Net Safety Monitoring SafeGuard Operating Manual

Net Safety TM SafeGuard Controller

User Manual

Reference Manual

MAN-0115, Rev. A

April 2016

Important Instructions

Rosemount designs, manufactures, and tests products to function within specific conditions. Because these products are sophisticated technical instruments, it is important that the owner and operation personnel must strictly adhere both to theinformation printed on the product nameplate and to all instructions provided in this manual prior to installation, operation, and maintenance.

Installing, operating, or maintaining the product improperly could lead to serious injury or death from explosion or exposure to dangerous substances. Comply with all information on the product, in this manual, and in any local and national codes that apply to the product. Do not allow untrained personnel to work with this product. Use Net Safety parts and work procedures specified in this manual.

No part of the hardware, software, or documentation may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language or computer language, in any form or by any means, without prior written permission of Rosemount. While great efforts have been made to ensure the accuracy and clarity of this document, Rosemount assumes no liability resulting

from any omissions in this document of from misuse of the information obtained herein. The information in this document has beencarefully checked and is believed to be entirely reliable with all of the necessary information included. Rosemount reserves the rightto make changes to any products described herein to improve reliability, function, or design and reserves the right to revise this

document and make changes from time to time in content hereof with no obligation to notify any persons of revisions or changes. Rosemount does not assume any liability arising out of the application or any use of any product or circuit described herein; neither does it convey license under its patent rights or the rights of others.

This manual should be read carefully by all individuals who hve or will have responsibility for using, maintaining, or servicing this product.

The Detector is not field repairable due to the meticulous alignment and calibration of the sensors and the respective circuits. Do not attempt to modify or repair the internal circuits or change their settings, as this will impair the system’s performance and void the Rosemount warranty.

Warranty

Limited Warranty

Resale Products

Limitation of Remedy and Liability

Liability) herein, Seller warrants that (a) the licensed firmware embodied in the Goods will execute the programming instructions provided by Seller; (b) that the Goods manufactured by Seller will be free from defects in materials or workmanship under normal use and care; and (c) Services will be performed by trained personnel using proper equipment and instrumentation for the particular Service provided. The foregoing warranties will apply until the expiration of the applicable warranty period. Sensors and detectors are warranted against defective parts and workmanship for 24 months from the date of purchase and other electronic assemblies for 36 months from the date of purchase. Products purchased by Seller from a third party for resale to Buyer ( Buyer agrees that Seller has no liability for Resale Products beyond making a reasonable commercial effort to arrange for procurement and shipping of the Resale Products. If Buyer discovers any warranty defects and notifies Seller thereof in writing during the applicable warranty period, Seller shall, at its option, (i) correct any errors that are found by Seller in the firmware or Services; (ii) repair or replace FOB point of manufacture that portion of the Goods found by Seller to be defective; or (iii) refund the purchase price of the defective portion of the Goods/Services. All replacements or repairs necessitated by inadequate maintenance; normal wear and usage; unsuitable power sources or environmental conditions; accident; misuse; improper installation; modification; repair; use of unauthorized replacement parts; storage or handling; or any other cause not the fault of Seller, are not covered by this limited warranty and shall be replaced or repaired at Buyer’s sole expense and Seller shall not be obligated to pay any costs or charges incurred by Buyer or any other party except as may be agreed upon in writing in advance by Seller. All costs of dismantling, reinstallation, freight and the time and expenses of Seller’s personnel and representatives for site travel and diagnosis under this limited warranty clause shall be borne by Buyer unless accepted in writing by Seller. Goods repaired and parts replaced by Seller during the warranty period shall be in warranty for the remainder of the original warranty period or 90 days, whichever is longer. This limited warranty is the only warranty made by Seller and can be amended only in a writing signed by an authorized representative of Seller. The limited warranty herein ceases to be effective if Buyer fails to operate and use the Goods sold hereunder in a safe and reasonable manner and in accordance with any written instructions from the manufacturers. THE WARRANTIES AND REMEDIES SET FORTH ABOVE ARE EXCLUSIVE. THERE ARE NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED, AS TO MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS OR SERVICES.

