacement of the
unit claimed to be defective.
Tampering with the equipment and altering it for uses other than the intended use or replacement
of parts not supplied by the company, shall immediately void and cancel all the warranties with
respect to the affected products.
The warranties specified herein are in lieu of any and all other warranties, express or implied. In
no event, whether as a result of breach of warranty or alleged negligence, shall PEM-TECH be
liable for special or consequential damages, including, but not limited to, loss of profits or revenue,
loss of equipment or down time costs.

Model PT500
Gas Monitor / Controller
Rev. 2

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SERVICE POLICY
Pem-Tech has service facility at the factory. For all the repairs contact at our toll free number 1-800379-3894 or visit our website www.pem-tech.com
For all repairs call us for a Return Material Authorization number (RMA). Inform us briefly the
nature of the problem and obtain shipping address. Properly pack the equipment before shipping.
Also include your complete shipping address and contact name and phone number.
For non-warranty repairs you must provide the limit to repair costs. State if a quote for repair cost
is required before you can authorize the repair cost. For this an additional charge may be
applicable.

NOTE:
1. For all the repairs under warranty, serial number must be legible on the items being repaired.
2. Shipping point is FOB Houston.

Model PT500
Gas Monitor / Controller
Rev. 2

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TABLE OF CONTENTS
1.0 Overview
1.1 Data Display
1.2 Front Panel
1.2.1 Keypad Switches
1.3 Specifications
1.3.1 DC Power Supply
1.3.2 130 Watt AC-DC Power Supply
1.3.3 Relays

2.0 Installation and Startup


2.1
2.2
2.3
2.4
2.5

DC Power Input
Connecting Sensor to Monitor
Connection Board
Alarm Wiring Diagram
Wiring to Alarm Station
2.5.1 Wiring Diagram

5
6
6
6
7
7
7
7

8
9
9
10
11
12
14

3.0 Startup

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15
16
16
16
16
16

4.0 Edit Configurations

17

Spare Parts List

20

3.1 Apply Power


3.2 Normal Operation and Alarms
3.2.1 Normal Operation
3.2.2 Alarms
3.2.3 Alarm Reset
3.2.4 Alarm Bypass & Acknowledge

4.1. Channel Configuration


4.1.1 Change sensor Type
4.1.2 Modify Alarm Levels

Model PT500
Gas Monitor / Controller
Rev. 2

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1.0 OVERVIEW
Model PT500 series monitor & controller is designed to monitor and display data for up to
4 remote mounted sensors. The controller features LCD display, 3 fully programmable
alarm relay contacts, and a sensor fault or malfunction relay. Also on the front panel are
LEDs for visual alarm indicators.

Figure 1.

Model PT500 Controller, Front view

Model PT500
Gas Monitor / Controller
Rev. 2

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1.1 DATA DISPLAY


LCD display for continuous gas reading. Also to display monitor configuration and user
prompts during programming mode.

1.2 FRONT PANEL


On front panel are visual alarm indicators and keypad switches to program controller
configuration. Also RESET and ACK key switches are used to Reset and acknowledge any active
alarms.

1.2.1 KEYPAD SWITCHES


RESET:

When pressed in normal mode it will Reset any currently active alarms.

ACK: Pressing the key will bypass or acknowledge active alarms for 30 minutes. If any
sensor is still in alarm state the alarm relays will be activated again.
PRGM:

Press this key to enter into controller configuration mode.

ENTER, UP & DOWN: These keys are used while editing controller configuration.

Model PT500
Gas Monitor / Controller
Rev. 2

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1.3 SPECIFICATIONS
1.3.1

30 WATTS AC DC POWER SUPPLY

On board AC to DC power supply to power the gas controller and also to supply DC
power to remote sensors. The AC power input is universal 100 240 VAC and auto
switching.
Power Supply: 100-240 VAC @ 0.9 A Max.

