Millennium Enterprises AD-ST1400-25, MLP-A-AR User Manual
MILLENNIUM
Oxygen Gas Detector
User Manual
Models:
MLP-A/AR/AD-ST1400-25
&
(all available options)
Part Number: MAN-0060 Rev 04
August 2008
Net Safety Monitoring Inc
IMPORTANT INFORMATION
This manual is for informational purposes only. Although every effort has been
made to ensure the correctness of the information, technical inaccuracies may
occur and periodic changes may be made without notice. Net Safety Monitoring
Inc., assumes no responsibility for any errors contained within this manual.
If the products or procedures are used for purposes other than as described in the
manual, without receiving prior confirmation of validity or suitability, Net
Safety Monitoring Inc., does not guarantee the results and assumes no
obligation or liability.
No part of this manual may be copied, disseminated or distributed without the
express written consent of Net Safety Monitoring Inc.
Net Safety Monitoring Inc., products are carefully designed and manufactured from
high quality components and can be expected to provide many years of trouble free
service. Each product is thoroughly tested, inspected and calibrated prior to
shipment. Failures can occur which are beyond the control of the manufacturer.
Failures can be minimized by adhering to the operating and maintenance
instructions herein. Where the absolute greatest of reliability is required,
redundancy should be designed into the system.
Warranty
Net Safety Monitoring Inc., warrants its ST1400 sensor against defective parts
and workmanship for a period of 6 months from date of purchase; other
electronic assemblies for 36 months from date of purchase.
No other warranties or liability, expressed or implied, will be honoured by Net
Safety Monitoring Inc.
Contact Net Safety Monitoring Inc., or an authorized representative for details.
We welcome your input at Net Safety Monitoring. If you have any comments
please contact us at the phone/address below or visit our web site and complete
our on-line customer survey: www.net-safety.com.
Contact Information
Net Safety Monitoring Inc.
2721 Hopewell Place NE
Calgary, AB T1Y 7J7
Canada
Telephone: (403) 219-0688 Fax: (403) 219-0694
www.net-safety.com
E-mail: netsafe@net-safety.com
Copyright © 2005 Net Safety Monitoring Inc.
Printed in Canada
Net Safety Monitoring Inc
TABLE OF CONTENTS
Important Information
Warranty
Contact Information
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
The Product ...................................................................................................... 1
The Sensor ............................................................................................................. 1
The Controller ....................................................................................................... 1
The Manual ........................................................................................................... 1
Step 1 — Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Locate Controller/Sensor ................................................................................. 2
Figure 1: Locate Sensor/Controller .......................................................................... 2
Figure 2: Dimensional Drawings ............................................................................. 3
Step 2 — Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Unpack ............................................................................................................. 3
Figure 3: Components .............................................................................................. 3
Mount .................................................................................................................... 4
Step 3 — Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Field Installation .............................................................................................. 4
Seal ................................................................................................................... 4
Connecting Wires .................................................................................................. 4
Board Assembly .................................................................................................... 5
Figure 4: Millennium Module Boards ...................................................................... 5
Figure 5: Wiring—Controller and Sensor ................................................................ 6
Sensor and Controller ...................................................................................... 6
Table 1: Controller/Sensor Connections .................................................................. 6
RS-485 Communication ........................................................................................ 6
Sensor Separation ............................................................................................ 7
Figure 6: Wiring—Sensor Separation ...................................................................... 7
Non-Isolated/Isolated Wiring .......................................................................... 8
Terminal Connection ............................................................................................. 8
Figure 7: Non-isolated Terminal Connection .......................................................... 8
Figure 8: Isolated Terminal Connection .................................................................. 8
Current Output ....................................................................................................... 8
Figure 9: Jumper Positions ....................................................................................... 8
Remote Reset ................................................................................................... 9
Figure 10: Remote Reset ......................................................................................... 9
MODBUS Termination ....................................................................................9
Figure 11: Modbus Termination Jumpers ................................................................9
Step 4 — Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 12: Controller Functionality ........................................................................10
Table 2: Status LEDs, Display Messages and Current Loop .................................11
RTU Registers .....................................................................................................11
Table 3: RTU Status Register (40002) Read Only (Binary) ..................................11
Calibration Button ...............................................................................................11
Magnetic Reed Switch .........................................................................................12
Power Up .............................................................................................................12
Current Loop Measurement (Test Jacks) .............................................................12
Status LED ...........................................................................................................12