. Subject to the limitations contained in Section 10 (Limitation of Remedy and

) shall carry only the warranty extended by the original manufacturer.

DELAY IN PERFORMANCE. THE REMEDIES OF BUYER SET FORTH IN THE AGREEMENT ARE EXCLUSIVE. IN NO EVENT, REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF ACTION (WHETHER BASED IN CONTRACT, INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY, OTHER TORT OR OTHERWISE), SHALL SELLER’S LIABILITY TO BUYER AND/OR BUYER’S CUSTOMERS EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED OR SERVICES PROVIDED BY SELLER GIVING RISE TO THE CLAIM OR CAUSE OF ACTION. BUYER AGREES THAT IN NO EVENT SHALL SELLER’S LIABILITY TO BUYER AND/OR BUYER’S CUSTOMERS EXTEND TO INCLUDE INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAMAGES. THE TERM “CONSEQUENTIAL DAMAGES” SHALL INCLUDE, BUT NOT BE LIMITED TO, LOSS OF ANTICIPATED PROFITS, REVENUE OR USE AND COSTS INCURRED INCLUDING WITHOUT LIMITATION FOR CAPITAL, FUEL AND POWER, AND CLAIMS OF BUYER’S CUSTOMERS.

. SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY

Contents

Section 1: Introduction ................................................1

Section 2: Operation ....................................................6

1.1 Important safety issues ....................................................................... 1

1.2 General description ............................................................................. 2

1.3 Data display screens ............................................................................ 3

Trend screen ........................................................................... 3

1.3.1

1.3.2 Bar Graphs screen .................................................................. 4

1.3.3 Combination screen ............................................................... 4

1.4 Specifications ...................................................................................... 4

1.4.1 DC power supply requirements ............................................... 4

1.4.2 150 watt AC– 24 Vdc power supply ......................................... 4

