MSA FiveStar Technical Manual

FiveStar® Alarm

Technical Manual

WARNING

"

THIS MANUAL MUST BE CAREFULLY READ BY ALL INDIVIDUALS WHO
HAVE OR WILL HAVE THE RESPONSIBILITY FOR SERVICING THE PRODUCT.
Like any piece of complex equipment, this instrument will perform as
designed only if it is used and serviced in accordance with the manufacturer’s
instructions. OTHERWISE IT COULD FAIL TO P E RFORM AS DESIGNED AND
PERSONS WHO RELY ON THIS PRODUCT FOR THEIR SAFETY COULD
SUSTAIN SEVERE PERSONAL INJURY OR DEATH.

The warranties made by Mine Safety Appliances Company with respect to the product are voided if
the product is not used and serviced in accordance with the instructions in this manual. Please
protect yourself and others by following them. We encourage our customers to write or call
regarding this equipment prior to use or for any additional information relative to use or repairs.

CAUTION

"

For safety rea son s, thi s equ ipm ent mu st be oper ate d by qua lifie d pers onne l
only. Read and understand the instruction manual completely before
operating.

In the U.S., to contact your nearest stocking location, dial toll-free 1-800-MSA-2222. To contact MSA
International, dial 1-412-967-3000 or 1-800-MSA-7777.

This manual pertains to:

North American approved instruments with Serial Number prefix "F" and "G"
Australian approved instruments with Serial Number prefix "A"
EN approved instruments with Serial Number prefix "A".

© MINE SAFETY APPLIANCES COMPANY 2005 - All Rights Reserved

Manufactured by

MSA INSTRUMENT DIVISION

P.O. Box 42 7, Pi tt sb ur gh, P ennsylva nia 15230

(L) Rev 9 710440

MSA Portable Instrument Warranty

1. Warranty-

ITEM WARRANTY PERIOD

Chassis and electronics
All sensors, unless otherwise specified Two years

Pump and drive unit Two years
Rechargeable batteries Two years

This warranty does not cover filters, fuses, etc. Certain other accessories
not specifically list ed here may have different warranty periods. This
warranty is valid only if the product is maintained and used in accordance
with Seller’s instructions and/or recommendations. The Seller shal l be
released from all obligations under this warranty in the event repairs or
modifications are made by per sons other than its own or authorized
service personnel or if the warranty claim results from physical abuse or
misuse of the product. No agent, employee or representative of the
Seller has any authority to bind the Seller to any affirmation,
representation or warrant y concerning this product. Seller makes no
warranty concerning components or accessories not manufactured by
the Seller, but will pass on to the Purchaser all warranties of
manufacturers of such components. THIS WARRANTY IS IN LIEU OF

ALL OTHER WARRANTIES, EXPRESSED, IMPLIED OR
STATUTORY, AND IS STRICTLY LIMITED TO THE TERMS
HEREOF. SELLER SPECI FIC ALLY DIS CLAI MS ANY WARRA NTY
OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR
PURPOSE.

Lifetime (MSA will support product
for five years after production ends)

2. Exclusive Remedy- It is express ly agreed that P urchaser’s sol e and
exclusive remedy for breach of the above warranty, for any tortious
conduct of Sell er, or for any ot her cause of ac tion, shall be the r epair
and/or replacement at Seller’s option, of any equipment or parts
thereof, which after examination by Seller is proven to be defective.
Replacement equipment and/or parts will be provided at no cost to
Purchaser, F.O.B. Seller’s Pl ant. Failure of Seller to successfully
repair any nonconforming product shall not cause the remedy
established hereby to fail of its esse ntia l pu rpo se.

3. Exclusion of Consequential Damages- Purchaser specifically
understands and agrees that under no circumstances will seller be
liable to purchase r for econom ic, special, inci dental or co nsequential
damages or losses of any kind whatsoever , incl udi ng but not limited
to, loss of anticip ated prof its and any othe r loss ca used by r eason of
nonoperation of the goods. This exclusio n is applicable to clai ms for
breach of warranty, tortious conduct or any other cause of action
against seller.

Technical Manua l Table of Contents

Table of Contents

Chapter 1

Set-up and Conf iguration. . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Sensor Autoconfiguration and Replacement . . . . . . . . . . . . . 1-2

" CAUT ION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Repla c i n g a Senso r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 3

Figu re 1-1. Sensor Replac e me n t. . . . . . . . . . . . . . . . . . . . . . . . . 1-3

" CAUT ION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

" WARN ING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Instal l i n g a New Type of Sens o r. . . . . . . . . . . . . . . . . . . 1- 4

Table 1-1. Allowable Sensor Installation Loc ations. . 1-5

Figure 1-2. Sensor and Zebra Strip Loc ations in Sensor Cavity 1-5

" WARN ING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

" CAUT ION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Figu re 1-3. Removin g the Jumper. . . . . . . . . . . . . . . . . . . . . . . . 1-6

Removing a Senso r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

" CAUT ION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Sensor Au to co n figur a t i o n. . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Figu re 1-4. New Sensor Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Figure 1-5. Sensor Update? Yes/No . . . . . . . . . . . . . . . . . . . . . 1-8

Figu re 1-6. Please Wait . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Figu re 1-7. Units Measure d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Figu re 1-8. Gases Measure d . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Figure 1-9. Sample Combustible Alarm Setpoints. . . . . . . . . . . . 1-9

Figure 1-10. Sample O

Alarm Setp o i n ts . . . . . . . . . . . . . . . . . . 1-9

2

Figu re 1-11. Sample Toxic Alarm Setpoin t s . . . . . . . . . . . . . . . . 1- 9

Table 1-2. Default Factory Alarm Setpoints. . . . . . 1-10

FiveStar Alarm TOC-1

Table of Contents Technical Manual

Figu re 1-12. Accept Alarms Reset/Show /O K. . . . . . . . . . . . . . . 1-10

" CAUT ION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Figure 1-13. Check Sensor Cover/ Label Empty Slots / Quit - OK 1 -11

Manual Sensor Configuration. . . . . . . . . . . . . . . . . . . . . 1-12

To Enter the Sensor Setup Mode Manually . . . . . . . . . 1-12

Chapter 2

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Optional Fresh Air Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Activa ting the Fresh Air Setup Option. . . . . . . . . . . . . . . 2-1

To Cancel Fresh Air Setup . . . . . . . . . . . . . . . . . . . . . . . 2-1

Figu re 2-1. Fresh Air Setu p ? . . . . . . . . . . . . . . . . . . . 2-1

To Perform Fresh Air Setup . . . . . . . . . . . . . . . . . . . . . . 2-2

Calib r a t i o n Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Preparing to Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

WARN ING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

"

Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Figu re 2-2. Calibra tion - No/Yes ?. . . . . . . . . . . . . . . 2-3

Figu re 2-3. Apply Fresh Air. . . . . . . . . . . . . . . . . . . . 2-3

Figu re 2-4. Adjusti n g Zeroe s. . . . . . . . . . . . . . . . . . . 2-4

Figure 2-5. Combustible Gas Calibration Display . . . 2-4

Figu re 2-6. Calibration Cap Installa ti o n . . . . . . . . . . . 2-5

Figure 2-7. Snap Calibration Cap Installation . . . . . . 2-5

Oxygen Sensor Calibration Check. . . . . . . . . . . . . . . . . . 2-6

Figure 2-8. Combustible Gas Span Adjustment . . . . 2-6

Toxic Gas Sensor Calibration . . . . . . . . . . . . . . . . . . . . . 2-7

To repeat calibration procedure: . . . . . . . . . . . . . . . . . . 2-7

To end calibration procedure: . . . . . . . . . . . . . . . . . . . . . 2-7

Figu re 2-9. Remove Cal Cap . . . . . . . . . . . . . . . . . . 2-7

Figure 2-10. Saving Calibration

Please Wait . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Figu re 2-11. Power OFF. . . . . . . . . . . . . . . . . . . . . . . 2-7