1.3.2 RELAYS
Provided on the connection board are four (4) programmable common alarm relays for
Alarm 1, 2, & 3. Also a sensor fault or malfunction relay. All Relays are rated 5 Amps @
30VDC or 240 VAC

1.3.3 ENCLOSURE
Nema 4X Wall mount Fiberglass enclosure.
Weight:
8 Lbs.
Dimension: 11.5H x 10W x 6.5D

1.3.4 TEMPERATURE RANGE


-25 C to 50 C

1.3.5

VISAUL ALARM INDICATORS

Amber LED indicator on the front panel for Low or AL1


Red LED for AL2 & AL3 alarm status
Red LED for Sensor Fault / Malfunction

Model PT500
Gas Monitor / Controller
Rev. 2

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2.0 INSTALLATION AND START UP


PT500 series is a wall mount gas monitor & controller. The fiberglass enclosure is rated
Nema 4x weatherproof and can be mounted outdoor. Refer to figure 2 for overall
enclosure dimension and mounting holes. The mounting feet for the fiberglass enclosure
are provided separately. The monitor should be installed approximately 5 feet above
ground. Extreme temperature condition must be avoided. Avoid installing the unit with
the front facing direct sunlight. An overhead weather deflecting shield is highly
recommended. Conduit entries or cable glands must be installed at the bottom of the
enclosure by the user.

Figure 2. Fiberglass enclosure, dimensional overview

Model PT500
Gas Monitor / Controller
Rev. 2

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2.1 AC POWER INPUT


A terminal block is provided on the connection board for AC power input.
figure 4 for power connection.

Refer to

Do not turn on the power until all sensors wires (if connected) are secure.

2.2 CONNECTING SENSORS TO THE MONITOR


Terminal contacts/blocks are provided on the connection board for the remote sensors.
The terminals are labeled as CH-1, CH-2 and so on. Furthermore, each contact on the
terminal is labeled as +, -, & E for SENSOR SUPPLY, SENSOR GND, and 4-20mA
Sensor Input. Sensors should be connected to the connection board by a 3 conductor
shielded cable. To connect sensor cable simply remove or pull the screw terminal block
from its header base, connect the wires from the sensor and plug it back in. Be sure to
check the wires connecting the sensor and Channel Input terminal on the PT500
connection board are as shown in figure 3 below.
The Sensor Supply terminals are fused to prevent short circuit damage to the unit.
( Fuses are labeled as F1 thru F4 for channel 1 thru Channel 4 respectively).

PCB 13-148

GND
+V

DC IN

NO
COM
NC

F AULT

SENSOR FUSES

NO
COM
NC
NO
COM
NC

NO
COM
NC
NO
COM
NC

ALARM-3 ALARM-4

F3

ALARM-1 ALARM-2

F1

CH-3

CH-1

+
E

F4

CH-4

CH-2

+
E

RS485

TT+

F2

Figure 3.

Wiring sensor to PT500 connection board assembly.


Note: complete connection boards are not shown for clarity.

Model PT500
Gas Monitor / Controller
Rev. 2

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2.3 CONNECTION BOARD ASSEMBLY


To access the connection board loosen the 2 panel screws on right side of the front panel.
This will allow the hinged front panel to swing out. All cables must be brought in thru the
cable glands on the bottom of the enclosure. The user must install the cable glands.

HI NGE D DOOR WITH CLE AR VI EWING WINDOW - NOT SHOWN

PCB 13-148

GND
+V

DC IN

NO
COM
NC

F AUL T

SENSOR FUSES

REMOTE
ACK

F2

F4

F1

F3

MALF RELAY OUT

Ala rm- 4

Ala rm- 3

Ala rm- 2

Ala rm- 1

CH-3

FIELD
WIRING

NO
COM
NC

AC SERVI CEPOWER INPUT

CH- 3

NO
COM
NC

NO
COM
NC

AL ARM -3 ALARM -4

NO
COM
NC

AL ARM -1 ALARM -2

CH-4

+
E

CH-4

CH-1

FIELD
WIRING

+
E

CH- 1

CH-2
RS485 Data
Lo op if Used

ACKSwitch

+
E

CH-2

+
E

RS48 5

TT+

Lights/Siren
|
Power

Figure 4. PT500 Connection board assembly , layout diagram.