1.4.3 Relays ..................................................................................... 5

1.4.4 Ambient temperature range ................................................... 5

1.4.5 Humidity range ....................................................................... 5

1.4.6 Altitude ................................................................................... 5

1.4.7 Housings ................................................................................. 5

1.4.8 Non-intrusive magnetic keypad............................................... 5

1.4.9 Approvals ................................................................................ 5

2.1 Basic operation ................................................................................... 6

2.2 Setup menu configuration .................................................................. 6

2.2.1 Changing menu variables using the key pad ............................ 7

2.3 Channel configuration menus ............................................................. 7

2.3.1 Channel setup entry menu ...................................................... 8

2.3.2 Alarm 1 / Alarm 2 / Horn Relay Setup menu ............................. 9

2.3.3 Alarm 3 / Fault Alarm menu ................................................... 10

2.3.4 Data from? menu to set input source .................................... 10

2.3.5 Min / Max Raw counts entries ................................................ 11

2.3.6 Marker menus ....................................................................... 12

2.3.7 Sensor Life detection (- this feature is not used at this time) .. 12

2.3.8 Linearization menu ............................................................... 13

2.3.9 Configure menu .................................................................... 13

2.3.10 Eunits / Measurement Name ASCII data fields ........................ 13

2.3.11 Input measurement range ..................................................... 13

2.3.12 Decimal point resolution ....................................................... 14

2.3.13 Turning off unused channels ................................................. 14

2.3.14 Copy Data to? ....................................................................... 14

2.3.15 Cal mode .............................................................................. 14

2.4 System configuration menus ............................................................. 15

2.4.1 Common Alarm Relays 1 and 2 .............................................. 16

2.4.2 SG10-0195 Discrete relay Failsafe mode ................................ 17

2.4.3 Common horn relay and local piezo....................................... 18

2.4.4 Comm Port menus ................................................................ 19

2.4.5 Eight / sixteen channel modes ............................................... 19

2.4.6 Sensor Information (this feature is not used at this time) ....... 20

2.5 Authorization mode .......................................................................... 20

2.6 LCD contrast adjustment ................................................................... 21

Section 3: Inputs and Outputs .................................... 21

3.1 Main I/O interface PCB....................................................................... 21

3.1.1 Modbus Communication between SafeGuard and Digital

Millennium II Series Transmitters. .......................................... 22

3.2 Input/output optional PCBs ............................................................... 24

3.2.1 Optional analog input PCB # SG10-0158 ............................... 24

3.2.2 Optional discrete relay PCB # SG10-0195 .............................. 26

3.2.3 Optional 4-20mA analog output board # SG10-0167 ............. 28

3.2.4 Optional 24VDC 150 watt power supply ................................ 29

Section 4: System diagnostics .................................... 30

Section 5: Modbus ..................................................... 32

5.1 Modbus RS-485 ports ........................................................................ 32

5.2 Modbus slave register locations......................................................... 32

Section 6: Dimensions................................................ 39

6.1 SafeGuard PM panel / rack mount enclosure...................................... 39

6.2 SafeGuard n4 NEMA 4X wall mount fiberglass enclosure ................... 40

6.3 SafeGuard main I/O & option PCB footprint dimensions .................... 42

Section 7: How to return equipment .......................... 43

Section 8: Appendix ................................................... 44

Appendix A: Electrostatic sensitive device (ESD) ......................................... 44

MAN-0115 Rev A

WARNINGS:

Shock Hazard

WARNING- EXPLOSION HAZARD

WARNING:

Section 1: Introduction

operation. Failure to do so could result in serious injury or death.

Read & understand contents of this manual prior to

1.1 Important safety issues

The following symbols are used in this manual to alert the user of important instrument operating issues:

•

• NEMA 4X wall mount models should be fitted with a locking mechanism

This symbol is intended to alert the user to the presence of important operating and maintenance (servicing) instructions.

This symbol is intended to alert the user to the presence of dangerous voltage within the instrument enclosure that may be sufficient magnitude to constitute a risk of electric shock.

instrument.

after installation to prevent access to high voltages by unauthorized personnel (see Figure 6.2).

- Disconnect or turn off power before servicing this

• Only the combustible monitor portions of this instrument have been

assessed by CSA for C22.2 No. 152 performance requirements.

• This equipment is suitable for use in Class I, Division 2, Groups A, B, C, and

D or non-hazardous locations only.

•

• Use a properly rated CERTIFIED AC power (mains) cable installed as per

IMPAIR SUITABILITY FOR CLASS I, DIVISION 2.

HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NONHAZARDOUS.

UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS.

local or national codes

- SUBSTITUTION OF COMPONENTS MAY

- DO NOT REPLACE FUSE UNLESS POWER

- DO NOT DISCONNECT EQUIPMENT

MAN-0115 Rev A 2

• A Certified AC power (mains) disconnect or circuit breaker should be

Note: LEL Gas sensors are connected to the SafeGuard Controller via Net Safety Transmitters. They are NOT connected directly to the SafeGuard Controller at this time. Perform calibrations of the transmitter/sensor head. Calibrations may however be performed at the SafeGuard if the transmitter/sensor configuration is in a location not easily accessible. See Cal Mode.

mounted near the SafeGuard Controller and installed following applicable local and national codes. If a switch is used instead of a circuit breaker, a properly rate CERTIFIED fuse or current limiter is required to installed as

local or national codes. Markings for positions of the switch or

per breaker should state (I) for on and (O) for off.

• Clean only with a damp cloth without solvents.

• Equipment not used as prescribed within this manual may impair overall

safety.

