Net Safety AD-ST1400-25, MLP-A/AR, MLP-A-ST1400-25, MLP-AR-ST1400-25, MLP-AD-ST1400-25 User Manual

MILLENNIUM
Oxygen Gas Detector
User Manual
Models:
MLP-A/AR/AD-ST1400-25 & (all available options)
Part Number: MAN-0060 Rev 04
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.
War rant y
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
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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
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MLP-A/AR/AD-ST1400-25 1
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
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 1 — PLAN
Step 2 — INSTALL
Step 3 — WIRE
Step 4 — OPERATE
Step 5 — CALIBRATE
Step 6 — MONITOR
Step 7 — MAINTAIN
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MLP-A/AR/AD-ST1400-25 2
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
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.
Sensor
Conduit to
Controller
Apply Calibration Gas
Controller
Calibration Cup
About eye level
CCS-1
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MLP-A/AR/AD-ST1400-25 3
Figure 2: Dimensional Drawings
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
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.
Controller Housing
Housing Cover
Millennium Faceplate
Ribbon connecting faceplate/controller
Sensor Housing
5.60”
2.60”
5.68”
4.06”
5.31”
(144.3 mm)
(142.2 mm)
(134.9 mm)
(103.1 mm)
(66.0 mm)
4.82” (122.4 mm)
2.89” (73.4 mm)
4.82”
(122.4 mm)
5.10” (129.5 mm)
9.92” (252.0 mm)
10.51” (267.0 mm)
Controller with sensor
Multi-purpose Junction Box with sensor
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MLP-A/AR/AD-ST1400-25 4
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.
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.
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).
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MLP-A/AR/AD-ST1400-25 5
Board Assembly
There are three different fixed boards, two optional relay boards and an optional Modbus board which make up the PCB Assembly. Depending upon requirements, either a Electromechanical or Solid State Relay Board module can be used. Boards are field replaceable. Simply loosen the three locking standoffs, remove one board, insert the other board and tighten screws.
Note: Boards are susceptible to ESD. Refer to Appendix A, "Electrostatic Sensitive Device (ESD)", on page 20.
Figure 4: Millennium Module Boards
Ter mi nal
Sensor
Option Board
Board
Board
Solid State Relay Board
Fault
+
-
Low
+
-
High
+
-
Electromechancial Relay Board
FNO
FAULT
normally open FCOM common FNC normally closed LNO
L
OW
normally open LCOM common LNC normally closed HNO
HIGH
normally open HCOM common HNC normally closed
Modbus Terminals
A B COM Shld
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Figure 5: Wiring—Controller and Sensor
Note: If the 4-20 mA signal is not used, connect a jumper between the 4-20
terminal and the COM terminal on the Terminal Board.
SENSOR AND CONTROLLER
WA R NI N G :
Power to the unit must be OFF before wiring.
Note: The Sensor may be factory installed to the Controller. If so, you need
only connect the Power Terminals.
1. Remove the Controller’s Housing Cover.
2. Connect the Sensor to the Sensor Terminals (if necessary) and the Output Terminals to the output signal wires.
Note: For Sensor Separation instructions, see Figure 6, "Wiring—Sensor
Separation", on page 7.
3. Replace the Controller’s Housing Cover.
4. Turn Controller On.
5. Ensure display reads
Start Delay , Status LED is Red Slow Flash and
current output displays 3.0 mA. This is the start-up delay sequence which will last approximately 90 seconds.
RS-485 Communication
Connect devices in a chain via the Modbus terminals. The last device in the chain requires end of line termination (refer to "MODBUS Termination" on page 9).
RST
+24V
COM
4-20
ISO
Red+
Blk
Shld
Red Blk
-
­Shld
Terminal Board
Sensor Wire s
Ter mi nal s
Modbus RTU
to PLC
A
B
COM
-
Ter min al s
Power
RST +24V COM 4-20 ISO
Ter mi nal s
Sensor
Sensor Board
Ta bl e 1 : Controller/Sensor Connections
Sensor Board Terminals Terminal Board Power
Sensor Wire
Controller (Sensor Board)
Controller (Terminal Board)
Power Connections
Red = Red (+24 V) RST = Remote Reset Black = Blk (Sig) +24V = Power (+)
-COM=Power(-)
- 4-20 = Current Loop Output
Shield = Shld ISO = +24 V isolated
4-20 power
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SENSOR SEPARATION
Figure 6: WiringSensor Separation
As the Sensor must be located in one location and the Controller in a location where it can be easily reached, it is often necessary to “separate” the Controller and Sensor.
The Sensor separation kit (SEP) is composed of a junction box and terminal strip. Refer to the Net Safety Multi-purpose Junction Box manual (MAN-0081) for terminal designation when wiring for sensor separation.