Special Instructions for Instr uments

with Chlorin e Dioxid e Senso r s. . . . . . . . . . . . . . . . . . . . . 2-8

Calib r a t i o n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Figure 2-12. Setup for Chlorine Diox ide Generator

Bypas s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

TOC-2 FiveStar Alarm

Technical Manua l Table of Contents

Chapter 3

Troubleshooting and Maintenance . . . . . . . . . . . . . . . . . 3-1

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Table 3-1. Troubleshooting Guidelines . . . . . . . . . . . 3-1

Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Batter y Pac k Repla ce ment . . . . . . . . . . . . . . . . . . . . . . . 3-4

Remove the Batte r y Pack . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Repla c e the Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Sensor Rep l a cemen t . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Main Electro n i cs Board Replacement. . . . . . . . . . . . . . . 3-4

" CAUTIO N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Figu re 3-1. Battery Pack Removal. . . . . . . . . . . . . . . 3-4

" CAUTIO N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

" CAUTIO N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Figure 3-2. Display Connector . . . . . . . . . . . . . . . . . . 3-5

" WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Sensor Bo a rd Repla ce m e n t. . . . . . . . . . . . . . . . . . . . . . . 3-6

" CAUTIO N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Figure 3-3. Sequence for Tightening Screws . . . . . . 3-6

" WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Display Module Replacement. . . . . . . . . . . . . . . . . . . . . 3-7

" CAUTIO N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

" CAUTIO N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Figure 3-4. Keypad Ribbon Cable Replacement . . . . 3-9

" WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Chapter 4

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Table 4-1. North American/Australian Common

Acces so r y Par ts Lis t. . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Figure 4-1. North American

(through Serial Number Prefix "E")

Repla c e ment Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Table 4-2. North American

(through Serial Number Prefix "E")

Repla c e ment Parts List . . . . . . . . . . . . . . . . . . . . . . . 4- 3

Tabl e 4-3. Replacement Sensor s. . . . . . . . . . . . . . . . 4- 3

FiveStar Alarm TOC-3

Table of Contents Technical Manual

Figure 4-2. Australian and European A pproved
Replacement Parts and North American
(Serial Number Prefix "F" or Higher)

Repla c e ment Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Table 4-4. North American
(Serial Number Prefix "F" or " G")

Repla c e ment Parts List. . . . . . . . . . . . . . . . . . . . . . . . 4-5

Table 4-5. Australian/European Replacement Parts List. 4-6
Table 4-6. Pump and Aspirator Assembly

Repla c e ment Parts List. . . . . . . . . . . . . . . . . . . . . . . . 4-7

Figu re 4-3. Replacement Parts. . . . . . . . . . . . . . . . . . 4-7

Figure 4-4. Battery and Fuse Location . . . . . . . . . . . 4-8

Table 4-7. Replaceable Battery Pack P arts List . . . . 4-8

TOC-4 FiveStar Alarm

Technical Manua l Chapter 1, Setup and Configuration

Chapter 1
Set-up and Configuration

The user must be familiar with the pr ocedures in the FiveStar
Alarm Instruction Manual, including all c autions and warnings.
The FiveStar Alarm can be configured in many ways to meet
your changing gas detection needs. T here are four means for
making instrument configuration changes (t he first two are
described in the instruction manual, t he third is described in this
chapter, and the fourth is ac cessible only with FiveStar LINK):

1. At instrument turn-O N ,
the following setup option is available:

• Fresh Air Setup (if enabled).

2. When attaching the battery to the instrument,
the following setup options are available:

• Language for displays (if enabled)

• Operating Beep

• Peak / STEL / TWA displays (all/none)

• Set time and date

• Sens or configuration.

3. During Sensor setup or sensor autoconfiguration,
the following setup options are available:

• LEL versus CH

• Gas sensors installed

• Reset alarm settings to factory defaults.

4. FiveStar Link is a separately-supplied software package for
communicating to the FiveStar instrument with a personal
computer. To operate, FiveStar Link requires a set of
software and an Infrared adapter. These components may
be purchased together (as P/N 710988) or separately.

With FiveStar Link software, the following options can be reset:

FiveStar Alarm 1-1

combustible display

4

Chapter 1, Setup and Configuration Technical Manual

• Eight-character instrument "name" shown on
instrume n t star tup (d efau lt is "PASSPORT")

• Change alarm setpoints

• Set backlight time-out (1 minute to 20 minutes)

• Operating beep

• Individually turn ON/OFF Peak, STEL

and/or TWA pages

• Disable Fresh Air Setup (available only in
instruments with software V1.2 or higher)

• Set Time and Date (available only in instruments
with software V1.2 or higher)

• Disable Autoconfigure (available only in instruments
with software V1.2 or higher)

• Enable or disable Data Tagging
(software V2.0 or higher)

• Enable or disable the "display alarms" on start-up
option (software V2.01 or higher)

• Enable or disable the multilingual function
(English/Spanish/Canadian French
software V2.01 or higher)

• Disable Autocalibration capability
(software V3.0 or higher)

• Change Periodic Datalog intervals
(software V3.0 or higher).

Sensor Autoconfiguration
and Replacement

When a sensor is replaced, when a new t ype of sensor is
installed or when a sensor is removed, the FiveStar Alarm steps
the user through an "autoconfigur ation" program. All instruments
leave the factory with the autoc onfigure feature enabled. The
FiveStar Link program may be used to dis able this feature if the
user desires.

1-2 FiveStar Alarm

Technical Manua l Chapter 1, Setup and Configuration

The autoconfiguration feature allows the user to change the
instrument sensor configuration as the user’s gas sensing needs
change. The unit steps through the autoconfiguration sequence
(listed later in this chapter) when the instrument recognizes that:

• a new serial number sensor is installed (a replacement)

• a sensor is removed

• a new type of gas sensor is added.

CAUTION

"

When removing or installing the combustible gas sensor,
remove the battery pack. Otherwise, the sensor pins may
short to the case and cause an "ERROR 5" message (damage
to the combustible sensor circuit).

Replacing a Sensor

To replace a sensor in your FiveStar A larm:

1. Verify that instrument is OFF; remove the battery pack.

2. Remove sensor cover screws and cover.

3. Gently lift out and properly dispose of sensor to be replaced.

4. Inspect the condition of electrical contact "Zebra Strip" located
below the sensor.

• The "Zebra Strip" is a small, black conductive elastomer

which makes contact to the sensor memory chip on the
bottom of the sensors (see Chapter 4, FIGURE 4-1).

• If this is not in place or is not making good contact,

the instrument will not properly recognize the
installed sensors.

5. If the Zebra Strip is damaged or missing,
replace it with a new Zebra Strip (P/N

655188) before installing new sensor.

6. If replacement sensor is equipped with a
shorting plate, clip or wire attached to
its pins, remove plate, clip or wire
before inserting the replacement
sensor.

7. Carefully align the new sensor contact
pins with the sockets on the Sensor
Board.

FiveStar Alarm 1-3

Figure 1-1.

Sensor Replacement

Chapter 1, Setup and Configuration Technical Manual

8. Press the new sensor into place.

9. Replace the sensor gasket and sensor cover.

10. Re-install screws to hold down the sensor cover.

CAUTION

"

Do not operate the instrument without the sensor cover
fully installed. The zebra strips require pressure to enable
proper contact. Without proper contact, data may be written
improperly to the sensor memory and the data may become
corrupted, rendering the sensor unusable.

NOTE: NO, Cl2, ClO2, and NH3 sensors are "biased"

sensors. As such, they require approximately 12
hours once installed (with battery pack attached, but
turned OFF) for the output to stabilize. Allow the unit
to stabilize before calibrating and using in the field.

11. Replace cover before turning instrument back ON to
verify configuration.

• The sensor cover holds the sensors down firmly against

the Zebra Strips to ensure proper electrical contact.

12. Turn the instrument ON and proceed through sensor setup.

• The instrument proceeds to a sensor update mode similar

to that for adding or deleting a sensor. See "Sensor
Autoconfiguration" later in this chapter for instructions.