1.2 General description

The Net Safety Monitoring Inc. SafeGuard 16 channel Controller is designed to display and control alarm event switching for up to sixteen detectors (Flame detectors or transmitters with gas sensor) data points. It may also be set as an eight channel SafeGuard Controller for applications needing fewer inputs. Alarm features such as ON and OFF delays, Alarm Acknowledge, and a dedicated horn relay make the SafeGuard Controller well suited for many multi-point monitoring applications. Data may be input to the SafeGuard Controller by optional analog inputs or the standard Modbus® RTU master RS-485 port. A Modbus RTU slave RS485 port is also standard for sending data to PC’s, PLC’s, DCS’s, or even other SafeGuard Controllers. Options such as analog I/O and discrete relays for each alarm are easily added to the addressable I and therefore require 2 boards for 16 channel applications.

C bus. Option boards have 8 channels

A 240 x 128 pixel graphic LCD readout displays monitored data as bar graphs, trends and engineering units. System configuration is through user friendly menus and all configuration data is retained in non-volatile memory during power interruptions. The SafeGuard Controller’s front panel is shown below in Figure 1.0 displaying the 8 channel bar graph screen. Additional data screens are shown in Figure 2.0.

MAN-0115 Rev A

ALARM RESET

Figure 1.0

1.3 Data display screens

The SafeGuard Controller offers 3 distinct graphic displays for depicting the monitored data. These are Bar Graphs, 24 Hour Trend and Combination. Each is shown in Figure 2.0.

1.3.1 Trend screen

The SafeGuard Controller’s Trend screen shown in Figure 2.0 displays a 24 hour trend of input data for the channel selected. Horizontal tic marks are each hour and vertical tic marks are each 10% of full scale. Dashed lines indicate alarm levels. The graphic LCD is 240 pixels wide so each pixel represents 1/10 hour, or 6 minutes worth of data. The trend is 100 pixels high so each represents 1% of full scale in amplitude. Since each data point must be collected for 6 minutes before it may be displayed, it is likely input values will fluctuate during this interval. Therefore, MAX, MIN and AVERAGE values are stored in RAM memory for each 6 minute subinterval. To accurately portray the trend, a vertical line is drawn between MIN & MAX values for each 6 minute subinterval. The AVERAGE value pixel is then left blank, leaving a gap in the vertical line. This is demonstrated in the noisy area of the 24 hour trend in Figure 2.0. If the MAX & MIN values are within 2% of each other there is no need for the vertical line and only the AVERAGE value pixel is darkened as in the quiet areas.

The top portion of each trend screen indicates channel #, real time reading in engrg. units, measurement name, range, and MIN, MAX & AVERAGE values for the preceding 24 hour period. The SI field on the top right indicates number of seconds remaining in the current 6 minute subinterval.

MAN-0115 Rev A 4

1.3.2 Bar Graphs screen

When wiring transmitters (detectors) to the SafeGuard Controller refer to 3.1.1 Optional Analog Input PCB # SG10-0158 and Figure 3.3.

The SafeGuard Controller’s Bar Graphs screen shown in Figure 2.0 allows all active channels to be viewed simultaneously. Both engineering units values and bar graph values are indicated in real time. Lines across the bars indicate the alarm trip points making it easy to identify channels at or near alarm. A feature in the Systems menu tree allows new alarms to always force the LCD to the bar graphs screen. This is useful for applications requiring channels with alarms to be displayed.

1.3.3 Combination screen

The SafeGuard Controller’s Combination screen shown in Figure 2.0 offers a view of a single channel but displays the data as a 30 minute trend, bar graph and large engineering units. It is also useful for testing inputs for stability since MAX, MIN & AVERAGE values refresh each time this screen is selected. For example, to test stability over a one hour period for an input, begin timing as soon as the channel is selected. One hour later record the MAX, MIN & AVERAGE values. The difference between MAX & MIN indicates peak to peak excursions over the one hour period and AVERAGE is the average for the hour. Longer or shorter tests may also be run. The numeric value shown below the bar-graph indicates number of minutes samples have been taken. After 999 minutes the AVERAGE buffer overflows and the error message UPDATE appears in the AVERAGE field. Exiting this screen resets the buffer and clears the error message.