Shielded copper instrument wire (minimum 18 AWG) should be used for separations up to 500 feet. Shielded copper instrument wire (minimum 16 AWG) should be used for separations up to 2000 feet. Consult the factory if a greater separation distance is required.
Ensure that the appropriate wire is used for Class 1/Division 1 hazardous applications.
Note: If the 4-20 mA signal is not used, connect a jumper between the 4-20
terminal and the COM terminal on the Terminal Board.
RST
+24V
COM
4-20
ISO
Red
Blk
Shld
Terminal Board
Sensor Board
Sensor Ter mi nal s*
Ter mi nal s
Modbus RTU
to PLC*
Power Ter mi nal s*
To designated terminal board and oxygen sensor. See MAN-0081 Multi-purpose Junction Box manual
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NON-ISOLATED/ISOLATED WIRING
Terminal Connection
Figure 7: Non-isolated Terminal Connection
Figure 8: Isolated Terminal Connection
Current Output
To set an isolated current output, simply move the Jumper (shorting jack) to the isolated current position (refer to Figure 9, "Jumper Positions", on page 8).
Note: Unless otherwise specified, all models ship with non-Isolated current
output.
Figure 9: Jumper Positions
RST
+24V
COM
4-20
ISO
Power
to Monitor
Supply
Terminal Board Power Terminal Strip
RST
+24V
COM
4-20
ISO
Power
to Monitor
Supply
Terminal Board Power Terminal Strip
Jumper—Position Jumper
(shorting jack) over pins to set power source for current output.
Position3&2=
Non-isolated (default)
Position 1 & 2 = Isolated
Termination Jumper—Is non-
functional inthis application and can be placed in any position or removed entirely.
Ter min al Bo ard
Sensor Board
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REMOTE RESET
The Millennium can be set for remote reset. A normally open Push Button Switch must be connected between the RST and the COM terminals on the Terminal Board and the Relay Option Latch Status must be set to
Latching .
Figure 10: Remote Reset
MODBUS TERMINATION
Devices are networked in a daisy chain. The device located at the end of the chain requires end of line termination. Place both jumpers over the pins, as shown in Figure 11, "Modbus Termination Jumpers", on page 9, for end of line termination.
Figure 11: Modbus Termination Jumpers
RST
+24V
COM
4-20
ISO
Terminal Board
PowerTerminal Strip
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STEP 4 — OPERATE
The Controller faceplate contains most functional elements of the user interface. Below is a description of that functionality.
Figure 12: Controller Functionality
Status
Red
Slow Flash: Gas present Flast flash : Cal or Fault Solid: Overrange
Pull
Here
Green
Short Blips: Normal operation. No gas present
C
a
l
/
R
e
s
e
t
M
a
g
n
e
t
O
n
S
i
d
e
Off
Power
On
Pull Here
Current O/P Check
Connect current probes
to meter jacks and
read mA output
Calibration/Setup
-Hold Cal/Reset or magnet until countdown is zero (~10 sec)
-Follow instruction on display
Magnetic Reed Switch - provides non-intrusive access for programming, calibrating and resetting.
-Place magnet against Housing (where indicated) for less than one second to initiate a basic system reset (clear a latched alarm) and make selections.
-Place magnet against Housing (where indicated) and hold to program, view current settings and calibrate.
Refer to "Magnetic Reed Switch" on page 12 for further information.
Scrolling 8-character display ­provides various status messages and prompts. Refer to "Status LEDs, Display Messages and Current Loop" on page 11.
Pull Here knob - unscrew the two screws and gently pull to remove faceplate. Removal allows access to terminal boards. The faceplate remains attached by the ribbon cable.
Statu s Li ght (Red and Green) ­indicates status of unit. Refer to "Status LEDs, Display Messages and Current Loop" on page 11 for detailed explanation of states/status.
Current Test Jacks - to take current loop measurements use the following procedure:
-Insert your current meter leads into the Test Jacks.
-Set external devices to bypass, if necessary, to avoid unwanted alarm response
-Review current loop measurements.
Refer to "Current Loop Measurement (Test Jacks)" on page 12 and Table 2, "Status LEDs, Display Messages and Current Loop", on page 11.
Calibration Button -providesintrusive access for programming, calibrating and resetting.
-Push for less than one second to initiate a basic system reset (clear a latched gas alarm) and make selections.
-Push and hold to program, view current settings and calibrate.
Refer to "Calibration Button" on page 11 for further information.
ON/OFF Switch - used to turn Controller on and off. Housing must be removed to access.
Pull Here knob - unscrew the two screws and pull to remove faceplate. Removal allows access to PCBs. The faceplate remains attached by the ribbon cable.
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RTU Registers
Register 40001 = % output (read only) Register 40002 = RTU Status (read only) Register 40101 = Reset latched relays (write)
Calibration Button
The Calibration Button provides access to the Millennium’s Main Menu, which in turn allows calibration and options to be reviewed and set. Refer to Figure 12, "Controller Functionality", on page 10 for more information.