• If instrument autoconfiguration is disabled, the instrument

shows an error message. See "Manual Sensor
Configuration" later in this chapter for instructions on
manual configuration.

WARNING

"

Verification of calibrati on response is required; otherwise the
instrument will not perform as required and persons who rely
on this product for their safety could sustain serious personal
injury or death.

Installing a New Type of Sensor

1. Verify that unit is OFF.

2. Remove battery.

3. Remove sensor cover screws and sensor cover (FIGURE 1-2).

1-4 FiveStar Alarm

Technical Manua l Chapter 1, Setup and Configuration

4. Verify that the electrical

contact Zebra Strip
below sensor is not
missing or damaged.

• The Zebra Strip is a
small, black
conductive elastomer
which makes contact
to the sensor memory
chip on the bottom of
the sensors
(FIGURE 4-1).

• If Zebra Strip is not in
place or making good
contact, the unit will
not properly
recognize the installed
sensors.

• If the Zebra Strip is
damaged or missing,
replace it with a new
Zebra Strip

Figure 1-2. Sensor and Zebra Strip

Locations in Sensor Cavity

(P/N 655188) before
installing the sensor.

5. Install new sensor in appropriate location noted in TABLE 1-1.

Table 1-1. Allowable Sensor Installati on Locations

SENSOR TYPE BIASED ALLOWABLE POSITIONS

Combustible
Oxygen
Carbon Monoxide
Hydrogen Sulfide
Nitric Oxide
Nitrogen Dioxide
Sulfur Dioxide
Phosphine
Ammonia
Chlorine
Chlorine Dioxide

NO
NO
NO
NO

YES - SEE NOTE

NO
NO

NO
YES - SEE NOTE
YES - SEE NOTE
YES - SEE NOTE

Comb. ONLY
O2 ONLY
Tox 1, 2, 3
Tox 1, 2, 3
Tox 3 ONLY
Tox 1, 2, 3
Tox 1, 2, 3
Tox 1, 2, 3
Tox 3 ONLY
Tox 3 ONLY
Tox 3 ONLY

NOTE: Biased sensors must be factory installed in units with

Serial No. Prefixes of "F" or lower. For units with

FiveStar Alarm 1-5

Chapter 1, Setup and Configuration Technical Manual

Figure 1-3.

Removing the Jumper

Serial No. Prefixes of "G" or higher, be sure to
remove the jumper pin from the Tox 3 position (See
FIGURE 1-3) before installing sensor.

WARNING

"

Be sure to remove the sensor cover label covering the new
location if there was no sensor in that position before. Failure
to remove this label prevents the sensor from detecting
gases which may result in serious personal injury or death.

6. Carefully align the contact pins of the new sensor with the
Sensor Board sockets; press the new sensor into place.

7. Replace the sensor gasket and sensor cover.

8. Re-install screws to hold down sensor cover.

Do not operate instrument without the sensor cover fully
installe d. The zebra stri ps require pressure to ena ble proper
contact. Without proper contact, data may be improperly written
to the sensor memory and data may become corrupted,
renderin g the sensor unusable .

• The sensor cover holds the sensors down firmly against

the Zebra Strips to ensure proper electrical contact.

1-6 FiveStar Alarm

CAUTION

"

Technical Manua l Chapter 1, Setup and Configuration

9. Install battery pack. Instrument will turn ON. Proceed through

sensor setup.
NOTE: NO, Cl

, and NH3 sensors are "biased" sensors. As

2

such, they require approximately 12 hours once
installed (with battery pack attached, but turned
OFF) for the output to stabilize. Allow the unit to
stabilize before calibrating and using in the field.

• When turned ON, the instrument now proceeds to a
sensor update mode similar to that for adding or deleting a
sensor. See "Sensor Autoconfiguration" later in this
Chapter for instructions.

• If the instrument autoconfiguration is disabled, the
instrument shows an error message. Refer to "Manual
Sensor Configuration" later in this chapter for instructions
on how to enter the configuration manually.

Removing a Sensor

To remove a sensor from the instrument:

1. Verify that the instrument is turned OFF.

2. Remove battery pack.

3. Remove the sensor cover screws and sensor cover.

4. Gently lift out the sensor that is no longer required.

5. Place the "Missing Sensor" label (P/N 710478) on the
underside of the sensor cover for the position where the
sensor was removed.

CAUTION

"

Failure to install the "Missing Sensor " label exposes the sensor
cavity to dirt and water, may lead to instrument damage and
can also increase instrument response and clear times when
operated in pumped mode.

6. Replace sensor gasket and sensor cover.

7. Re-install the screws to hold down the sensor cover.

• The cover should be in place before turning the instrument

back ON to verify configuration.

• The sensor cover holds the sensors down firmly against

the Zebra Strips to ensure proper electrical contact.

8. Install battery pack.

FiveStar Alarm 1-7

Chapter 1, Setup and Configuration Technical Manual

9. Turn the instrument ON and proceed through sensor setup.

• If the instrument autoconfiguration is disabled, the

instrument shows an error
message. Refer to "Manual
Sensor Configuration" later in
this chapter for instructions on
how to enter the configuration
manually.

Sensor Autoconfiguration

If the Sensor autoconfigurat ion is
enabled, the following occurs after
replacing a sensor, installing a new
type of sensor or removing a sens or;
the instrument:

• automatically enters configuration
mode when turned ON

• pr oc eeds through the following
sequence to verify and store the new
configuration into instrument memory:

Turn the instrument ON by pressing t he
ON/OFF button:

Sensor Update? Yes/No

Figure 1-4.

New Sensor Setup

Figure 1-5.

• Instrument display flashes the
"welcome" screen; FIGURE 1-4
appears on the display.

• S c reen changes to FIGURE 1-5.

• P r essing the skip PAGE (SKIP) button

exits the autoconfiguration sequence.

• Instrument displays an error message;
an alarm sounds.

Figure 1-6.

Please Wait

• Instrument must be turned OFF to
silence the alarm.

• P r essing the RESET (YES) button
causes instrument to re-read
sensor memories.

• FIGURE 1-6 screen appears.

• Instrument now allows user to select

format for the combustible display.

1-8 FiveStar Alarm

Figure 1-7.

Units Measured

Technical Manua l Chapter 1, Setup and Configuration

• Pressing PAGE ( LEL) button causes
the combustible readings to display
as 0-100% LEL.

• P r essing the RESET (YES) button
causes the instrument to display
combustible readings as direct
0-5% Methane.

• Instrument stores this data and
reads the remainder of the sensor
memory chips "Please Wait" displays.

Figure 1-8.

Gases Measured

• Screen then flashes the units of
gases measured (FIGURE 1-7).

• Dis play flashes the sensors that the
instrument recognizes (FIGURE 1-8).

• Instrument displays alarm setpoints
for the installed sensors.

• The screen automatically scrolls from
gas to gas in five-second intervals
(FIGURES 1-8 through 1-10).

• To hold an alarm setpoint reading for

Figure 1-9. Sample
Combustible Alarm

Setpoints

more than five seconds, press and
hold the RESET button.

• To continue, release RESET button.

• To skip through alarm displays faster,

press the PAGE button.

• The instrument then asks user to
verify that alarm setpoints are
acceptable (FIGURE 1-12).

• P r essing the PAGE (RESET) button

Figure 1-10. Sample

O

Alarm Setpoints

2

causes the instrument to restore the
default alarm values stored in the
sensor memories.

• After resetting the alarm
setpoints, the instrument again
scrolls through the alarms
pages.

• Once the alarm setpoints are
reset, the "Accept Alarms"
screen no longer reappears.

Figure 1-11.

