MODELS: R1G, R2G and R4G
UNI-TROLTM GAS CONTROLLER
One, Two and Four-Channel Rack-Mount Controller
ISO
9001
Certified Company
Part Number: MAN-0004 Rev. 1
Copyright © 2002 Net Safety Monitoring Inc.
Printed in Canada
This manual is provided for informational purposes only. Although the information contained in this
manual is believed to be accurate, it could include technical inaccuracies or typographical errors.
Changes are, therefore, periodically made to the information within this document and incorporated
without notice into subsequent revisions of the manual. Net Safety Monitoring Inc. assumes no
responsibility for any errors that may be contained within this manual.
This manual is a guide for the use of a Gas controller and the data and procedures contained within
this document have been verified and are believed to be adequate for the intended use of the
controller. If the controller 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.
Net Safety Monitoring Inc. , warrants its sensors and detectors against defective parts and
workmanship for a period of 24 months from date of purchase and other electronic assemblies for 36
months from date of purchase.
No other warranties or liability, expressed or implied, will be honored by Net Safety Monitoring Inc.
Contact Net Safety Monitoring Inc. or an authorized distributor for details.
Table of Contents
Unit I
GENERAL INFORMATION
DESCRIPTION................................................................ 1
FEATURES .................................................................. 1
SPECIFICATIONS ............................................................. 1
Figure 3 - Controller Face-Plate................................... 2
Figure 1 - Controller Dimensions............................................ 2
BASIC OPERATION ........................................................... 2
FACEPLATE DESCRIPTION .............................................. 2
OUTPUTS ............................................................. 3
Figure 3 - Jumper Selections for an Isolated or Non-isolated Current Output ......... 3
PROGRAMMING OPTIONS ...............................................4
EXTERNAL RESET ..................................................... 5
AUTOMATIC DIAGNOSTICS AND FAULT IDENTIFICATION..................... 5
OPERATING MODES .................................................... 5
Unit II
SYSTEM INSTALLATION
INSTALLATION ...............................................................7
SENSOR LOCATIONS ................................................... 7
GENERAL WIRING REQUIREMENTS....................................... 8
CONTROLLER WIRING .................................................. 8
DIP SWITCH SETTINGS ....................................................... 15
Figure 7a - Relay and Dip Switch Positions ..................................15
ACTIVE CHANNELS .................................................... 15
CALIBRATION GAS CONCENTRATION .................................... 16
POWER-UP TIME DELAY .......................................... 17
ALARM SETTINGS ..................................................... 18
LATCHING/NON-LATCHING SELECTION .................................. 19
ENERGIZED/DE-ENERGIZED SELECTION ................................. 19
RELAY SETTINGS............................................................ 20
Figure 7c - Relay Settings ................................................ 20
INSTALLATION CHECKLIST.................................................... 20
Unit III
SYSTEM OPERATION
MENU AND FUNCTION SELECTION ............................................. 22
START-UP PROCEDURE ...................................................... 23
MAIN MENU SELECTIONS ..................................................... 24
ERROR CHECK MODE (Err Chc) ......................................... 24
SET-POINT DISPLAY MODE (SPd) ........................................ 25
SENSOR CALIBRATION (CAL) ........................................... 26
SENSOR REPLACEMENT MODE (SrP) .................................... 28
SPECIAL FUNCTION MENU SELECTIONS ........................................28
FORCED CURRENT OUTPUTS (FoP) ..................................... 28
CURRENT CALIBRATION MODE (CuC) .................................... 29
ADDRESS SET MODE (Adr Set) (OPTIONAL) ............................... 29
CHANNEL DISPLAY(Chd) ............................................... 29
BYPASS (bPS) ........................................................ 29
OPERATING MODES ......................................................... 30
RESET MODE ......................................................... 30