Press and hold the Calibration Button to Calibrate and access Main Menu.
Briefly press to make a selection (select
YES? ).
WA R NI N G :
Opening the Controller’s Housing should be avoided when the presence of gas is possible (when in a hazardous environment). Do not power up the system, with the Housing removed, unless the area has been de-classified.
Ta bl e 2 : Status LEDs, Display Messages and Current Loop
Status LED
State Current O/P RED or GREEN Display
Options Review/Settings
3.0 mA n/a n/a
Standard level of Oxygen present
17.4 mA
Blip/ blink
20.9 %O2
Start-up delay (90 sec) 3.0 mA
Slow flash
Start Delay
Access Main Menu 3.0 mA n/a
Switch On
10-0
Memory Error (contact factory)
2.5 mA
Slow flash
Memory Error
Black or Red Sensor lead open
2.5 mA
Slow flash
Sensor Fault
Auto zero set 3.0 mA Solid
Apply Clean
Air
Apply calibration gas 3.3 mA
Fast flash
Apply 20.9%
O2
Span is set, remove gas
3.6 mA Solid
Remove gas
Low alarm set point - Flash
XX Low Alarm
High alarm set point - Flash XX High Alarm
Non-standard levels of Oxygen present
>17.4 mA or <17.4 mA
Blip/ blink
% O2 shown left
side display
Calibration procedure failed/Sensor failed
3.0 / 3.3 mA Flash Flash
Fail Cal
Over 25% Range 20 mA Solid
<25%O2
Table 3: RTU Status Register (40002) Read Only (Binary)
RTUstat_fault 0x0001 (fault sensor...)
RTUstat_low_alarm 0x0002 low alarm tripped
RTUstat_high_alarm 0x0004 high alarm tripped
RTUstat_low_alarm_latched 0x0008 low alarm latched
RTUstat_high_alarm_latched 0x0010 high alarm latched
RTUstat_powerUp 0x0080 power up delay
RTUstat_cal_cycle 0x0100 calibration cycle in progress
RTUstat_zeroing 0x0200
RTUstat_apply_span_gas 0x0400
RTUstat_calibrating 0x0800
RTUstat_remove_gas 0x1000
RTUstat_cal_complete 0x2000
RTUstat_mem_error 0x4000 memory error
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Magnetic Reed Switch
The Magnetic Reed Switch is provided to avoid opening the Housing in an environment where gas may be present. The Magnetic Reed Switch functions in the same manner as the Calibration Button but in a non-intrusive manner. Refer to Figure 12, "Controller Functionality", on page 10 for more information.
Attached to the side of the Controller is a magnet:
Place and hold the magnet to the Controller’s Housing (10 o’clock position) to Calibrate and access Main Menu.
Briefly place the magnet to the Controller’s Housing (10 o’clock position) to make a selection (select
YES? ).
Power Up
Turn power switch On. A 90 second warm-up routine will begin. The display reads
Start Delay Millennium Net Safety
, Status LED is Red Slow Flash and
current output displays 3.0 mA.
When power is applied, the system is automatically tested to ensure proper functionality.
After warm-up, the Controller will enter normal operation, the display reads
%O2, Status LED will Green Blip/blink and analog output will change to
4.0 mA.
Current Loop Measurement (Test Jacks)
Use a standard meter to measure current loop during various states. The Controller’s Housing cover must be removed to access the Test Jacks.
Refer to Table 2, “Status LEDs, Display Messages and Current Loop,” on page 11 for a detailed list and Figure 12, "Controller Functionality", on page 10 for more information.
Status LED
The Status LED will remain solid, flash, blip and/or blink, in either Red or Green, to indicate various states. Refer to Table 2, “Status LEDs, Display Messages and Current Loop,” on page 11 for a detailed list.
THE MAIN M ENU
The Main Menu provides access to various functional settings and viewing of current settings.
• Calibrate Sensor - Calibrate sensor.
• Review Relay Settings - Review the current Fault, Low and High alarm settings. This is a read only section.
• Set Relay Options - Set the Low and High alarm settings.
• Select Modbus Options.
• Restricted Menu - Select low power options.
• Select a display language - English, Spanish or French.
Note: The current output will drop to 3.0 mA while in the Main Menu.
Accessing the Main Menu
There are two ways to activate the Main Menu:
• Calibration Button found on the faceplate (the Housing cover must be removed to access)
• Magnetic Reed Switch (a magnet must be used to activate)
Main Menu Functionality
1. Ensure that the Controller has been turned on and no fault is present.
2. Hold the magnet against the Reed Switch or press and hold the Calibration
Button until the message
Switch On displays and the countdown (10 to 0)
finishes.
