Rosemount Manual: Millennium SIR100 IR Combustible Gas Detector | Rosemount Manuals & Guides

MILLENNIUM

Infrared Combustible

Gas Detector

User Manual

Models:

MLP-A-SIR100,

MLP-AD-SIR100
&
(all available options)

MLP-AR-SIR100

Part Number: MAN-0059 Rev 07

July 2008

Net Safety Monitoring Inc

IMPORTANT INFORMATION

This manual is for informational purposes only. Although every effort has been
made to ensure the correctness of the information, technical inaccuracies may
occur and periodic changes may be made without notice. Net Safety Monitoring
Inc., assumes no responsibility for any errors contained within this manual.

If the products or procedures are used for purposes other than as described in the
manual, without receiving prior confirmation of validity or suitability, Net
Safety Monitoring Inc., does not guarantee the results and assumes no
obligation or liability.

No part of this manual may be copied, disseminated or distributed without the
express written consent of Net Safety Monitoring Inc.

Net Safety Monitoring Inc., products are carefully designed and manufactured from
high quality components and can be expected to provide many years of trouble free
service. Each product is thoroughly tested, inspected and calibrated prior to
shipment. Failures can occur which are beyond the control of the manufacturer.
Failures can be minimized by adhering to the operating and maintenance
instructions herein. Where the absolute greatest of reliability is required,
redundancy should be designed into the system.

Warranty

Net Safety Monitoring Inc., warrants its sensors against defective parts and
workmanship for a period of 24 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
Canada
T1Y 7J7
Telephone: [phone] Fax: [phone]
www.net-safety.com
E-mail: [e-mail]

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

External Equipment ............................................................................................... 3

Mount .................................................................................................................... 4

Step 3 — Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Field Installation .............................................................................................. 4

Seal ................................................................................................................... 4

Connecting Wires .................................................................................................. 4

Board Assembly .................................................................................................... 5

Figure 4: Millennium Modular Boards ................................................................... 5

Figure 5: Wiring—Controller and Sensor ............................................................... 6

Sensor and Controller ...................................................................................... 6

Table 1: Controller/Sensor Terminal 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 (400002) 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

Set Relay Options ...........................................................................................14

Table 4: Default Relay Settings .............................................................................14

Setting Relay Options ..........................................................................................15

Select Gas Curve ............................................................................................15

Select Display Language ................................................................................15

Modbus Options .............................................................................................16

Node Address ......................................................................................................16

Baud Rate ............................................................................................................16

Alarms ............................................................................................................16

Sensor Fault .........................................................................................................16

Gas Present ..........................................................................................................16

Sensor Life ...........................................................................................................16

Reset ...............................................................................................................17

Manual Reset .......................................................................................................17

Remote Reset .................................................................................................17

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Outputs ........................................................................................................... 17

Relay .................................................................................................................... 17

Modbus ................................................................................................................ 17

Current ................................................................................................................. 17

Step 7 — Maintain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Periodic Response Check ............................................................................... 18

Troubleshoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

How to Return Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Spare Parts/Accessories ................................................................................. 19

Table 5: Part Numbering ....................................................................................... 19

Face Rotation Option ..................................................................................... 19

Figure 14: Non-standard Orientations ................................................................... 19

Rotate PCB Assembly .........................................................................................19

Appendix A: Electrostatic Sensitive Device (ESD) . . . . . . . . . . . .20

Appendix B: Resistance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Table 6: Wire Resistance In Ohms ........................................................................ 21

Appendix C: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Net Safety Monitoring Inc.

INTRODUCTION

The Millennium series is Net Safety's latest innovation in a line of continuously
evolving industrial gas detectors and sensors. The microcontroller based system
provides fast, accurate and continuous monitoring of gases in extreme
environments.

THE PRODUCT

The Sensor

Step 1 — PLAN

Step 2 — INSTALL

Step 3 — WIRE

The SIR100 digital infrared sensor employs a simple and effective optical
design. There are no mirrors to be fogged, fouled, misaligned or cleaned. The
entire optical path is protected from airborne contaminates such as mist, dust
and oil and de-fogging heaters are not required.

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 a 1-man, intrusive calibration or 2-man non-intrusive calibration.

The Controller has convenient user interface functionality to make installation,
operation and maintenance easy.

The Manual

The manual has been designed to make installation of the Millennium product
easy. To ensure proper installation, follow the steps outlined in the following
pages. If you encounter problems during operation, consult the troubleshooting
section or contact your sales representative.

Step 4 — OPERATE

Step 5 — CALIBRATE

Step 6 — MONITOR

Step 7 — MAINTAIN

MLP-A-AR-D-SIR100 1

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STEP 1 — PLAN

LOCATE CONTROLLER/SENSOR

Prior to the installation process, a location plan for placing the Controller and
Sensor should be developed. Although there are no absolute rules for
determining the quantity and location of a sensor or controller, the following
points should be considered when planning the installation.

• Locate the Controller where it will be accessible and visible.

• Carefully locate Sensor in an area where gases may potentially accumulate.

• Use redundant systems to enhance protection and reliability.

• Light gases tend to rise; heavy gases tend to accumulate in low areas.

• Consider air movement patterns within the facility.

• Consider the construction of the facility (such as trenches where heavy gases
may accumulate or peaks where light gases may accumulate).