FORCED RESET MODE ................................................ 30
NORMAL OPERATING MODE ............................................ 30
FORCED DISPLAY (FdP) ................................................ 31
Unit IV
SYSTEM MAINTENANCE
ROUTINE MAINTENANCE ..................................................... 31
MANUAL CHECK OF OUTPUT DEVICES .................................. 31
SYSTEM CHECK IN NORMAL MODE ..................................... 31
SENSOR REPLACEMENT .............................................. 32
TROUBLESHOOTING ........................................................ 32
Appendix B
Record Of Dip Switch Settings ............................................ 35
Wire Resistance In Ohms................................................ 36
SENSOR REPLACEMENT MODE (SrP) ......................................... 28
SPECIAL FUNCTION MENU SELECTIONS ............................................. 29
FORCED CURRENT OUTPUTS (FoP) ........................................... 29
CURRENT CALIBRATION MODE (CuC) ........................................ 29
ADDRESS SET MODE (Adr Set) (OPTIONAL) .................................... 29
CHANNEL DISPLAY (Chd) ................................................... 29
BYPASS (Bps) .............................................................. 30
OPERATING MODES ............................................................... 30
RESET MODE .............................................................. 30
FORCED RESET MODE ...................................................... 31
NORMAL OPERATING MODE ................................................ 31
FORCED DISPLAY (FdP) ..................................................... 31
UNIT IV - SYSTEM MAINTENANCE
ROUTINE MAINTENANCE .......................................................... 32
MANUAL CHECK OF OUTPUT DEVICES ....................................... 32
SYSTEM CHECK IN NORMAL MODE .......................................... 32
SENSOR REPLACEMENT .................................................... 32
TROUBLESHOOTING ............................................................... 33
DEVICE REPAIR AND RETURN ...................................................... 33
Table 9 - Troubleshooting Guide ................................................. 34
Appendix A .......................................................................... i
Appendix B ......................................................................... ii
Appendix C ......................................................................... iii
Unit I
GENERAL INFORMATION
DESCRIPTION
The Uni-Trol R1G, R2G and R4G Controllers accept 4-20 mA DC analog input signals from Net Safety
Combustible and toxic gas sensors. Controller response includes actuation of relays for direct control of
field response devices, 4-20mA outputs and a full array of faceplate indicators. The type of controller and
its range can be determined from the model number as shown below:
RXG-100-LEL = 0 to 100% LEL controller
RXG-100-H2S = 0 to 100ppm H
RXG-1000-CO = 0 to 1000ppm CO controller
RXG-20-SO2 = 0 to 20ppm SO
NOTE
The controller displays the gas concentration in parts per million (p.m.) for all types of gases
unless it is a combustible gas controller which shows the gas concentration as % of lower
explosive limit (LEL).
FEATURES
< Controller accepts 4 to 20 mA analog inputs from Net Safety Combustible and toxic gas sensors.
< Two digital displays, one bar graph display, and high intensity LEDs indicate important system
status.
< AutoCal feature provides easy and accurate calibration.
< Microprocessor-based controller is easily field programmable.
< 4-20mA current outputs to send important system information to other devices.
< Relay alarm and fault outputs.
S controller
2
controller
2
SPECIFICATIONS
< Operating Voltage:
24 Volts DC. Device can operate between 18 and 32 Volts DC
< Power Consumption (Controller only):
2.4 Watts nominal, 4.4 Watts maximum (100 mA nominal, 180 mA maximum at 24 Volts
DC)
Maximum start-up current is 1.5 Amperes for 10 milliseconds. Power supplies with
foldback current limiting are not recommended
< Maximum Ripple:
Ripple should not exceed 5 Volts peak-to-peak. The sum of DC plus ripple must be
Volts DC and
< Temperature Range:
Operating: -40ºC to +85ºC (-40ºF to +185ºF)
Storage: -55ºC to +150ºC (-65ºF to +302ºF)
< Relay Contacts:
Normally open/normally closed contacts rated at 5 Amperes at 30 Volts DC/250 Volts
AC
#32 Volts DC
$18
- 1 -
< Current Outputs:
Two 4-20mA DC current, with a maximum external loop resistance of 600
Volts DC
< Dimensions:
Refer to Figure 1
< Shipping Weight (approximate):
2 lbs. (0.9 kilograms).
