Rosemount Millennium SIR100 IR Combustible Gas Detector Manuals & Guides

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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: (403) 219-0688 Fax: (403) 219-0694 www.net-safety.com E-mail: netsafe@net-safety.com

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

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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.

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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.

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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.

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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

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Figure 5: Wiring—Controller and Sensor

Terminal Board

RST

+24V

COM

4-20

COM

Modbus RTU Terminals

to PLC

ISO

+Vdc

Sig A

Sig B

COM

Shld

RST +24V COM 4-20 ISO

Wht Blu Red Blk Shld

Power Terminals

Sensor Terminals

SENSOR AND CONTROLLER

WARNING:

Power to the unit must be OFF before wiring.

Note: The Sensor may be factory installed to the Controller. If so, you need

only connect the Power Terminals.

4. Remove the Controller’s Housing Cover.

5. Connect the Sensor to the Sensor Terminals (if necessary) and the Output

Terminals to the output signal wires.

Tab l e 1 : Controller/Sensor Terminal Connections

Sensor Terminals Power Terminals

Sensor Wire

White = +Vdc RST = Remote Reset Blue = Sig A +24V = Power (+) Red = Sig B COM = Power (-) Black = COM (-)

Shield Shld

Controller (Sensor Board)

Controller (Terminal Board)

4-20

ISO

Power Connections

= Current Loop

Output

= +24 V isolated

4-20 power

Note: For Sensor Separation instructions, see Figure 6, "Wiring—Sensor

Sensor Board

Sensor Wires

Green Wire Earth Ground

6. Replace the Controller’s Housing Cover.

7. Turn Controller On.

8. Ensure display reads

Separation", on page 7.

Start Delay, Status LED is Red Slow Flash and

current output displays 3.0 mA. This is the start-up delay sequence which

SIR100 Sensor

will last approximately 90 seconds.

RS-485 Communication

Connect devices in a chain via the Modbus terminals. The last device in the chain requires end of line termination (refer to "MODBUS Termination" on

Note: If the 4-20 mA signal is not used, connect a jumper between the 4-20

terminal and the COM terminal on the Terminal Board.

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page 9).

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SENSOR SEPARATION

Figure 6: Wiring—Sensor Separation

Power

Terminal B oard

Terminals*

Modbus RTU Terminals

to PLC*

Sensor Terminals*

RST

+24V

COM

4-20

ISO

+Vdc

Sig A

Sig B

COM

Shld

Sensor Board

As the Sensor must be located where gas is likely to accumulate and the Controller where it can be easily reached, it is often necessary to “separate” the Controller and Sensor.

The Sensor separation kit (SEP) is composed of a junction box and terminal strip. Refer to the Net Safety Multi-purpose Junction Box(MAN-0081) for terminal designation when wiring for sensor separation.

Shielded copper instrument wire (minimum 18 AWG) should be used for separations up to 500 feet. Shielded copper instrument wire (minimum 16 AWG) should be used for separations up to 2000 feet. Consult the factory if a greater separation distance is required.

To designated terminal board and SIR Sensor. See MAN-0081 Multi-purpose Junction Box.

Shield

Ensure that the appropriate wire is used for Class 1/Division 1 hazardous applications.

Note: If the 4-20 mA signal is not used, connect a jumper between the 4-20

terminal and the COM terminal on the Terminal Board.

WARNING:

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NON-ISOLATED/ISOLATED WIRING

Terminal Connection

Figure 7: Non-isolated Terminal Connection

Termina l B oard Power Terminal

RST

+24V

COM

4-20

ISO

to Monitor

Figure 8: Isolated Terminal Connection

Terminal Board Power Terminal

RST

+24V

COM

4-20

ISO

to Monitor

Power Supply

Current Output

To set an isolated current output, simply move the Jumper (shorting jack) to either the isolated or non-isolated current position (refer to Figure 9, "Jumper Positions", on page 8).

Note: Unless otherwise specified, all models ship with non-Isolated current

output.

Figure 9: Jumper Positions

Termina l B oard

Position 1 & 2 = Isolated

Sensor Board

Jumper—Position Jumper

(shorting jack) over pins to set power source for current output.

Position 3 & 2 =

Non-isolated (default)

SIR100 Sensor RS-485 Terminator—Jumper must remain installed over pins 1 & 2.

