Net Safety Monitoring ST3 XChems Operating Manual

Reference Manual

XChem Electrochemical Sensors

Part Number: MAN-0132, rev. 10

Release: April 2016

Important Instructions

Installing, operating or maintaining a Net Safety 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.

Net Safety Monitoring, Inc (Net Safety) 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 the information printed on the
product nameplate and to all instructions provided in this manual prior to installation, operation, and
maintenance.

Notice

The contents of this publication are presented for informational purposes only, and while every effort
has been made to ensure their accuracy, they are not to be construed as warranties or guarantees,
expressed or implied, regarding the products or services described herein or their use or applicability.
All sales are governed by Net Safety’s terms and conditions, which are available upon request. We
reserve the right to modify or improve the designs or specifications of such products at any time.

Net Safety does not assume responsibility for the selection, use or maintenance of any product.
Responsibility for proper selection, use and maintenance of any Net Safety products remains solely with
the purchaser and end user.

To the best of Net Safety’s knowledge the information herein is complete and accurate. Net Safety
makes no warranties, expressed or implied, including implied warranties of merchantability and fitness
for a particular purpose with respect to this manual and, in no event, shall Net Safety be liable for any
incidental, punitive, special or consequential damages including, but not limited to, loss of production,
loss of profits, loss of revenue or use and costs incurred including without limitation for capital, fuel and
power, and claims of third parties.

Product names used herein are for manufacturer or supplier identification only and may be
trademarks/registered trademarks of these companies.

Net Safety and the Net Safety logo are registered trademarks of Net Safety Monitoring, Inc. The
Emerson logo is a trademark and service mark of the Emerson Electric Company.

Copyright © 2016 by Rosemount, Shakopee, MN

All rights reserved. No part of this work may be reproduced or copied in any form or by any means - graphic,
electronic, or mechanical without first receiving written permission of Rosemount, Shakopee, MN

Warranty

Limited Warranty

Resale Products

Limitation of Remedy and Liability

1.

and 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 as per Section
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

7.4. Products purchased by Seller from a third party for resale

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

2.

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

Reference Manual Table of Contents

Table of Contents I

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

Section 2 : Installation ................................................................................................. 2

Section 3 : Operation ................................................................................................. 10

Section 4 : Maintenance ............................................................................................ 13

Section 5 : Electrostatic sensitive device ..................................................................... 17

Section 6 : Wire resistance table ................................................................................ 18

Section 7 : Specifications ........................................................................................... 19

MAN-0132, Revision 10 April 2016

Contents

1.1 Models covered .................................................................................................................. 1

1.2 Service support ................................................................................................................... 1

1.3 Return of material............................................................................................................... 1

1.4 Product recycling/disposal .................................................................................................. 1

2.1 Unpacking and inspection .................................................................................................. 2

2.2 Locate sensor ..................................................................................................................... 2

2.3 Sensor direct mount or sensor separation ........................................................................... 2

2.3.1 Sensor direct mount ............................................................................................. 2

2.3.2 Sensor separation ................................................................................................. 2

2.4 Dimensions ........................................................................................................................ 4

2.5 Mounting ........................................................................................................................... 5

2.6 Wiring ................................................................................................................................ 6

2.6.1 Field installation .................................................................................................... 6

2.6.2 Sensor separation distance ................................................................................... 7

2.6.3 Installation to transmitter or junction box ............................................................. 7

2.6.4 Sensor wiring ........................................................................................................ 7

2.6.5 External ground .................................................................................................... 8

2.7 Calibration .......................................................................................................................... 9

2.8 Installation checklist ........................................................................................................... 9

3.1 Sensor configuration settings ........................................................................................... 10

3.2 Sensor power up ............................................................................................................... 10

3.3 Sensor end of life diagnostic ............................................................................................. 10

3.4 Sensor communication ..................................................................................................... 11

3.5 Net Safety Millennium II Basic transmitter configuration ................................................... 11

3.5.1 Hydrogen sulfide sensor (ST320) ........................................................................ 12

3.5.2 Carbon monoxide sensor (ST360) ....................................................................... 12

3.6 Fault conditions ................................................................................................................ 12

4.1 Cross sensitivities ............................................................................................................. 13

4.1.1 Hydrogen sulfide sensor (ST320) ........................................................................ 13

4.1.2 Carbon monoxide sensor (ST360) ....................................................................... 14

4.2 Bump testing .................................................................................................................... 14

4.3 Sensor replacement procedure ......................................................................................... 14

4.4 Troubleshooting ............................................................................................................... 16

4.5 Storage ............................................................................................................................ 16

4.6 Spare parts and accessories .............................................................................................. 16

7.1 Performance ..................................................................................................................... 19

7.1.1 Response time .................................................................................................... 19

7.1.2 Accuracy ............................................................................................................. 19

7.1.3 Zero Drift ............................................................................................................ 19

Reference Manual

II Table of Contents

Section 8 : Certifications ............................................................................................ 22

Section 9 : Ordering information ................................................................................ 23

