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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3 - Controller
Face-Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1 - Controller Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FACEPLATE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3 - Jumper Selections for an Isolated or Non-isolated Current Output . . . . . . . . .
PROGRAMMING OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXTERNAL RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC DIAGNOSTICS AND FAULT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . .
OPERATING MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
2
2
2
3
3
4
5
5
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
START-UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN MENU SELECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ERROR CHECK MODE (Err Chc) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SET-POINT DISPLAY MODE (SPd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENSOR CALIBRATION (CAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENSOR REPLACEMENT MODE (SrP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL FUNCTION MENU SELECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FORCED CURRENT OUTPUTS (FoP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CURRENT CALIBRATION MODE (CuC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADDRESS SET MODE (Adr Set) (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHANNEL DISPLAY(Chd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BYPASS (bPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESET MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FORCED RESET MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NORMAL OPERATING MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FORCED DISPLAY (FdP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
23
24
24
25
26
28
28
28
29
29
29
29
30
30
30
30
31
Unit IV
SYSTEM MAINTENANCE
ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL CHECK OF OUTPUT DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM CHECK IN NORMAL MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix B
31
31
31
32
32
Record Of Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Resistance In Ohms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENSOR REPLACEMENT MODE (SrP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL FUNCTION MENU SELECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FORCED CURRENT OUTPUTS (FoP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CURRENT CALIBRATION MODE (CuC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADDRESS SET MODE (Adr Set) (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHANNEL DISPLAY (Chd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BYPASS (Bps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESET MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FORCED RESET MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NORMAL OPERATING MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FORCED DISPLAY (FdP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
36
28
29
29
29
29
29
30
30
30
31
31
31
UNIT IV - SYSTEM MAINTENANCE
ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL CHECK OF OUTPUT DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM CHECK IN NORMAL MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DEVICE REPAIR AND RETURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 9 - Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
32
32
32
33
33
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 H2S controller
RXG-1000-CO = 0 to 1000ppm CO controller
RXG-20-SO2 = 0 to 20ppm SO2 controller
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.
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 $18
Volts DC and #32 Volts DC
<
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
-1-
<
Current Outputs:
Two 4-20mA DC current, with a maximum external loop resistance of 600S at 18-32
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.
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
Selectable Normally
Open/Closed
Selectable Normally
Energized/De-Energized
Selectable Latching/Nonlatching
LOW1
Y
Y2
Y
Y
2
N3
N4
N5
HIGH
Y
FAULT
Y
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-
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-
R1G-XXXX CONTROLLER
NON-ISOLATED CURRENT OUTPUT
J16
ALARM RELAY CONTACTS ARE
JUMPER SELECTABLE AS N.O.
OR N.C.
FAULT RELAY COIL IS
NORMALLY ENERGIZED
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
-
24Vdc+
14 + 24Vdc SYSTEM POWER
15 AREA 1 CURRENT OUTPUT
16
TO USER EQUIPMENT
4-20mA LOOP
CUT SHIELD
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)
SHIELD TO SYSTEM COMMON J17 (18,19)
SENSOR POWER 24Vdc. J17 (20 OR 21)
SENSOR INPUT 1. J17 (9)
SYSTEM COMMON. J17 (18,19)
SENSOR
CONTROLLER
SENSOR
BLK
CUT SHIELD
CONTROLLER
BLK
BLK
RED
RED
RED
BLK
RED
WHT
WHT
TX-LEL-C-24
TRANSMITTER
OR
JB AND
TERMINAL
BOARD
ST1200 H2S SENSOR
OR OTHER 2 WIRE SENSOR
TRANSMITTER
SC1100 LEL SENSOR
Figure 4a - Wiring for R1G with Non-Isolated Current Output
-9-
R1G-XXXX CONTROLLER
ISOLATED CURRENT OUTPUT
J16
ALARM RELAY CONTACTS ARE
JUMPER SELECTABLE AS N.O.
OR N.C.
FAULT RELAY COIL IS
NORMALLY ENERGIZED
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
-
24Vdc+
14 + 24Vdc SYSTEM POWER
15 AREA 1 CURRENT OUTPUT
16
-
24Vdc+
4-20mA LOOP
TO USER EQUIPMENT
CUT SHIELD
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)
SHIELD TO SYSTEM COMMON J17 (18,19)
SENSOR POWER 24Vdc. J17 (20 OR 21)
SENSOR INPUT 1. J17 (9)
SYSTEM COMMON. J17 (18,19)
SENSOR
CONTROLLER
SENSOR
BLK
CUT SHIELD
CONTROLLER
BLK
BLK
RED
RED
RED
BLK
RED
WHT
WHT
TX-LEL-C-24
TRANSMITTER
OR
JB AND
TERMINAL
BOARD
ST1200 H2S SENSOR
OR OTHER 2 WIRE SENSOR
TRANSMITTER
SC1100 LEL SENSOR
Figure 4b - Wiring for R1G with Isolated Current Output
- 10 -
R2G-XXXX CONTROLLER
NON-ISOLATED CURRENT OUTPUT
J16
ALARM RELAY CONTACTS ARE
JUMPER SELECTABLE AS N.O.
OR N.C.
1
FAULT RELAY
2
FAULT RELAY
FAULT RELAY COIL IS
NORMALLY ENERGIZED
3
HIGH ALARM RELAY
4
HIGH ALARM RELAY
5
AREA 1 LOW ALARM RELAY
6
AREA 1 LOW ALARM RELAY
7
AREA 2 LOW ALARM RELAY
8
AREA 2 LOW ALARM RELAY
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 SENSOR INPUT 2
11 NOT USED
12 NOT USED
13 - 24Vdc SYSTEM POWER
-
24Vdc+
14 + 24Vdc SYSTEM POWER
15 AREA 1 CURRENT OUTPUT
16
TO USER EQUIPMENT
4-20mA LOOP
CUT SHIELD
AREA 2 CURRENT OUTPUT
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) OR SENSOR INPUT 2 J17 (10)
SENSOR POWER 24Vdc. J17 (20 OR 21)
SHIELD TO SYSTEM COMMON
J17 (18,19)
SHIELD TO SYSTEM COMMON J17 (18,19)
SENSOR POWER 24Vdc. J17 (20 OR 21)
SENSOR INPUT 1. J17 (9) OR SENSOR INPUT 2 J17 (10)
SYSTEM COMMON. J17 (18,19)
SENSOR
CONTROLLER
SENSOR
BLK
CUT SHIELD
CONTROLLER
BLK
BLK
RED
RED
RED
BLK
RED
WHT
WHT
TWO (2)
TX-LEL-C-24
TRANSMITTER
OR
TWO (2)
JB AND
TERMINAL
BOARD
ST1200 H2S SENSOR
OR OTHER 2 WIRE SENSOR
TRANSMITTER
SC1100 LEL SENSOR
Figure 5a - Wiring for R2G with Non-Isolated Current Output
- 11 -
R2G-XXXX CONTROLLER
ISOLATED CURRENT OUTPUT
J16
ALARM RELAY CONTACTS ARE
JUMPER SELECTABLE AS N.O.