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REMOTE RESET

The Millennium can be set for remote reset. A normally open Push Button Switch must be connected between the RST and the COM terminals on the Terminal Board and the Relay Option Latch Status must be set to

Latching.

Figure 10: Remote Reset

RST

Termina l B oard

Power Terminal Strip

+24V

COM

4-20

ISO

MODBUS TERMINATION

Devices are networked in a daisy chain. The device located at the end of the chain requires end of line termination. Place both jumpers over the pins, as shown in Figure 11, "Modbus Termination Jumpers", on page 9, for end of line termination.

Figure 11: Modbus Termination Jumpers

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STEP 4 — OPERATE

The Controller faceplate contains most functional elements of the user interface. Below is a description of that functionality.

Figure 12: Controller Functionality

Scrolling 8-character display -

Magnetic Reed Switch - provides non-intrusive access for

programming, calibrating and resetting.

-Place magnet against Housing (where indicated) for less than one second to initiate a basic system reset (clear a latched alarm) and make selections.

-Place magnet against Housing (where indicated) and hold to program, view current settings and calibrate.

Refer to "Magnetic Reed Switch" on page 12 for further information.

ON/OFF Switch - used to turn Controller on and off. Housing must be removed to access.

Pull Here knob - unscrew the two screws and pull to remove faceplate. Removal allows access to PCBs. The faceplate remains attached by the ribbon cable.

Current Test Jacks - to take current loop measurements use the following procedure:

-Insert your current meter leads into the Test Jacks.

-Set external devices to bypass, if necessary, to avoid unwanted alarm response

-Review current loop measurements.

Refer to "Current Loop Measurement (Test Jacks)" on page 12 and Table 2, "Status LEDs, Display Messages and Current Loop", on page 11.

provides various status messages and prompts. Refer to "Status LEDs, Display Messages and Current Loop" on page 11.

Power

Calibration/Setup

Pull Here

-Hold Cal/Reset or magnet until countdown is zero (~10 sec)

-Follow instruction on display

Current O/P Check

Connect current probes

to meter jacks and

read mA output

Off

Status

Red

Slow Flash: Gas present Flast flash : Cal or Fault Solid: Overrange

Green

Short Blips: Normal operation. No gas present

Here

Pull Here knob - unscrew the two screws and gently pull to remove faceplate. Removal allows access to terminal boards. The faceplate remains attached by the ribbon cable.

Pull

Status Light (Red and Green) - indicates status of unit. Refer to "Status LEDs, Display Messages and Current Loop" on page 11 for detailed explanation of states/ status.

Calibration Button - provides intrusive access for programming, calibrating and resetting.

-Push for less than one second to initiate a basic system reset (clear a latched gas alarm) and make selections.

-Push and hold to program, view current settings and calibrate.

Refer to "Calibration Button" on page 12 for further information.

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Tab l e 2 : Status LEDs, Display Messages and Current Loop

Status LED

State Current O/P

RED or

GREEN

Calibrate Sensor Set Relay Options

3.0 mA n/a n/a

Review Settings

Normal operation 4.0 mA

Start-up delay (90 sec) 3.0 mA

Slow flash

Blip/ blink

Access Main Menu 3.0 mA Solid

Memory Error (contact factory)

White, Blue, Red or Black Sensor lead open

2.5 mA

Slow flash

Auto zero set 3.0 mA Solid

Apply calibration gas 3.3 mA

Fast flash

Span is set, remove gas 3.6 mA Solid

Return to normal operation

3.6 mA Solid

Display

00 %LEL

Start Delay

Switch On 10-0

Memory Error

Sensor Fault

Setting zero

Apply 50% Span

Remove gas

Cal. Complete

Gas present >4.0-20.0 mA

Calibration procedure failed/Sensor failed

3.0 / 3.3 mA Flash Flash

Blip/ blink

1 to 100% full Scale

Fail Cal

RTU Registers

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Tab l e 3 : RTU Status Register (40002) Read Only (binary)

RTUstat_fault 0x0001 fault (sensor...)

RTUstat_low_alarm 0x0002 low alarm tripped

RTUstat_high_alarm 0x0004 high alarm tripped

RTUstat_low_alarm_latched 0x0008 low alarm latched

RTUstat_high_alarm_latched 0x0010 high alarm latched

RTUstat_powerUp 0x0080 power up delay

RTUstat_cal_cycle 0x0100 calibration cycle in progress

Magnetic Reed Switch

The Magnetic Reed Switch is provided to avoid opening the Housing in an environment where gas may be present. The Magnetic Reed Switch functions in the same manner as the Calibration Button but in a non-intrusive manner. Refer to Figure 12, "Controller Functionality", on page 10 for more information.