April 2016 MAN-0132, Revision 10

7.1.4 Repeatability ...................................................................................................... 19

7.1.5 Detection Range ................................................................................................. 19

7.1.6 Calibration Frequency ......................................................................................... 20

7.1.7 Unpowered storage time .................................................................................... 20

7.2 Environmental .................................................................................................................. 20

7.2.1 Storage temperature .......................................................................................... 20

7.2.2 Operating temperature ...................................................................................... 20

7.2.3 Relative humidity ................................................................................................ 20

7.2.4 Metallurgy (housing) .......................................................................................... 20

7.2.5 Ingress protection ............................................................................................... 20

7.2.6 Weight ............................................................................................................... 20

7.3 Electrical ........................................................................................................................... 21

7.3.1 Voltage ............................................................................................................... 21

7.3.2 Power Consumption ........................................................................................... 21

7.4 Separation ........................................................................................................................ 21

7.5 Warranty .......................................................................................................................... 21

8.1 North America .................................................................................................................. 22

8.2 IECEx ................................................................................................................................ 22

8.3 EMI/EMC ........................................................................................................................... 22

Reference Manual

1

MAN-0132, Revision 10 April 2016

Section 1: Introduction

1.1 Models covered

The Net Safety XChem electrochemical toxic gas sensors are designed specifically for use with the Net
Safety Millennium II Transmitter (models M21, M22, or M2B). This sensor is both versatile and reliable
for fast, accurate, and continuous monitoring of gases in extreme environments.

The sensor assembly consists of a factory sealed explosion proof enclosure (housing) rated for
hazardous locations and a replaceable sensor module. This sensor must only be used with a Net Safety
Millennium II series transmitter. If the sensor is connected to any other model of transmitter, it will not
function and may result in the sensor or transmitter being damaged.

1.2 Service support

Technical support for this product can be provided by contacting your local Emerson Process
Management/Net Safety representative or by contacting the Net Safety Technical Support department
at [phone] or [e-mail]

.

1.3 Return of material

To expedite the repair and return of this product, proper communication between the customer and
the factory is important. Before returning a product for repair, call [phone] or e-mail

[e-mail]

On the return of the equipment, include the following information:

1. RMA number provided to you by Net Safety

2. Company name and contact information

3. Ship all equipment, prepaid to:

Rosemount
6021 Innovation Blvd.
Shakopee, MN 55379

4. Mark all packages with the RMA number and type of return (e.g. return for evaluation).

Pack items to protect them from damage and use anti-static bags or aluminum-backed cardboard as
protection from electrostatic damage.

All equipment must be shipped prepaid. Collect shipments will not be accepted.

for a Return Material Authorization (RMA) number.

1.4 Product recycling/disposal

Recycling of equipment and packaging should be taken into consideration and disposed of in
accordance with local and national legislations/regulations.

Reference Manual

2

April 2016 MAN-0132, Revision 10

Section 2: Installation

2.1 Unpacking and inspection

Carefully remove all of the components from the packaging and verify them against the enclosed
packing list. Inspect all components for any obvious damage such as broken or loose parts. If you find
any components missing or damaged, notify your local Net Safety representative or the factory
immediately.

Recycling of packaging should be taken into consideration and disposed of in accordance with local and
national legislations/regulations.

2.2 Locate sensor

Prior to installing the sensor, a plan should be developed for placement of the sensor. Although there
are no absolute rules for determining the quantity of detectors or location of a sensor, the following
points should be considered when planning the installation.

• Carefully locate the sensor in an area where gases may potentially accumulate, considering that

light gases tend to rise and heavy gases tend to fall and accumulate in low areas.

• Use redundant systems to enhance protection and reliability.

• Consider air movement patterns in the facility.

• Consider the construction of the facility such as trenches where heavy gases or peaks where light

gases may accumulate.

• Seek advice from experts knowledgeable about the gas to be detected.

• Refer to the regulatory publications that discuss guidelines for your industry.

2.3 Sensor direct mount or sensor separation

2.3.1 Sensor direct mount

The sensor can be directly attached to a Net Safety Millennium II transmitter and placed in an
appropriate location for detecting the target gas, or the sensor can be separated and remotely
mounted away from the Net Safety Millennium II transmitter. The sensor should be accessible for
calibration and maintenance purposes. The transmitter should be located where it is accessible and
visible.

2.3.2 Sensor separation

If the sensor is to be remotely mounted from the transmitter, the sensor must be connected to a
certified junction box. In this case, the transmitter is typically located near eye-level for easy access and
the sensor is mounted where the gas is likely to accumulate.

In order to ease the calibration process a calibration cup (CCS-1) can be attached to the bottom of the
sensor housing and calibration tubing run from the calibration cup to a convenient place for applying
the calibration gas, eliminating the need to access the sensor directly. In this case, to compensate for
the effect of distance, consider decreasing the calibration tubing length to some length where the end
of the tubing to the gas canister is still accessible or increase the calibration gas flow rate between the