Net Safety™ Millennium
Toxic Gas Detector
User Manual
Models:
MLP-A/AR/AD-ST1XXX
Number: MAN-0043 Rev 16
February 2016
MLP-LP-A/AR/ARS-ST1XXX
IMPORTANT INFORMATION
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.
Warranty
1. Limited Warranty. Subject to the limitations contained in
Section 10 (Limitation of Remedy 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 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
(Resale Products) shall carry only the warranty extended by the
original manufacturer. 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 repa irs neces si ta ted 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.
2. Limitation of Remedy and Liability. SELLER SHALL NOT
BE LIABLE FOR DAMAGES CAUSED BY 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. If you have any
comments please contact us by phone, at the address below or visit
our web site EmersonProcess.com/FlameGasDetection
.
Contact Information
Emerson Process Managem ent
6021 Innovation Blvd.
Shakopee, MN 55379
T +1 866 347 3427
F +1 952 949 7001
Safety.CSC@Emerson.com
MAN-0043 Rev 16 MLP-A/AR/AD-ST1XXX & MLP- LP-A/AR/ARS-ST1XXX 3
Table of Contents
Introduction ........................................................................................ 6
The Product ........................................................................................ 6
The Controller (Transmitter) ...................................................... 6
The Manual ................................................................................ 6
SECTION 1: PLAN .......................................................................... 7
1.1 LOCATE CONTROLLER / SENSOR .................................... 7
SECTION 2: Install ............................................................................ 9
Unpack ........................................................................................... 9
SECTION 3: Wire ........................................................................... 10
Field Installation .......................................................................... 10
Seal ............................................................................................... 10
Connecting Wires ..................................................................... 11
Board Assembly ....................................................................... 11
Sensor and Controller .................................................................. 12
Relay Board ............................................................................. 13
RS-485 Communication ........................................................... 13
Sensor Separation......................................................................... 13
CURRENT OUTPUT .................................................................. 13
NON-ISOLATED AND ISOLATED POWER
CONFIGURATIONS .................................................................. 14
Remote Reset ............................................................................... 14
Modbus Termination .................................................................... 14
SECTION 4: OPERATE .................................................................. 15
Calibration Button .................................................................... 17
Magnetic Reed Switch ............................................................. 17
Power Up.................................................................................. 17
Current Loop Measurement (Test Jacks) ................................. 17
Status LED ............................................................................... 17
The Main Menu ............................................................................ 18
Main Menu Functionality ......................................................... 18
SECTION 5: Calibrate ..................................................................... 18
Calibration Procedure .................................................................. 18
Biased Sensor - Ammonia ............................................................ 19
Steps in Calibration Procedure ..................................................... 20
Remote Calibration ...................................................................... 20
Abort Calibration ..................................................................... 21
Calibration Failure ................................................................... 21
SECTION 6: Monitor....................................................................... 21
Review Relay Settings ................................................................. 21
Set Relay Option .......................................................................... 22
Steps in setting relay options ....................................................... 22
Modbus Options ........................................................................... 22
Node Address ........................................................................... 22
Baud Rate ................................................................................. 23
MAN-0043 Rev 16 MLP-A/AR/AD-ST1XXX & MLP- LP-A/AR/ARS-ST1XXX 4
Set-Up response to extreme Over-range Gas Signal .................... 23
Exposure to an extremely high over-range level of gas ........... 23
To configure the controller. ..................................................... 23
Enter Restricted Menu ................................................................. 24
Set Low Power Options - Optional .............................................. 24
Select Display Language .............................................................. 24
Alarms .......................................................................................... 25
Sensor Fault ............................................................................. 25
Sensor Drift .............................................................................. 25
Gas Present................................................................................... 25
Sensor Life ............................................................................... 25
Reset ............................................................................................. 25
Manual Reset ........................................................................... 25
Remote Reset ........................................................................... 25
Outputs ......................................................................................... 25
How to Return Equipment ............................................................... 28
Spare Parts/Accessories ............................................................... 28
FACE ROTATION OPTION ...................................................... 31
Rotate PCB Assembly .............................................................. 31
Appendix A: .................................................................................. 32
Electrostatic Sensitive Device (ESD)............................................... 32
Appendix B: Resistance Table ......................................................... 33
Appendix B: Resistance Table (cont’d ) ........................................... 34
Appendix C: Sensor Specifications .................................................. 35
Controller Specifications .................................................................. 36
Relays (Optional) ..................................................................... 25
Modbus .................................................................................... 26
Current ..................................................................................... 26
SECTION 7: Maintain ..................................................................... 26
Periodic Response Check ............................................................. 26
Troubleshoot ................................................................................ 26
Table 6: Troubleshooting guide ............................................... 27
MAN-0043 Rev 16 MLP-A/AR/AD-ST1XXX & MLP- LP-A/AR/ARS-ST1XXX 5
Introduction
The Millennium series is a part of Net Safety’s 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 electrochemical toxic gas sensor is a tested and proven design
which ensures accurate and reliable response to tox ic gases. T he
sensor will operate in the most severe environments whilst ensuring
that detection of dangerous and toxic gases is being consistently
done.
The Controller (Transmitter)
The Millennium Controller has an explosion-proof Housing, rated
Class 1, Division 1, Groups B, C, and D for hazardous appl ications.
It was designed for either a one-man, intrusive calibration or twoman non-intrusive calibration. The Controller has convenient user
interface functionality to make installation, operation and
maintenance easy.
SECTION 1 PLAN
SECTION 2 INSTALL
SECTION 3 WIRE
SECTION 4 OPERATE
SECTION 5 CALIBRATE
SECTION 6 MONITOR
SECTION 7 MAINTAIN
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.