1.4 Specifications

1.4.1 DC power supply requirements

Standard SafeGuard Controller power requirements are 10-30VDC @ 3 watts applied to terminals 9 & 11 of TB2 on the standard I/O PCB (see section 3.0). Optional features increase power consumption as described below:

• Discrete Relay PCB option; add 2 watts per PCB (assumes all 8 relays are

energized).

• Analog Input PCB option; add 1/2 watt.

• 4-20mA Output PCB option; add 1 watt.

• TB2 terminals 10 & 12 of the standard I/O PCB provide a maximum of

500mA fused output power for powering of auxiliary external devices such as relays, lamps or transmitters. Power consumed from these terminals should be considered when calculating system power consumption.

1.4.2 150 watt AC– 24 Vdc power supply

*110-120 VAC @3.2A max

MAN-0115 Rev A

RESISTIVE

IMPORTANT

*220-240VAC @ 1.6A max

* A slide switch on the front of the power supply selects AC input range.

The SG10-0172 150 watt power supply (Figure 3.6) is for powering the SafeGuard Controller and up to 16 detectors. A minimum of 5 watts per channel is available for powering of external transmitters.

1.4.3 Relays

Common relays are standard and menus provide voting logic for ALARM 1, ALARM 2, FAULT and HORN. Discrete relays are optional. Relays are Form C dry contacts and are rated at 5 Amp for 28 VDC and 250 ~VAC

must be installed with inductive loads to prevent RFI noise spikes. Relay wiring should be kept separate from low level signal wiring.

: Appropriate diode (DC loads) or MOV (AC loads) snubber devices

loads.

1.4.4 Ambient temperature range

-25 to +50 degrees C

1.4.5 Humidity range

0 to 90% R. H. Non-Condensing.

1.4.6 Altitude

Recommended up to 2000 meters

1.4.7 Housings

• *General purpose panel mount weighing 7 lbs and including hardware for

19” rack mounting (Figure 6.1).

• *NEMA 4X wall mount in fiberglass enclosure weighing 17 lbs (Figure

6.2).

1.4.8 Non-intrusive magnetic keypad

The SafeGuard Controller’s operator interface includes five front panel touch keys. A magnetic keypad option offers these five keys with adjacent magnetic keys. This option is included as a standard feature. It is useful in applications where it may be inconvenient to open the enclosure’s door to access the touch keypad.

1.4.9 Approvals

CSA C22.2 No 1010.1 and ISA S82.02; CSA C22.2 No 152 for combustibles; UL 1604 / C22.2 No 213 (Div 2 Groups A,B,C,D); EN55011 & EN61000 (CE Mark). CSA File # = 219995 and may be seen at: CSA-International.org.

MAN-0115 Rev A 6

Section 2: Operation

UP/DOWN

EDIT

UP/DOWN

EDIT

NEXT,

EDIT

UP/DOWN

EDIT

2.1 Basic operation

The SafeGuard Controller offers 3 graphic screens for viewing monitored data and a Set-Up menu screen for operator interface to configuration menus. They are shown below in Figure 2.0. The Bar Graphs screen allows viewing of all active channels simultaneously. The Trend screen displays a 24 hour trend one channel at a time. The Combination screen displays a bar graph, large engineering units and a 30 minute trend one channel at a time. Input channels may be displayed in sequence with the data screens. When SafeGuard power is applied, the graphic LCD returns to the screen active when power was last removed.

keys. The

key switches between the 3 graphic

Setup menus are entered by pressing the desired menu using the selected menu’s tree of variables. This Setup mode may be exited manually by pressing relays and front panel alarm LED indicators remain active during the Setup mode. An AUTHORIZE menu offers a password feature to prevent tampering with the SafeGuard Controller’s parameters.