< Certification:
Designed to meet CSA and FM specifications for ordinary locations.
S at 18-32
Figure 1 - Controller Dimensions
BASIC OPERATION
FACEPLATE DESCRIPTION
The controller faceplate provides LEDs for identifying status conditions, two
digital displays and a bar graph display for indicating the sensor inputs, and
MENU/SET and SELECT/RESET push-buttons for programming, calibrating
and resetting the system. Refer to Figure 2 for the location of indicators and
push-buttons.
< Digital Displays - Two digital displays are used to display the sensor
inputs in both the Normal and Calibrate Modes; one display indicates
the channel and one display indicates the corresponding sensor input.
In the event of a fault, it identifies the nature of the fault using an
alphanumeric code. In the Normal Operating Mode, each channel is
sequentially displayed for 5 seconds. In other operating modes, the
digital displays show the alarm set-points, programmed calibration gas
concentration, or the communication addresses for the Digital
Communication. A negative zero drift condition is indicated by a
minus sign in the left-hand digit. Since at least one display is always
lit, it also functions as a power indicator.
- 2 -
Figure 3 - Controller
Face-Plate
< Bar Graph Display - The common 10-segment bar graph display provides readings of the four
sensor inputs in 5% of full range increments (ie. for a 50ppm controller each segment represents
2.5ppm, which is 5% of the full range of 50ppm), from 0% to 50% of full range; all 10 segments
are illuminated for 50% of full range and higher gas concentrations.
< High Alarm LED (HI) - Flashes in response to a sensor signal that exceeds the high set-point.
< Low Alarm LED (LOW) - Flashes in response to a sensor signal that exceeds the low set-point.
< Calibrate LED (CAL) - is illuminated while the controller is in the Calibrate Mode.
< Fault LED (Fault) - is illuminated upon detection of an overall system fault or a channel related
fault.
< Channel LEDs - are illuminated when status on the corresponding channel is displayed on the
common indicators (digital displays and bar graph). During power-up, a channel LED is on if the
channel is selected for operation.
< MENU/SET Push-Button - is used for changing the menu display as well as other system
programming and calibration functions.
< SELECT/RESET Push-Button - is used for menu selection and other system programming, as
well as for resetting the controller.
OUTPUTS
Relay Outputs:
The relay outputs have SPDT contacts rated at 5 Amperes at 30 Volts DC or 250 Volts AC. The four relays
include an Area 1 low alarm (channels 1 and 2), an Area 2 low alarm (channels 3 and 4), one common high
alarm, and a fault alarm.
RECOMMENDATION
The fault relay output should not be used to activate an automatic shutdown procedure. The fault
output indicates a potential problem with the controller, not an alarm condition.
Current Outputs:
Two 4-20mA DC current outputs for transmitting system information to other devices are also included.
The current outputs can be wired for isolated or non-isolated operation by changing the positions of J12 and
J18, as shown in Figure 3. Refer to Table 1 for a description of the current output signal levels.
- 3 -
Figure 3 - Jumper Selections for an Isolated or Non-isolated
Current Output
Current Output Situation
0mA Open or shorted signal output, or loss of power
1mA Fault or Power up
2mA Power Fault
3mA Sensor Calibration
4mA to 20mA 0 to 100% of full scale
Table 1 - Current Outputs
PROGRAMMING OPTIONS
A set of dip-switches, located on the circuit board, can be used to ‘program’ various options and set-points,
including:
< the channels selected for operation,
< low and high alarm settings,
< calibration gas concentration,
< power-up delay time (either 45 or 90 seconds),
< latching/non-latching selection, and
< energized/de-energized selection
The alarm outputs are programmable for either normally energized or normally de-energized operation
(programmable as a group only, not individually). The fault output is normally energized. The low alarm
outputs are programmable for either latching or non-latching operation. The high alarm output is always
latching and the fault output is non-latching. Refer to Table 2.
