MODEL: S1G-100-LEL and S2G-100-LEL with PE1100
UNI-TROL™ GAS CONTROLLER
Single-Channel Field Mount Controller with LEL Sensor
REVISED: MAY, 1998
WARRANTY POLICY
The products of Net Safety Monitoring Inc, are carefully designed and m anufactured from high
quality com ponents and can be expected to provide m any years of trouble free service. Each
product is thoroughly tested, inspected and burned-in prior to shipm ent. Failures can occur which
are beyond the control of the m anufacturer. Failures can be m inim ized by adhering to the
operating and m aintenance instructions herein. W here 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
workm anship for a period of 24 m onths from date of purchase and other electronic assem blies for
36 m onths from date of purchase.
No other warranties or liability, expressed or im plied, will be honoured by Net Safety
Monitoring Inc.
Contact Net Safety Monitoring Inc. or the authorized distributor for details.
Table of Contents
Unit I - GENERAL INFORMATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1 - Controller Dimensions in Inches . . . . . . . . . . . . . . . . . .
Figure 2 - Controller Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . .
BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FACEPLATE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELAY OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECOMMENDATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CURRENT OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3 - Jumper Selections For Isolated or Non-Isolated Current
Table 1 - Current Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROGRAMMING OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 2 - Selectable Output Options . . . . . . . . . . . . . . . . . . . . . . .
EXTERNAL RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC DIAGNOSTICS AND FAULT IDENTIFICATION . . .
OPERATING MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NORMAL OPERATING MODE . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESET MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FORCED RESET MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENSOR REPLACEMENT MODE(SrP) . . . . . . . . . . . . . . . . . . . .
SENSOR CALIBRATION MODE(CAL) . . . . . . . . . . . . . . . . . . . . .
SET-POINT DISPLAY (Spd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADDRESS SET (Adr Set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ERROR MESSAGE DISPLAY (ErrChc) . . . . . . . . . . . . . . . . . . . . .
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Output
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1
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2
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3
3
3
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4
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5
5
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6
6
6
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7
7
7
UNIT II - GENERAL INFORMATION (SENSOR)
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INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENSOR LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL W IRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROLLER W IRING . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5a - W iring for S1G with Non-Isolated Current Output
Figure 5b - W iring for S1G W ith Isolated Current Output . . . .
Figure 6a - W iring for S2G with Non-Isolated Output . . . . . . .
Figure 6b - W iring for S2G W ith Isolated Current Output . . . .
DIP SW ITCH SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7a - Dip Switch Position . . . . . . . . . . . . . . . . . . . . . . .
Figure 7b - Dip Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACTIVE CHANNELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CALIBRATION GAS CONCENTRATION . . . . . . . . . . . . . . .
POW ER-UP TIME DELAY . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALARM SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LATCHING/NON-LATCHING SELECTION . . . . . . . . . . . . . .
Table of Contents (Cont)
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DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . .
Figure 4 - Sensor and Transmitter Dimensions .
LOW ER EXPLOSIVE LIMIT . . . . . . . . . . . . . . . . . . . . . .
Table 3 - Flammable Gas Volume for 100% LEL
OPERATIONS OVERVIEW . . . . . . . . . . . . . . . . . . . . . .
Table 4 - K Factor for Various Gases . . . . . . . . .
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UNIT III - GENERAL INFORMATION (SENSOR)
12
12
12
13
14
15
16
17
18
18
18
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19
19
20
ENERGIZED/DE-ENERGIZED SELECTION . . . . .
RELAY SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9a - Relay Positions . . . . . . . . . . . .
Figure 9b - Relay Settings . . . . . . . . . . . . .
Table 5 - Summary of Dip Switch Settings
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21
21
21
21
22
UNIT IV - SYSTEM OPERATION
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32
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34
34
........
MENU AND FUNCTION SELECTION . . . . . . . . . .
Table 6a - Menu and Function Selection . .
Table 6b - Main Menu Selection . . . . . . . .
Table 7 - Special Function Menu Selection
START-UP PROCEDURE . . . . . . . . . . . . . . . . . . .
MAIN MENU SELECTIONS . . . . . . . . . . . . . . . . . .
ERROR CHECK MODE(ERR CHC) . . . . .
SET-POINT DISPLAY MODE (SPd) . . . . .
Table 8 - System Status Codes . . . . . . . . .
SENSOR CALIBRATION (CAL) . . . . . . . . . . . . . . .
GENERAL INFORMATION . . . . . . . . . . . .
CALIBRATION PROCEDURE . . . . . . . . .
SENSOR REPLACEMENT MODE (SrP) .
SPECIAL FUNCTION MENU SELECTIONS . . . . .
FORCED CURRENT OUTPUTS (FoP) . .
CURRENT CALIBRATION MODE (CuC) .