3. An option will scroll across the display followed by the prompt
YES? .
4. To select an option, momentarily place the magnet to the Reed Switch or
press the Calibration Button at the
YES? prompt.
5. If you do not wish to select that option wait until the next option appears
and then select
YES? .
6. A selection is acknowledged with a flashing
YES .
7. If no option is selected, the Controller returns to
0 (normal operation).
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STEP 5 — CALIBRATE
CALIBRATION P ROCEDURE
WARNING: The calibration procedure requires about 5 minutes to complete. If gas is not applied at the appropriate time, a calibration failure may occur (refer
to "Calibration Failure" on page 14 for specific information).
For accurate performance, the concentration of gas, corresponding to 0 to 25% oxygen is converted to a linear 4 to 20 mA output signal which can be poweredfrom the primary dc supply of the instrument. Power up the unit for at least 4 hours BEFORE first calibration.
The following calibration procedure should be followed to ensure an accurate correlation between the 4 to 20 mA output signal and the gas concentration.
Calibration Procedure
1. Confirm successful power up of ControllerLED Green Blip/blink every 2 seconds; no fault indicated.
2. Flow certified ZERO AIR at a rate of 0.5 litres per minute through the calibration cup for 1 minute to ensure clean air environment.
3. Use the Calibration Button or Reed Switch to access the Main Menu and wait for countdown to complete.
4. When
Calibrate Sensor YES? displays, use the Calibration Button or Reed Switch to select YES?
Selection will be confirmed by a flashing YES .
5. When
Apply Clean Air
displays apply clean air.
6. When
Apply 20.9% O2 displays, apply O2 at a rate of 0.5 litres per minute using the calibration cup.
7. The display will show
Calibrating
as the internal settings are being modified (current loop 3.3 mA).
8. Remove span gas when the message
Remove Gas displays (Status LED Green solid and 3.6 mA output).
9. The message
Cal Complete will display when calibration is complete.
10. Apply zero gas (clean air) again to purge system.
Note: Always apply test gas after calibration to verify operation.
Figure 13: Calibration Procedure
Select YES?
Display Shows
Action
Calibrate Sensor YES?
Apply clean (zero air)
Apply Clean Air
Apply 20.9% O2
Apply O2
Calibrating
Remove Gas
Remove gas
Cal Complete
Net Safety Monitoring Inc
MLP-A/AR/AD-ST1400-25 14
Calibration Failure
If the calibration procedure fails, the display shows
Fail Cal , the Status LED
alternates Red and Green flashes and the analog output changes back and forth from 3.0 to 3.3 mA.
The unit remains in a failed state until manually reset. After the Manual Reset, the unit will return to normal operation based on previous calibration values. Refer to "Manual Reset" on page 17 for instructions.
STEP 6 — MONITOR
REVIEW RELAY S ETTINGS
This is a read-only mode; changes cannot be made.
Ste p 1: Press and hold the Calibration Button or the magnet to the Reed
Switch to enter the Main Menu; wait for the countdown, from 10 to 0, to end.
Ste p 2: When
Review Relay Settings displays press the Calibration
Button or use the Reed Switch to select. The flashing
YES confirms the selection.
Ste p 3: The Fault Alarm is fixed (
Energized/Non-Latching ) and
displays first. Then the Low Alarm level, coil and latch status display, followed by the High Alarm level, coil and latch status.
Ste p 4: At this point, the option to
Set Relay Options YES? is
displayed.
Net Safety Monitoring Inc.
MLP-A/AR/AD-ST1400-25 15
RELAY OPTIONS
Use to set the alarm level, coil status and latch status for the Low and High relays (Fault Alarm is fixed).
The following table describes the default settings for the sensor.
Ta bl e 4 : Default Relay Settings
Setting Relay Options
There are two settings for Relay Options: Low and High. The Fault Relay is fixed as Energized/Non-latching and cannot be changed. The low alarm level, coil energization and latch status for low alarm are set first; high alarm level, coil energization and latch status for high alarm are then set. All ranges are in 10 to 25%. Low Alarm levels and High Alarm levels will display if reached.
Ste p 1: When
Set Relay Options YES?
displays press the Calibration Button or use the Reed Switch to select. The flashing
YES confirms the selection.
Ste p 2: The message
Set Low
displays. Low alarm set-points are displayed
in increments of 1, beginning at 10 and cannot be set above 20.
Ste p 3: When the required level displays, press the Calibration Button or
use the Reed Switch to select. The level chosen will flash to confirm the selection.
Ste p 4: The message
Coil Status
displays. The display then shows
Energized YES? and then De-Energized YES?
Ste p 5: Press the Calibration Button or use the Reed Switch to select.
The flashing
YES confirms the selection. If no selection is made, the
Coil Status option is repeated.