Sample Toxic Al arm

Setpoints

FiveStar Alarm 1-9

Chapter 1, Setup and Configuration Technical Manual

Figure 1-12. Accept Alarms

Reset/Show/OK

Table 1-2. Default Factory Alarm Setpoints

SENSOR TYPE

COMBUSTIBLE

OXYGEN

CARBON MONOXIDE
HYDROGEN SULFIDE
NITRIC OXIDE
NITROGEN DIOXIDE
SULFUR DIOXIDE
PHOSPHINE
AMMONIA
CHLORINE
CHLORINE DIOXIDE

EXPOSURE

WARN

LEL - N/A

0.5% CH

DEFICIENCY ENRICHMENT

19.5 22.0

LOW ALARM HIGH ALARM STEL TWA

35 1200 400 35
10 100 15 10
25 100 25 25

52052
59052

-0.310.3

-253525

-2.01.00.5

-0.50.30.1

LOW ALARM HIGH ALARM

10% LEL o r

4

1.0% CH4

60% LEL o r

3.0 CH

4

• P r essing the ON/OFF (SHOW) button allows the user to scroll
through the "Show Alarm Setpoints" screens again.

• P r essing the RESET (OK) button accepts the alarm setpoints.

• The instrument now returns to the "Sensor Update?"

Query screen.

• Pressing RESET (YES) returns the instrument to the
autoconfiguration sequence above.

• During autoconfiguration, if the instrument did not
recognize a sensor installed in the unit, recheck the
sensor Zebra Strip condition. Also ensure that the sensor
cover is screwed down tight to obtain a solid contact
between the sensor memory board and the sensor board.

1-10 FiveStar Alarm

Technical Manua l Chapter 1, Setup and Configuration

Figure 1-13. Check Sensor Cover/

Label Empty Slots / Quit - OK

• Pressing PAGE (SKIP) exits the autoconfigure sequence.

• The instrument displays the FIGURE 1-13 screen to remind the

user to:

• c hec k the sensor cover to ensure that "missing sensor"
labels (P/N 710478) cover slots where sensors are
not installed

• verify there are no "sensor missing" labels over any
position where a sensor is installed.

CAUTION

"

Failure to install the "Missing Sensor" label exposes the sensor
cavity to dirt a nd water and ma y lead to ins trument damag e.
This can also increase instrument respons e and clear times
when operate d in pumped modes.

• P r essing the PAGE (QUIT) button powers down the instrument.

• P r essing the RESET (OK) button sends the unit into the

calibration mode.

• See Chapter 2 for "Calibration Procedure."
NOTE: Once the instrument has performed the

autoconfiguration procedure, any newly installed
sensor must be calibrated prior to use.

NOTE: For instruments with software versions lower than 1.2,

FiveStar Alarm 1-11

all calibration data will be reset to the default values
in the sensor memories; the entire instrument must
be recalibrated.

It is recommended that all sensor calibrations be checked
after autoconfiguration is run and prior to instrument
use.

Chapter 1, Setup and Configuration Technical Manual

Manual Sensor Configuration

For instruments with the autoconf iguration feature disabled, the
sensor setup sequence can be ent ered manually. A variation of
this sequence must also be used for ins truments with software
versions lower than 1.2.

To Enter the Sensor Setup Mode Manually

1. Make sure the instrument is turned OFF.

2. Remove the battery pack.

3. Press and hold the RESET button.

4. Re-install the battery pack while holding the RESET button.

• The instrument enters the Sensor Setup mode.

To enter the setup mode with ins truments containing software
versions lower than 1.2:

1. Make sure the instrument is turned OFF.

2. Remove the battery pack.

3. Press and hold the RESET button.

4. Re-install the battery pack while holding the RESET button.

• The instrument screen turns black.

5. Immediately press and hold the PAGE button until the setup
query page appears.

• The instrument enters the Sensor Setup mode.

1-12 FiveStar Alarm

Technical Manua l Chapter 2, Calibra tion

Chapter 2
Calibration

Optional Fresh Air Setup

The FiveStar Alarm can be set to allow the user to automatically
zero the measurement systems and calibrate the oxygen system
when the unit is turned ON.

Activating the Fresh Air Setup Option

Configuration of the Fresh Air Set up is done by way of the MSA
LINK program. See instructions in the MSA LINK program
softwar e for this infor mation.

When this feature is activat ed and the instrument is turned ON,
the FiveStar Alarm completes its self-tests and asks if a Fres h
Air Setup is desired (FIGURE 2- 1).

To Cancel Fresh Air Setup

• If the PAGE ( NO) button is pressed or if no button is pressed
within five seconds, the instrument does not perform a Fresh Air
Setup. Instead, it goes on to operate in the normal measure
mode and displays the Exposure page.

FiveStar Alarm 2-1

Figure 2-1.

Fresh Air Setup?

Chapter 2, Calib ration Technica l Manual

To Perform Fresh Air Setup

Press the RESET (YES) button within five seconds .

• The FiveStar Alarm begins to perform a Fresh Air Setup.

• Oxygen is set at 20.8 percent.

• All other gases are set at zero.

NOTE: If the Fresh Air Setup feature is activated and an error

message is displayed, press the RESET button to
exit the Fresh Air Setup and enter the Measure
mode. This may occur if the original readings were
outside of the limits for the Fresh Air Setup feature.
This is to protect the user from zeroing out
potentially hazardous gases.

Persons responsible for the use of the FiveStar Alarm must
determine whether or not the Fresh A ir Setup option should be
used. The user’s abilities, training, and normal work practices
must be considered when making this decis ion.

Calibration Adjustment

FiveStar Alarm calibration can be adjusted easily by using gases
of known mixtures and concentrations .

Preparing to Calibrate

Before starting, be certain t hat the instrument is in normal fresh
air, free of combustible or toxic gases. If the ambient air has
contaminants, use bottled zero air (20.8% oxygen in nitrogen)
when applying fresh air. To prepare t o calibrate:

1. Turn OFF the FiveStar Alarm.

2. Allow the instrument to stabilize for several minutes in fresh
air at the temperature and air pressure of intended use.

WARNING

"

The FiveStar Alarm does not provide any protection while
the calibration is being adjusted. Do not rely on the
instrument for protection at this time; otherwise, serious
personal injury or death could result.

2-2 FiveStar Alarm

Technical Manua l Chapter 2, Calibra tion

Calibration Procedures

1. Press the ON/OFF button; immediately and simultaneously

press and hold the PAGE and the RESET buttons.

Figure 2-2.

Calibration - No/Yes?

• An alternative method is to push and hold the PAGE and
the RESET buttons; then, press the ON/OFF button.

• The instrument turns ON (FIGURE 2-2):

To Cancel Calibration:

Press the PAGE (NO) button or wait five seconds.

• The FiveStar Alarm begins warming up and enters the
Exposure display page.

To Continue Calibration:

2. Press the RESET (YES) button.

• Display prompts you for Fresh Air (FIGURE 2-3).

Apply fresh air if this was not done in step 1.

To Cancel:

Press the PAGE (QUIT) button.

FiveStar Alarm 2-3

Figure 2-3.

Apply Fresh Air

• Instrument beeps and automatically shuts OFF.

Chapter 2, Calib ration Technica l Manual

To Proceed:

4. Press the RESET (READY) button.

5. Wait approximately 15 seconds for the FiveStar Alarm to
complete the fresh air adjustments.

• During this time, the FIGURE 2-4 display appears.

Figure 2-4.

Adjusting Zeroes

After the fresh air adjustments are made, the FiveStar Alarm is
ready to complete span calibration.

Figure 2-5.

Combustible Gas Calibration Display

• The display appears (FIGURE 2-5):

The user can calibrate the gas sensors in the following order:

• Combustible Gas

• Oxygen

• Toxic Gas #1

• Toxic Gas #2

• Toxic Gas #3

2-4 FiveStar Alarm

Technical Manua l Chapter 2, Calibra tion

Press the PAGE (SKIP)
button to skip calibration
for any gases you do not
want to change.

6. There are three means

to supply gas to the
FiveStar instrument
for c alibra tion:

• M etal Calibration Cap
(P/N 710572):
To attach the Metal
Calibration Cap:

a. Align the screw

heads in the

Calibration Cap Installation

Figure 2-6.