ADDRESS MODE (Adr Set) . . . . . . . . . . .
CHANNEL DISPLAY (Chd) . . . . . . . . . . . .
BYPASS (bPS) . . . . . . . . . . . . . . . . . . . . .
OPERATING MODES . . . . . . . . . . . . . . . . . . . . . .
RESET MODE . . . . . . . . . . . . . . . . . . . . . .
FORCED RESET MODE . . . . . . . . . . . . .
NORMAL OPERATING MODE . . . . . . . . .
FORCED DISPLAY (FdP) . . . . . . . . . . . . .
UNIT V - SYSTEM MAINTENANCE
ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . .
MANUAL CHECK OF OUTPUT DEVICES
SYSTEM CHECK IN NORMAL MODE . . .
SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . .
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . .
DEVICE REPAIR AND RETURN . . . . . . . . . . . . . .
Table 10 - Troubleshooting Guide . . . . . . .
Unit I
GENERAL INFORMATION (CONTROLLER)
DESCRIPTION
TheS1G and S2G Uni-Trol™ Controller accepts input directly from PE1100 com bustible gas
sensors. The controller is designed to accept the m illivolt signal from the SC1100 LEL sensor
without the need for a transm itter to change the signal to a 4-20m A current signal. Controller
response includes actuation of relays for direct control of field response devices, 4-20m A DC
current output and, a full array of faceplate indicators.
FEATURES
<
<
<
<
<
<
Controller accepts m illivolt inputs (PE1100 LEL sensor).
Two digital displays, one bar graph display, and high intensity LEDs indicate im portant
system status inform ation.
AutoCal feature provides easy and accurate calibration.
Microprocessor-based controller is easily field program m able.
4-20m A current output send im portant system inform ation to other devices.
Relay alarm and fault outputs.
SPECIFICATIONS
<
Operating Voltage:
24 Volts DC. Device can operate between 18 and 32 Volts DC
<
Pow er Consumption (Controller Only):
3.0 W atts nom inal, 5.2 W atts m axim um (125 m A nom inal, 215 m A m axim um at
24 Volts DC).
Maxim um startup current is 1.0 Am peres for 5 seconds. Power supplies with fold
back current lim iting are not recom m ended
<
M aximum Ripple:
Ripple should not exceed 5 Volts peak-to-peak. The sum of DC plus ripple m ust
be $18 Volts DC and #32 Volts DC.
<
Temperature Range:
Operating:
Storage:
-40ºC to +85ºC
-55ºC to +150ºC
(-40ºF to +185ºF)
(-65ºF to +302ºF)
<
Relay Contacts:
Form C norm ally open/norm ally closed contacts rated for 5 Am peres at 30 Volts
DC/ 250 Volts AC
<
Current Outputs:
One 4-20m A DC current, with a m axim um external loop resistance of 600S at 1832 Volts DC.
<
Dimensions:
Refer to Figure 1
-1-
<
Shipping W eight (Approxim ate):
6 lbs. (2.7 kilogram s)
<
Certification:
CSA certified for hazardous locations, Class 1, Division 1, Groups B, C, and D.
Figure 1 - Controller Dimensions in Inches
Figure 2 - Controller Front Panel
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 input, and m agnetically activated MENU/SET and
SELECT/RESET reed switches (see the appendix for activation instructions) for program m ing,
calibrating and resetting the system . Refer to Figure 2 for the location of indicators and switches.
<
Digital Displays - Two digital displays are used to display the sensor input in both the
Norm al 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 alphanum eric code. In the Norm al Operating Mode the gas concentration at the
sensor is shown. In other operating m odes, the digital displays show the alarm set-points,
program m ed calibration gas concentration, output current, or the com m unication
addresses for the CAN interface. A negative zero drift condition is indicated by a m inus
sign in the left-hand digit. Since at least one display is always lit, they also function as a
power indicator.
<
Bar Graph Display - The com m on 10-segm ent bar graph display provides readings of
the sensor input in 5% LEL increm ents, from 0% to 50% LEL; all 10 segm ents are
illum inated when 50% LEL is exceeded.
<
High Alarm LED (HI) - Flashes in response to a sensor signal that exceeds the high
alarm set-point.
<
Low Alarm LED (LOW ) - Flashes in response to a sensor signal that exceeds the low
alarm set-point.
<
Calibrate LED (CAL) - is illum inated while the controller is in the Calibration Mode.
-2-
<
Fault LED (Fault) - is illum inated upon detection of an overall system fault or a channel
related fault.
<
Channel LEDs - are illum inated when status on the corresponding channel is displayed
on the com m on indicators (digital displays and bar graph). During power-up, a channel
LED is on if the channel is selected for operation.
<
M ENU/SET Reed Sw itch - is used for changing the m enu display resetting the controller
calibration and other system program m ing and calibration functions.