Attached to the side of the Controller is a magnet:

• Place and hold the magnet to the Controller’s Housing (10 o’clock position) to Calibrate and access Main Menu.

• Briefly place the magnet to the Controller’s Housing (10 o’clock position) to make a selection (select

YES?).

RTUstat_zeroing 0x0200

RTUstat_apply_span_gas 0x0400

RTUstat_calibrating 0x0800

RTUstat_remove_gas 0x1000

RTUstat_cal_complete 0x2000

RTUstat_mem_error 0x4000 memory error

Calibration Button

The Calibration Button provides access to the Millennium’s Main Menu, which in turn allows calibration and options to be reviewed and set. Refer to Figure 12, "Controller Functionality", on page 10 for more information.

• Press and hold the Calibration Button to Calibrate and access Main Menu.

• Briefly press to make a selection (select

WARNING:

Opening the Controller’s Housing should be avoided when the presence of gas is possible (when in a hazardous environment). Do not power up the system, with the Housing removed, unless the area has been de-classified.

YES?).

Power Up

Turn power switch On. A 90 second warm-up routine will begin. The display

Start Delay Millennium Net Safety, Status LED is Red Slow Flash

reads and current output displays 3.0 mA.

When power is applied, the system is automatically tested to ensure proper functionality.

After warm-up, the Controller will enter normal operation, the display reads

, Status LED will Green Blip/blink and analog output will change to 4.0

%LEL

mA.

Current Loop Measurement (Test Jacks)

Use a standard meter to measure current loop during various states. The Controller’s Housing cover must be removed to access the Test Jacks.

Refer to Table 2, “Status LEDs, Display Messages and Current Loop,” on page 11 for a detailed list and Figure 12, "Controller Functionality", on page 10 for more information.

Status LED

The Status LED will remain solid, flash, blip and/or blink, in either Red or Green, to indicate various states. Refer to Table 2, “Status LEDs, Display Messages and Current Loop,” on page 11 for a detailed list.

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THE MAIN MENU

The Main Menu provides access to various functional settings and viewing of current settings.

• Calibrate Sensor.

• Review Relay Settings (optional) - Review the current Fault, Low and High alarm settings. This is a read only section.

• Set Relay Options (optional) - Set the Low and High alarm settings.

• Select Gas Curve (methane or propane).

• Select a display language - English, Spanish or French.

• Select Modbus Options.

Note: The current output will drop to 3.0 mA while in the Main Menu.

Accessing the Main Menu

There are two ways to access the Main Menu:

• Calibration Button found on the faceplate (the Housing cover must be removed to access)

• Magnetic Reed Switch (a magnet must be used to activate)

Main Menu Functionality

1. Ensure that the Controller has been turned on and no fault is present.

2. Hold the magnet against the Reed Switch or press and hold the Calibration Button until the message

3. An option will scroll across the display followed by the prompt

YES?.

4. To select an option, momentarily place the magnet to the Reed Switch or press the Calibration Button at the

5. If you do not wish to select that option wait until the next option appears and then select

6. A selection is acknowledged with a flashing

7. If no option is selected, the Controller returns to

YES.

00 %LEL (normal operation).

YES?.

Switch On displays and the countdown (10 to 0) finishes.

YES? prompt.

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STEP 5 — CALIBRATE

CALIBRATION PROCEDURE

WARNING: The calibration procedure requires about 5 minutes to

complete. If gas is not applied at the appropriate time, a calibration failure may occur (refer to "Calibration Failure" on page 14 for specific information).

For accurate performance, the Millennium should be calibrated using 50% span of the specific gas of concern. The concentration of gas, corresponding to 100% of full scale, is converted to a linear 4 to 20 mA output signal which can be powered from the primary dc supply of the instrument. Power up the unit for at least 4 hours BEFORE first calibration.

Note: Air movement, drafts and wind can cause dilution of calibration gas

flow which can cause an erroneous calibration and inaccurate performance. To avoid this, use a Calibration Cover to cover the slots on the Sensor. The cover MUST be removed for normal operation. When slots are covered, inject calibration gas at a rate of 1.0 litre per minute or greater; when not covered, ensure area is free of drafts/wind and inject calibration gas at a rate of

3.0 litres per minute or greater. The following calibration procedure should be followed to ensure an accurate correlation between the 4 to 20 mA output signal and the gas concentration.