OR N.C.
FAULT RELAY COIL IS
NORMALLY ENERGIZED
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
AREA 2 LOW ALARM RELAY
8
AREA 2 LOW ALARM RELAY
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 SENSOR INPUT 2
11 NOT USED
12 NOT USED
13 - 24Vdc SYSTEM POWER
-
24Vdc+
14 + 24Vdc SYSTEM POWER
15 AREA 1 CURRENT OUTPUT
16
-
24Vdc+
4-20mA LOOP
TO USER EQUIPMENT
CUT SHIELD
AREA 2 CURRENT OUTPUT
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) OR SENSOR INPUT 2 J17 (10)
SENSOR POWER 24Vdc. J17 (20 OR 21)
SHIELD TO SYSTEM COMMON
J17 (18,19)
SHIELD TO SYSTEM COMMON J17 (18,19)
SENSOR POWER 24Vdc. J17 (20 OR 21)
SENSOR INPUT 1. J17 (9) OR SENSOR INPUT 2 J17 (10)
SYSTEM COMMON. J17 (18,19)
SENSOR
CONTROLLER
SENSOR
BLK
CUT SHIELD
CONTROLLER
BLK
BLK
RED
RED
RED
BLK
RED
WHT
WHT
TWO (2)
TX-LEL-C-24
TRANSMITTER
TWO (2)
JB AND
TERMINAL
BOARD
OR
ST1200 H2S SENSOR
OR OTHER 2 WIRE SENSOR
TRANSMITTER
SC1100 LEL SENSOR
Figure 5b - Wiring for R2G with Isolated Current Output
- 12 -
R4G-XXXX CONTROLLER
NON-ISOLATED CURRENT OUTPUT
J16
ALARM RELAY CONTACTS ARE
JUMPER SELECTABLE AS N.O.
OR N.C.
FAULT RELAY COIL IS
NORMALLY ENERGIZED
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
AREA 2 LOW ALARM RELAY
8
AREA 2 LOW ALARM RELAY
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 SENSOR INPUT 2
11 SENSOR INPUT 3
12 SENSOR INPUT 4
13 - 24Vdc SYSTEM POWER
-
24Vdc+
14 + 24Vdc SYSTEM POWER
15 AREA 1 CURRENT OUTPUT
16
TO USER EQUIPMENT
4-20mA LOOP
SHIELD TO SYSTEM COMMON J17 (18,19)
SENSOR POWER 24Vdc. J17 (20 OR 21)
AREA 2 CURRENT OUTPUT
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) OR SENSOR INPUT 2 J17 (10) OR
SENSOR INPUT 3 J17 (11) OR SENSOR INPUT 4 J17 (12)
SENSOR POWER 24Vdc. J17 (20 OR 21)
SHIELD TO SYSTEM COMMON
J17 (18,19)
SENSOR INPUT 1. J17 (9) OR SENSOR INPUT 2 J17 (10) OR SENSOR INPUT 3
J17 (11) OR SENSOR INPUT 4 J17 (12)
SYSTEM COMMON. J17 (18,19)
CUT SHIELD
CUT SHIELD
SENSOR
CONTROLLER
SENSOR
BLK
CONTROLLER
BLK
BLK
RED
RED
RED
BLK
RED
WHT
WHT
FOUR (4)
TX-LEL-C-24
TRANSMITTER
OR
FOUR (4)
JB AND
TERMINAL
BOARD
ST1200 H2S SENSOR
OR OTHER 2 WIRE SENSOR
TRANSMITTER
SC1100 LEL SENSOR
Figure 6a - Wiring for R4G with Non-Isolated Current Output
- 13 -
R4G-XXXX CONTROLLER
ISOLATED CURRENT OUTPUT
J16
ALARM RELAY CONTACTS ARE
JUMPER SELECTABLE AS N.O.
OR N.C.
FAULT RELAY COIL IS
NORMALLY ENERGIZED
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
AREA 2 LOW ALARM RELAY
8
AREA 2 LOW ALARM RELAY
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 SENSOR INPUT 2
11 SENSOR INPUT 3
12 SENSOR INPUT 4
13 - 24Vdc SYSTEM POWER
-
24Vdc+
14 + 24Vdc SYSTEM POWER
15 AREA 1 CURRENT OUTPUT
16
-
24Vdc+
4-20mA LOOP
TO USER EQUIPMENT
SHIELD TO SYSTEM COMMON J17 (18,19)
SENSOR POWER 24Vdc. J17 (20 OR 21)
SENSOR INPUT 1. J17 (9) OR SENSOR INPUT 2 J17 (10) OR SENSOR INPUT 3
J17 (11) OR SENSOR INPUT 4 J17 (12)
SYSTEM COMMON. J17 (18,19)
AREA 2 CURRENT OUTPUT
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) OR SENSOR INPUT 2 J17 (10) OR
SENSOR INPUT 3 J17 (11) OR SENSOR INPUT 4 J17 (12)
SENSOR POWER 24Vdc. J17 (20 OR 21)
SHIELD TO SYSTEM COMMON
J17 (18,19)
CUT SHIELD
CUT SHIELD
SENSOR
CONTROLLER
SENSOR
BLK
CONTROLLER
BLK
BLK
RED
RED
RED
BLK
RED
WHT
WHT
FOUR (4)
TX-LEL-C-24
TRANSMITTER
FOUR (4)
JB AND
TERMINAL
BOARD
OR
ST1200 H2S SENSOR
OR OTHER 2 WIRE SENSOR
TRANSMITTER
SC1100 LEL SENSOR
Figure 6b - Wiring for R4G with Isolated Current Output
- 14 -
DIP SWITCH SETTINGS
NOTE
See Table 4 for a list of the standard factory settings.
It is essential that the controller be properly programmed before applying power to the system. There are
three banks of dip switches located on the controller. Each switch bank has eight individual switches that
can be set to an on or off position.
NOTE
The dip switches are located on the circuit board. The switch banks are numbered from bottom to
top as numbers SW3, SW4, and SW5. Refer to Figure 7a. Individual switches are referenced as
‘X.Y’, where ‘X’ refers to the bank number and ‘Y’ refers to the switch number on ‘X’ bank. For
example, switch 3.4 (SW3.4) is switch number four on bank number three.
Switches are set as either OFF or ON. Refer to Figure 7b.
Figure 7a - Relay and Dip Switch Positions
Figure 7b - Dip Switch
NOTE
IT IS VERY IMPORTANT THAT POWER TO THE CONTROLLER IS RECYCLED AFTER ANY
DIP SWITCH CHANGES, TO MAKE THE CHANGES TAKE EFFECT!
ACTIVE CHANNELS
Switches for setting the active channels (the channels that are to have sensors/transmitters attached) can be
found on Switch Bank 3, switches 1 to 4 (SW3.1 through SW3.4). Set the designated switch to OFF if the
channel is to be connected (sensor attached), and ON if the channel is not to be used.