• 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.

WARNING:

To compensate for distance when remotely calibrating (sensor wired for
separation), decrease the tubing diameter or increase the calibration gas flow
rate between gas canister and sensor. Always confirm calibration by applying
gas at the sensor (not separated).

Figure 1: Locate Sensor/Controller

Conduit to Controller

Controller

Option 1

Sensor is located lower to the ground to detect heavy gases

The Sensor is attached directly to the Controller. A Calibration Cover is slipped
onto the bottom of the Sensor and the calibration gas is attached to the side
calibration fitting.

Side Calibration Fitting

Tubing for Calibration Gas

SIR100

Sensor

See "Wiring—Controller and Sensor" on page 6 for detailed instructions.

Option 2

Calibration Cover

Locate Sensor separate from Controller using a Junction Box.
The Controller is located near eye-level. Conduit is run from the Controller to
the Sensor. A Junction Box is used to connect the conduit from the Controller to
the Sensor. A Calibration Cover is slipped onto the Sensor to concentrate the
gas. Tubing can be run from the side calibration fitting on the Sensor to a

TIP:

The Calibration Cover (CC-SIR100-SEP) prevents air circulation
affecting the Calibration process and concentrates the gas during
calibration.

convenient location accessible for calibration gas to be applied.

See "Sensor Separation" on page 7 for detailed instructions.

MLP-A-AR-D-SIR100 2

Net Safety Monitoring Inc.

Figure 2: Dimensional Drawings

5.31"

(134.9 mm)

Controller and SIR Sensor

4.06”

(103.1 mm)

2.60”

(66.0 mm)

5.60”

(142.2 mm)

4.82”

(122.4 mm)

5.68”

(144.3 mm)

2.89”

(73.4 mm)

13.11”

(333.0 mm)

STEP 2 — INSTALL

UNPACK

Carefully remove all components from the packaging. Check components
against the enclosed packing list and inspect all components for obvious
damage such as broken or loose parts.

If you find any components missing or damaged, notify the representative or
Net Safety Monitoring immediately.

Figure 3: Components

Controller Housing

Millennium Faceplate

Housing Cover

Ribbon connecting
faceplate/controller

SIR100 Sensor

Multi-purpose Junction box
and SIR Sensor

7.46”

(189.4 mm)

12.62”

(320.5 mm)

External Equipment

It is necessary that reliable monitoring and indicating devices or systems be
connected to the detector. These devices must be designed to produce clear
visual and audible danger signals when high signal levels occur.

Note: A Certified Junction Box is used when Sensor and Controller are separated.
Refer to MAN-0081 for terminal designation.

MLP-A-AR-D-SIR100 3

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Mount

The Controller should be mounted near eye-level and be easily accessible for
calibration and maintenance purposes. The Sensor should be placed where gas
is likely to accumulate.

Ensure all devices are securely mounted, taking into consideration all
requirements.

Use the Face Rotation Option to mount the Millennium
Controller at a different orientation (refer to "Face
Rotation Option" on page 20 for detailed instructions).

STEP 3 — WIRE

FIELD INSTALLATION

WARNING: Wiring codes and regulations may vary. Wiring must comply

with applicable regulations relating to the installation of electrical equipment in
a hazardous area and is the responsibility of the installer. 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.

• When developing a RS-485 chain of devices, the last device in the chain
requires end of line termination.

• RS-485 connection 2-wire, multipoint serial line.

SEAL

• Water-proof and explosion-proof conduit seals are recommended to prevent
water accumulation within the enclosure.

• Seals should be located as close to the device as possible and not more than
18 inches (46 cm) away.

• Explosion-proof installations may require an additional seal where conduit
enters a non-hazardous area. Ensure conformity with local wiring codes.

• When pouring a seal, use a fibre dam to assure proper formation of the seal.
Seals should never be poured at temperatures below freezing.

• The jacket and shielding of the cable should be stripped back to permit the
seal to form around the individual wires. This will prevent air, gas and water
leakage through the inside of the shield and into the enclosure.

• It is recommended that explosion-proof drains and conduit breathers be used.
In some applications, alternate changes in temperature and barometric
pressure can cause 'breathing' which allows moist air to enter and circulate
inside the conduit. Joints in the conduit system are seldom tight enough to
prevent this 'breathing'.

Note: Seals are not required for all Class 1 Division 2 locations in Canada.

However, to fully avoid any exposure, the use of seals are still
recommended, especially for installations that use high-pressure or
steam cleaning devices in proximity to the controller and/or sensor.

Connecting Wires

1. Use a small screw driver to gently press down and hold the spring connector

open.

2. Insert appropriate wire into open connector hole.

3. Release screw driver to secure wire.

MLP-A-AR-D-SIR100 4

Net Safety Monitoring Inc.

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 21.

Figure 4: Millennium Modular Boards

Solid State Relay Board/Terminals

Fault

Low

High

+

­+

­+

Option Board

-

Terminal
Board

Electromechancial Relay Board/Terminals

FNO
FCOM common
FNC normally closed
LNO
LCOM common
LNC normally closed
HNO
HCOM common
HNC normally closed

MLP-A-AR-D-SIR100 5

normally open

FAULT

normally open

LOW

normally open

HIGH

Modbus
Ter min als

A
B
COM

-

Sensor
Board