MODELS: U1G, U2G and U4G
UNI-TROL GAS CONTROLLER
TM
One, Two and Four-Channel Field-Mount Controller
Part Number: M AN-0003-00 Rev. 5
March 2004
Important Information
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.
2711 39th Ave., N.E.
Calgary, AB T1Y 4T8
Canada
Telephone: (403) 219-0688 Fax: (403) 219-0694
www.net-safety.com
E-mail: netsafe@net-safety.com
Copyright © 2004 Net Safety Monitoring Inc.
Printed in Canada
Table of Contents
Warranty
Contact Information
Unit I GENERAL INFORMATION .................................- 1 -
DESCRIPTION ..............................................................- 1 -
FEATURES ................................................................- 1 -
SPECIFICATIONS ...........................................................- 1 -
Figure 1 - Controller Dimensions..........................................- 2 -
BASIC OPERATION - CONTROLLER ...........................................- 2 -
FACEPLATE DESCRIPTION ............................................- 2 -
Figure 2 - Controller Front Panel ..........................................- 3 -
OUTPUTS ...........................................................- 3 -
Current Outputs ...........................................................................................................-3-
Figure 3 - Jum per Selection for Isolated or Non-Isolated Current Outputs . . . . . . . . . . - 4 -
Table 1 - Current Output Signal Levels .....................................- 4 -
PROGRAMMING OPTIONS .............................................- 4 -
Table 2 - Selectable Output Options .......................................- 5 -
EXTERNAL RESET ...................................................- 5 -
AUTOMATIC DIAGNOSTICS AND FAULT IDENTIFICATION . . . . . . . . . . . . . . . . . . - 5 -
OPERATING MODES ........................................................- 5 -
Normal Operating Mode: ................................................- 6 -
Reset Mode: .........................................................- 6 -
Forced Reset Mode: ...................................................- 6 -
Forced Display (FdP): ..................................................- 6 -
Sensor Replacement Mode (SrP): ........................................- 7 -
Sensor Calibration Mode (CAL): ..........................................- 7 -
Set-Point Display (Spd): ................................................- 7 -
Address Set (Adr Set) (Do not use): .......................................- 7 -
Error Message Display (Err Chc): .........................................- 7 -
Channel Display (Chd): .................................................- 7 -
Unit II SYSTEM INSTALLATION..................................- 8 -
INSTALLATION .............................................................- 8 -
SENSOR LOCATIONS .................................................- 8 -
GENERAL WIRING REQUIREMENTS ...........................................- 8 -
CONTROLLER WIRING ................................................- 9 -
Figure 4a - Wiring for U1G with Non-isolated Current Output . . . . . . . . . . . . . . . . . . . . -10
Figure 4b - Wiring for U1G with Isolated Current Output . . . . . . . . . . . . . . . . . . . . . . -11 -
Figure 5a - Wiring for U2G with Non-isolated Current Output . . . . . . . . . . . . . . . . . . . -12 -
Figure 5b - Wiring for U2G with Isolated Current Output . . . . . . . . . . . . . . . . . . . . . . -13 -
Figure 6a - Wiring for U4G with Non-isolated Current Output . . . . . . . . . . . . . . . . . . . -14 -
Figure 6b - Wiring for U4G with Isolated Current Output . . . . . . . . . . . . . . . . . . . . . -15 --
DIP SWITCH SETTINGS .....................................................- 16 -
Figure 7a - Dip Switch .................................................- 16 -
Figure 7b - Dip Switch Position ..........................................- 16 -
ACTIVE CHANNELS ..................................................- 16 -
CALIBRATION GAS CONCENTRATION ..................................- 17 -
POWER-UP TIME DELAY ........................................- 18 -
ALARM SETTINGS ...................................................- 19 -
LATCHING/NON-LATCHING SELECTION ................................- 20 -
ENERGIZED/DE-ENERGIZED SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 21 -
RELAY SETTINGS..........................................................- 21 -
Figure 8a - Relay Settings ..............................................- 21 -
Figure 8b - Relay Position ..............................................- 21 -
INSTALLATION CHECKLIST..................................................- 21 -
Table 3 - Summary of Dip Switch Settings .................................- 22 -
Table 4 - Factory Dip Switch Settings .....................................- 22 -
Unit III SYSTEM OPERATION .................................. - 23 -
MENU AND FUNCTION SELECTION .......................................... - 23 -
Table 5 - Menu and Function Selection ................................... - 23 -
Table 6 - Main Menu Selection.......................................... - 24 -
Table 7 - Special Function Menu Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 24 -
START-UP PROCEDURE ................................................... - 24 -