<
SELECT/RESET Reed Sw itch - is used for m enu selection, and other system
program m ing, for resetting the controller.
OUTPUTS
Relay Outputs:
The relay outputs have SPDT contacts rated for 5 Am peres at 30 Volts DC or 250 Volts AC. The
four relays include an Area 1 low alarm (channel 1), an Area 2 low alarm (channel 2) one com m on
high alarm , and 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 4-20m A DC current output for transm itting system inform ation to other devices are also
included. The current outputs can be wired for isolated or non-isolated operation by changing the
jum pers as shown in Figure 3. Refer to Table 1 for a description of the current output signal
levels.
-3-
Figure 3 - Jumper Selections For Isolated or
Non-isolated Current Output
Current Output
Situation
0m A
Open or shorted signal output, or loss of power
1m A
Fault or Power-Up
2m A
Power Fault
3m A
Calibration
4m A to 20m A
0 to 100% LEL gas concentration
Table 1 - Current Outputs
-4-
PROGRAM M ING OPTIONS
A set of dip-switches, located on the circuit board, can be used to “program ” various options and
set-points, including:
<
channels selected for operation,
<
low and high alarm settings,
<
calibration gas concentration,
<
power-up delay tim e (either 45 or 90 seconds),
<
latching / non-latching relay action
<
energized / de-energized relay action
The alarm relays are program m able for either norm ally energized or norm ally de-energized
operation (program m able as a group only, not individually). The fault relay is norm ally energized.
The low alarm relays are program m able for either latching or non-latching operation. The high
alarm relay is always latching and the fault relay is non-latching. Refer to Table 2.
Jum per selections are provided for norm ally open or norm ally closed relay outputs and for isolated
or non-isolated current outputs.
OUTPUT
Selectable Norm ally
Open/Closed
Selectable Norm ally
Energized/De-Energized
Selectable
Latching/Non-latching
LOW 1
Y
Y2
Y
HIGH
Y
Y2
N3
FAULT
Y
N4
N5
Table 2 - Selectable Output Options
1
Low alarms are programed together, not individually
2
Programmable together, not individually
3
High alarm relay is always latching
4
Fault relay is normally energized
5
Fault relay is non-latching
EXTERNAL RESET
A norm ally open, m om entary closure switch can be connected between the external reset term inal
and the negative power term inal to provide rem ote reset capabilities.
AUTOM ATIC DIAGNOSTICS AND FAULT IDENTIFICATION
The m icroprocessor-based controller features self-testing circuitry that continuously checks for
problem s that could prevent proper system response. W hen power is applied, the m icroprocessor
autom atically tests m em ory. In the Norm al Operating Mode, it continuously m onitors the input
signals from the sensor to ensure proper functioning. In addition, a "watchdog" tim er is m aintained
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 tim e.
-5-
If a fault is detected, the Fault LED illum inates, the digital display identifies that a fault has
occurred, the fault relay output becom es de-energized, and the current output drops to less than 1
m A.
The nature of the fault can be identified by a num eric code, which can be viewed in the Fault
Message Display m ode.
OPERATING M ODES
The controller can operate in any of the m odes discussed in this section. Operating m odes other
than Norm al are selected by activating the appropriate MENU/SET and SELECT/RESET switches
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 M ode:
If no alarm s or faults are present, the Module will be in a Level 1 Display Mode; the bar graph and
digital display indicate the sensor inputs. Relay outputs are in their norm al state, and the current
output corresponds to the sensor input.
If a low alarm condition occurs, the controller will be in a Level 2 Display Mode; the bar graph and
digital display will display the gas concentration at the sensor. The low alarm LED will flash, the
low alarm relay changes state, and the current output changes to indicate the alarm . If the signal
decreases below the low set-point again, the low alarm relay returns to its norm al state if
program m ed for non-latching operation and rem ains unchanged if program m ed for latching
operation. The current output returns to norm al. The low alarm LED will rem ain illum inated, but
will no longer flash.
If a high alarm condition occurs, the m odule will be in a Level 3 Display Mode; the bar graph and
digital display will display the gas concentration at the sensor and the high alarm LED will flash.
Reset M ode:
The system is reset by activating the SELECT/RESET switch located on the front panel of the
controller. (Refer to Figure 2) W hen the SELECT/RESET switch is activated m om entarily, all
outputs return to their norm al condition if no alarm s or faults are present. (basic reset).
Forced Reset M ode:
If the controller receives a signal beyond 100% LEL from the sensor, a reset will not clear the
alarm s, even if the channel has returned to levels below the low alarm set point. The error
resulting from this occurrence m ust be cleared and a forced reset applied. To apply a forced
reset, activate the SELECT/RESET switch for 1 second, the LEDs turn off and the outputs return
to their norm al condition. The rem ote reset perform s a forced reset.