Cap with the
holes for
the sensor
cover screws
(FIGURE 2-6).

b. Holding the

Calibration Cap
in place, wrap
the strap around
the unit and
through
the strap slot;
pull the strap
snug.

• Plastic Calibration Cap
(P/N 710824):
To attach the Plastic

Snap Calibration Cap Installation

Figure 2-7.

Calibration Cap:

a. To properly secure the Cap, it is necessary for the

sensor cover to have the snap-on features on the
two sides.

b. Position the Calibration Cap label "Front" indicator

towards the instrument display and snap the Cap on
the sensor cover (FIGURE 2-7).

FiveStar Alarm 2-5

Chapter 2, Calib ration Technica l Manual

• Add-on Pump Module:
To attach the Add-on Pump Module, refer to FiveStar
Instruction Manual (P/N 710436), FIGURE 2-47.

Once the calibration sampling device is attached, apply
calibration gas at 0.25 lpm flow rate.

a. Attach a 0.25-lpm (liters-per-minute) Flow Controller to the

gas tank.

b. Attach calibration tubing to the Five Star calibration

cap inlet.

c. Attach the other end of the calibration tubing to the

0.25-lpm Flow Controller.

d. Turn the knob on the gas tank in a counterclockwise direction.

7. Press the RESET (READY) button.

8. Wait for the readings to stabilize.
NOTE: During calibration, the display reading may appear

more unstable than normal. The display’s digital
filtering has been disabled to provide the most rapid
reading possible.

9. After the display stabilizes,
adjust the display reading to
agree with the known amount
of calibration gas.

a. Push t he PA GE ( D OW N)

button to lower the reading.

b. Push the RESET (UP)

button to raise the reading.

• Holding either button
causes the reading to
change continuously.

Figure 2-8.

Combustible Gas Span

Adjustment

10. Push the ON/OFF (OK) button to accept the reading.

• The new reading is stored in memory, and the FiveStar
Alarm automatically moves to next reading.

Oxygen Sensor Calibration Check

After the combustible gas calibration is completed, the instrument
automatically moves to the oxygen s ensor calibration check. The
zero adjustment previously calibrated the oxygen sensor to

2-6 FiveStar Alarm

Technical Manua l Chapter 2, Calibra tion

20.8%. Do not adjust the oxygen reading t o the cylinder value, as
slight variations may occur; however , verify that the oxygen
reading is within the limits stated on the cylinder. Software
version 2.11 and higher only allows the user to review the
oxygen reading. After verifying t hat the reading is within the limits
stated on the cylinder, simply pres s the PAGE (SKIP) button to
continue to the toxic gas calibr ation.

Toxic Gas Sensor Calibration

After the oxygen calibration check is
completed, the FiveStar Alarm automatically
moves to the toxic gas page. Each toxic gas
calibration can be completed in the same
way as the combustible gas calibrat ion. It
may be necessary to change gas samples to
provide the proper gas.

• When all of the selected calibrations are
set, a long beep sounds and the display
reads (FIGURE 2-9):

To repeat ca lib ra tio n procedure:

Press the PAGE (NO) button.

Figure 2-9.

Remove Cal Cap

To end calibration procedure:

Remove the calibration cap and press the

RESET (YES) button.

• The (FIGURE 2-10)
display appears:

• Calibration gases clear from the
sensors (about 30 seconds).

• For instruments with software
versions 1.2 or higher, the
instrument automatically turns
ON and goes into the normal
operation mode.

• For instruments with software versions lower than

1.2, A long beep sounds and the FiveStar Alarm
turns OFF automatically (FIGURE 2-11):

FiveStar Alarm 2-7

Figure 2-10.

Saving Calibration

Please Wait

Figure 2-11.

Power OFF

Chapter 2, Calib ration Technica l Manual

Special Instructions for Instruments
with Chlorine Dioxide Sensors

Calibration

FiveStar Alarms equipped with chlorine dioxide s ensors may be
calibrated directly, using s third par ty-supplied chlorine dioxide
generator, or using cylinders of chlorine gas.

When calibrating with a chlorine dioxide generator you must
either ensure the flow supplied by the generator exceeds the
FiveStar pump draw (typically between 0.25 and 0.40 lpm) or you
can supply the gas directly through a calibration cap. Hooking the
pump directly to the generator may r esult in altering the
concentration supplied; therefore, a "Tee" must be used to bleed

Figure 2-12.

Setup for Chlorine Dioxide Generator Bypass

off the excess flow (FIGURE 2- 12).
If a "Tee" is used, you m ust make sure the flow through t he free

leg of the tubing is positive to be sure no air is being drawn in,
reducing your sample concentration. Once set up, follow the
instructions in the Technical manual (P /N 710440) for calibrating
the FiveStar Alarm and set t he chlorine dioxide reading to the
known concentration from the generator.

When using a cylinder of chlorine gas , set the reading to one-half
the known concentration of t he cylinder (e.g., for MSA P/N
710331, 2 ppm, set the reading to 1. 00 ppm chlorine dioxide).

2-8 FiveStar Alarm

Technical Manua l Chapter 3, Troubleshooting and Maint en ance

Chapter 3
Troubleshooting and Maintenance

Troubleshooting

The FiveStar Alarm will operate reliably for years when cared for
and maintained properly. If the instrument becomes inoperative,
follow the Troubleshooting Guidelines in TABLE 3-1. These
represent the most likely causes of a problem. You may return
inoperative instruments to MSA for repair.

MSA Instrument Division
Repair and Service Department
1000 Cranberry Woods Drive
Cranberry Township, PA 16066-5207
1-800-MSA-INST

To contact MSA International, please call:

1-412-967-3000 or 1-800-MSA-7777

The instrument displays an error code if it detects a problem
during startup or operation. S ee TABLE 3-1 for a brief descript ion
of the error and proper cor rective action. When an inoperative
component is located by using the guidelines, it may be replaced
by using one of the following procedur es:

Table 3-1. Troubleshooting Guidelines

REPLACE

PROBLEM

Does not turn ON
Does not complete Self-Tests
Display segments missing or stuck
"ERROR" message after battery installation
"ERROR" message during use
Battery pack does not hold charge
Combustible sensor does not calibrate
Oxygen sensor does not calibrate
Toxic sensor does not calibrate
Clock not holding time.

*

Recharge or replace the cells before replacing battery pack.

In all of the above cases and for any other problems, you may return the FiveStar Alarm to
MSA for repairs.

BATTERY

PACK

DISPLAY

*

MODULE

√√

√

SENSOR

√

√
√
√

MAIN

ELECTRONICS

MODULE

√

√
√

√

FiveStar Alarm 3-1

Chapter 3, Troubleshooting and Maint enance Technical Manu al

Table 3-1. Troubleshooting Guidelines (continued)

ERROR

CODE

1

2

3
4

5

6
7
8
9

10

11
12

13
14
15
16
17
18
19
20
21
22

23

24
25

26

DESCRIPTION CORRECTIVE ACTION

Sensor board error Check/replace sensor board

EEPROM error

Pressure sensor error Replace the main board
unused

Combustible sensor error

Oxygen Sensor error C heck/Replace the oxygen sensor
Combustible sensor zero error Check/replace the combustible sensor
Cannot write EEPROM Check/replace the main board
Battery type failure Replace battery pack

No sensors detected
Multiple sensors removed

from instrument
Combustible sensor missing Check combustible sensor and zebra strip
Oxygen sensor missing Check Oxygen sensor and zebra strip
Toxic 1 sensor missing Check Toxic 1 sensor and zebra strip
Toxic 2 sensor missing Check Toxic 2 sensor and zebra strip
Toxic 3 sensor missing Check Toxic 3 sensor and zebra strip
Multiple new sensors detected Run through sensor configuration
New combustible sensor installed Run through sensor configuration
New oxygen sensor installed Run through sensor configuration
New Toxic 1 sensor installed Run through sensor configuration
New Toxic 2 sensor installed Run through sensor configuration
New Toxic 3 sensor installed Run through sensor configuration
Multiple se nsors inst alled in

illegal sites
Improper sensor installed in

combustible site
improper sensor installed in

oxygen site
Improper sensor installed in

Toxic 1

Reinitialize the instrument (follow procedure for
manual sensor configuration and answer yes
to query to reinitialize the EEPROM)

Check/replace combustible sensor; if this does
not clear the error, replace the sensor board

(In an Australian approved instrument,
check the fuse on the main board if replacing
the sensor does not clear the error.)