OUTPUT
1
LOW
Selectable Normally
Open/Closed
YY2Y
Selectable Normally
Energized/De-Energized
HIGH Y Y
FAULT Y N
Table 2 - Selectable Output Options
1
2
3
4
5
Low alarms are programmed together, not individually
Programmable together, not individually
High alarm relay is always latching
Fault relay is normally energized
Fault relay is non-latching
- 4 -
Selectable Latching/Non-
latching
2
4
3
N
5
N
EXTERNAL RESET
A normally open, momentary closure switch can be connected between the external reset terminal and the
negative power terminal to provide remote reset capabilities.
AUTOMATIC DIAGNOSTICS AND FAULT IDENTIFICATION
The microprocessor-based controller features self-testing circuitry that continuously checks for problems
that could prevent proper system response. When power is applied, the microprocessor automatically tests
memory. In the Normal Operating Mode, it continuously monitors the input signals from the
sensor/transmitter to ensure proper functioning. In addition, a ‘watchdog’ timer is maintained to ensure that
the program is running correctly. The timer resets the micro-controller if it enters erroneous processor
states within a reasonable period of time.
If a fault is detected, the Fault LED illuminates, the digital display identifies that a fault has occurred, the
fault relay output becomes de-energized, and the current output drops to 1 mA. The nature of the fault can
be identified by a numeric code, which can be viewed in the Fault Message Display mode.
OPERATING MODES
The controller can operate in any of the modes discussed in this section. Operating modes other than
Normal are selected by pressing the appropriate MENU/SET and SELECT/RESET buttons located on the
controller front panel. Refer to Figure 2 for a diagram of the controller front panel.
NOTE
This section is intended to acquaint the user with the basic operation of the controller. Refer to
‘Unit III’ for detailed instructions and description.
Normal Operating Mode:
If no alarms or faults are occurring, the module will be in a Level 1 Display Mode; the bar graph and digital
display sequentially indicate the sensor inputs for 5 seconds on each channel, and all the LEDs are off
except the appropriate channel LEDs. Relay outputs are in their normal state, and the current outputs
correspond to the sensor inputs.
If a low alarm condition occurs on any channel, the module will be in a Level 2 Display Mode; the bar
graph and digital display will display only the channel that is in alarm. If more than one channel is in
alarm, the channel with the highest alarm will be displayed and the channel LED for any other channel(s) in
alarm will flash. The low alarm LED will flash, the low alarm relay(s) change state, and the current outputs
change to indicate the alarm. If the signal(s) decreases below the low set-point again, the corresponding
alarm relays return to their normal state if programmed for non-latching operation and remain unchanged if
programmed for latching operation. The current outputs will return to the normal output level. The low
alarm LED will still illuminate whenever the channel which had the alarm condition is displayed.
If a high alarm condition occurs, the module will be in a Level 3 Display Mode; the bar graph and digital
display will cycle through all channels with a high alarm condition. While one channel is displayed, the
channel LED for any other channel in a high or low alarm state will flash.
NOTE
When 1 or more channels are in a high alarm condition and 1 or more channels are in a low
alarm condition, only the channels in the high alarm condition will be cycled on the display. The
channel LED for any channel in the low alarm condition will flash.
- 5 -
Reset Mode:
The Reset Function is entered by pressing the SELECT/RESET button located on the front panel of the
controller. (Refer to Figure 2) When the SELECT/RESET button is activated momentarily, all LEDs turn
off and all outputs return to their normal condition if no alarms or faults are occurring (basic reset).
Forced Reset Mode:
If any of the channels receives a reading beyond 100% of full scale, a reset will not clear the alarms, even if
the channel has returned to levels below the low alarm set point. The error resulting from this occurrence
must be cleared and a forced reset applied. To apply a forced reset, press the SELECT/RESET button for 3
second, the LEDs turn off and the outputs return to their normal condition. The remote reset performs a
forced reset.
NOTE
The remote reset performs a reset function only. It cannot be used for other controller functions.
Forced Display (FdP):
This mode forces a sequential display of all the active channels. It can be used during alarm situations
when the digital and bar graph display normally remain on the
channel with the highest alarm condition. This function is also useful while in menu functions that do not
show the sensor readings.