NOTE
The remote reset performs a reset function only. It cannot be used for other controller
functions.
Sensor Replacem ent M ode (SrP):
This m ode inhibits all controller outputs to allow replacem ent of the sensor without rem oving
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 m ode. The right display will show the
status of the sensor being replaced (‘NoS’ m eans 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.
-6-
All other display features will be inhibited. In order to exit this m ode the SELECT/RESET switch
m ust be activated.
Sensor Calibration M ode (CAL):
The Uni-Trol™ Controller uses a fully autom atic calibration procedure that requires no adjustm ents
by the operator. The controller displays ‘Air’ on the left display and channel status on the right
display while autom atically perform ing the zero adjustm ents. Next the controller will signal the
user to apply calibration gas by alternating ‘gAS’ and ‘in’ on the left display. W hen the controller
detects that the gas has been applied to the sensor, the left display will read ‘gAS’. Once the
controller has finished the gain adjustm ents it will alternate ‘Cut’ and ‘gAS’ on the left display,
telling the user that it is tim e to rem ove the calibration gas. Upon com pletion of calibration the
controller will autom atically return to norm al operating m ode, after the gas level has dropped
below 50% of the low alarm setting.
If the operator fails to com plete 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 Norm al Operating Mode and continue to use the previous calibration data. A fault
indication will be displayed until a reset occurs. If the m icroprocessor determ ines that the sensor
is approaching the end of its useful life, a fault code will indicate this.
W hile in the calibration m ode, all controller outputs are inhibited and the ‘Cal’ LED is illum inated.
Set-Point Display (Spd):
In this m ode, the digital display sequentially shows the
program m ed low and high alarm set-points, calibration gas concentration, and com m unication
addresses. Each value is displayed for approxim ately 2 seconds.
Address Set (Adr Set): DO NOT USE THIS FUNCTION
The com m unication addresses for the CAN bus are set in this m ode, which is found in the special
function m enu. The MENU/SET and SELECT/RESET switches are used to raise and lower the
address. This m ode can only be exited by allowing ten seconds to go by without activating either
switch.
Error M essage Display (ErrChc):
The m icroprocessor-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 m essage after the last channel in the
cycling routine.
NOTE
If no errors exist, this function is hidden and can not be accessed.
-7-
Unit II
GENERAL INFORMATION (SENSOR)
DESCRIPTION
The Net Safety Monitoring Inc. SC1100 com bustible gas sensor head consists of an explosionproof enclosure, which contains sensor electronic circuitry. The sensors used are catalytic
oxidation sensors, or pellistors, designed to provide continuous m onitoring of com bustible gasses
such as m ethane and butane, etc. in the percent lower explosive lim its (LEL). Each sensor is a
m atched pair of detector and reference elem ents which are operated in a W heatstone Bridge
circuit.
FEATURES
High degree of poison resistance m eans sensors will m aintain their sensitivity over extended
periods of operation.
<
Designed and m anufactured for low drift over tem perature extrem es.
SPECIFICATIONS
<
Range:
0 to 100% LEL
<
Operating Hum idity Range:
0 to 100% relative hum idity
<
Response Time:
Less than 30 seconds to reach 90% of full scale reading with m ethane (in still air).
<
Zero Drift:
Typically less than 2% LEL per m onth
<
Sensor Life:
Operation:
Storage:
2 to 5 years expected.
Indefinite
<
Calibration Cycle:
60 to 90 Days Groups
<
Certification:
CSA certified for hazardous locations,
Class 1, Division 1, Groups B, C, and D.
-8-
Figure 4 - Sensor and Transmitter Dimensions
LOWER EXPLOSIVE LIMIT
A com bustible gas is one that will burn when m ixed with air (or oxygen) and ignited. The lower
explosive lim it (LEL), or lower flam m able lim it (LFL), of a com bustible gas is defined as the
sm allest am ount of the gas that will support a self-propagating flam e when m ixed with air and
ignited. In gas detection system s, the am ount of gas present is specified in term s of % LEL; 0%
LEL being a com bustible gas-free atm osphere and 100% LEL being an atm osphere in which the
gas m ix is at its lower explosive lim it. The relationship between % LEL and % by volum e differs
from gas to gas. Refer to Table 3.
GAS, 100% LEL
CONCENTRATION
Hydrogen (H 2)
4.0%
Methane (CH 4)
5.0%
Ethane (C 2H 6)
3.0%
Ethylene (C 2H 4)
2.7%
Pentane (C 5H 12)
1.5%
Propane (C 3H 8)
2.2%
Table 3 -Flammable Gas Volume for 100% LEL
For data on other gases, refer to NFPA 5th Edition 325M.
-9-
The LEL of gas is affected by tem perature and pressure. As the temperature increases, the LEL
decreases and hence the explosion hazard increases.