The Main Menu ..............................................................................................12
Accessing the Main Menu ...................................................................................12
Main Menu Functionality ....................................................................................12
Step 5 — Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Calibration Procedure .....................................................................................13
Calibration Procedure ..........................................................................................13
Figure 13: Calibration Procedure ...........................................................................13
Calibration Failure .........................................................................................14
Step 6 — Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Review Relay Settings ....................................................................................14
Relay Options .................................................................................................15
Table 4: Default Relay Settings ..............................................................................15
Setting Relay Options ..........................................................................................15
Modbus Options .............................................................................................16
Node Address ......................................................................................................16
Baud Rate ............................................................................................................16
Enter Restricted Menu ....................................................................................16
Set Low Power Options - Optional ......................................................................16
Select Display Language ................................................................................17
Alarms ............................................................................................................17
Sensor Fault .........................................................................................................17
Non-standard O2 Levels ......................................................................................17
Sensor Life ...........................................................................................................17
Reset ...............................................................................................................17
Manual Reset .......................................................................................................17
Remote Reset .......................................................................................................17
Net Safety Monitoring Inc
Outputs ........................................................................................................... 18
Relays - Optional ................................................................................................. 18
Modbus ................................................................................................................ 18
Current ................................................................................................................. 18
Step 7 — Maintain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Periodic Response Check ............................................................................... 18
Troubleshoot .................................................................................................. 18
How to Return Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Spare Parts/Accessories ................................................................................. 19
Table 5: Part Numbering ........................................................................................ 19
Face Rotation Option ..................................................................................... 19
Figure 14: Non-standard Orientations .................................................................... 19
Rotate PCB Assembly ......................................................................................... 20
Appendix A: Electrostatic Sensitive Device (ESD) . . . . . . . . . . . .20
Appendix B: Resistance Table in OHMS . . . . . . . . . . . . . . . . . . . .21
Appendix C: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Net Safety Monitoring Inc.
INTRODUCTION
The Millennium series is Net Safety's latest innovation in a line of continuously
evolving industrial gas detectors and sensors. The microcontroller based system
provides fast, accurate and continuous monitoring of gases in extreme
environments.
THE PRODUCT
The Sensor
Step 1 — PLAN
Step 2 — INSTALL
Step 3 — WIRE
The electrochemical sensor is a proven design ensuring an accurate and
repeatable response within a detection range of 0 to 25% oxygen.
The Controller
The Millennium Controller has an explosion-proof Housing, rated Class 1,
Division 1, Groups B, C, and D for hazardous applications. It was designed for
either intrusive or non-intrusive calibration.
The Manual
The manual has been designed to make installation of the Millennium product
easy. To ensure proper installation, follow the steps outlined in the following
pages. If you encounter problems during operation, consult the troubleshooting
section or contact your sales representative.
Step 4 — OPERATE
Step 5 — CALIBRATE
Step 6 — MONITOR
Step 7 — MAINTAIN
MLP-A/AR/AD-ST1400-25 1
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STEP 1 — PLAN
LOCATE CONTROLLER/SENSOR
Prior to the installation process, a location plan for placing the Controller and
Sensor should be developed. Although there are no absolute rules for
determining the quantity and location of a sensor or controller, the following
points should be considered when planning the installation.
• Locate the Controller where it will be accessible and visible.
• Oxygen deficiency can be caused by O2 consumption from such activities as
chemical reactions or combustion and/or displacement by other gases.
• Use redundant systems to enhance protection and reliability.
• Consider air movement patterns within the facility.
• Seek advice from experts knowledgeable about the primary gas to be
detected.
• Use common sense and refer to various regulatory publications that discuss
general guidelines for your industry.
The two most common installation options are as follows.
Option 1
Locate Sensor separate from Controller using a certified (Net Safety Muti-propose)
Junction Box.
The Controller is located near eye-level. Conduit is run from the Controller to
the Sensor. The Multi-purpose Junction Box is used to connect the conduit from
the Controller to the Sensor. A Calibration Cup can be attached to the Sensor.
Tubing can be run from the calibration cup to a convenient location accessible
for calibration gas to be injected. Refer to MAN-0081 for Multi-purpose Junction
Box Terminal designations.
Option 2
The Sensor is attached directly to the Controller. A Calibration Cup and tubing
may also be used to facilitate calibration as in Option 1 above.
See "Sensor and Controller" on page 6 for detailed instructions.