MAN-0043 Rev 16 MLP-A/AR/AD-ST1XXX & MLP- LP-A/AR/ARS-ST1XXX 6
CCS-1
SECTION 1: PLAN
1.1 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 determining the quantity and location of a sensor or
controller, the following points should be considered when planning
the installati on .
• 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 the air movement patterns within the facility.
• Consider the construction of the facility (suc h as trench es
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 the regulatory publications
that discuss guidelines for your industry. The two most
common installations options are as follows.
Option 1
Locate the sensor separate from the controller using a Certified
Junction Box. If the Net Safety Multi-purpose Junction Box is
being used, refer to MAN-0081 for terminal designations.
The controller is located near eye- level. Conduit is run from the
controller to the sensor. A Calibration Cup (CCS-1) can be attached
to the sensor. Tubing can be run from the CCS-1 to a convenient
location accessible for calibration g as to be injected.
Option 2
The sensor is attached directly to the controller. See “Wiring –
Controller and Sensor” for details. The CCS-1 and tubing is used to
facilitate ca lib ration.
TIP: The Calibration Cup (CCS-1) allows for tubing to be affixed to
a sensor mounted in remote locations. The tubing s 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 mounted low to the ground.
Figure 1: Locate Sensor/Controller - Separated
MAN-0043 Rev 16 MLP-A/AR/AD-ST1XXX & MLP- LP-A/AR/ARS-ST1XXX 7
Controller with sensor
Multi-purpose Junction box with sensor
Figure 2 below shows the Controller with sensor and the Multipurpose Junction box with sensor.
Figure 2: Dimensional Drawing
MAN-0043 Rev 16 MLP-A/AR/AD-ST1XXX & MLP- LP-A/AR/ARS-ST1XXX 8
Controller Faceplate
Controller Base Housing
Sensor Housing
Ribbon connecting
Controller Housing
SECTION 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
Note: ST1XXX series sensors are shipped in a white plastic container inside the packaging. Remove sensor from container then carefully fit
sensor inside Sensor Housing prior to operation.
MAN-0043 Rev 16 MLP-A/AR/AD-ST1XXX & MLP- LP-A/AR/ARS-ST1XXX 9
cover
faceplate to controller
If necessary use the Face Rotation Option to mount the
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.
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.
Millennium Controller at a different orientation. Refer to “Face
Rotation Option” for detailed instructions.
SECTION 3: Wire
Field Installa t ion
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. See some wiring considerations below.
• If the 4
the 4
• 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.
–20 mA signal is not used, connect a jumper between
–20 mA terminal and the Common terminal.
• The maximum distance between sensor and controller is
limited by the resistance of the connecting wiring, which is a
function of the gauge wire being used. See Append ix B.
• When developing a RS-485 chain of devices, the last device
in the chain requires end of line termination.
• RS-485 connection 2-wire, m u ltipo in t s er ial line.
Seal
The use of seals is recommended to further protect the sy stem
against any unwanted water ingression, and equipment should be
installed according to applicable local electrical codes. Seals are
especially recommended for installations that use high-pressure or
steam cleaning devices in proximity to the transmitter and/or sensor.
• 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 ensure 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.
MAN-0043 Rev 16 MLP-A/AR/AD-ST1XXX & MLP- LP-A/AR/ARS-ST1XXX 10
Solid State Relay Board
Fault
+
-
Low
+
-
High
+
-
Electromechanical Relay Boar d
FNO
Normally open
FCOM
Common
FNC
Normally closed
LNO
Normally open
LCOM
Common
LNC
Normally closed
HNO
Normally open
HCOM
Common
HNC
Normally closed
Modbus
A B COM
-
Terminal Board
Option Board
Sensor Board
Figure 5: Millennium Module Boards
• 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'.
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.
Figure 4: Securing wires
Note: Boards are susceptible to ESD. Refer to Appendix A:
Electrostatic Sensitive Device (ESD)
Fault
Board Assembly
There are three diffe ren t user- allowed removable boards; relay
board (Solid State or Electromechanical), Option board and Modbus
board. These Boards are field replaceable. Simply loosen the locking
standoffs, remove one board, insert the other board and tighten
screws. Depending upon requirements, either an Electromechanical
or Solid State Relay Board module can be used.
MAN-0043 Rev 16 MLP-A/AR/AD-ST1XXX & MLP- LP-A/AR/ARS-ST1XXX 11
Low
High
Terminals
Sensor Terminals
Sensor
Terminal
Power Terminals
Controller
(Terminal Board)
RST
↔
Remote Reset
+24VDC
↔
Power(+)
COM
↔
Power(-)
4–20
↔
Current loop output
ISO
↔
+24V isolated 4–20
Modbus RTU
RST
Red
Sensor
Power
ST1XXX Sensor
Sensor
wires
Table 2: Controller Terminal connec ti on
Table 1: Sensor Terminal connection
Sensor
Terminal
Sensor and Cont roll e r
Warning Power to the unit must be OFF before wiring.
Also ensure area is de-classified before remov ing housing cover.
Note: The sensor may be factory fitted 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 necess a ry )
and the Power Terminals to power and output signal wires.
3. Turn controller on (put ON/OFF Switch in ‘On’ position).
4. Replace Controller’s Housing cover. Apply power to unit.
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.
Refer to Tables 1and 2 along with Figure 6, for wiring.
Wire
Red ↔ Red(+24V)
Black ↔ BLK(Sig)
Shield ↔ Shld
designations
Figure 6: Wiring - Controller and Sensor
Board
A
B
Com
Terminals to PLC
Board
Power Connections
+24VDC
Com
Terminal
4–20
IS0
Blk
Terminal
Shld
MAN-0043 Rev 16 MLP-A/AR/AD-ST1XXX & MLP- LP-A/AR/ARS-ST1XXX 12
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