Ste p 6: The message
Latch Status
displays.Thedisplaythenshows
Latching YES? and then Non-Latching YES?
Ste p 7: Press the Calibration Button or use the Reed Switch to select.
The flashing
YES confirms the selection. If no selection is made, the
Latch Status option is repeated.
Ste p 8: The message
Set High displays.
The High Alarm level must be set between 21 and 25.TheHigh Alarm level is displayed in increments of 1 beginning at the Low Alarm set-point (as set in Step 3).
Ste p 9: Repeat Steps 4 through 7 to complete the High Alarm level, coil
and latch status settings.
Note: If no selection is made, a 5 minute timer expires, in which case the unit
returns to normal operation.
Millennium
Model Number
Alarm Levels
Relay Coil
Statu s
Low High Fault
Latching
Non Latching
Energized
De-energized
MLP-A/AR/AD­ST1400 (25%range)
20% 22%
Energized /Non-latching
**
Net Safety Monitoring Inc
MLP-A/AR/AD-ST1400-25 16
MODBUS OPTIONS
The digital RS-485 Modbus RTU protocol is used. There are two Modbus options: Node Address and Baud Rate.
Node Address
Each device connected to the chain must be assigned a unique node address (1-
255). The last number in the address is selected first.
Step 1: When
Modbus Setup? YES? displays press the Calibration Button
or use the Reed Switch to select. The flashing
YES confirms the selection.
Step 2: The current node address will display
Node: 000 .
Step 3: Wait for the prompt
New Address? YES?
and press the Calibration
Button or use the Reed Switch to select.
Step 4: Use the Calibration Button or Reed Switch to select each of three
numbers in the new address:
- select the last number in the address first:
0 thru 9.
- select the next number in the address:
0 thru 9.
- select the first number in the address last:
012 .
Baud Rate
The transmission speed must be defined.
Step 1: When
Modbus Setup? YES? displays press the Calibration Button
or use the Reed Switch to select. The flashing
YES confirms the selection.
Step 2: After setting the Node Address, the current Baud Rate will display
XX.X BPS .
Step 3: Wait for the prompt
New Baud Rate? YES? and press the
Calibration Button or use the Reed Switch to select.
Step 4: The available baud rates will display:
2400s , 4800s , 9600s,14.4s ,
19.2s , 28.8s , 38.4s , 57.6s .
Step 5: UsetheCalibrationButtonorusetheReedSwitchtoselectbaud
rate when it displays.
Step 6: The flashing
YES confirms the selection.
ENTER RESTRICTED M ENU
The Restricted Menu allows you to set the Low Power Options.
Ste p 1: Press and hold the Calibration Button or the magnet to the Reed
Switch to enter the Main Menu; wait for the countdown, from 10 to 0, to end.
Ste p 2: When
Enter restricted menu YES? displays press the
Calibration Button or use the Reed Switch to select. The flashing
YES confirms the selection.
Ste p 3: When
Are you sure?YES? displays press the Calibration Button
or use the Reed Switch to select. The flashing
YES confirms the selection.
Set Low Power Options - Optional
Two optional low power features are available to reduce overall power consumption. Use this option to:
• Dim the LED display although display will still be visible in most lighting conditions (default setting)
• Disable the 4 to 20 mA analog output for applications requiring only relay output (default setting)
Ste p 1: Enter the Restricted Menu (refer to "Modbus Options" on page 16).
Ste p 2: When
Set Low Power Opti ons YES? displays press the Calibration
Button or use the Reed Switch to select. The flashing
YES confirms the selection.
Ste p 3: When
Lower Display Brightness YES? displays press the
Calibration Button or use the Reed Switch to select or wait until
Display Full Brightness YES? displays and select.
The flashing
YES confirms the selection.
Ste p 4: When
Disable 4 - 20mA O/P YES? displays press the Calibration
Button or use the Reed Switch to select or wait until
Enable 4 -
20mA O/P YES?
displays and select.
The flashing
YES confirms the selection.
Net Safety Monitoring Inc.
MLP-A/AR/AD-ST1400-25 17
SELECT DISPLAY LANGUAGE
Step 1: After the Restricted Menu the option Select Display Language
YES?
displays. Press the Calibration Button or use the Reed Switch to select. The flashing
YES confirms the selection.
Step 2: When the required language displays (
English , Espanol ,
Francais
press the Calibration Button or use the Reed Switch to
select.
The flashing
YES confirms the selection.
Note: Factory default is English.
ALARMS
Sensor Fault
WARNING:
The fault detection circuitry does not monitor the operation of external response equipment or the external wiring to these devices. It is important that these devices be checked periodically to ensure they are operational.