Model PT500
Gas Monitor / Controller
Rev. 2

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2.4 Alarm Wiring diagram


Figure 5 below illustrates a typical wiring diagram for connecting an alarm device to a
relay contacts. Note that contacts are dry or potential free. Refer to the wiring details
provided by the manufacturer of alarm devices.
The relay contacts are form C type contacts. Refer to section on monitor configuration
for setting the alarm levels. Other alarm devices are also connected in similar manner as
one shown below. Also refer to section 2.5.1 and figure 6 for wiring a complete alarm
station.

ALARM x

NO
COM
NC

+V

+
LIGHT

Typical Load

-V

Figure 5. Typical Alarm Wiring diagram

Model PT500
Gas Monitor / Controller
Rev. 2

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2.5 ALARM CONFIGURATION AND WIRING


Distinct Visual Low Alarm
Common Audible High Alarm
Figure 6 shows a sample wiring diagram to connect PT500 alarm relays to an Alarm
Station. Typical alarm station consists of 2 distinct color strobe lights and a buzzer or
siren. The color of strobe light visually distinguishes between the low toxic and
combustible gas alarm. The buzzer or horn is for high alarm for either toxic or
combustible. On PT500 connection board three relays are configured in order to have
distinct low alarm for toxic and LEL combustible and a common high alarm (siren) for
both toxic and combustible. Alarm relay 1 is wired for Low toxic gas alarm, alarm relay 2
for low combustible alarm and alarm relay 3 for common high alarm. Alarm relay 4 is not
used in this configuration. Assuming that CH1 and CH2 are configured for toxic (say
H2S) and CH3 and CH4 are configured as LEL(combustibles). PT500 alarms must be
configured as follows:
Assume the toxic and LEL alarm levels are as listed in table below
Sample alarm levels / set-points

Low Alarm

Sensor
Type

High Alarm

Toxic (H2S)

10

15

LEL

20

40

Using the Edit Alarm Levels option (see section 4.0) program the alarm levels for each
channel as follows:

Ch #

Sensor Type

Alarm-1 or
Low Alarm
Relay

H2S

H2S

LEL

LEL

Model PT500
Gas Monitor / Controller
Rev. 2

Alarm-2 or
Hi Alarm
Relay

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In the above table for H2S channels 1 & 2 Relay-1 is designated for Alarm 1 or Low alarm
and Relay-3 is designated for Alarm 2 or High alarm.
Similarly for LEL channels 3 & 4 Relay-2 is designated for Alarm 1 or Low alarm and
Relay-3 is designated for Alarm 2 or High alarm.

Given above alarm level and relay configuration and wiring to alarm station as shown in
figure 6 the audio and visual alarm devices are activated as outlined in the table below.

Sensor

Gas Reading

Toxic

Greater than or Equal to 10


But
Less than 15

(H2S, CO, NO,


NO2, SO2,
Etc. )

Greater than or equal to 15

Sensor

Gas Reading

LEL

Greater than or Equal to 20


But
Less than 40

Alarm Relay
# Activated
1

1&3

Alarm Relay
# Activated
2

Strobe / Horn

Amber Strobe

Amber Strobe
& Horn

Strobe / Horn

Red Strobe

Combustible

Greater than or equal to 40

Model PT500
Gas Monitor / Controller
Rev. 2

2&3

Red Strobe
& Horn

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2.5.1. Wiring Diagram

Light and Siren Alarm Station

+ Si ren

+ Red Strobe

+ Amber Strobe

Return

Figure 6. Wiring PT500 to an Alarm Station

Model PT500
Gas Monitor / Controller
Rev. 2

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3.0 Start Up
Complete the following procedures for the normal unit operation.
1. Complete the mounting and wiring procedures described in earlier sections.
2. Follow gas sensor & transmitter operation manual for proper wiring of sensors with
the monitor.
3. Verify all the wiring connections to be correct and secure.