Check to see if sensors and Zebra strips are
in place

Check to see if sensors and Zebra strips are
in place

Check sensor placement against TABLE 1-1

Check sensor placement against TABLE 1-1

Check sensor placement against TABLE 1-1

Check sensor placement against TABLE 1-1

3-2 FiveStar Alarm

Technical Manua l Chapter 3, Troubleshooting and Maint en ance

Table 3-1. Troubleshooting Guidelines (continued)

ERROR

CODE

27

28
29

30

31
32

33
34
35

36

37

38

39

40

41

99

DESCRIPTION CORRECTIVE ACTION

Improper sensor installed in
Toxic 2 si te

Improper sensor installed in
Toxic 3 si te

Biased sensor installed in illegal
site

Multiple sensor memories
corrupted

Combustible sensor memory
corrupt

Oxygen sensor memory corrupt Replace Oxygen sensor
Toxic 1 sensor memory corrupt Replace Tox ic 1 sensor
Toxic 2 sensor memory corrupt Replace Tox ic 2 sensor
Toxic 3 sensor memory corrupt Replace Toxic 3 sensor
Multiple sensor memories

incompat ible with instr ument
software

Combustible sensor memory
incompat ible with instr ument
memory

Oxygen sensor memory
incompat ible with instr ument
memory

Toxic 1 sensor memory
incompat ible with instr ument
memory

Toxic 2 sensor memory
incompat ible with instr ument
memory

Toxic 3 sensor memory
incompat ible with instr ument
memory

Battery Error

Check sensor placement against TABLE 1-1

Check sensor placement against TABLE 1-1

Check sensor placement against TABLE 1-1
Check and replace sensors one at a time to

isolate failed sensors
Replace Combustible sensor

Check and replace sensors one at a time to
isolate incorrect sensors

Replace Combustible sensor

Replace Oxygen sensor

Replace Toxic 1 sensor

Replace Toxic 2 sensor

Replace Toxic 3 sensor

Check battery on another instrument; replace
battery if the error follows the battery;
otherwise, replace the main board

For messages 11 to 22, instruments with software version 1.2 or higher will enter the
autoconfiguration mode directly at turn-ON, if autoconfiguration is enabled. If
autoconfiguration is disabled or your instrument software is earlier than version 1.2, the user
must run through the key sequence on battery attachment given in Chapter 1, "Manual
Sensor Configuration."

FiveStar Alarm 3-3

Chapter 3, Troubleshooting and Maint enance Technical Manu al

Repair Procedures

Battery Pack Replacement

Remove the Battery Pack

1. Turn battery mounting screw on the
back of the instrument in a
counterclockwise direction until screw
turns freely.

2. Pull out the battery pack by gripping it
at the edge of the battery pack case
and pulling it away from the unit (FIGURE 3-1).

Replace the Battery Pack

3. Insert the front of the battery pack under the lip on the case
and snap the bottom of the battery pack into the case.

4. Turn the battery mounting screw on the back of the
instrument in a clockwise direction until screw is tight.

Sensor Replacement

See Chapter 1, "Replacing a Sensor" for instructions.

Figure 3-1.

Battery Pack Removal

Main Electronics Board Replacement

CAUTION

"

Before handling the PC boards, ensure you are properly
grounded; otherwise, static charges from your body could
damage the electronics. Such damage is not covered by
the warranty. Grounding straps and kits are available from
electronics suppliers.

1. Turn power OFF.

2. Remove the Calibration Cap, if installed.

3. Turn the battery mounting screw on the back of instrument in
a counterclockwise direction until screw turns freely.

4. Pull out the battery pack by gripping it at the edge of the
battery pack case and pulling it away from the unit.

5. Remove the six case mounting screws from back of the case.

6. Carefully remove the back of the case.

3-4 FiveStar Alarm

Technical Manua l Chapter 3, Troubleshooting and Maint en ance

CAUTION

"

When removing the back of the case, be careful not to pull
the buzzer wire from the connector. This is a fragile connector;
use minimum force necessary to prevent breakage; breakage
of this wire is not covered under warranty. If removing the
connector, place a flat screwdriver at the back of the connector
and gently pry connector loose.

7. Remove the buzzer connector.

8. Disconnect the white ribbon connector from the main board

socket by CAREFULLY lifting up the brown locking tabs until
they stop (FIGURE 3-2).

9. Locate the edge of the main pc board that is furthest from the

display; grasp this edge and gently lift the board straight up
and away from the unit until it is free.

10. Holding the white connector, gently rock the main pc board

and pull it away from the connector.
NOTE: Retain foam rubber gasket accompanying pc board.

11. Connect the new main pc board to the white ribbon

connector by gently rocking the pc board into place; latch
down the two tabs located on either side of the ribbon socket.

12. Replace gasket and insert the new main pc board into

position; gently press down until the board snaps into place.

13. Reconnect the buzzer wire.

14. Replace the main pc board, ensuring gasket is appropriately

placed around the entire perimeter of the instrument.

CAUTION

"

When replacing the back of the case, tuck the buzzer wire
between the display board and the main board to prevent
damage to the wir e.

15. Replace back of

the case and
tighten the six
case-mounting
screws securing
the back of
the case in the

Figure 3-2.

Display Connector

FiveStar Alarm 3-5

Chapter 3, Troubleshooting and Maint enance Technical Manu al

sequence shown in FIGURE 3-3.
NOTE: Do not over-tighten screws.

16. Reconnect battery pack.

17. Completely recalibrate the FiveStar Alarm.

WARNING

"

Verification of calibration response is r equired;
otherwise, the instrument will not perform as
required and persons who rely on this product
for their safety could sustain serious personal
injury or death.

Figure 3-3.

Sensor Board Replacement

1. Turn power OFF.

2. Remove the Calibration Cap, if installed.

3. Turn the battery mounting screw on the back of the
instrument in a counterclockwise direction until the screw
turns freely.

4. Pull out the battery pack by gripping it at the edge of the
battery pack case and pulling it away from the unit.

5. Remove the four screws retaining the sensor cover.

6. Remove the sensor cover and retain the gasket.

7. Remove all sensors by gently rocking them back and forth
and lifting them from their sockets.

8. Turn the unit over and remove the six screws from the bottom
plate.

9. Carefully remove the back of the case.

Sequence for

Tightening Screws

CAUTION

"

When removing the back of the case, be careful not to pull
the buzzer wire from the connector. This is a fragile
connector. If removing connector, use minimum force
necessary to prevent breakage; breakage of this wire is not
covered under warranty. If removing connector, place a flat
screwdriver at the back of the connector and gently pry
connector loose.

3-6 FiveStar Alarm

Technical Manua l Chapter 3, Troubleshooting and Maint en ance

10. Remove the white ribbon connector from the main board

socket by CAREFULLY pulling up the brown tabs (located
on the sensor side) until they stop.

11. Locate the edge of the main pc board furthest from the

display; grasp this edge and gently lift the board away from
the unit until it is free.

12. Hold the white connector; gently rock and pull the main pc

board away from the connector; retain foam rubber gasket
accompanying main pc board (replace gasket, if needed).

13. Remove the two white plastic retaining rings located near the

top portion of the sensor board; remove and retain the two
screws or black rubber bumpers at bottom portion of board.

14. Place fingers on the other side (top side) of unit and gently

rock and push the sensor board out and away from the case;
retain the orange bottom gasket.