MAIN MENU SELECTIONS .................................................. - 25 -
ERROR CHECK MODE (Err Chc) ....................................... - 25 -
SET-POINT DISPLAY MODE (SPd) ..................................... - 26 -
Table 8 - System Status Codes ......................................... - 27 -
SENSOR CALIBRATION (CAL) ............................................... - 28 -
General Information ................................................. - 28 -
Calibration Procedure................................................. - 28 -
SENSOR REPLACEMENT MODE (SrP) .................................. - 29 -
SPECIAL FUNCTION MENU SELECTIONS ..................................... - 30 -
FORCED CURRENT OUTPUTS (FoP) ................................... - 30 -
CURRENT CALIBRATION MODE (CuC) ................................. - 30 -
ADDRESS SET MODE (Adr Set) (Do not use) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 30 -
CHANNEL DISPLAY(Chd) ............................................. - 31 -
BYPASS (bPS) ...................................................... - 31 -
OPERATING MODES ....................................................... - 31 -
RESET MODE ...................................................... - 31 -
FORCED RESET MODE .............................................. - 31 -
NORMAL OPERATING MODE ......................................... - 32 -
FORCED DISPLAY (FdP) ............................................. - 33 -
Unit IV SYSTEM MAINTENANCE................................ - 33 -
ROUTINE MAINTENANCE ................................................... - 33 -
MANUAL CHECK OF OUTPUT DEVICES ................................ - 33 -
SYSTEM CHECK IN NORMAL MODE ................................... - 33 -
SENSOR REPLACEMENT ............................................ - 34 -
REPLACEMENT PARTS .................................................... - 34 -
DEVICE REPAIR AND RETURN .............................................. - 35 -
Table 9 - Troubleshooting Guide ................................... - 36 -
Appendix A Electrostatic Sensitive Device Handling Procedure . . . . . - 37 -
Appendix B Procedure For Activating Reed Switches . . . . . . . . . . . . . . - 38 -
Appendix C Record of Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . - 39 -
Appendix D Wire Resistance In Ohms . . . . . . . . . . . . . . . . . . . . . . . . . . . - 40 -
Unit I GENERAL INFORMATION
DESCRIPTION
The Uni-Trol™ U1G, U2G and U4G 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, 4-20 mA outputs and a full array of faceplate indicators.
The type of controller and its range can be determined from the example model number as shown
below:
UXG-100-LEL = 0 to 100% LEL controller
UXG-100-H2S = 0 to 100 ppm H S controller
UXG-1000-CO = 0 to 1000 ppm CO controller
UXG-20-SO2 = 0 to 20 ppm SO controller
NOTE
The controller displays the gas concentration in parts per million (ppm) for all types of
gases unless it is a combustible gas controller in w hich case the gas concentration is
shown as % of lower explosive limit (LEL).
FEATURES
C Controller accepts 4 to 20 mA analog inputs from Net Safety combustible and toxic gas
sensors
C Non-Intrusive one person calibrations
C Two digital displays, one bar graph display and high intensity LEDs indicate important
system status
C AutoCal feature provides easy and accurate calibration
C Microprocessor-based controller is easily field program m able
C 4-20 mA current outputs to send important system information to other devices
C Relay alarm and fault outputs
2
2
SPECIFICATIONS
C Operating Voltage:
24 Volts dc. Device can operate between 18 and 32 V dc
C Power Consumption (Controller Only):
2.4 Watts nominal, 4.4 Watts maximum (100 mA nominal, 180 mA maximum at
24 V dc)
Maximum start-up current is 1.5 Amperes for 10 milliseconds. Power supplies
with foldback current limiting are not recommended.
C Maximum Ripple:
Ripple should not exceed 5 Volts peak-to-peak. The sum of dc plus ripple must
be $18 V dc and #32 V dc
C Temperature Range:
Operating: -40ºC to +85ºC (-40ºF to +185ºF)
Storage: -55ºC to +150ºC (-65ºF to +302ºF)
C Relay Contacts:
Normally open/normally closed contacts rated at 5 Amperes at 30 V dc/ 250 V ac
- 1 -
C Current Outputs:
Two 4-20 mA dc current, with a maximum external loop resistance of 600 S at
18-32 V dc
C Dimensions:
Refer to Figure 1
C Shipping Weight (Approximate):
2 lbs. (0.9 kilograms)
C Certification:
CSA Certified for Class 1, Division 1 Group B, C and D hazardous locations.
Figure 1 - Controller Dimensions
BASIC OPERATION - CONTROLLER
FACEPLATE DESCRIPTION
The controller faceplate provides a number of LEDs for identifying status conditions, two digital
displays and a bar graph display for indicating the sensor inputs, as well as MENU/SET and
SELECT/RESET magnetic reed switches for programming, calibrating and resetting the system.
Refer to Figure 2.
S 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 Norm al O perating Mode, each channel is sequentially
displayed for 5 seconds. In other operating modes, the digital displays show the alarm
set-points and programmed calibration gas concentration. A negative zero drift condition
is indicate d by a minus sign in the left-hand digit. Since at least one display is always lit, it
also functions as a power indicator.