SW3.1: OFF:
ON:
channel 1 connected
channel 1 not connected
SW3.2: OFF:
ON:
channel 2 connected
channel 2 not connected
SW3.3: OFF:
ON:
channel 3 connected
channel 3 not connected
SW3.4: OFF:
ON:
channel 4 connected
channel 4 not connected
- 15 -
CALIBRATION GAS CONCENTRATION
Calibration gas concentration for all channels are set together using the dip switches on the circuit board.
To select the calibration gas concentration of 50% of full scale, set SW3.5 to OFF. If a selectable value
(from 20% to 99% of full scale) is required, set SW3.5 to ON; SW4.1 through SW4.7 must then be used to
select the calibration gas concentration.
SW3.5: OFF:
ON:
calibration gas set to 50%
(ignore SW4.1 - SW4.7)
calibration gas selectable
(set SW4.1 - SW4.7)
NOTE
If SW3.5 is set to ‘’ (‘ON’), it is very important to accurately set SW4.1 to SW4.7.
If the selectable option is chosen, the calibration gas concentration must be set. This is done on Switch
Bank 4, switches 1 through 7 (SW4.1 to SW4.7). The required calibration gas concentration must be set
with these switches using the binary counting system. ON selects the value listed below; OFF selects a
zero.
SW4.1:
SW4.2:
SW4.3:
SW4.4:
SW4.5:
SW4.6:
SW4.7:
ON:
ON:
ON:
ON:
ON:
ON:
ON:
1%
2%
4%
8%
16%
32%
64%
calibration
gas
concentration
The switches can be used in combination to select concentrations from 20% to 99% of full scale.
Combustible Gas Controller Example:
SW4.1:
SW4.2:
SW4.3:
SW4.4:
SW4.5:
SW4.6:
SW4.7:
OFF
OFF
ON
ON
ON
ON
OFF
calibration gas
concentration
= 60% LEL
1000ppm Toxic Gas Controller Example:
SW4.1:
SW4.2:
SW4.3:
SW4.4:
SW4.5:
SW4.6:
SW4.7:
OFF
OFF
ON
ON
ON
ON
OFF
calibration gas
concentration
= 600ppm
- 16 -
100ppm Toxic Gas Controller Example:
SW4.1:
SW4.2:
SW4.3:
SW4.4:
SW4.5:
SW4.6:
SW4.7:
OFF
OFF
ON
ON
ON
ON
OFF
calibration gas
concentration
= 60ppm
50ppm Toxic Gas Controller Example:
SW4.1:
SW4.2:
SW4.3:
SW4.4:
SW4.5:
SW4.6:
SW4.7:
OFF
OFF
ON
ON
ON
ON
OFF
calibration gas
concentration
= 30ppm
25ppm Toxic Gas Controller Example:
SW4.1:
SW4.2:
SW4.3:
SW4.4:
SW4.5:
SW4.6:
SW4.7:
OFF
OFF
ON
ON
ON
ON
OFF
calibration gas
concentration
= 15ppm
20ppm Toxic Gas Controller Example:
SW4.1:
SW4.2:
SW4.3:
SW4.4:
SW4.5:
SW4.6:
SW4.7:
OFF
OFF
ON
ON
ON
ON
OFF
calibration gas
concentration
= 12ppm
NOTE
If a calibration gas concentration greater than 99% or less than 20% of full scale is programmed,
the controller will give a configuration error (E90) when power is applied.
POWER-UP TIME DELAY
SW3.6 is used to select the power-up time delay.
SW3.6: OFF:
45 seconds
ON:
90 seconds
NOTE
SW3.7 and SW3.8 are not used.
- 17 -
ALARM SETTINGS
Switch bank 4, switch 8 (SW4.8) is used to set the low and high alarm to a default or selectable value. If
SW4.8 is (‘OFF’) the low alarm will be set to 20% of the full scale and the high alarm to 40% of full scale.
If SW4.8 is ‘’ (‘ON’), the low and high alarm are selectable, using SW5.3 to SW5.8.
SW4.8: OFF:
low alarm @ 20% full scale
high alarm @ 40% full scale
(ignore SW5.3 - SW5.8)
selectable alarm
(set SW5.3 - SW5.8)
ON:
NOTE
If SW4.8 is set to ‘’ (‘ON’), it is very important to accurately set SW5.3 to SW5.8.
If the selectable option is chosen, the alarms must be set with SW5.3 to SW5.8. The low alarm can be set
from 5% to 40% of full scale and the high alarm is automatically set at twice the low alarm value. The low
alarm value is set using the binary counting system. ‘’ (‘ON’) selects the value listed below; (‘OFF’)
selects a zero.
SW5.3:
SW5.4:
SW5.5:
SW5.6:
SW5.7:
SW5.8:
ON:
ON:
ON:
ON:
ON:
ON:
1%
2%
4%
8%
16%
32%
The switches can be used in combination to select low alarm settings from 5% to 40% of full scale. If a low
alarm level less than 5% or greater than 40% of full scale is programmed, the controller will give a
configuration error (E90) upon power up.
Combustible Gas Controller Example:
SW5.3:
SW5.4:
SW5.5:
SW5.6:
SW5.7:
SW5.8:
OFF
OFF
ON
ON
OFF
OFF
low alarm 12% LEL
high alarm 24% LEL
1000ppm Toxic Gas Controller Example:
SW5.3:
SW5.4:
SW5.5:
SW5.6:
SW5.7:
SW5.8:
OFF
OFF
ON
ON
OFF
OFF
low alarm 120ppm
high alarm 240ppm
- 18 -
100ppm Toxic Gas Controller Example:
SW5.3:
SW5.4:
SW5.5:
SW5.6:
SW5.7:
SW5.8:
OFF
OFF
ON
ON
OFF
OFF
low alarm 12ppm
high alarm 24ppm
50ppm Toxic Gas Controller Example:
SW5.3:
SW5.4:
SW5.5:
SW5.6:
SW5.7:
SW5.8:
OFF
OFF
ON
ON
OFF
OFF
low alarm 6ppm
high alarm 12ppm
25ppm Toxic Gas Controller Example:
SW5.3:
SW5.4:
SW5.5:
SW5.6:
SW5.7:
SW5.8:
OFF
OFF
ON
ON
OFF
OFF
low alarm 3ppm
high alarm 6ppm
20ppm Toxic Gas Controller Example:
SW5.3:
SW5.4:
SW5.5:
SW5.6:
SW5.7:
SW5.8:
OFF
OFF
ON
ON
OFF
OFF
low alarm 2.4ppm
high alarm 4.8ppm
NOTE
IT IS VERY IMPORTANT THAT POWER TO THE CONTROLLER IS RECYCLED AFTER ANY
DIP SWITCH CHANGES, TO MAKE THE CHANGES TAKE EFFECT!