Self-testing circuitry continuously checks for problems that could prevent proper response. When power is applied, the microcontroller automatically tests the system to ensure that it is functioning properly. During normal operation, it continuously monitors the signal from the internal sensor source. In addition, a "watchdog" timer is maintained to ensure the program is running correctly. When a system fault is detected, the Status LED will Red Slow flash, the display show
Sensor Fault and analog output change to 2.5 mA.
Non-standard O2 Levels
When levels >20.9 or <20.9 are detected, the display shows the oxygen level, in percent, on the left side of the display and the LED will blip green. Current output will vary, depending on the O2 level.
If an alarm set-point is reached, the %O2 still displays to the left but a High Alarm or Low Alarm message will scroll to the right and the LED will blip/ blink red. Current output will vary, depending on the O2 level.
Over range is reached if the O2 level exceeds 25%. The display shows
<25%O2, the LED goes solid red and 20 mA is delivered.
Sensor Life
Depending on various factors, sensor response may slowly deteriorate over time. If calibration becomes impossible for any reason, the display will show
Fail Cal , the analog output will switch repeatedly between 3.0 mA and 3.3
mA and the Status LED alternates Red and Green flashes.
RESET
Manual Reset
A Manual Reset is required after a calibration failure or to clear a latched relay alarm. Simply place and hold the magnet against the Reed Switch or press and hold the Calibration Button for 3-5 seconds. The unit will return to normal operation using previous calibration values.
Remote Reset
If Relay Option is set to Latching (refer to "Setting Relay Options" on page 15) and an open Push Button Switch is connected between the RST terminal and the COM terminal on the Terminal Board, Remote Reset is possible. Also refer to "Remote Reset" on page 9 for details.
)
Net Safety Monitoring Inc
MLP-A/AR/AD-ST1400-25 18
OUTPUTS
Relays - Optional
Note: The fault relay output is not used to activate an automatic shutdown
procedure. The fault output indicates a potential problem with the Controller not an alarm condition.
Standard electro-mechanical relay outputs have Form C SPDT contacts rated 5 Amperes at 30 V dc/ 250 V ac. Three relay outputs are available; one for Fault; one for Low alarm; and one for High alarm. All relays have normally open and normally closed contacts available at the output terminals.
The fault relay is set for normally energized operation and is non-latching. If a system fault is detected, the fault relay becomes de-energized. The fault relay is factory set and cannot be altered. The Low alarm and High alarm relays can be selected for either normally energized or normally de-energized operation and latching/non-latching.
Modbus
Digital RS-485 Modbus RTU protocol is used.
Register 40001 = % output (read only) Register 40002 = Status (read only) Register 40101 = Reset latched alarms (write)
Note: Many registers are used by the controller. Please do not write outside
the three registers.
Current
A 4-20 mA dc current output is used to transmit the alarm status and fault codes to other devices. This output can be wired for isolated or non-isolated operation. A 17.4 mA output indicates normal operation; a value >17.4 or <17.4 mA out­put indicates an abnormal amount of oxygen. Current output of 2.5 mA indi­cates the presence of a system fault.
STEP 7 — MAINTAIN
PERIODIC RESPONSE C HECK
We recommend a typical response check or calibration is performed on the Millennium every 3 months. A typical response check involves the application of calibration gas to the sensor, then the observation of the response LEDs, analog output, display and external monitoring equipment. Be sure to prevent unwanted response of external monitoring devices and equipment during this procedure. If the Millennium response to calibration gas is within its specified accuracy then it is not necessary to perform a calibration. For example, when 12% oxygen is applied, the response is expected to be between 10.4 mA (10% O2) and 12.96 mA (14% O2). An additional consideration is the accuracy tolerance of the calibration gas which may be + or - a few percent.
TROUBLESHOOT
Response to the input should be checked and, if necessary, calibration should be performed whenever any of the following occur. Refer to "Calibration Procedure" on page 13 for calibration instructions.
• Excess negative drift is indicated by 2.5 mA current output
• Sensor or transmitter is connected or disconnected
• Long term exposure or high concentration exposure to gas
The Millennium is not designed to be repaired in the field. If a problem should develop, first calibrate the device and carefully check for faulty wiring. If it is determined that the problem is caused by an electronic failure, the device must be returned to the factory for repair. Refer "How to Return Equipment" on page 19 for detailed instructions.
Net Safety Monitoring Inc
MLP-A/AR/AD-ST1400-25 19
HOW TO RETURN EQUIPMENT
A Material Return Authorization number is required in order to return equipment. Please contact Net Safety Monitoring at (403) 219-0688
before returning equipment or consult our Service Department to possibly avoid returning equipment.
If you are required to return equipment, include the following information:
1. A Material Return Authorization number (provided over the phone to you
by Net Safety).
2. A detailed description of the problem. The more specific you are regarding
the problem, the quicker our Service department can determine and correct the problem.
3. A company name, contact name and telephone number.
4. A Purchase Order, from your company, authorizing repairs or request for
quote.