15. Insert new sensor board and reverse the above procedure for

complete sensor board replacement.
NOTE: When replacing the sensor board, this board must

slide in under the keyboard ribbon cable.

16. Calibrate the FiveStar Alarm.

WARNING

"

Verifica tion of ca librati on respons e is requ ired; otherwi se t he
instrument will no t p erform as r equired an d pers ons who re ly
on this product for their safety could sustain serious personal
injury or de ath.

Display Module Replacement

1. Turn power OFF.

2. Remove the Calibration Cap, if installed.

3. Turn the battery mounting screw on the back of the

instrument in a counterclockwise direction until the screw
turns freely.

4. Pull out the battery pack by gripping it at the edge of the

battery pack case and pulling it away from the unit.

5. Remove the four screws retaining the sensor cover.

6. Remove the sensor cover and retain the gasket.

FiveStar Alarm 3-7

Chapter 3, Troubleshooting and Maint enance Technical Manu al

7. Remove all sensors by gently rocking them back and forth
and lifting them from their sockets.

8. Turn unit over and remove the six case-mounting crews from
the back of the case.

9. Carefully remove the back of the case.

CAUTION

"

When removing the back of the case, be careful not to pull
the buzzer wire from the connector. If removing the
connector, place a flat screwdriver at the back of the
connector and gently pry loose; otherwise the connector
may be damaged. When replacing the back of the case,
tuck the wire between the display board and the main board
to prevent damage to the wire.

10. Remove the white ribbon connector from the main board
socket by CAREFULLY pulling the brown tabs on the sensor
side up gently until they stop.

11. Locate the edge of the main pc board that is furthest from the
display; grasp this edge and gently lift the board away from
the unit until it is free.

12. Holding the white connector, gently rock the main pc board
and pull it away from the connector; retain foam rubber
gasket accompanying the main pc board.

13. Remove the two white plastic retaining rings located near the
top portion of the sensor board.

14. Remove and retain the two screws at the bottom portion of
the board.

15. Place fingers on the other side (top side) of unit and gently
rock and push the sensor board out and away from the case;
retain orange bottom gasket.

16. Using a pair of needle nose pliers, remove keypad cable from
the socket located on the right side of the display board.

17. Pull keypad cable away from the unit.

18. Grasping the display module, gently rock and pull it up and
away from case.

19. To re-assemble, gently place new display module into unit
and rock module firmly into place.

3-8 FiveStar Alarm

Technical Manua l Chapter 3, Troubleshooting and Maint en ance

Figure 3-4.

Keypad Ribbon Cable Replacement

20. Grasp keypad ribbon cable, form cable into loop and insert

ribbon edge into socket on the right-hand corner
(FIGURE 3-4).

21. Replace sensor board and gasket removed in step 15 above.

NOTE: Ensure sensor board is oriented so sensor socket

pins face the sensor area.

21. Replace the white retaining rings and the two sensor

board screws.

22. Reconnect the main pc board back to the white ribbon

connector by gently rocking the pc board into place and
latching down the two tabs located on either side of the
ribbon socket.

23. Replace gasket and insert the new main pc board into

position; gently press down until the board snaps into place.

24. Reconnect the buzzer wire.

CAUTION

"

When replacing the back of the case, tuck the wire between
the display board and the main board to prevent damage
to the wire.

25. Replace the main pc board, ensuring gasket is appropriately

placed around the entire perimeter of the instrument.

26. Replace the six screws securing the back of the case.

27. Ensure zebra strips are included in their appropriate locations.

28. Place sensors into their appropriate positions.

FiveStar Alarm 3-9

Chapter 3, Troubleshooting and Maint enance Technical Manu al

29. Replace gasket and sensor cover and attach with four screws.

30. Reconnect battery pack.

31. Completely recalibrate the FiveStar Alarm.

WARNING

"

Verification of calibration response is required; otherwise
the instrument will not perform as required and persons
who rely on this product for their safety could sustain serious
personal injury or death.

3-10 FiveStar Alarm

Technical Manua l Chapter 4, Part s Li st

Chapter 4
Parts List

Table 4-1. North Amer i can/ Australian Commo n A ccessory Parts List

NORTH

PART

Calibration Cap
Probe - 1 ft.
Probe - 3 ft.
Sampling Line - 5 ft.
Sampling Line - 10 ft.
Sampling Line - 15 ft.
Sampling Line - 25 ft.
Replacement Filter, Probe (pkg. of 10)
Charge Stand, Omega
Charger, Omega 120 VAC, 50/60 Hz
Charger, Omega 220 VAC, 50/60 Hz
Charger, Omega 110/220 VAC, Five Unit, 50/60

Hz
Charger, Omega, 8-28 VDC
Universal Fast Charger Kit
Universal Stand, Fast Charger
Universal Power Supply, Fast Charger
Protective Jacket, Orange Nylon, Diffusion
Protective Jacket, Orange Nylon, Pumped
Leather Carrying Case, Diffusion
Leather Carrying Case, Pumped
Calibr ation Kit Mo del RP with 0. 25 lpm Regu lator
Calibration Gas - 58% LEL pentane simulant /

15% O

2

Calibration Gas - 58% LEL pentane simulant /
15% O2; 60 ppm CO

Calibration Gas - 10 ppm H2S
Calibration Gas - 58% LEL pentane simulant /

; 300 ppm CO

15% O

2

Calibration Gas - 10 ppm NO
Calibration Gas - 50 ppm NO
Calibration Gas - 10 ppm SO
Calibration G as - 58% LE L pentane s imulant /

; 300 ppm CO and 1 0 ppm H2S

15% O

2

Calibration Gas - 58% LEL pentane simulant /

; 10 ppm H2S

15% O

2

2

2

AMERICAN

APPROVED

PART NO.

710824 710824 710824
800332 800332 *
800333 800333 *
497332 497332 *
497333 497333 *
497334 497334 *
497335 497335 *
801582 801582 801582
710570 N/A N/A
494716 N/A N/A
495965 N/A N/A

801759 N/A N/A

800525 N/A N/A
10065553 * 10065556
10065552 * N/A

710774 * 10013426

711242 711242 N/A

711120 711120 N/A

710864 227722 710864

711119 711119 711119

477149 477149 477149

478192 478192 478192

478191 478191 478191

467898 467898 467898
10010162 10010162 10010162

808977 808977 808977

812144 812144 812144

808978 808978 808978

804770 804770 804770

804769 804769 804769

*These accessories m ay vary ac cording to th e country o f use;

please cont act your nearest MSA Dis tributor Office for d etails.

AUSTRALIAN

APPROVED

PART NO.

EN

APPROVED

PART NO.

FiveStar Alarm 4-1

Chapter 4, Parts List Technical Manual

North American (through Serial Number Prefix "E") Replacement Parts

NOTE: This version does not have the sealing gasket aro und t he sensor cover

4-2 FiveStar Alarm

Figure 4-1.

(Item 18)

.

Technical Manua l Chapter 4, Part s Li st

Table 4-2. North Amer ic an

(through Serial Number Prefix "E")

Replacement Parts List

FIGURE

4-1

ITEM NO.

1
2
3
4
5
6
7
8

9
10
11
12
15
16
17

18
19

20

PART/COMPONENT

Case Assembly, Main, Top
Case Assembly, Main, Bottom
Case Gasket
Sensor Gasket (under sensors)
Sensor Cover Gasket (above sensors)
Main PC Board Gasket
PC Board Sensor Gasket
Display PC Board
Main PC Boar d
Sensor PC Board
O-Ring, Battery Screw Retaining
O-Ring, Sealing
Screw (4-40 x 3/8, black)
Screw (4 x 1/4, self-threading)
Captive Screw (6-32 x 17/32)
Sensor Cover Labels (for missing sensors)
Sensor Cover
Zebra Strip
NO, NO2, SO2 Diffusion Barrier (pkg. of five)
Sensor Area Cover Gasket
Battery Pack, Standard Ni-Cd Rechargeable
Battery Pack Assembly, Replaceable
Pump Assem bly, Add-on
Aspirator As sembly

NORTH AMERICAN

APPROVED INSTRUMENT

PART NO.

non-saleable
non-saleable

710307
710395
710428
710397
710396
815475
815473
815477
637519

59676
636227
655087
638457
710487
710309
655188
711290
711358
710427
710955
710790
710959

Table 4-3. Replacement Sensors

PART

Oxygen Sensor
Combustible Sensor
CO Sensor
H2S Sensor
NO Sensor
NO2 Sensor
SO2 Sensor
PH3 (Phosphine) Sensor
NH3 (Ammonia) Sensor
Cl2 (Chlorine) Sensor

NORTH

AMERICAN

APPROVED

PART NO.