LATCHING/NON-LATCHING SELECTION
Switch Bank 5, switch 1 is used to set the low alarm relays for latching or non-latching operation; the high
alarm is always latching and the fault is always non-latching.
SW5.1: OFF:
ON:
low alarm relay latching operation
low alarm relay non-latching operation
ENERGIZED/DE-ENERGIZED SELECTION
Switch Bank 5, switch 2 (SW5.2) is used to set the high and low alarm relays for normally energized or
normally de-energized operation; the fault relay is always normally energized.
SW5.2: OFF:
ON:
alarm relays normally energized
alarm relays normally de-energized
- 19 -
NOTE
IT IS VERY IMPORTANT THAT POWER TO THE CONTROLLER IS RECYCLED AFTER ANY
DIP SWITCH CHANGES, TO MAKE THE CHANGES TAKE EFFECT!
Refer to Table 3, at the end of this unit, for a summary of the dip switch settings and Table 4 for the
standard factory settings.
RELAY SETTINGS
There are four relays on the controller circuit board that can be set up for normally open or normally closed
operation by changing the positions of the ‘FAULT’, J2', ‘J3' and ‘J4' which are located beside the relays.
See Figure 7a for the location of the relays on the circuit board and Figure 7c for the correct settings.
Figure 7c - Relay Settings
INSTALLATION CHECKLIST
The following checklist is provided as a means of double checking the system to be sure that all phases of
system installation are complete and have been performed correct.
T
Controller is securely mounted and sensor is oriented correctly
T
All cable shields are properly grounded at one end only
T
Explosion-proof conduit seals have been installed at all conduit entries (if conduit is
being used)
T
Sensor to controller wiring is correct
T
Power wiring to the controller is installed and power source is operational
T
External loads are properly connected to the controller
T
Controller is programmed as needed. Record this information for future reference. A
table is provided in the appendix for this purpose
T
Controller is properly installed in the housing
T
Proper ventilation is provided to prevent overheating of the controller
- 20 -
SWITCH
OPEN OFF
CLOSED ON
SW3.7 & SW3.8
NOT USED
SW3.1
Channel 1 connected
Channel 1 not connected
SW3.2
Channel 2 connected
Channel 2 not connected
SW3.3
Channel 3 connected
Channel 3 not connected
SW3.4
Channel 4 connected
Channel 4 not connected
SW3.5
Calibration gas concentration is set to
50% of full scale (ignore SW4.1 to
SW4.7)
Calibration gas concentration is
selectable using SW4.1 to SW4.7
SW3.6
Power-up time delay is 45 seconds
Power-up time delay is 90 seconds
SW4.1 - SW4.7
Set calibration gas concentration from
20% to 99% of full scale
SW4.8
LOW alarm @ 20% of full
scale/HIGH alarm @ 40% of full
scale (ignore SW5.3 to SW5.8)
Selectable alarm settings using SW5.3 to
SW5.8 (LOW = 5% to 40% of full scale;
HIGH = 2 x LOW)
SW5.1
LOW alarm relay is latching
LOW alarm relay is non-latching
SW5.2
LOW and HIGH alarm relays
normally energized
LOW and HIGH alarm relays normally
de-energized
SW5.3 - SW5.8
Set LOW alarm settings from 5% to 40%
of full scale (HIGH alarm is twice the
LOW alarm setting)
Table 3 - Summary of Dip Switch Settings
Switch
LEL
100ppm H2S
50ppm H2S
20ppm SO2
3.1
OFF
OFF
OFF
OFF
3.2
OFF
OFF
OFF
OFF
3.3
OFF
OFF
OFF
OFF
3.4
OFF
OFF
OFF
OFF
3.5
OFF
OFF
ON
ON
3.6
OFF
ON
ON
ON
3.7
NOT USED
NOT USED
NOT USED
NOT USED
3.8
NOT USED
NOT USED
NOT USED
NOT USED
4.1
OFF
OFF
OFF
OFF
4.2
OFF
OFF
OFF
ON
4.3
OFF
OFF
OFF
OFF
4.4
OFF
OFF
ON
OFF
4.5
OFF
OFF
OFF
ON
4.6
OFF
OFF
ON
ON
4.7
OFF
OFF
OFF
OFF
4.8
OFF
ON
ON
ON
5.1
ON
ON
ON
ON
5.2
ON
ON
ON
ON
5.3
OFF
OFF
OFF
ON
- 21 -
Switch
LEL
100ppm H2S
50ppm H2S
20ppm SO2
5.4
OFF
ON
OFF
OFF
5.5
OFF
OFF
ON
OFF
5.6
OFF
ON
OFF
ON
5.7
OFF
OFF
ON
ON
5.8
OFF
OFF
OFF
OFF
CH1 CONNECTED
CH2 CONNECTED
CH3 CONNECTED
CH4 CONNECTED
LOW ALARM =
20%
HIGH ALARM =
40%
CAL. GAS = 50%
45 Sec. POWER UP
RELAYS:
Non-latching
Normally
De-energized
CH1 CONNECTED
CH2 CONNECTED
CH3 CONNECTED
CH4 CONNECTED
LOW ALARM = 10PPM
HIGH ALARM = 20PPM
CAL. GAS = 50PPM
45 Sec. POWER UP
RELAYS:
Non-latching
Normally De-energized
CH1 CONNECTED
CH2 CONNECTED
CH3 CONNECTED
CH4 CONNECTED
LOW ALARM =
10PPM
HIGH ALARM =
20PPM
CAL. GAS =
20PPM
45 Sec. POWER UP
RELAYS:
Non-latching
Normally Deenergized
CH1
CONNECTED
CH2
CONNECTED
CH3
CONNECTED
CH4
CONNECTED
LOW ALARM =
5PPM
HIGH ALARM =
10PPM
CAL. GAS =
10PPM
45 Sec. POWER
UP
RELAYS:
Non-latching
Normally Deenergized
Table 4 - Factory Dip Switch Settings
Unit III
SYSTEM OPERATION
MENU AND FUNCTION SELECTION
The controller has various functions and menus that can be entered by pressing the MENU/SET (and
SELECT/RESET) buttons for a specified amount of time. Table 5 indicates how to enter the various
menus and functions.
BUTTON
TIME
FUNCTION OR MENU
SELECT/RESET
< 0.5 sec
Basic Reset
SELECT/RESET
3 sec
Forced Reset
MENU/SET
2 sec
Forced Display [FdP]
MENU/SET
5 sec
Main Menu
20 sec
Special Function Menu
MENU/SET & SELECT/RESET
Simultaneously
Table 5 - Menu and Function Selection
- 22 -
Further explanation on how to enter the functions will be given in the following discussion. The Main
Menu has five functions within it (See Table 6) and the Special Function Menu has five functions (See
Table 7).
To enter the Main Menu, press the MENU/SET button for approximately 5 seconds, until ‘Err Chc’ or
‘SPd’ is displayed, then release it. Once in the Main Menu, the next selection can be brought up by
pressing the MENU/SET button. The SELECT/RESET button is used to accept a currently displayed
selection.