Figure 13: Calibration Procedure

Display Shows

Calibrate Sensor YES?

Setting Zero

Apply 50% Span

Calibration Procedure

The unit can be set up to detect Methane or Propane. To determine the gas to be detected go to “Select Gas Curve” option in the menu and make the selection, then calibrate with the target gas. See “Select Gas Curve” option on page 16.

1. Confirm successful power up of Controller—LED Green Blip/blink every 2

seconds; no fault indicated.

2. Flow certified ZERO AIR at a rate of 1.0 litre per minute to the calibration nipple/fitting, when using the Calibration Cover. If separated or not using the Calibration Cover, a rate of at least 3.0 litres per minute is

3. Press and hold the Calibration Button or use the Reed Switch to access the Main Menu and wait for countdown (10-0) to complete.

4. When

Calibrate Sensor YES? displays, use the Calibration Button or

Reed Switch to select

YES?

Selection will be confirmed by a flashing YES.

5. When

6. Wait for

Setting Zero displays apply clean air.

Apply 50% LEL to display and apply specific gas. If in windy

conditions and using a Calibration Cover, apply at a rate of 1.0 litre per minute otherwise 3.0 litres per minute is recommended.

7. The display will show

8. Remove span gas when the message (Status LED

9. The message

Green solid and 3.6 mA output).

Cal Complete will display when calibration is complete.

Calibrating as gas detected.

“Remove Gas”

10. Apply zero gas (clean air) again to purge system.

Note: Always apply test gas after calibration to verify operation.

Calibrating

Remove Gas

Cal Complete

recommended.

displays

Action

Select YES?

Apply clean (zero air)

Calibration Failure

If the calibration procedure fails, the display shows

Fail Cal, the Status LED

alternates Red/Green flashes and the analog output changes back and forth from

3.0 to 3.3 mA.

The unit remains in a failed state until manually reset. After the Manual Reset, the unit will return to normal operation based on previous calibration values. See "Manual Reset" on page 18 for instructions.

MLP-A-AR-D-SIR100 14

Apply specific gas

STEP 6 — MONITOR

REVIEW RELAY SETTINGS

This is a read-only mode; changes cannot be made.

Step 1: Press and hold the Calibration Button or the magnet to the Reed

Switch to enter the Main Menu; wait for the countdown, from 10 to

Remove gas

Apply clean air to purge system

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0, to end.

Step 2: When

Review Relay Settings displays press the Calibration

Button or use the Reed Switch to select. The flashing

Step 3: The Fault Alarms are fixed (

YES confirms the selection.

Energized / Non-Latching) and

display first. Then the Low Alarm level, coil and latch status display, followed by the High Alarm level, coil and latch status.

Step 4: At this point, the option to

Set Relay Options YES? is displayed.

SET RELAY OPTIONS

Use to set the alarm level, coil status and latch status for the Low and High relays (Fault Alarm is fixed).

Tab l e 4 : Default Relay Settings

Alarm Levels Coil Status

Millennium

Model Number

MLP-A/AR/AD 20% 40%

Low High Fault

Energ./Nonlatching

Latching

Non Latching

Energized

De-energized

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Net Safety Monitoring Inc

Setting Relay Options

There are two settings for Relay Options: Low and High. The Fault Relay is fixed as Energized/Non-latching and cannot be changed. The low alarm level, coil energization and latch status for low alarm are set first; high alarm level, coil energization and latch status for high alarm are then set. All ranges are in %LEL.

Step 1: When

Step 2: The message

Step 3: When the required level displays, press the Calibration Button or

Step 4: The message

Step 5: Press the Calibration Button or use the Reed Switch to select.

Step 6: The message

Set Relay Options YES? displays press the Calibration

Button or use the Reed Switch to select. The flashing

YES confirms the selection.

Set Low displays. Low Alarm set-points are then

displayed in increments of 5 (5 to 95).

use the Reed Switch to select. The level selected will flash to confirm the selection.

Coil Status displays. The display then shows

Energized YES? and then De-Energized YES?.

The flashing

YES confirms the selection. If no selection is made,

Coil Status option is repeated.

Latch Status displays. The display then shows

Latching YES? and then Non-Latching YES?.

SELECT GAS CURVE

Steps to set up target gas (Methane or Propane).