The relationship between LEL and pressure is fairly com plex, but at approxim ately one
atm osphere, a pressure increase usually lowers the LEL. The LEL of a gas is not significantly
affected by the hum idity fluctuations norm ally encountered in the operation of a gas detection
system .
OPERATION OVERVIEW
The sensors used are catalytic oxidation sensors, or pellistors, designed to m easure
concentrations of com bustible gases in air up to their lower explosive lim it. Each sensor is a
m atched pair of detector and reference elem ents which are operated in a W heatstone Bridge
circuit. The active elem ent, which com prises a coil of platinum wire em bedded within a catalytic
bead is capable of oxidizing com bustible gases while the inert reference elem ent com pensates for
changes in am bient tem perature and hum idity. The heat generated during oxidation increases the
tem perature and resistance of the detector elem ent, producing an out-of-balance signal in the
W heatstone Bridge circuit proportional to the concentration of com bustible gas.
Table 4 lists the theoretical factors by which the signal with a calibration gas should be m ultiplied
to give the signal for other gases. The following form ula m ay be used:
NOTE
These figures are theoretical, and may differ from sensor to sensor. For best results, the
sensors should be calibrated with the gas they are intended to detect.
Example:
For an instrum ent calibrated with Methane and used to detect Propane.
K M E T H A N E = 112.0
K P R O P A N E = 61.8
Signal shown for 50%LEL Propane is calculated as follows:
Signal = 50% x 61.8 / 112 = 27.6%
-10-
GAS
K
GAS
K
GAS
K
Acetaldehyde
67.3
n-Decane
36.7
Dim ethyl Ether
70
Acetic Acid
60.8
Diethylam ine
54.6
Methylethylether
49.3
Acetic Anhydride
51.5
Dim ethylam ine
64.7
Methylethylketone
46.2
Acetone
57.8
2,3-Dim ethylpentane
44.6
Methyl Form ate
75
Acetylene
63.6
2,2-Dim ethylpropane
44.4
Methylm ercaptan
67.9
Alkyl Alcohol
57.1
Dim ethylsulphide
48.6
Methylpropionate
57.2
Am m onia
142
1,4-Dioxane
50
Methyl n-propylketone
45.4
n-Am yl Alcohol
36.6
Ethane
75.8
Naphthalene
38.1
Aniline
44.1
Ethyl Acetate
57.4
Nitrom ethane
64.8
Benzene
45.6
Ethyl Alcohol
81.5
n-Nonane
35.2
Biphenyl
28
Ethylam ine
58.9
n-Octane
41.9
1,3-Butadiene
62.5
Ethyl Benzene
39.9
n-Pentane
51.3
n-Butane
65.5
Ethylcyclopentane
44.4
iso-Pentane
51.9
iso-Butane
57.8
Ethylene
79.1
Propane
61.8
Butene-1
50.8
Ethyleneoxide
57.9
n-Propyl Alcohol
52.7
cis-Butene-2
54.2
Diethyl Ether
51.8
n-Propylam ine
54.1
trans-Butene-2
56.7
Ethyl Form ate
49.5
Propylene
57.7
n-Butyl Alcohol
38.4
Ethylm ercaptan
62.8
Propyleneoxide
51.2
iso-Butyl Alcohol
59.2
n-Heptane
43.2
iso-Propylether
48.8
tert-Butyl Alcohol
83.1
n-Hexane
41.2
Propyne
46.5
n-Butyl Benzene
35.2
Hydrazine
50.4
Toluene
45.2
iso-Butyl Benzene
35.8
Hydrogencyanide
53.4
Triethylam ine
44.6
n-Butyric Acid
42.5
Hydrogen
85.8
Trim ethylam ine
54.3
Carbon Disulphide
19.8
Hydrogen Sulphide
45.6
Vinylethylether
46.9
Carbon Monoxide
84.4
Methane
112
o-Xylene
40.1
Carbon Oxysulphide
105
Methyl Acetate
55.6
m -Xylene
43.8
Cyanogen
99.9
Methyl Alcohol
96.2
p-Xylene
43.8
Cyclohexane
46
Methylam ine
86.5
Cyclopropane
69.7
Methylcyclohexane
49.4
Table 4 - K Factor for Various Gases
-11-
Unit III
SYSTEM INSTALLATION
INSTALLATION
SENSOR LOCATIONS
Proper location of the sensors is essential for providing m axim um protection. The m ethod for
deciding the m ost effective num ber and placem ent of sensors varies depending on the conditions
at the job site. The individual perform ing the installation m ust rely on experience, com m on sense,
and knowledge of plant operations to determ ine the num ber of sensors needed and the best
controller locations to protect the area adequately.
The following factors are im portant 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 m anuals and follow guidelines for sensor installation.