Failure to activate any buttons for a period of 10 seconds will result in the controller returning to the
Normal Operating Mode. Selecting the Return function will also return the controller to the Normal
Operating Mode. When ‘rtn’ is on the lower digital display, momentarily press the SELECT/RESET
button.
Summary of Main Menu:
Enter Main Menu:
Find Desired Function:
Select Function:
Next Function:
Exit Main Menu:
MENU/SET for 5 sec.
MENU/SET
SELECT/RESET
MENU/SET
no buttons for 10 sec. or Select RETURN function
UPPER DIGITAL
DISPLAY
LOWER DIGITAL
DISPLAY
Chc
Err
Error Check (hidden if no errors)
blank
SPd
Set Point Display
blank
CAL
Calibration
blank
SrP
Sensor Replacement
rtn
Return
blank
Table 6 - Main Menu Selection
FUNCTION
UPPER DIGITAL
DISPLAY
LOWER DIGITAL
DISPLAY
blank
FOP
Forced current output
blank
CUC
Current output calibration
Adr
SEt
Set network address
blank
Chd
Channel display
blank
bPS
Bypass
blank
rtn
Table 7 - Special Function Menu Selection
Return
FUNCTION
START-UP PROCEDURE
1
Output loads that are normally actuated by the system should be secured. Remove power
from all of the output devices to prevent undesired activation.
2
Check all external wiring for proper connections. Be sure that the sensor has been wired
properly.
3
Before installing the controller, inspect it to verify that it has not been physically
damaged in shipment. Check the dip switches on the controller for proper programming.
- 23 -
4
Apply power to the system.
NOTE
The controller has a 45 or 90 second delay (as programmed), before beginning normal operation,
after power is applied to the system. During this time the outputs are inhibited, the Fault LED is
illuminated, the upper digital display cycles through the active channels, and the lower digital
display counts down from 45 or 90. This delay allows time for the sensors to stabilize before
beginning normal operation.
5
Put the controller in the Set-point Display Mode to check the present alarm set-points and
calibration gas concentration. If changes are required, refer to the ‘Dip Switch Setting’
section of the manual.
6
Calibrate the sensor(s); refer to the Sensor Calibration Procedure.
7
Remove mechanical blocking devices (if used) and restore power to the output loads.
MAIN MENU SELECTIONS
ERROR CHECK MODE (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 during the Error Message Display Mode.
Two types of faults are identified: system faults and channel faults. Table 7 lists the codes and the
corresponding conditions.
If a fault should occur:
<
the normally energized fault output is de-energized,
<
the Fault LED is illuminated, and
<
if no alarm is occurring and the controller is sequentially displaying each sensor input, the message
‘Err’ ‘Fnd’ (upper and lower displays) will be displayed after each sequence.
To view the fault code, enter the Main Menu, then momentarily press the SELECT/RESET button when
‘Err’ is displayed on the lower digital display. Next, press the MENU/SET button repeatedly; the upper
digital display will sequentially show:
‘SYS’ ‘CH1' ‘CH2' ‘CH3' ‘CH4' ‘Clr’ -
system faults
channel 1 faults
channel 2 faults
channel 3 faults
channel 4 faults
clear faults
NOTE
If no errors exist, this function is hidden and can not be accessed.
To select the fault to be displayed, momentarily press the SELECT/RESET button when the required fault
is being displayed on the upper digital display. The upper digital display will show the channel (or system)
and the lower digital display will show the fault code, for 5 seconds then move to the next channel.
- 24 -
NOTE
Faults that affect the actual function of the controller (50, 60, 70, 9X) can impair the ability of the
controller to maintain an alarm output.
All faults automatically reset except the 9X, 20, and 10 faults. After the fault condition has been corrected,
the fault output automatically switches to the normal (energized) state, the DC current output returns to
normal, and the Fault LED turns off. Clearing 9X faults requires removing operating power from the
controller for approximately one second. Clearing 20 and 10 requires a reset.
CAUTION
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 that they are operational.
SET-POINT DISPLAY MODE (SPd)
In this mode, the digital displays sequentially display the low and high alarm, calibration gas concentration,
and communication address, automatically. This function is used to check the present alarm and calibration
gas set-point values, and the communications address.
1
To enter the Set-point Display Mode, enter the Main Menu, press the MENU/SET button
repeatedly until ‘Spd’ is displayed on the lower digital display, then momentarily press
the SELECT/RESET button.
2
The Low LED goes on, ‘LoA’ is shown on the upper digital display, and the low alarm
set-point is shown on the lower digital display for 2 seconds.
3
The Low LED goes out, the High LED goes on, ‘HiA’ is shown on the upper digital
display, and the high alarm set-point is shown on the lower display for 2 seconds.
4
The High LED goes out, the Cal LED goes on, ‘CAL’ is shown on the upper display, and
the calibration gas concentration (in percent LEL) is shown on the lower display for 2
seconds.
5
The Cal LED goes out, ‘Adr’ is shown on the upper display and the lower digital display
shows the communication address for the CAN interface for 2 seconds.
6
Finally, the controller returns to the normal operating mode (it is no longer in the main
menu).
7
If adjustments to the set-points are required, the settings on the programming dip switches
must be changed; Refer to ‘DIP SWITCH SETTINGS’ in the ‘SYSTEM
INSTALLATIONS’ section of this manual for instructions. If adjustments are required
for the communication addresses, refer to the Address Set procedure. When the set-point
levels are acceptable, record this information for future reference and proceed to
‘CALIBRATION.’
NOTE
IT IS VERY IMPORTANT THAT POWER TO THE CONTROLLER IS RECYCLED AFTER ANY
DIP SWITCH CHANGES, TO MAKE THE CHANGES TAKE EFFECT!
- 25 -
STATUS
CONDITION
WHAT TO DO
E90
Dip Switch Configuration error
Check dip switch settings and recycle power.
E91
RAM or processor failure
Consult the Factory.
E94
Set-point and calibration data lost
Consult the Factory.
E95
Internal 5 volt supply failure during start-up
Consult the Factory.
E96
External 24 volt supply failure during startup
Consult the Factory.
E97
EEPROM failure
Consult the Factory.
E98
Duplicate Communication address.
Check Communication address and change
to a vacant address.
E99
Lost communication.
Check communication wiring, disconnect
controller, and re-connect it. If this does not
help, contact the factory.
CHx E80
Sensor output is more than 26 mA
Check wiring and signal output from sensor.
CHx E70
External reset switch has been activated for
15 seconds or longer. Self clearing when
switch is released.
Check external reset switch for a short, or
faulty operation.
CHx E40
Sensor (or transmitter) input failure; input is
below 1 mA.
Check wiring and signal output from sensor.
CHx E30
Negative zero drift; sensor (or transmitter) is
-9% full scale or lower.
Calibrate transmitter.