Step 1:

Press and hold the Cal/Reset button or use the magnet to access the Main menu and wait for countdown(10-0) to complete. Skip / ignore “Calibrate sensor” option and wait for “Select Gas Curve” option.

Step 2: When the message

Select Gas Curve YES? displays press the

Calibration Button or use the Reed Switch to select. The flashing

Step 3: The message

Button or use the Reed Switch to select or wait for

Yes?

to display and select.

Step 4: The flashing

YES confirms the selection.

Methane %LEL Yes? displays. Use the Calibration

Propane %LEL

YES confirms the selection and will continue to flash

for a few seconds. The Millennium display will shortly return to normal operation

00 %LEL.

Note: If the gas curve is modified, the Millennium must be recalibrated (refer

to "Calibration Procedure" on page 14).

SELECT DISPLAY LANGUAGE

Step 7: Press the Calibration Button or use the Reed Switch to select.

The flashing

YES confirms the selection. If no selection is made,

Latch Status option is repeated.

Step 8: The message

Set High displays.

The High Alarm level cannot be set to a value lower than the Low Alarm level (as set in Step 3), nor higher than the maximum of 100% LEL. The High Alarm level is displayed in increments of 5

greater than the Low Alarm level (as set in Step 3).

Step 1: When Select Display Language YES? displays press the

Calibration Button or use the Reed Switch to select. The flashing

Step 2: When the required language displays (

Francais) press the Calibration Button or use the Reed Switch to

YES confirms the selection.

English, Espanol,

select. The flashing

YES confirms the selection.

Note: Factory default is English.

Step 9: Repeat Steps 3 through 7 to complete the High Alarm level, coil

and latch status settings.

Note: If no selection is made, a 5 minute timer expires, in which case the unit

returns to normal operation.

MLP-A-AR-D-SIR100 16

Net Safety Monitoring Inc.

MODBUS OPTIONS

The digital RS-485 Modbus RTU protocol is used. There are two Modbus options: Node Address and Baud Rate.

Node Address

Each device connected to the chain must be assigned a unique node address. The last number in the address is selected first.

Step 1: When

Step 2: The current node address will display

Step 3: Wait for the prompt

Step 4: Use the Calibration Button or Reed Switch to select each of three

Baud Rate

Modbus Setup? YES? displays press the Calibration Button

or use the Reed Switch to select. The flashing

YES confirms the selection.

Node: 000.

New Address? YES? and press the Calibration

Button or use the Reed Switch to select.

numbers in the new address:

- select the last number in the address first:

- select the next number in the address:

- select the first number in the address last:

0 thru 9.

0 1 2.

ALARMS

Sensor Fault

WARNING:

The fault detection circuitry does not monitor the operation of external response equipment or the external wiring to these devices. It is important that these devices be checked periodically to ensure they are operational.

Self-testing circuitry continuously checks for problems that could prevent proper response. When power is applied, the microcontroller automatically tests the system to ensure that it is functioning properly. During normal operation, it continuously monitors the signal from the internal sensor source. In addition, a "watchdog" timer is maintained to ensure the program is running correctly. When a system fault is detected, the Status LED will Red Slow flash, the displays shows

Gas Present

When gas is present, 1 to 100% Full Scale will display, the analog output switches to between 4 and 20 mA and the Status LED Blip/blinks Red.

Sensor Life

Sensor Fault and analog output changes to 2.5 mA.

The transmission speed must be defined.

Depending on various factors, sensor response may slowly deteriorate over a period of years. If calibration becomes impossible for any reason, the display

Step 1: When

Modbus Setup? YES? displays press the Calibration Button

or use the Reed Switch to select. The flashing

YES confirms the selection.

will show

Fail Cal, the analog output will switch repeatedly between 3.0 mA

and 3.3 mA and the Status LED alternates Red and Green flashes.

Step 2: After setting the Node Address, the current Baud Rate will display

XX.X BPS.

Step 3: Wait for the prompt

New Baud Rate? YES? and press the

Calibration Button or use the Reed Switch to select.

Step 4: The available baud rates will display:

19.2s, 28.8s, 38.4s, 57.6s.

2400s, 4800s, 9600s,14.4s,

Step 5: Use the Calibration Button or use the Reed Switch to select baud

rate when it displays.

Step 6: The flashing

MLP-A-AR-D-SIR100 17

YES confirms the selection.