Sensors m ust be accessible for testing and calibration.
Exposure to excessive heat or vibration can cause prem ature failure of electronic devices,
and should be avoided if possible.
GENERAL W IRING REQUIREM ENTS
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 recom m ended 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 m ust not be used for wiring to other electrical equipm ent.
NOTE
The S1G and S2G controllers have been certified, as ‘No Seal Required’ since it will not
ignite an explosive atmosphere, under normal operating conditions. Net Safety
Monitoring Inc. does, however, recommend conduit seals to prevent moisture damage.
Since m oisture can be detrim ental to electronic devices, it is im portant that m oisture not be
allowed to contact the electrical connections of the system . Moisture in the air can becom e
trapped within sections of conduit. Therefore, the use of conduit seals is recom m ended to
prevent dam age to electrical connections caused by condensation within the conduit.
These seals m ust be watertight and explosion-proof and should be installed even if they are not
required by local wiring codes. A seal should be located as close to the device as possible. Never
should this seal be located m ore than 18 inches (46 cm ) from the device. W hen an explosionproof installation is required, an additional seal m ay be needed at any point where the conduit
enters a non-hazardous area. Always observe the requirem ents of local codes.
-12-
W hen pouring a seal, the use of a fibre dam is required to assure proper form ation of the seal.
The seals should never be poured in tem peratures that are below freezing, since the water in the
sealing com pound will freeze and the com pound will not dry properly. Contam ination problem s
can then result when tem peratures rise above the freezing point and the com pound thaws.
The shielding of the cable should be stripped back to perm it the seal to form around the individual
leads, rather than around the outside of the shield. This will prevent any siphoning action that can
occur through the inside of the shield.
It is recom m ended that conduit breathers also be used. In som e applications, alternate changes in
tem perature and barom etric pressure can cause 'breathing', which allows the entry and circulation
of m oist air throughout the conduit. Joints in the conduit system and its com ponents are seldom
tight enough to prevent this 'breathing'. Moisture in the air can condense at the base of vertical
conduit runs and equipm ent enclosures, and can build up over a tim e. This can be detrim ental to
electronic devices. To elim inate this condition, explosion-proof drains and breathers should be
installed to bleed off accum ulated water autom atically.
The m axim um distance between the sensor and controller is lim ited by the resistance of the
connecting wiring, which is a function of the gauge of the wire being used. Three wire, 18 AW G,
shielded cable is recom m ended. If the recom m ended wire is used, the sensors m ay be located
up to 500 feet from the controller.
CAUTION
All terminations between the controller and sensors must be good tight electrical
connections. If proper connections are not made, the voltage monitoring circuit in the
controller will not function properly and the sensors may be damaged or operate
incorrectly.
CONTROLLER W IRING
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 sensor direct, Unitrol controllers (S1G and S2G) can be configured for an isolated or nonisolated current output by changing a jum per on one of the controllers circuit boards (see 6a
Figure 3). Figure 5 and 6 show the term inal configuration for the controllers. Figures 5a and 6a
show the proper wiring of the controller for a non-isolated current output. Figure 5b and 6b show
the proper wiring of the controller for an isolated current output.
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 between the minus
side of the DC power supply and chassis ground for best immunity against
electromagnetic interference.
-13-
-14-
-15-
-16-
-17-
DIP SWITCH SETTINGS
It is essential that the controller be properly program m ed 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 bottom side of the display circuit board. The switch
banks are numbered from right to left as numbers SW 3, SW 4, and SW 5. Refer to
Figure 8a. 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 (SW 3.4)
is switch number four on bank number three. ‘Switches are set as either “ON” or “OFF”.
Refer to Figure 8b.
NOTE
IT IS VERY IMPORTANT THAT POW ER TO THE CONTROLLER IS RECYCLED
AFTER ANY DIP SW ITCH CHANGES, TO MAKE THE CHANGES TAKE EFFECT!
Figure 7b - Dip Switch
Figure 7a - Dip Switch Position
ACTIVE CHANNELS
Switches for setting the active channels (the channels that are to have sensors/transm itters
attached) can be found on Switch Bank 3, switch 1 (SW 3.1). 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.
SW 3.1 will be set to the ‘OFF’ position for you.
SW 3.1: OFF:
ON:
channel 1 connected
channel 1 not connected
NOTE
SW 3.2 to SW 3.4 are not used and should be turned ‘ON’.
CALIBRATION GAS CONCENTRATION:
Calibration gas concentration is set using the dip switches on the circuit board. To select the
calibration gas concentration of 50% LEL, set SW 3.5 to ‘OFF.’ If a selectable value (from 20% to
99%) is required, set SW 3.5 to ‘ON’; SW 4.1 through SW 4.7 m ust then be used to select the
calibration gas concentration. SW 3.5 is factory set to the ‘OFF’ position.