CHx E20
Time ran out while waiting for the user to
apply gas to the sensor.
Restart calibration procedure.
CHx E21
Sensor (or transmitter) output is too low;
enough offset to get an accurate calibration
is not being generated.
Calibrate transmitter or replace sensor.
CHx E22
Sensor can not be calibrated.
Calibrate transmitter or replace sensor.
CHx E23
Sensor is too sensitive for the detector to
read 100% full scale.
Calibrate transmitter or replace sensor.
CHx E24
Zero point is more than 6% below standard
value.
Calibrate transmitter.
CHx E25
Zero point is more than 6% above standard
value.
Calibrate transmitter.
CHx E10
Calibration was successful, but sensor
reaching end of life or time to change jumper
position on transmitter.
Be prepared to calibrate transmitter or
replace sensor at next calibration time.
CHx goP
Over-range error (reading greater than 100%
of full range).
Table 8 - System Status Codes
Insure area has been de-contaminated then
perform a forced reset.
(Chx = Channel number)
SENSOR CALIBRATION (CAL)
General Information:
Various factors affect the interval between periodic calibrations. Exposure to certain contaminants in the
air, accumulation of contaminants on the filter, or an extended period of normal operation can cause
changes in sensitivity. Since each application is different, the length of time between regularly scheduled
- 26 -
calibrations can vary from one installation to the next. In general, the more a system is checked, the greater
the reliability. A calibration must be performed:
<
<
<
when a new system is initially put into service,
when the sensor is replaced, or
when a controller is replaced.
IMPORTANT
To ensure adequate protection, the detection system must be calibrated on a regularly scheduled
basis.
The Controller uses a fully automatic calibration procedure that requires no adjustments by the operator.
The controller performs the zero adjustments, then signals the operator when to apply and when to remove
the calibration gas.
While in the Sensor Calibrate Mode, all controller outputs are inhibited, the current output is 3mA, and the
Cal LED is illuminated.
NOTE
If the sensor is being replaced, refer to the 'Sensor Replacement' section (under 'Maintenance') in
this manual for information regarding replacement and calibration of the sensor.
Calibration Procedure:
1
The sensor should be allowed to stabilize for a minimum of 4 hours, although it is best to
allow 24 hours for the sensor to stabilize.
2
Be certain that the controller is properly programmed for the gas concentration being used
for calibration. (Refer to ‘SET-POINT DISPLAY MODE’ to check programmed value.)
Reprogram the controller if required. (Refer to ‘DIP SWITCH SETTINGS.’) Failure to
do so will greatly impair system response.
NOTE
IT IS VERY IMPORTANT THAT POWER TO THE CONTROLLER IS RECYCLED AFTER ANY
DIP SWITCH CHANGES, TO MAKE THE CHANGES TAKE EFFECT!
3
Be sure that only clean air is present at the sensor. The microprocessor begins taking zero
readings immediately upon entering the Calibrate Mode. If the possibility of background
gases exists, purge the sensor with clean air to assure an accurate calibration.
4
Enter the Main Menu, press the MENU/SET button repeatedly until ‘CAL’ is shown on
the lower digital display, then momentarily press the SELECT/RESET button.
5
Once in the sensor calibrate mode, the lower digital display will continue to show ‘CAL’
and the upper digital display will show ‘Chn’. Press the MENU/SET button repeatedly
until the desired channel is shown on the upper digital display, then momentarily press
the RESET/SELECT button.
6
Once the required channel has been selected, the controller will automatically start taking
zero readings. The upper digital display will show ‘Air’ and the lower display will flash a
value close to zero. When the zero calculations are complete (30 seconds minimum), the
lower digital display stops flashing and reads '00'; the upper display will now alternately
display ‘gas’ and ‘in’.
7
Apply the calibration gas to the sensor. The lower digital display starts to flash, and the
value indicated on the display rises. The bar graph display also indicates the level of gas
at the sensor, but does not flash. The upper display will show ‘gas’.
- 27 -
8
When the microprocessor has completed the gain adjustments (30 seconds minimum), the
lower digital display stops flashing and the upper display will alternately display ‘Cut’
and ‘gas’.
9
Remove the calibration gas. When the gas level falls to half the low alarm set-point, the
controller automatically returns to the normal operating mode.
10
If another sensor must also be calibrated, return to step 1.
If the operator fails to complete the calibration procedure or if the sensitivity of the sensor has deteriorated
to the extent that calibrations cannot be successfully completed, a calibration fault (‘E2X’ status) will be
generated. The system will automatically revert to the former calibration settings (after 10 minutes or when
the gas level drops below the lowest set-point). If a successful calibration cannot be accomplished, replace
the sensor and calibrate (refer to the transmitter/sensor manual, as some transmitters will have gain jumpers
which need to be changed and the sensor may still be useful).
If the microprocessor determines that the sensor is approaching the end of its useful life or the gain jumper
on the transmitter needs to be changed, ‘E10' will be indicated on the digital display. This does not indicate
a system malfunction, but is intended to notify the operator of this condition. A successful calibration can
still be performed, but the operator should be prepared to change the sensor at the time of the next
calibration. Press SELECT/RESET after completing calibration to clear the display.
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 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 count down (45 or 90 seconds) for the replaced sensor,
and the affected current output will drop to 1mA.
SPECIAL FUNCTION MENU SELECTIONS
FORCED CURRENT OUTPUTS (FoP)
The forced current output mode is used to check the current output calibration and the operation of any
devices connected to the current outputs.
To enter the forced current output mode, enter the special function menu. When ‘FoP’ is shown on the
lower display, press the SELECT/RESET button. Upon successful entry into this mode the upper display
will flash ‘gPn’. Press the MENU/SET button until the desired area output is reached (‘GPA’ = Area 1 and
‘GPb’ = Area 2), then press the SELECT/RESET button.
When an area has been chosen for forced current output, the upper display will alternate between ‘GPX’
and ‘FoP’ and the lower display will show what type of current output (in gas concentration) is being
placed on the current output line.
The push-button switches are used to change the current output. To exit this function, hold the
SELECT/RESET button down until ‘rtn’ is shown on the lower display. Release the button, and the
controller will return to the normal operating mode in 10 seconds if no buttons are pushed.
- 28 -
CURRENT CALIBRATION MODE (CuC)
The next selection in the special function menu is the current calibration mode. This mode is selected to
calibrate the current outputs. The Area output to calibrate is chosen as in the Forced Current Output Mode.
Once an area has been selected, the upper display will alternate between ‘CuC’ and the area that is being
calibrated (‘GPX’, where X indicates group A or B). The lower display will show a constant which will
rise and fall as the current is adjusted (does not show the current on the outputs). Place a milliamp metre
between the Area current output and system common. Use the push-buttons to raise and lower the current.