5. Ship all equipment, prepaid to:
Net Safety Monitoring Inc
2721 Hopewell Place NE Calgary, Alberta, Canada
T1Y 7J7
6. Mark all packages: RETURN for REPAIR
Waybills, for shipments from outside Canada, must state:
Equipment being returned for repair All charges to be billed to the sender
Also, please ensure a duplicate copy of the packing slip is enclosed inside the box indicating item 1-4 along with the courier and account number for returning the goods.
All Equipment must be Shipped prepaid. Collect shipments will not be accepted.
Pack items to protect them from damage and use anti-static bags or aluminum­backed cardboard as protection from electrostatic discharge.
SPARE PARTS/ACCESSORIES
FACE ROTATION OPTION
In some applications, it is necessary for the Millennium Controller to be mounted in a non-standard orientation. To accommodate such installations and ensure that the display will appear at the correct angle for viewing, the PCB Assembly can be rotated inside the Controller.
Figure 14: Non-standard Orientations
Note: Ensure orientation allows for connections and excess wire within Controller
Housing.
Tab l e 5: Part Numbering
Description Net Safety Part Number
PCBA-0252ETerminal Connector Board
FRO-001
90 Degrees Rotation Plate
CCS-1
Magnet-1
Magnet assembly
Calibration Cup
ML7-TX100
Transmitter for MLP series c/w Display, Terminal & Input board
ML7RS305
Mechanical Relay Board for MLP series
ML7OP100
Option Board c/w connectors for Mechanical Relay board
ML7-ORL305
Electromechanical Relay Board c/w Option board
Oxygen (O2) Sensor
ST1400-25
THSG-FULL-O2
Oxygen Sensor housing(light blue)
THSG-FULL-O2-SS
Oxygen Sensor housing(light blue)
ML7-MB100
ML7 Modbus Output Board
Net Safety Monitoring Inc
MLP-A/AR/AD-ST1400-25 20
Rotate PCB Assembly
1. Remove the Controller’s Housing Cover.
2. Turn the power to the detector off.
3. Unscrew both the knobs marked "Pull Here".
4. Lift Controller faceplate from Housing and allow to hang from ribbon
cable.
5. Unscrew the two metal standoffs.
6. Carefully remove the PCB Assembly from the Housing.
7. The Rotator plate is secured to the bottom of the Housing and is accessible
after the PCB Assembly has been removed.
8. Rotate the PCB Assembly to desired position and line up the standoffs with
the mounting holes.
9. Insert standoffs in the appropriate horizontal or vertical mounting holes.
10. Tighten standoffs to secure PCB Assembly.
11. Replace faceplate and tighten "Pull Here" knobs.
12. Return power to detector and replace Housing Cover.
WARNING:
See Appendix A, "Electrostatic Sensitive Device (ESD)", on
page 20 for handling instructions of electronic components.
Appendix A: E
LECTROSTATIC SENSITIVE DEVICE (ESD)
Electrostatic discharge (ESD) is the transfer, between bodies, of an electrostatic charge caused by direct contact or induced by an electrostatic field.
The most common cause of ESD is physical contact. Touching an object can cause a discharge of electrostatic energy
—ESD! If the charge is sufficient and
occurs near electronic components, it can damage or destroy those components.
In some cases, damage is instantaneous and an immediate malfunction occurs. However, symptoms are not always immediate
—performance may be marginal
or seemingly normal for an indefinite period of time, followed by a sudden failure.
To eliminate potential ESD damage, review the following guidelines:
• Handle boards by metal shields
taking care not to touch electronic
components
• Wear grounded wrist or foot straps, or ESD shoes or heel grounders to dissipate unwanted static energy
• Prior to handling boards, dispel any charge in your body or equipment
• Ensure components are transported and stored in static safe packaging
• When returning boards, carefully package in the original carton and static protective wrapping
• Ensure ALL personnel are educated and trained in ESD Control Procedures
In general, exercise accepted and proven precautions normally observed when handling electrostatic sensitive devices.
A warning label is placed on the packaging, identifying product using electrostatic sensitive semiconductor devices.
Standoffs
PCB Assembly
Faceplate
Ribbon cable
Vertical Mounting Holes (Insert Standoffs)
Horizontal Mounting
(Insert Standoffs)
Holes
Net Safety Monitoring Inc.
MLP-A/AR/AD-ST1400-25 21
Appendix B: RESISTANCE TABLE IN OHMS
Note: Resistance shown is one way. This figure should be doubled when determining closed loop resistance.