3.1 Apply Power


Apply power to the monitor and verify following conditions.
1. LCD should display startup messages for few seconds and then go into normal
operation mode by displaying sensor readings. Since monitor supplies the DC power
to the sensors, therefore, a short time is allowed for the sensors to stabilize.
2. Verify that the channel configuration and the sensor connected to that channel input
are the same.
3. Verify and change alarm set points according to your specifications.
Note: To verify or change alarms or channel configuration refer to monitor
configuration section.

Model PT500
Gas Monitor / Controller
Rev. 2

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3.2 NORMAL OPERATION AND ALARMS


3.2.1 Normal Operation
During normal operation the monitor will display the channel number sensor type with
current sensor readings. The controller continuously monitors all sensors that are
connected. Once properly configured and if all the sensor readings are below alarm level
then all the alarm relays and the visual alarm LED indicators on the front panel should be
off. If any channel is programmed as N/A (disabled) then ---- will be displayed for the
channel.

3.2.2 Alarms
PT500 monitor is equipped with four (4) alarm relay contacts. The monitor activates the
alarm relays when any of the sensors exceeds the programmed alarm set point. Also LEDs
on the front panel will also light up for visual alarm indication.
Standard alarm set points are programmed at the factory before shipment. The user must
verify the alarm set points and make changes if desired. Refer to section on Programming
Alarm Set points.

3.2.3 Alarm Reset


Once the gas concentration has dropped below the alarm level the relay will deactivate
itself. However, this is true only if the relay is configured as non-latching (NL). If the relay
is configured latching then it must be deactivated manually. To deactivate the latching
alarm simply press and hold RESET switch on the front panel for few seconds. The
monitor will deactivate the relays and visual LED indicators and will display ***** RESET
**** message on the LCD for few seconds.
Note: If the gas concentration continues to be higher than the programmed alarm set point the
alarm will be activated again.

3.2.4 Alarm Bypass or Acknowledge


In the Alarm Acknowledge mode the monitor will not activate the alarm relays if any of
the sensor reading exceeds the programmed alarm level. Press and hold the ACK switch
until the Acknowledge message is displayed on the LCD. The displayed message will
indicate the alarm bypass time. This bypass time period is programmed at the factory.
Once the Alarm Bypass time has expired the relays will be activated if the concentration
on the sensor exceeds the programmed alarm level. To terminate the alarm bypass mode
simply press the RESET switch until the monitor displays the RESET message on the LCD.
Model PT500
Gas Monitor / Controller
Rev. 2

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4.0 EDIT CONFIGURATION


Press and hold the PRGM key on the front panel to initiate the sequence of programming
options. Following are the options.
Press ENTER to

Press ENTER to

Edit Sensor Type

Edit Alarms

Press ENTER to
Quit & Return

Use the UP / DOWN arrow keys to display and switch between options. When the
desired option is displayed on the LCD press the ENTER key to select.

4.1 EDIT / MODIFY SENSOR TYPE


This option allows the user to change the configuration of each channel. Each line on the
LCD displays the current sensor type (H2S, LEL, CO, OXYgen, etc ).
The channel edit screen is displayed as follows:
Ch1
Ch2
Ch3
Ch4

H2S (ppm)
H2S (ppm)
LEL ( % )
* N/A

The edit screen allows the user to change the sensor type by using the UP & Down arrow
keys to change the sensor type and the ENTER key to accept the change. The channel # to
be edited must be pointed by an arrow in front of it.