-18-
SW 3.5: OFF:
ON:
calibration gas set to 50%
(ignore SW 4.1 - SW 4.7)
calibration gas selectable
(set SW 4.1 - SW 4.7)
NOTE
If SW 3.5 is set to ‘ON’, it is very important to accurately set SW 4.1 to SW 4.7. If SW 3.5 is
set to ‘OFF’ position, the settings of SW 4.1 to SW 4.7 are inconsequential.
If the selectable option is chosen (above), the calibration gas concentration m ust be set. This is
done on Switch Bank 4, switches 1 through 7 (SW 4.1 to SW 4.7). The required calibration gas
concentration m ust be set with these switches using the binary counting system . “ON” selects the
value listed below; “OFF” selects a zero.
SW 4.1:
SW 4.2:
SW 4.3:
SW 4.4:
SW 4.5:
SW 4.6:
SW 4.7:
ON:
ON:
ON:
ON:
ON:
ON:
ON:
1%
2%
4%
8%
16%
32%
64%
calibration
gas
concentration
The switches can be used in com bination to select concentrations from 20% to 99% LEL.
Example:
SW 4.1
SW 4.2
SW 4.3
SW 4.4
SW 4.5
SW 4.6
SW 4.7
OFF
OFF
ON
ON
ON
ON
OFF
calibration gas
concentration
= 60% LEL
NOTE
If a calibration gas concentration greater than 99% or less than 20% is programmed, the
controller will give a configuration error (E90) when power is applied.
POW ER-UP TIM E DELAY
SW 3.6 is used to select the power-up tim e delay:
SW 3.6: OFF:
ON:
45 seconds
90 seconds
NOTE
SW 3.7 and SW 3.8 are not used.
ALARM SETTINGS
Switch bank 4, switch 8 (SW 4.8) is used to set the Low and High alarm to a default or selectable
value. If SW 4.8 is ‘OFF’ the Low Alarm will be set to 20% LEL and the High Alarm to 40% LEL.
If SW 4.8 is ‘ON’, the low and high alarm are selectable, using SW 5.3 to SW 5.8. Switch 4.8 is set
to the ‘OFF’ position at the factory.
SW 4.8: OFF:
low alarm @ 20%
high alarm @ 40%
(ignore SW 5.3 - SW 5.8)
-19-
ON:
selectable alarm
(set SW 5.3 - SW 5.8)
NOTE
If SW 4.8 is set to ON, it is very important to accurately set SW 5.3 to SW 5.8. If SW 4.8 is
set to the ‘OFF’ position, the settings of SW 5.3 to SW 5.8 are inconsequential.
If the selectable option is chosen (SW 4.8 is ‘ON’), the alarm s m ust be set with SW 5.3 to SW 5.8.
The low alarm can be set from 5% to 40% LEL and the high alarm is autom atically 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.
SW 5.3:
SW 5.4:
SW 5.5:
SW 5.6:
SW 5.7:
SW 5.8:
ON:
ON:
ON:
ON:
ON:
ON:
1%
2%
4%
8%
16%
32%
The switches can be used in com bination to select low alarm settings from 5% to 40% LEL. If a
low alarm level less than 5% or greater than 40% is program m ed, the controller will give a
configuration error(E90) upon power up.
Example:
SW 5.3
SW 5.4
SW 5.5
SW 5.6
SW 5.7
SW 5.8
OFF
OFF
ON
ON
OFF
OFF
low alarm 12% LEL
high alarm 24% LEL
NOTE
IT IS VERY IMPORTANT THAT POW ER TO THE CONTROLLER IS RECYCLED
AFTER ANY DIP SW ITCH 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.
SW 5.1: OFF:
ON:
low alarm relay
low alarm relay
latching operation
non-latching operation
NOTE
IT IS VERY IMPORTANT THAT POW ER TO THE CONTROLLER IS RECYCLED
AFTER ANY DIP SW ITCH CHANGES, TO MAKE THE CHANGES TAKE EFFECT!
Refer to Table 3, at the end of this unit, for a sum m ary of the dip switch settings.
ENERGIZED/DE-ENERGIZED SELECTION
Switch Bank 5, switch 2 (SW 5.2) is used to set the high and low alarm relays for norm ally
energized or norm ally de-energized operation; the fault relay is always norm ally energized. SW 5.2
is factory set to the ‘ON’ position.
SW 5.2: OFF:
alarm relays norm ally energized
ON:
alarm relays norm ally de-energized
-20-
RELAY SETTINGS
There are three relays on the controller circuit board that can be set up for norm ally open or
norm ally closed operation by m oving the jum pers which are located below the relays. See Figure
9a for the location of the relays on the circuit board and Figure 9b for the correct settings.