or automatically when no keys are pressed for 5 minutes. Alarm

from any data screen, and scrolling to

keys. Pressing

again enters the

Figure 2.0

2.2 Setup menu configuration

Variables inside system and channel menu trees allow optimum SafeGuard Controller configuration for a wide range of demanding multi-point monitoring applications. Access to menus is via the Setup mode by pressing activating the Setup screen shown in Figure 2.0. Menu trees are provided for each of the 16 channels and another for system variables. Select the desired menu by scrolling with

and

to enter the menus.

and

MAN-0115 Rev A

UP/DOWN

YES/NO

ON/OFF

EDIT

UP/DOWN

EDIT

2.2.1 Changing menu variables using the key pad

Upon entering a menu, a pointer controlled by the selected variable. Some are simple the ASCII character possibilities. Allowed ASCII characters are as follows: ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz blank space !"#$%&`()*+,-./0123456789:;<=>?@.

the next position within a field. When the field is complete, and loads it into non-volatile memory where it is retained indefinitely. With no cursor present, the most recent data display.

key. Others, such as Measurement Name and Eunits fields may have many

scrolls through each allowed entry. The

closes open menus in reverse order and returns the LCD to

places a cursor over the item and

keys indicates the

entries toggled by pressing

key moves the cursor to

clears the cursor

2.3 Channel configuration menus

Figure 2.1 illustrates the menu tree for configuring Channel variables. These items affect only the specific channel selected. System specific variables are in the menu tree shown in section 2.3.

MAN-0115 Rev A 8

Figure 2.1

2.3.1 Channel setup entry menu

The entry menu shown on the left side of Figure 2.1 allows access to all

configuration variables for the selected channel. These are Alarm 1, Alarm 2, Ala r m 3, Data From? Linearize, Configure and Calibrate.

MAN-0115 Rev A

Setpoint

Latching YES

Alarm Reset

YES

TRIP ON

HIGH

LOW

ON DELAY / OFF DELAY

OFF

Note:

ON DELAY

OFF

Alarm Reset

2.3.2 Alarm 1 / Alarm 2 / Horn Relay Setup menu

Alarms 1 and 2 are identical except A1 may not be acknowledged and front panel LED indicators are yellow while A2’s are red. Since their configuration menus are the same only one is shown in Figure 2.2 for clarity.

Figure 2.2

The first entry determines the engineering units. For example, if a channel monitors 0-50 ppmH2S and the alarm must trip at 10 ppm, the correct entry is 10.00.

•

• The

even though an alarm condition no longer exists. alarm group’s common relay, front panel LED, and optional discrete relay to latch. soon as the alarm condition clears.

to determine if the alarm activates upon exceeding or falling below the setpoint.

affecting how long the setpoint must be surpassed before an alarm event transition occurs. may be as long as 120 minutes. Delays are useful in many applications to prevent nuisance alarms and unwanted cycling into and out of alarm conditions.

For

determines either manual or automatic alarm reset operation.

requires a manual

allows all outputs for this alarm to automatically reset as

is set to

the alarm is activated after the ‘set time’ is reached. For

for increasing alarms or

delays are limited to 10 seconds while

value where the alarm trips. It is entered in

(see Figure 1) to unlatch the alarm

entries allow ON and

also causes this

for decreasing alarms

time delays

delays

DELAY the alarm remains activated for the duration of the ‘set

time’, after the alarm condition has passed.

• The HORN ON entry allows linking this alarm to the common horn relay. NO causes the alarm to have no effect upon the horn relay. Entering YES

causes this alarm to turn the horn relay on steady, or, to pulse it depending upon horn configuration in the system menu (see section

2.3.3).

Discrete LED indicators on the front panel indicate the status of each alarm and relay. Any new alarm event causes the associated LED to flash until

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