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RESET

Manual Reset

A Manual Reset is required after a calibration failure or to clear a latched relay alarm. Simply place and hold the magnet against the Reed Switch or press and hold the Calibration Button for 3-5 seconds. The unit will return to normal operation using previous calibration values.

Remote Reset

If Relay Option is set to and an open Push Button Switch is connected between the RST terminal and the COM terminal on the Terminal Board, Remote Reset is possible. Also refer to "Remote Reset" on page 9 for details.

Latching (refer to "Setting Relay Options" on page 16)

OUTPUTS

Relay

Note: The fault relay output is not used to activate an automatic shutdown

procedure. The fault output indicates a potential problem with the

Controller not an alarm condition. Standard electro-mechanical relay outputs have Form C SPDT contacts rated 5 Amps at 30 V dc/ 250 V ac. Three relay outputs are available; one for Fault; one for Low alarm; and one for High alarm. All relays have normally open and normally closed contacts available at the output terminals.

Modbus

Digital RS-485 Modbus RTU protocol is used.

Note: Many registers are used by the controller. Please do not write outside

the three registers.

Current

A 4-20 mA dc current output is used to transmit the alarm status and fault codes to other devices. This output can be wired for isolated or non-isolated operation. A 4.0 mA output indicates normal operation; a 4.0 - 20.0 mA output indicates the presence of gas. Current output of 2.5 mA indicates the presence of a system fault.

The fault relay is set for normally energized operation and is non-latching. If a system fault is detected, the fault relay becomes de-energized. The fault relay is factory set and cannot be altered. The Low alarm and High alarm relays can be selected for either normally energized or normally de-energized operation and latching/non-latching.

MLP-A-AR-D-SIR100 18

Net Safety Monitoring Inc

STEP 7 — MAINTAIN

PERIODIC RESPONSE CHECK

Net Safety Monitoring recommends that a bump test be performed every 90 days to ensure continued functionality and accuracy of the detector. Full calibration is recommended when the sensor fails to meet acceptable accuracy standards. This involves the application of calibration gas to the sensor, then the observation of the response LEDs, analog output, and external monitoring equipment. Be sure to prevent unwanted response of external monitoring devices and equipment during this procedure. If the Millennium response to calibration gas is within the specified accuracy then it is not necessary to perform a calibration. For example, when 50% of full scale is applied, the response is expected to be between 11.5 mA (47% of full scale) and 12.5 mA (53% of full scale). An additional consideration is the accuracy tolerance of the calibration gas which may be + or - a few percent. If the calibration gas is + or 10% of full scale then the reading may be from 10.7 mA (42% of full scale) to

13.3 mA (58% of full scale).

TROUBLESHOOT

Response to the input should be checked and, if necessary, calibration should be performed whenever any of the following occur. Refer to "Calibration Procedure" on page 14 for calibration instructions.

• Sensor or transmitter is connected or disconnected

• Gas Curve is modified

The Millennium is not designed to be repaired in the field. If a problem should develop, first calibrate the device and carefully check for faulty wiring. If it is determined that the problem is caused by an electronic failure, the device must be returned to the factory for repair. Refer "How to Return Equipment" on page 19 for detailed instructions.

HOW TO RETURN EQUIPMENT

A Material Return Authorization number is required in order to return equipment. Please contact Net Safety Monitoring at (403) 219-0688 returning equipment or consult our Service Department to possibly avoid returning equipment.

If you are required to return equipment, include the following information:

1. A Material Return Authorization number (provided over the phone to you by Net Safety).

2. A detailed description of the problem. The more specific you are regarding the problem, the quicker our Service department can determine and correct the problem.

3. A company name, contact name and telephone number.

4. A Purchase Order, from your company, authorizing repairs or request for quote.

5. Ship all equipment, prepaid to:

Net Safety Monitoring Inc

2721 Hopewell Place NE Calgary, Alberta, Canada

T1Y 7J7

6. Mark all packages: RETURN for REPAIR

Waybills, for shipments from outside Canada, must state:

Equipment being returned for repair All charges to be billed to the sender

Also, please ensure a duplicate copy of the packing slip is enclosed inside the box indicating item 1-4 along with the courier and account number for returning the goods.