Sensor Replacement Mode (SrP):
This mode inhibits all controller outputs to allow replacement of the sensor(s) without removing power
from the controller. Alarm set-points and calibration gas concentration are not affected. The upper display
will show ‘SrP’ while in the sensor replace mode. The lower display will show the status of the sensor
being replaced (‘NoS’ means no sensor is connected). The fault LED is on and the fault relay is deenergized. The channel LED will be on for the sensor being replaced.
All other sensors remain active during sensor replace mode. If an alarm condition occurs on one of the
active channels while in this mode, the appropriate channel LED will flash and relays and current outputs
will act accordingly. All other display features will be inhibited. In order to exit this mode the
SELECT/RESET button must be pressed. The controller will perform a power-up countdown (45 or 90
seconds) for the sensor that was replaced and the affected current output will be 1mA during this time.
Sensor Calibration Mode (CAL):
™
The Uni-Trol
Controller uses a fully automatic calibration procedure that requires no adjustments by the
operator. The controller displays ‘Air’ on the upper display and the channel status on the lower display
while automatically performing the zero adjustments. Next the controller will signal the user to apply the
calibration gas by alternating ‘gas’ and ‘in’ on the upper display. When the controller detects that the gas
has been applied to the sensor, the upper display will read ‘gas’. Once the controller has finished the gain
adjustments it will alternate ‘Cut’ and ‘gas’ on the upper display, telling the user that it is time to remove
the calibration gas. Upon completion of the calibration the controller will automatically return to the
normal operating mode.
If the operator fails to complete the calibration procedure, if an error in the calibration procedure occurs, or
if a successful calibration cannot be completed, the microprocessor will automatically return to the Normal
Operating Mode and continue to use the previous calibration data. A fault indication will be displayed until
a reset occurs. If the microprocessor determines that the sensor is approaching the end of its useful life, a
fault code will indicate this.
- 6 -
While in the calibration mode, all controller outputs for the affected channel are inhibited, the current
output is 3mA, and the ‘Cal’ LED is illuminated. All other channels remain active, however if an alarm
condition occurs, the only display indication will be a flashing channel LED, all other display features will
be inhibited.
Set-Point Display (Spd):
In this mode, the digital display sequentially shows the programmed low and high alarm set-points,
calibration gas concentration, and communication addresses. Each value is displayed for approximately 2
seconds.
Address Set (Adr Set):
The communication addresses for Digital Communications are set in this mode, which is found in the main
menu. The MENU/SET and SELECT/RESET buttons are used to raise and lower the address. This mode
can only be exited by allowing ten seconds to go by without pressing either button.
Error Message Display (Err Chc):
The microprocessor-based controller features self-testing circuitry that continuously checks for problems
that could prevent proper system response. As a diagnostic and troubleshooting tool, identifiable faults are
displayed on the digital display, using error codes, during the Error Message Display Mode. The controller
will also display an error message after the last channel in the cycling routine.
Channel Display (Chd):
In this mode, the displays can be forced to monitor only one channel, as long as no alarms are occurring, on
other channels. If an alarm occurs on the channel that is being monitored, the controller will remain in the
manual display mode. If an alarm occurs on any other channel the controller will automatically return to
the Normal Operating Mode.
Unit II
SYSTEM INSTALLATION
INSTALLATION
SENSOR LOCATIONS
Proper location of the sensors is essential for providing maximum protection. The method for deciding the
most effective number and placement of sensors varies depending on the conditions at the job site. The
individual performing the installation must rely on experience, common sense, and knowledge of plant
operations to determine the number of sensors needed and the best controller locations to protect the area
adequately.
The following factors are important and should be considered for every installation:
< Sensors should be located where they are safe from potential sources of contamination
< Refer to sensor application manuals and follow guidelines for sensor installation
< Sensors must be accessible for testing and calibration
< Exposure to excessive heat or vibration can cause premature failure of electronic devices, and
should be avoided if possible
- 7 -
GENERAL WIRING REQUIREMENTS
NOTE
The wiring procedures in this manual are intended to ensure proper functioning of the device
under normal conditions. However, because of the many variations in wiring codes and regulations, total compliance to these ordinances cannot be guaranteed. Be certain that all wiring
complies with applicable regulations that relate to the installation of electrical equipment in a
hazardous area. If in doubt, consult a qualified official before wiring the system.