S 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 50 ppm controller each
segment represents 2.5 ppm, which is 5% of the full range of 50 ppm), from 0% to 50% of
full range; all 10 segments are illuminated for 50% of full range and higher gas
concentrations.
S High Alarm LED (HI) - Flashes in response to a sensor signal that exceeds the high
set-point.
S Low Alarm LED (LOW) - Flashes in response to a sensor signal that exceeds the low
set-point.
- 2 -
S Calibrate LED (CAL) - Illuminates when the controller is in the Calibrate Mode.
S Fault LED (Fault) - Illuminates upon detection of an overall system fault or a channel
related fault.
S Channel LEDs - 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.
S MENU/SET reed switch - Changes the menu display as well as other system
programming and calibration functions.
S SELECT/RESET reed switch - Menu selection and other system programming and
resets the controller.
Figure 2 - Controller Front Panel
OUTPUTS
Relay Outputs:
The relay outputs have SPDT contacts rated at 5 Amperes at 30 V dc or 250 V ac The four relays
include an Area 1 low alarm (channels 1 and 2), an Area 2 low alarm (channels 3 and 4), one
com mon 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 4-20 mA 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 jumpers, as shown in Figure 3. Refer to Table 1 for a description of the current output
signal levels.
- 3 -
Figure 3 - Jumper Selection for Isolated or Non-Isolated Current Outputs
Table 1 - Current Output Signal Levels
Current Output Situation
0 mA Open or shorted signal output or loss of power
1 mA Fault or Power up
2 m A Power Fault
3 mA Sensor Calibration
4 m A to 20 m A 0 to 100% of full scale
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
-energized / de-energized selection
- 4 -
The alarm outputs are DIP-switch programmable for either normally energized or normally deenergized operation (program m able 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.
Table 2 - Selectable Output Options
Selectable Norm ally
OUTPUT
12
LOW Y Y Y
Open/Closed
HIGH Y Y N
FAULT Y N N
Selectable Norm ally
Energized/De-Energized
23
45
Selectable
Latching/Non-latching
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
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/transm itter to ensure proper functioning. In addition, a ‘watchdog’ tim er is
maintained to ensure that the program is running correctly. The tim er resets the m icro-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 Error 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 activating the appropriate MENU/SET and SELECT/RESET reed
switches located on the controller front panel. Refer to Figure 2 for a diagram of the controller
front panel.
NOTE
This section provides an overview of the basic operation of the controller. Refer to ‘Unit
III’ for detailed instructions and description.
Normal Operating Mode:
- 5 -
If no alarms or faults are occur, 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 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 norm al state if
programmed for non-latching operation and remain unchanged if programmed for latching
operation. The current outputs will re turn to the normal output level. T he 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. W hile 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.
Reset Mode:
The Reset Function is entered by activating the SELECT/RESET reed switch located on the front
panel of the controller (refer to Figure 2). When the SELECT/RESET reed switch 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 receive 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, activate the SELECT/RESET reed switch for 1 second, the LEDs turn off and the outputs
return to their norm al condition. The rem ote 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):
- 6 -
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
left display will show ‘SrP’ while in the sensor replace mode. The right 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 de-energized. 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 reed switch must be activated. 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 1 mA during this time.
Sensor Calibration Mode (CAL):
The Uni-Trol Controller uses a fully autom atic calibration procedure that requires no adjustments
by the operator. The controller displays ‘Air’ on the left display and the channel status on the right
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 display. When the controller
detects that the gas has been applied to the sensor, the display will read ‘gAS’. Once the
controller has finished the gain adjustments it will alternate ‘Cut’ and ‘gAS’ on the 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 com pleted, the m icroprocessor will autom atically
return to the N orm al 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.
While in the calibration mode, all controller outputs for the affected channel are inhibited, the
current output is 3 mA, 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 m ode, the digital display sequentially shows the programmed low and high alarm set-points
and calibration gas concentration. Each value is displayed for approximately 2 seconds.
Address Set (Adr Set) (Do not use):
Do not use the communication addresses.
™
Error Message Display (Err Chc):
The microprocessor-based controller features self-testing circuitry that continuously checks for
problem s 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
- 7 -
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 adequately protect the area.
The following factors are important and should be considered for every installation:
< Sensors should be located where they are safe from potential sources of contam ination.
< 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.
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 equipm ent.
W ate r will dam age electronic devices. Moistu re 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.
W hen pouring a seal, use a fibre dam to assure proper form ation 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'.
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. Refer to the m anuals
- 8 -
on the sensors used (and transmitters if used) for maximum wiring distances and wiring
instructions.
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 inform ation on proper handling, refer to
the Appendix A.
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 proper wiring of
the controllers for non-isolated current outputs with 2 and 3 wire sensors. Figures 4b, 5b and 6b
show the proper wiring 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 (-ve to ground) for
best immunity against electromagnetic interference.
- 9 -
Figure 4a - Wiring for U1G with Non-isolated Current Output
- 10 -
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