815333 815333 815333 815333
710317 710317 710317 10047557
710656 710656 710656 710656
710657 710657 710657 710657
710662 710662 710662 710662
710663 710663 710663 710663

710664 710664 710664 710664
10011530 10011530 10011530 10011530
10012286 10012286 10012286 10012286
10012282 N/A N/A 10012282

AUSTRALIAN

APPROVED

PART NO.

EN

APPROVED

PART NO.

MSHA APPROVED

PART NO.

FiveStar Alarm 4-3

Chapter 4, Parts List Technical Manual

Australian and European Approved Replacement Parts

and North American (Serial Number Prefix "F" or Higher) Replacement Parts

NOTE: New version has the updated sensor cover and new sealing gasket

4-4 FiveStar Alarm

Figure 4-2.

(Item 14).

Technical Manua l Chapter 4, Part s Li st

Table 4-4. North Amer i can ( Serial N um ber P refi x "F" or "G ")

Replacement Parts Li st

FIGURE

4-2

ITEM

NO.

Case Assembly, Main, Top

1

Case Assembly, Main, Bottom

2

Case Gasket

3

Sensor Gasket (under sensors)

4

Sensor Cover Gasket (above sensors)

5

Main PC Board Gasket

6

PC Board Sensor Gasket

7

Display PC Board

8

Main PC Boar d

9

Sensor PC Board

10

O-Ring, Battery Screw Retaining

11

O-Ring, Sealing

12

Filter, Sensor Cover

13

Sensor Area Cover Gasket

14

Screw (4-40 x 3/8)

15

Screw (4 x 1/4, self-threading)

16

Captive Screw (6-32 x 17/32)

17

Sensor Cover

18

Zebra Strip

19

Insulator, PCB/PCB

20

Insulator, PC B/ Ca se Bottom

21

Insulator, PC B/ Ca se To p

22

Sensor Cover Labels (for missing
sensors)

Pump Module
Aspirator Module
Battery Pack, Standard Ni-Cd

Rechargeable
Battery Pack Assembly, Replaceable
Standard Belt Clip
Toxic Channel 3 Bias Jumper

* For chlorine compatible instruments , refer to FiveStar Instruction Manual (P/N 710436),

Chapter 4 - "Special Instructions."

PART/COMPONENT

SERIAL #

PREFIX "F"

BLACK

STYLE

non-saleable
non-saleable

710307 710307 710307
710395 710395 710395

10005104 10005104 10005104

710397 710397 710397
710396 710396 710396
815475 815475 815475
815473 10014273 10014273
815477 10013453 10013453
637519 637519 637519

59676 59676 59676
10005181 10005181 10005181*
10005101 10005101 10005101

636227 633290 636227
655087 655087 655087
638457 638457 638457

10005186 10008610 10005186*

655188 655188 655188

N/A N/A N/A
N/A 10006521 N/A

N/A 10011218 N/A
710487 710487 710487
710790 10008609 710790

710959 10008608 710959
710427 10008606 710427
710955 10008607 710955

710953 710953 710953

N/A 10013125 10013125

SERIAL #
PREFIX "G"
OR HIGH ER

PLATED

STYLE

non-saleable

non-saleable

SERIAL #

PREFIX
"G" OR

HIGHER

BLACK

STYLE

non-saleable
non-saleable

FiveStar Alarm 4-5

Chapter 4, Parts List Technical Manual

Table 4-5. Australian/ Eur opean Replacem ent Parts Li st

AUSTRALIAN/EUROPEAN

FIGURE

4-2

ITEM NO.

1
2
3
4
5
6
7
8

9

10
11
12
13
14
15
16
17
18
19
20
21
22

PART/COMPONENT

Case Assembly, Main, Top
Case Assembly, Main, Bottom
Case Gasket
Sensor Gasket (under sensors)
Sensor Cover Gasket (above sensors)
Main PC Board Gasket
PC Board Sensor Gasket
Display PC Board
Main PC Boar d

• German, Dutch and English

• Spanish, Italian and English

• German, French and English

• French, Dutch and English

Sensor PC Board
O-Ring, Battery Screw Retaining
O-Ring, Sealing
Filter, Sensor Cover
Sensor Area Cover Gasket
Screw (4-40 x 3/8, black)
Screw (4 x 1/4, self-threading)
Captive Screw (6-32 x 17/32)
Sensor Cover
Zebra Strip
Insulator, PCB/PCB
Insulator, PC B/ Cas e B ottom
Insulator, PC B/ Cas e To p
Sensor Cover Labels (for missing sensors)
Pump Module
Aspirator Module
Battery Pack, Standard Ni-Cd Rechargeable
Battery Pack Assembly, Replaceable
Standard Belt Clip

APPROVED INST RUMENT

PART NO.

AUSTRALIAN

APPROVEDENAPPROVED

non-saleable non-saleable
non-saleable non-saleable

710307 710307
710395 710395

10005104 10005104

710397 710397

710396 710396
10005335 711241
100053 33 s ee below

N/A 10011592
N/A 10011593
N/A 711152
N/A 10019220

10005337 711154

637519 637519

59676 59676
10005181 10005181
10005101 10005101

636227 633290
655087 655087
638457 655797

10005186 10008610

655188 655188
10006394 10006394
10006521 10006521
10011218 10011218

710487 710487
10007440 10008724
10009305 10008608

711024 10013094
10007351 N/A

710794 710794

4-6 FiveStar Alarm

Technical Manua l Chapter 4, Part s Li st

Table 4-6. Pump and A spirator Assembly Repl acem ent Parts List

FIGURE

4-3

ITEM NO.

1
2
3
4
5
6
7
8
9

-

-

PART

Filter c over screw s
Filter cover housing
Filter O-ring
Dust filter (package of 5)
Inlet water filter
Thumbscrew
Manifold
Aspirator and fittings
Manifold Gasket
Pump and drive (North

American version)
Pump and drive

(Australian version)
Pump and drive (EN

version)
Internal backup filter

PART NO.

DATE

CODED G99

(JULY ’99)

PART NO.

DATE CODED

H99

(AUG. ’99)

OR NEWE R

PART NO.

(CHLORINE-

COMPATIBLE

PUMP)

636418 636418 636418
811722 811722 811722
637009 637009 637009
808935 808935 N/A
710917 710917 636258
655553 655553 655553
710666 10005222 10005222
711149 711149 N/A

N/A 10007340 10007340

711195 711195 711195
10011686 N/A N/A
10011686 N/A N/A

634261 634261 634261

FiveStar Alarm 4-7

Figure 4-3.

Replacement Parts

Chapter 4, Parts List Technical Manual

Table 4-7. Replace abl e Bat tery Pack Parts List

PART

Replaceable Battery Pack

Spare Fuses

Replacement Internal Gasket

NORTH

AMERICAN

APPROVED

INSTRUMENT

PART NO.

NORTH

AMERICAN

PLATED

APPROVED

INSTRUMENT

PART NO.

AUSTRALIAN

APPROVED

INSTRUMENT

PART NO.

710955 10008607 10007351
655836 655836 10006582
710958 710958 710958

4-8 FiveStar Alarm

Figure 4-4. Battery and Fuse Location