Distance (Feet) AWG #20 AWG #18 AWG #16 AWG #14 AWG #12 AWG #10 AWG #8
100 1.020.640.400.250.160.100.06
200 2.031.280.800.510.320.200.13
300 3.051.921.200.760.480.300.19
400 4.062.551.611.010.640.400.25
500 5.083.202.011.260.790.500.31
600 6.093.832.411.520.950.600.38
700 7.11 4.47 2.81 1.77 1.11 0.70 0.44
800 8.12 5.11 3.21 2.02 1.27 0.80 0.50
900 9.145.753.612.271.430.900.57
1000 10.20 6.39 4.02 2.53 1.59 1.09 0.63
1250 12.70 7.99 5.03 3.16 1.99 1.25 0.79
1500 15.20 9.58 6.02 3.79 2.38 1.50 0.94
1750 17.80 11.20 7.03 4.42 2.78 1.75 1.10
2000 20.30 12.80 8.03 5.05 3.18 2.00 1.26
2250 22.80 14.40 9.03 5.68 3.57 2.25 1.41
2500 25.40 16.00 10.00 6.31 3.97 2.50 1.57
3000 30.50 19.20 12.00 7.58 4.76 3.00 1.88
3500 35.50 22.40 14.10 8.84 5.56 3.50 2.21
4000 40.60 25.50 16.10 10.00 6.35 4.00 2.51
4500 45.70 28.70 18.10 11.40 7.15 4.50 2.82
5000 50.10 32.00 20.10 12.60 7.94 5.00 3.14
5500 55.80 35.10 22.10 13.91 8.73 5.50 3.46
6000 61.00 38.30 24.10 15.20 9.53 6.00 3.77
6500 66.00 41.50 26.10 16.40 10.30 6.50 4.08
7000 71.10 44.70 28.10 17.70 11.10 7.00 4.40
7500 76.10 47.90 30.10 19.00 12.00 7.49 4.71
8000 81.20 51.10 23.10 20.20 12.70 7.99 5.03
9000 91.40 57.50 36.10 22.70 14.30 8.99 5.65
10 000 102.00 63.90 40.20 25.30 15.90 9.99 6.28
Net Safety Monitoring Inc.
MLP-A/AR/AD-ST1400-25 22
Appendix C: SPECIFICATIONS
SENSOR SPECIFICATIONS
CONTROLLER SPECIFICATION
SENSOR ELEMENT Oxygen O2 (ST1400)
Operating Temperature Range -20°C to +50°C (-4F to +122F)
%52ot0noitceteDfoegnaR
59Totsdnoces51<emiTesnopseR
raey/ssollangisfo%5<tfirDnapS
)leetssselniatslanoit
po(munimuladetaocredwop/dezidonAlairetaMerusolcnE
Certifications
CSA and NRTL/C certified for hazardous locations. Class I, Division 1, Groups C and D. IEC Rating Ex d IIB T6 NEMA 3R (Class 1, Zone 1, Grp IIB T6)
)bl0.1(gK5.0thgieW
LATIGID/GOLANAYALER/GOLANAGOLAN
AMUINNELLIM
Operating Temperature Range -20°C to +50°C (-4F to +122F)
Power Consumption @ 24 V dc Nom 68 mA / 1.63 W
Max90mA/2.16W
Nom 75 mA / 2.0 W
Max 108 mA / 2.6 W
Nominal 125 mA/3.01 W Maximum 155mA/3.73 W
Humidity Range 0 to 99% relative humidity, non-condensing
Operating Voltage Range 10.5 to 32.0 V dc
Enclosure Material Powder coated Copper Free Cast Aluminum (optional stainless steel)
Certifications CSA and NRTL/C certified for hazardous locations. Class I, Division 1, Groups B, C and D. NEMA 4X.
IEC Rating Ex d IIB+H2 T5 Note: With any Type 4 enclosure (electronics only-sensor remotely mounted in Class I, Division 1 area with seals between sensor and electronics), CSA and NRTL/C certified for hazardous locations, Class 1, Division 2, Groups A, B, C and D.
Weight 3.2 Kg (7.0 lb)
Outputs
- 4 to 20 mA - Into a maximum loop impedance of 800 Ohms at 32 V dc or 150 Ohms at 10.5 V dc. Isolated or non-isolated loop supply.
- Premium version - Form C contacts rated 5 Amps at 30 V dc / 250 V ac. Selectable energized / de-energized, latching/non-latching configurable low and high alarms. Fault relay is factory set as energized, non-latching and cannot be modified.
Low Power Version - Form A contacts rated.2.5 Amps at 60 V ac/dc. Selectable energized / de-energized, latching/non-latching configurable low and high alarms. Fault relay is factory set as energized, non-latching and cannot be modified.
- Digital RS 485 Modbus RTU Protocol
N
et Safety Monitoring Inc.,
2
721 Hopewell Place NE
C
algary, Alberta, Canada T1Y 7J7
T
elephone: (403) 219-0688 Fax: (403) 219-0694
E
-mail: netsafe@net-safety.com
w
ww.netsafety.com
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