All Equipment must be Shipped prepaid. Collect shipments will not be accepted.

before

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

MLP-A-AR-D-SIR100 19

Net Safety Monitoring Inc

SPARE PARTS/ACCESSORIES

Tab le 5: Part Numbering

Calibration Cover for windy conditions CC-SIR100-SEP

Magnet assembly

Aluminium or Stainless Steel Junction box

Terminal Connector Board

IR Adapter Ring/Flame Arrestor Housing

Replacement IR Sensor Assembly w/Methane & Propane curve, Aluminium housing

Replacement IR Sensor Assembly w/Methane & Pentane curve, Aluminium housing

Replacement IR Sensor Assembly w/Methane & Propane curve, Stainless Steel housing

Replacement IR Sensor Assembly w/Methane & Pentane curve, Stainless Steel housing

Magnet-1

JB-MPD-A/S

PCBA-0252D

SIR100-RING

SIR100-RING-SS

SIR100-100

SIR100P

SIR100-100-SS

SIR100-100P-SS

FACE ROTATION OPTION

In some applications, it is necessary for the Millennium Controller to be mounted in a non-standard orientation. To accommodate such installations and ensure that the display will appear at the correct angle for viewing, the PCB Assembly can be rotated inside the Controller.

Rotate PCB Assembly

1. Remove the Controller’s Housing Cover.

rebmuNtraPytefaSteNnoitpircseD

2. Turn the power to the detector off.

3. Unscrew both the knobs marked "Pull Here".

4. Lift Controller faceplate from Housing and allow to hang from ribbon cable.

5. Unscrew the two metal standoffs.

6. Carefully remove the PCB Assembly from the Housing.

7. The Rotator plate is secured to the bottom of the Housing and is accessible after the PCB Assembly has been removed.

8. Rotate the PCB Assembly to desired position and line up the standoffs with the mounting holes.

9. Insert standoffs in the appropriate horizontal or vertical mounting holes.

10. Tighten standoffs to secure PCB Assembly.

11. Replace faceplate and tighten "Pull Here" knobs.

12. Return power to detector and replace Housing Cover.

Vertical Mounting Holes (Insert Standoffs)

Horizontal Mounting Holes (Insert Standoffs)

Figure 14: Non-standard Orientations

Ribbon cable

Standoffs

PCB Assembly

Note: Ensure orientation allows for connections and excess wire within Controller

Housing.

MLP-A-AR-D-SIR100 20

WARNING:

page 21 for handling instructions of electronic components.

See Appendix A, "Electrostatic Sensitive Device (ESD)", on

Faceplate

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Appendix A: E

LECTROSTATIC SENSITIVE DEVICE (ESD)

Electrostatic discharge (ESD) is the transfer, between bodies, of an electrostatic charge caused by direct contact or induced by an electrostatic field.

The most common cause of ESD is physical contact. Touching an object can cause a discharge of electrostatic energy near electronic components, it can damage or destroy those components.

In some cases, damage is instantaneous and an immediate malfunction occurs. However, symptoms are not always immediate seemingly normal for an indefinite period of time, followed by a sudden failure.

To eliminate potential ESD damage, review the following guidelines:

• Handle boards by metal shields

• Wear grounded wrist or foot straps, or ESD shoes or heel grounders to dissipate unwanted static energy

• Prior to handling boards, dispel any charge in your body or equipment

• Ensure components are transported and stored in static safe packaging

• When returning boards, carefully package in the original carton and static protective wrapping

• Ensure ALL personnel are educated and trained in ESD Control Procedures

In general, exercise accepted and proven precautions normally observed when handling electrostatic sensitive devices.

A warning label is placed on the packaging, identifying product using electrostatic sensitive semiconductor devices.

—taking care not to touch electronic components

—ESD! If the charge is sufficient and occurs

—performance may be marginal or

MLP-A-AR-D-SIR100 21

Net Safety Monitoring Inc.