Once the current measured is as close to 4mA as possible, do not press any buttons for 10 seconds and the
constant shown on the lower display will change to a much higher number. This tells the operator that it is
time to calibrate the higher end of the current output range. Use the push-buttons to bring the current level
as close as possible to 20mA. Do not press any buttons for 10 seconds and the constant shown on the
display will change to a lower number. Now it is time to calibrate the current output to 3.3mA for when the
controller is in the calibration mode. Once this current level is set, do not press any buttons for 10 seconds
and the controller will return to the normal operating mode.
ADDRESS SET MODE (Adr Set) (OPTIONAL)
The next selection in the special function menu is the address set mode, used to set the controllers address
for the Digital Communication system. When the upper display shows ‘Adr’ and the lower display shows
‘SEt’ press the SELECT/RESET button. The upper display will alternate between ‘Adr’ and ‘SEt’ and the
lower display will show the current address. Use the push-buttons to raise and lower the address. Once the
address is correct, do not press any buttons for 10 seconds and the controller will return to the normal
operating mode.
CHANNEL DISPLAY(Chd)
In this mode, the displays can be forced to monitor only one channel, as long as no alarms are occurring. If
any alarm occurs, the controller will return back to the Normal Operating Mode for the situation when an
alarm is occurring.
Enter the Special Function Menu, press the MENU/SET button repeatedly until ‘Chd’ is displayed on the
lower digital display, then momentarily press the SELECT/RESET button. The upper digital display will
show ‘Chn’. Press the MENU/SET button repeatedly to toggle through the
(Channel Display Cont)
channels (CH1, CH2, CH3, or CH4). To select a channel, momentarily press the SELECT/RESET button
when the required channel is displayed, on the upper digital display. The displays will now only display the
information for the chosen channel.
To return to the normal operating mode, enter the manual display mode again and instead of selecting a
single channel, select ‘ALL’.
BYPASS (bPS)
The bypass mode is entered through the special functions menu. Enter the special functions menu and press
the MENU/SET button repeatedly until ‘bPS’ is shown on the lower digital display, then momentarily press
the SELECT/RESET button. The lower digital display will still show ‘bPS’ and the upper display will
show ‘gPn’. Select the group to put in bypass mode by pressing the MENU/SET button repeatedly until the
desired group is shown, then press the SELECT/RESET button momentarily.
While in bypass mode, the alarm outputs for the selected group(s) are inhibited. The HIGH alarm relay is
common to both groups, and is inhibited even if the unselected group has an alarm condition. CAUTION
SHOULD BE USED WHILE IN BYPASS MODE.
- 29 -
To exit the bypass mode, press the SELECT/RESET button momentarily.
OPERATING MODES
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 pressed momentarily, all LEDs turn
off and all outputs return to their normal condition if no alarms or faults are occurring.
FORCED RESET MODE
If any of the channels gets 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 in the error check mode and then a forced reset must be applied. To apply a forced reset, press
the SELECT/RESET button for 3 seconds, the LEDs turn off and the outputs return to their normal
condition. Remote reset performs a forced reset.
NOTE
The remote reset performs a reset function only. It cannot be used for other controller functions.
NORMAL OPERATING MODE
In Normal Operating Mode with no alarm:
<
<
<
<
<
The digital and bar graph displays are on and indicate the sensor(s) input(s). If only one channel is
active, then the displays will stay on that channel; if two or more channels are active, the displays
will sequentially display the channels, for 5 seconds each. The upper digital display will indicate
the channel (CH1, CH2, CH3, or CH4) and the lower digital display will indicate the sensor
reading.
The Channel LEDs will indicate which channel the digital display is referring to.
All other LEDs are off.
Alarm relays are in their normal state, energized or de-energized as programmed.
Fault relay is energized.
In the Normal Operating Mode with a low alarm(s) condition occurring:
<
<
<
<
<
<
Digital and bar graph displays indicate the sensor input(s) as outlined above.
If one channel is in alarm, the system will stay at that channel.
If more than one channel is in alarm, the channel with the ‘highest’ alarm condition will be
displayed. The channel LED of other channels will flash to notify that an alarm condition exists.
To force the display of a channel with a ‘lower’ alarm, go into the Forced Display Mode, as
outlined in the next section.
Low LED flashes.
Low alarm relay changes state.
Fault relay is energized and fault LED is off.
When the signal decreases below the low set-point:
<
<
<
<
The digital display and bar graph display continue to track the sensor input.
With latching operation programmed, low alarm relays will not change.
With non-latching operation programmed, low alarm relays will return to their normal state.
Low Alarm LEDs are on steady, while the affected channel is displayed, until reset.
- 30 -
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.
If one or more channels reach an ‘over-range’ (>100% of full scale) condition, the error must be cleared in
the error check mode and then a forced reset must be performed once the channel has returned to normal. A
basic reset will not clear an over-range error.
FORCED DISPLAY (FdP)
In the normal operating mode with no alarms occurring, the digital and bar graph displays will sequentially
display each of the channel sensor readings. If an alarm condition occurs, the displays will remain on the
channel with the alarm (or ‘highest’ alarm if more than one channel is in an alarm condition). In this
situation, the forced display mode can be used to temporarily view the sensor readings of the other
channels.
To enter the Forced Display Mode, press the MENU/SET button for 2 seconds, until the lower digital
display shows ‘FdP’. Momentarily press the SELECT/RESET button to select this function. The digital
displays will then sequentially display each of the active channels once before returning to the Normal
Operating Mode automatically.
Unit IV
SYSTEM MAINTENANCE
ROUTINE MAINTENANCE
To ensure reliable protection, it is important to check and calibrate the detection system on a regularly
scheduled basis. The frequency of these checks is determined by the requirements of the particular
installation.
MANUAL CHECK OF OUTPUT DEVICES
Fault detection circuitry continuously monitors for problems that could prevent proper system response. It
does not monitor external response equipment or the wiring to these devices. It is important that these
devices be checked initially when the system is installed, and periodically during the ongoing maintenance
program.
SYSTEM CHECK IN NORMAL MODE
The system must be checked periodically in the Normal Operating Mode to ensure that those items not
checked by the controller diagnostic circuitry (such as output relays) are functioning properly.
CAUTION
Be sure to secure all output devices actuated by the system to prevent unwanted activation of this
equipment, and remember to place these same output devices back into service when the checkout
is complete.
- 31 -
SENSOR REPLACEMENT
The area must be declassified or power to the sensor must be removed prior to replacing the sensor in a
hazardous area.
1
Enter the Main Menu; momentarily press the SELECT/RESET button once the message
‘SrP’ appears on the lower digital display.
2
Once in the sensor replace mode, the lower digital display will continue to show ‘SrP’
and the upper digital display will show a channel selection: CH1, CH2, CH3, or CH4.
If the channel that is first displayed corresponds to the senor to be replaced, momentarily
press the SELECT/RESET button to select that channel. If the first channel displayed is
not the required channel, press the MENU button; the upper digital display will
sequentially display the operational channels each time the MENU/SET button is
pressed. Press the SELECT/RESET button, once the required channel is displayed.