The use of shielded cable is highly recommended for any signal wires to protect against interference caused
by extraneous electrical 'noise'. This includes power and current outputs; relay outputs do not require
shielded cable. In applications where the wiring cable is installed in conduit, the conduit must not be used
for wiring to other electrical equipment.
Water will damage electronic devices. Moisture in the air can condense within electrical conduit and drain
into the enclosure, therefore, 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. Conform to local wiring codes.
When pouring a seal, use a fibre dam to assure proper formation of the seal. The 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'.
CONTROLLER WIRING
NOTE
The controller contains semiconductor devices that are susceptible to damage by electrostatic
discharge. An electrostatic charge can build up on the skin and discharge when an object is
touched. Therefore, use caution when handling, taking care not to touch the terminals or electronic components. For more information on proper handling, refer to the Appendix.
The Uni-Trol™ controllers can be wired for isolated or non-isolated current outputs by changing the
positions of ‘J12' and ‘J18', as shown in Figure 3. Figures 4a, 5a, and 6a show the terminal proper wiring
of the controller for non-isolated current outputs with 2 and 3 wire sensors. Figures 4b, 5b and 6b show
the proper wiring of the controller for isolated current outputs with 2 and 3 wire sensors.
NOTE
If local wiring codes permit, and if a ground fault monitoring system is not being used, the minus
side of the DC power source can be connected to chassis (earth) ground. Alternatively, a 0.47
microfarad, 100 Volt capacitor can be installed (negative side of power supply terminal 13, to
chases ground, terminal 8).
- 8 -
CUT SHIELD
NON-ISOLATED CURRENT OUTPUT
ALARM RELAY CONTACTS ARE
JUMPER SELECTABLE AS N.O.
OR N.C.
FAULT RELAY COIL IS
NORMALLY ENERGIZED
TO USER EQUIPMENT
SHIELD TO SYSTEM COMMON J17 (18,19)
SENSOR POWER 24Vdc . J17 (20 OR 21)
SENSOR INPUT 1. J17 (9)
SYSTEM COMMON. J17 (18,19)
R1G-XXXX CONTROLLER
J16
1
FAULT RELAY
2
FAULT RELAY
3
HIGH ALARM RELAY
4
HIGH ALARM RELAY
5
AREA 1 LOW ALARM RELAY
6
AREA 1 LOW ALARM RELAY
7
NOT USED
8
NOT USED
J17
1
CAN -
2
CAN +
3
REMOTE RESET
4
NOT USED
5
NOT USED
6
NOT USED
7
NOT USED
8
CHASIS GROUND
9
SENSOR INPUT 1
10
NOT USED
11
NOT USED
12
NOT USED
13
- 24Vdc SYSTEM POWER
14
+ 24Vdc SYSTEM POW ER
15
AREA 1 CURRENT OUTPUT
16
NOT USED
17
EXTERNAL POWER FOR CURRENT OUTPUT
18
SYSTEM COMMON
19
SYSTEM COMMON
20
SENSOR POWER (+24Vdc)
21
SENSOR POWER (+24Vdc)
SENSOR INPUT 1. J17 (9)
SENSOR POWER 24Vdc. J17 (20 OR 21)
SHIELD TO SYSTEM COMMON
J17 (18,19)
24Vdc
-
+
4-20mA LOOP
CUT SHIELD
CONTROLLER
SENSOR
BLK
RED
WHT
BLK
RED
WHT
TRANSMITTER
SC1100 LEL SENSOR
TX-LEL-C-24
OR
Figure 4a - Wiring for R1G with Non-Isolated Current Output
JB AND
TERMINAL
BOARD
SENSOR
BLK
RED
CONTROLLER
BLK
RED
ST1200 H2S SENSOR
OR OTHER 2 WIRE SENSOR
TRANSMITTER
- 9 -
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