Appendix B: RESISTANCE TABLE

Tab l e 6 : Wire Resistance In Ohms

Distance (Feet) AWG #20 AWG #18 AWG #16 AWG #14 AWG #12 AWG #10 AWG #8

100 1.020.640.400.250.160.100.06

200 2.031.280.800.510.320.200.13

300 3.051.921.200.760.480.300.19

400 4.062.551.611.010.640.400.25

500 5.083.202.011.260.790.500.31

600 6.093.832.411.520.950.600.38

700 7.11 4.47 2.81 1.77 1.11 0.70 0.44

800 8.12 5.11 3.21 2.02 1.27 0.80 0.50

900 9.145.753.612.271.430.900.57

1000 10.20 6.39 4.02 2.53 1.59 1.09 0.63

1250 12.70 7.99 5.03 3.16 1.99 1.25 0.79

1500 15.20 9.58 6.02 3.79 2.38 1.50 0.94

1750 17.80 11.20 7.03 4.42 2.78 1.75 1.10

2000 20.30 12.80 8.03 5.05 3.18 2.00 1.26

2250 22.80 14.40 9.03 5.68 3.57 2.25 1.41

2500 25.40 16.00 10.00 6.31 3.97 2.50 1.57

3000 30.50 19.20 12.00 7.58 4.76 3.00 1.88

3500 35.50 22.40 14.10 8.84 5.56 3.50 2.21

4000 40.60 25.50 16.10 10.00 6.35 4.00 2.51

4500 45.70 28.70 18.10 11.40 7.15 4.50 2.82

5000 50.10 32.00 20.10 12.60 7.94 5.00 3.14

5500 55.80 35.10 22.10 13.91 8.73 5.50 3.46

6000 61.00 38.30 24.10 15.20 9.53 6.00 3.77

6500 66.00 41.50 26.10 16.40 10.30 6.50 4.08

7000 71.10 44.70 28.10 17.70 11.10 7.00 4.40

7500 76.10 47.90 30.10 19.00 12.00 7.49 4.71

8000 81.20 51.10 23.10 20.20 12.70 7.99 5.03

9000 91.40 57.50 36.10 22.70 14.30 8.99 5.65

10 000 102.00 63.90 40.20 25.30 15.90 9.99 6.28

Note: Resistance shown is one way. This figure should be doubled when determining closed loop resistance.

MLP-A-AR-D-SIR100 22

Net Safety Monitoring Inc.

Appendix C: SPECIFICATIONS

• Response Time: <5 seconds to T20

<7 seconds to T40

SENSOR SPECIFICATIONS

• Operating Temperature Range: -40°C to +75°C (-40F to +167F)

• Linearity/Repeatability:

• Certification: CSA and NRTL/C certified for

• Weight: 0.9 Kg (2.0 lb)

• Enclosure Material: Powder Coated or Anodized Aluminum (optional stainless steel)

• Range of Detection: 0 to100% LEL methane/propane

• Accuracy:

±3% LEL up to 50% LEL

±5% LEL above 50% LEL

CONTROLLER SPECIFICATIONS

MILLENNIUM 4-20 mA ANALOG OUTPUT

Operating Temperature Range -40°C to +85°C (-40F to +185F)

Power Consumption

24 V dc @ 50 Span

Nominal 3.02 W

Maximum 3.38 W

Humidity Range 0 to 100% Relative humidity, non-condensing

Operating Voltage Range 10.5 to 32.0 V dc

Enclosure Material Powder coated Copper Free Cast Aluminum

4-20 mA with RELAY OUTPUT MODULE

Nominal 3.36 W

Maximum 4.5 W

±3% LEL / ±2% LEL

hazardous locations. Class I, Division 1, Groups B, C and D. IEC Rating Ex d IIB+H2 T5. Performance certified to CSA C22.2 No. 152.

DIGITAL

Nominal 3.02 W

Maximum 3.38 W

Certifications CSA and NRTL/C certified for hazardous locations. Class I, Division 1, Groups B, C and D. Temperature Code T5. Rating Ex

d IIB+H2 T5 (Class1, Zone 2, Group IIB+H2T5). Maximum operating ambient of 85

°C. Enclosure Type 4X.

Note: Electronics only-CSA and NRTL/C certified for hazardous locations Class I, Division 2 Groups A, B, C and D.

Weight 3.5 Kg (7.7 lb)

4 to 20 mA - Into a maximum loop impedance of 800 Ohms at 32 V dc or 150 Ohms at 10.5 V dc. Isolated or non-isolated loop supply.

2 Form C contacts rated 5 Amps at 30 V dc / 250 V ac. Selectable energized / de-energized, latching/non-latching configurable low and high alarms. Fault relay is factory set as energized, non-latching and cannot be modified.

Digital RS-485 Modbus protocol.

MLP-A-AR-D-SIR100 23

istributed by: et Safety Monitoring Inc.,

721 Hopewell Place NE Calgary, Alberta, Canada T1Y 7J7 Telephone: (403) 219-0688 Fax: (403) 219-0694

-mail: netsafe@net-safety.com

ww.net-safety.com

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