3
Once the required channel has been selected, the display reads '00' and the Channel LED
and Fault LED are illuminated. The controller is in the Sensor Replacement Mode.
Once in the Sensor Replacement Mode follow the instructions in the sensor manual for replacement.
NOTE
If power was removed from the controller during the sensor replacement procedure, the controller
will automatically return to the Normal Mode when power is restored (after a 45 or 90 second
time delay). To prevent the possibility of alarms, allow the system to warm up in the Sensor
Replacement Mode..
An adequate supply of spare sensors should be kept on hand for field replacement. For maximum
protection against contamination and deterioration, they should not be removed from the original protective
packaging until the time of installation.
TROUBLESHOOTING
Table 9 is intended to serve as an aid in locating the cause of a system malfunction. If this table is not
helpful, contact an authorized repair person.
The Uni-Trol™ Controller is not designed to be repaired by the customer in the field. If a problem should
develop, first carefully check for proper wiring, programming and calibration. If it is determined that the
problem is caused by an electronic defect, the device must be returned to the factory for repair.
NOTE
When replacing a controller, remove power before removing the device from the enclosure or
installing the replacement unit.
The sensor is not intended to be repaired. When calibration can no longer be properly performed, the
sensor must be replaced. The frequency of replacement will be determined by the amount and type of
contamination present at the particular installation. An adequate supply of spare sensors should be kept on
hand for field replacement. Always calibrate the sensor after it has been replaced.
- 32 -
DEVICE REPAIR AND RETURN
The unit is under full warranty for THREE YEARS (from date of purchase). Net Safety Monitoring Inc.
supplies all distributors with advance replacement units. These units are available to the user during the
warranty period. This allows Net Safety Monitoring Inc. to take the time to repair the unit completely while
customers keep their operations running smoothly with the advance replacement unit.
Prior to returning devices or components, contact the nearest local distribution office so that an RMI
(Return Material Identification) number can be assigned. A written statement describing the malfunction
must accompany the returned device or component to expedite finding the cause of the failure, thereby
reducing the time and cost of the repair to the customer. Pack the unit or component properly. Use
sufficient packing material in addition to an anti-static bag or aluminum-backed cardboard as protection
from electrostatic discharge.
PROBLEM
POSSIBLE CAUSE
No Faceplate indicators
illuminated.
<
<
Wiring to external power source.
Input power failure.
FAULT LED on, digital
display blank.
<
<
Power-up time delay (45 seconds).
If condition continues after 45 seconds, repeat power-up. If a problem
continues, check dip switches or replace controller.
E90 to E97 Status
<
Initialization failure. Repeat power-up. If successful, re-program
and re-calibrate. If not, replace controller.
E96 Status
<
Input power problem. Check operation of power source and power
wiring.
E70 Status
<
External reset activated for over 15 seconds. Check external switch
and wiring.
E40 Status
<
<
<
Sensor input problem. Check sensor and/or transmitter wiring and
calibration.
Faulty sensor. Replace and calibrate.
Faulty transmitter. Replace and calibrate.
E30 Status
<
<
<
Negative zero drift. Calibrate sensor.
Faulty sensor. Replace and calibrate.
Faulty transmitter. Replace and calibrate.
E20, E21 Status
<
Calibrate error. Re-calibrate.
E22, E23 Status
<
Sensor sensitivity out of tolerance. Calibrate transmitter. If problem
continues, replace sensor and calibrate.
E10 Status
<
Sensor reaching end of life - no problem at present time. Be prepared
to replace sensor at next calibration (calibration attempt might fail).
Table 9 - Troubleshooting Guide
- 33 -
Appendix A
Net Safety Monitoring Inc.
Electrostatic Sensitive Device Handling Procedure
With the trend toward increasingly widespread use of microprocessors and a wide variety of other
electrostatic sensitive semiconductor devices, the need for careful handling of equipment containing these
devices deserves more attention than it has received in the past.
Electrostatic damage can occur in several ways. The most familiar is by physical contact. Touching an
object causes a discharge of electrostatic energy that has built up on the skin. If the charge is of sufficient
magnitude, a spark will also be visible. This voltage is often more than enough to damage some electronic
components. Some devices can be damaged without any physical contact. Exposure to an electric field can
cause damage if the electric field exceeds the dielectric breakdown voltage of the capacitive elements
within the device.
In some cases, permanent damage is instantaneous and an immediate malfunction is realized. Often,
however, the symptoms are not immediately observed. Performance may be marginal or even seemingly
normal for an indefinite period of time, followed by a sudden and mysterious failure.
Damage caused by electrostatic discharge can be virtually eliminated if the equipment is handled only in a
static safeguarded work area and if it is transported in a package or container that will render the necessary
protection against static electricity. Net Safety Monitoring Inc. modules that might be damaged by static
electricity are carefully wrapped in a static protective material before being packaged. Foam packaging
blocks are also treated with an anti-static agent. If it should ever become necessary to return the module, it
is highly recommended that it be carefully packaged in the original carton and static protective wrapping.
Since a static safeguarded work area is usually impractical in most field installations, caution should be
exercised to handle the module by its metal shields, taking care not to touch electronic components or
terminals.
In general, always exercise all of the accepted and proven precautions that are normally observed when
handling electrostatic sensitive devices.
A warning label is placed on the packaging, identifying those units that use electrostatic sensitive
semiconductor devices.
*Published in Accordance with E1A
standard 471
i
Appendix B
Record Of Dip Switch Settings
DIP SWITCH
ON
SW3.1
SW3.2
SW3.3
SW3.4
SW3.5
SW3.6
SW3.7
SW3.8
SW4.1
SW4.2
SW4.3
SW4.4
SW4.5
SW4.6
SW4.7
SW4.8
SW5.1
SW5.2
SW5.3
SW5.4
SW5.5
SW5.6
SW5.7
SW5.8
ii
OFF
Appendix C
Wire Resistance In Ohms
Distance
(Feet)
AWG #20
100
1.02
0.64
0.40
0.25
0.16
0.10
0.06
200
2.03
1.28
0.08
0.51
0.32
0.20
0.13
300
3.05
1.92
1.20
0.76
0.48
0.30
0.19
400
4.06
2.55
1.61
1.01
0.64
0.40
0.25
500
5.08
3.20
2.01
1.26
0.79
0.50
0.31
600
6.09
3.83
2.41
1.52
0.95
0.60
0.38
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
9.14
5.75
3.61
2.27
1.43
0.90
0.57
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
AWG #18 AWG #16 AWG #14 AWG #12 AWG #10
AWG #8
NOTE: RESISTANCE SHOWN IS ONE WAY. THIS FIGURE SHOULD BE DOUBLED WHEN
DETERMINING CLOSED LOOP RESISTANCE.
iii
Distributed By:
2721 Hopewell Place NE
Calgary, Alberta, Canada T1Y 7J7
Telephone: (403) 219-0688 Fax: (403) 219-0694
www.net-safety.com
E-mail: netsafe@net-safety.com