Figure 1: Locate Sensor/Controller
Controller
Sensor
Calibration Cup
Apply Calibration Gas
TIP:
The Calibration Cup allows for tubing to be affixed
to a Sensor mounted in remote locations. The tubing
is directed to a level, usually close to the Controller,
for easy injection of calibration gas.
The Calibration Cup can also act as a splash guard,
protecting sensors when mounted low to the ground.
Conduit to
Controller
About
eye
level
CCS-1
MLP-A/AR/AD-ST1400-25 2
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Figure 2: Dimensional Drawings
5.31”
(103.1 mm)
(134.9 mm)
Controller with sensor
4.06”
5.60”
(142.2 mm)
(66.0 mm)
4.82”
(122.4 mm)
2.60”
5.68”
(144.3 mm)
2.89”
(73.4 mm)
10.51”
(267.0 mm)
STEP 2 — INSTALL
UNPACK
Carefully remove all components from the packaging. Check components
against the enclosed packing list and inspect all components for obvious
damage such as broken or loose parts.
If you find any components missing or damaged, notify the representative or
Net Safety Monitoring immediately.
Figure 3: Components
Controller Housing
Millennium Faceplate
Housing Cover
Ribbon connecting
4.82”
9.92”
(122.4 mm)
faceplate/controller
(252.0 mm)
Sensor Housing
5.10”
(129.5 mm)
External Equipment
It is necessary that reliable monitoring and indicating devices or systems be
connected to the transmitter. These devices must be designed to produce clear
visual and audible danger signals when high signal levels occur.
Multi-purpose Junction Box with sensor
MLP-A/AR/AD-ST1400-25 3
Net Safety Monitoring Inc
Mount
The Controller is usually mounted near eye-level and be easily accessible for
calibration and maintenance purposes. The Sensor should be placed where O2
may build up or where other gases are likely to build up and displace O2.
Ensure all devices are securely mounted, taking into consideration all
requirements.
Use the Face Rotation Option to mount the Millennium
Controller at a different orientation (refer to "Face
Rotation Option" on page 19 for detailed instructions).
STEP 3 — WIRE
FIELD INSTALLATION
WARNING: Wiring codes and regulations may vary. Compliance with
regulations is the responsibility of the installer. Wiring must comply with
applicable regulations relating to the installation of electrical equipment in a
hazardous area. If in doubt, consult a qualified official before wiring the system.
• If the 4-20 mA signal is not used, connect a jumper between the 4-20 terminal
and the Common terminal.
• The use of shielded cable is highly recommended for signal, input, output and
power wires to protect against interference caused by extraneous electrical or
electromagnetic 'noise'.
• In applications where the wiring cable is installed in conduit, the conduit
must not be used for wiring to other electrical equipment.
• The maximum distance between the Sensor and Controller is limited by the
resistance of the connecting wiring, which is a function of the gauge of the
wire being used (refer to " Resistance Table in OHMS" on page 21).
• When developing a RS-485 chain of devices, the last device in the chain
requires end of line termination.
• RS-485 connection 2-wire, multipoint serial line.
SEAL
• Water-proof and explosion-proof conduit seals are recommended to prevent
water accumulation within the enclosure.
• Seals should be located as close to the device as possible and not more than
18 inches (46 cm) away.
• Explosion-proof installations may require an additional seal where conduit
enters a non-hazardous area. Ensure conformity with local wiring codes.
• When pouring a seal, use a fibre dam to assure proper formation of the seal.
Seals should never be poured at temperatures below freezing.
• The jacket and shielding of the cable should be stripped back to permit the
seal to form around the individual wires. This will prevent air, gas and water
leakage through the inside of the shield and into the enclosure.
• It is recommended that explosion-proof drains and conduit breathers be used.
In some applications, alternate changes in temperature and barometric
pressure can cause 'breathing' which allows moist air to enter and circulate
inside the conduit. Joints in the conduit system are seldom tight enough to
prevent this 'breathing'.
Note: Seals are not required for all Class 1 Division 2 locations in Canada.
However, to fully avoid any exposure, the use of seals are still
recommended, especially for installations that use high-pressure or
steam cleaning devices in proximity to the controller and/or sensor.
Connecting Wires
1. Use a small screw driver to gently press down and hold the spring connector
open.
2. Insert appropriate wire into open connector hole.
3. Release screw driver to secure wire.
MLP-A/AR/AD-ST1400-25 4
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