4.1.1. Change Sensor Type


When the arrow is pointing to a channel number press the UP or Down arrow key
to select from the list of various sensor types.
Press and hold the arrow key until the desired sensor type is displayed. Sensor
type is selected from the list of following
H2S - Hydrogen Sulfide
LEL - Combustible Hydrocarbon
CO - Carbon Monoxide
Oxy - Oxygen Deficiency
NOx - Nitric Oxide
NO2 - Nitrogen Dioxide
HCL - Hydrogen Chloride

Model PT500
Gas Monitor / Controller
Rev. 2

Page 17

CL2 - Chlorine
N/A - Disable Channel Input
Press the ENTER key once sensor type for the channel has been selected.
The arrow symbol on the LCD will jump to the next line or channel to edit that
channel.
Configure all 4 channels for the sensor type and then press RESET key to exit the
channel configuration option. Pressing the RESET key will also save the
configuration in a non-volatile memory and return to normal option.

4.1.2. MODIFY ALARM LEVEL / SET POINTS


There are 4 programmable relays for alarms. Each channel can have up to 3 alarm relays
assigned for Alarm 1, 2, & 3. The alarms levels can be programmed anywhere between 0
and the full scale range of sensor connected to that channel. Note that setting the level to 0
for any of the alarms is to disable that alarm. Also refer to section 2.5 for an example
alarm configuration.
To begin programming the alarms initiate the programming option by pressing the
PRGM key. Press the Up/Down arrow key until the Edit Alarms option is displayed.
Press the ENTER key to select. Alarm levels for all channels are edited one at a time.
The LCD will display current alarm levels as follows:
Channel number

Alarm # and
Levels

Sensor Type

Ch: 1 - H2S (ppm)


AL1 10
R-1
NL
AL2
15
R-2
NL
AL3
20
R-3
L

Latching or Non-Latching
Alarm Relays

Designated Relay #

When arrow is pointing to AL1 - Level, press the Up arrow key to increase and
Down arrow key to decrease the alarm level.
The alarm levels can be set between 0 and the full scale range of the selected sensor
type. For example the full scale range of H2S and LEL type sensor is 100. The
alarm level can therefore, be set anywhere between 0 and 100. If the alarm is set to 00
then it is disabled only for that particular channel / sensor. Thus Alarm level can, therefore,
be set to 00 to disable for that channel.
Model PT500
Gas Monitor / Controller
Rev. 2

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When the desired alarm level is set press the ENTER key to accept the new alarm
level and the arrow will jump to R-x to designate the Relay # for that alarm. There
are 4 Alarm Relays available on the monitor. Use the UP and DN arrow keys to
select and designate alarm relay between 1 and 4. Again press the ENTER key to
accept the change and jump to next edit field to configure relays and latching or
non-latching.
When arrow is pointing to L(atching) or Non-L(atching) field use the UP and DOWN
arrow keys to toggle between L and NL and press ENTER when done.
After modifying all 3 fields for an alarm the arrow will jump to next line or next
alarm. Modify all 3 alarms in similar manner using the UP and DOWN arrow keys
to change the value and ENTER key to accept the change and skip to next data
field.
Press the RESET key to finish current channel alarm configuration and jump to next
channel.
Once all channels have been configured PT500 will save the alarm configuration into a
non-volatile memory and will display the message when finished.
Note:
If an alarm is configured as Latching alarm, and once activated it can only be deactivated by
pressing the RESET switch. Non-Latching alarms are, however, deactivated when the
concentration goes below the alarm set point for that channel.

Model PT500
Gas Monitor / Controller
Rev. 2

Page 19

Spare Parts List


Part Number
15-140

Description
117/220 VAC to 24 VDC power Supply
30 Watts

S-50-002

Main CPU Board assembly with LCD display

S-51-202

Connection and relay board assembly for

C-416

Model PT500
Gas Monitor / Controller
Rev. 2

4 Amp Buss fuse for sensor power

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