Figure 9a - Relay Positions
Figure 9b - Relay Settings
INSTALLATION CHECKLIST
The following checklist is provided as a m eans of double checking the system to be sure that all
phases of system installation are com plete and have been perform ed correct.
T
Controller is securely m ounted 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 program m ed as needed. Record this inform ation for future
reference. A table is provided in the appendix for this purpose
T
Controller is properly installed in the housing
-21-
T
Proper ventilation is provided to prevent overheating of the controller
SW ITCH
OPEN (OFF)
CLOSED (ON)
SW 3.7 & SW 3.8
NOT USED
SW 3.1
Channel 1 connected
Channel 1 not connected
SW 3.2
Channel 2 connected
Channel 2 not connected
SW 3.3
Channel 3 connected
Channel 3 not connected
SW 3.4
Channel 4 connected
Channel 4 not connected
SW 3.5
Calibration gas concentration is
set to 50% of full scale (ignore
SW 4.1 to SW 4.7)
Calibration gas concentration is selectable
using SW 4.1 to SW 4.7
SW 3.6
Power-up tim e delay is 45 seconds
Power-up tim e delay is 90 seconds
SW 4.1 - SW 4.7
Set calibration gas concentration from 20% to
99% of full scale
SW 4.8
LOW alarm @ 20% of full
scale/HIGH alarm @ 40% of full
scale (ignore SW 5.3 to SW 5.8)
Selectable alarm settings using SW 5.3 to
SW 5.8 (LOW = 5% to 40% of full scale; HIGH
= 2 x LOW )
SW 5.1
LOW alarm relay is latching
LOW alarm relay is non-latching
SW 5.2
LOW and HIGH alarm relays
norm ally energized
LOW and HIGH alarm relays norm ally deenergized
SW 5.3 - SW 5.8
Set LOW alarm settings from 5% to 40% of
full scale (HIGH alarm is twice the LOW alarm
setting)
Table 5 - Summary of Dip Switch Settings
Unit IV
SYSTEM OPERATION
MENU AND FUNCTION SELECTION
The controller has various functions and m enus that can be entered by activating the MENU/SET
(and SELECT/RESET) switches for a specified am ount of tim e. Table 6, below, indicates how to
enter the various m enus and functions.
SW ITCH
TIM E
FUNCTION OR M ENU
SELECT/RESET
< 0.5 sec
SELECT/RESET
1 sec
Forced Reset
M ENU/SET
2 sec
Forced Display [FdP]
M ENU/SET
5 sec
Main Menu
M ENU/SET & SELECT/RESET
Sim ultaneously
20 sec
Table 6a - Menu and Function Selection
-22-
Basic Reset
Special Function Menu
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 7) and the Special Function Menu has five
functions (See Table 8).
To enter the Main Menu, activate the MENU/SET switch for approxim ately 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 activating the MENU/SET switch. The SELECT/RESET switch is used to accept a
currently displayed selection.
Failure to activate any switches for a period of 10 seconds will result in the controller returning to
the Norm al Operating Mode. Selecting the Return function will also return the controller to the
Norm al Operating Mode. W hen “rtn” is on the lower digital display, m om entarily activate the
SELECT/RESET switch.
Summary of M ain M enu:
Enter Main Menu:
Find Desired Function:
Select Function:
Next Function:
Exit Main Menu:
M ENU/SET for 5 sec.
M ENU/SET
SELECT/RESET
M ENU/SET
no buttons for 10 sec. or Select RETURN function
LEFT DIGITAL
DISPLAY
RIGHT DIGITAL
DISPLAY
Err
Chc
Error Check (hidden if no errors)
blank
SPd
Set Point Display
blank
CAL
Calibration
blank
SrP
Sensor Replacem ent
blank
rtn
Return
FUNCTION
Table 6b - Main Menu Selection
LEFT DIGITAL
DISPLAY
RIGHT 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
Return
FUNCTION
Table 7 - Special Function Menu Selection
START-UP PROCEDURE
2
3
Output loads that are norm ally actuated by the system should be secured.
Rem ove power from all of the output devices to prevent undesired activation
Check all external wiring for proper connections. Be sure that the sensor has
been wired properly
-23-
4
Before installing the controller, inspect it to verify that it has not been physically
dam aged in shipm ent. Check the dip switches on the controller for proper
program m ing
5
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 left digital display cycles through the active channels, and
the right digital display counts down from 45 or 90. This delay allows time for the sensors
to stabilize before beginning normal operation.
6
Put the controller in the Set-point Display Mode to check the present alarm setpoints and calibration gas concentration. If changes are required, refer to the ‘Dip
Switch Setting’ section of the m anual
7
Calibrate the sensor(s); refer to the Sensor Calibration Procedure
8
Rem ove m echanical blocking devices (if used) and restore power to the output
loads
MAIN MENU SELECTIONS
ERROR CHECK M ODE (Err Chc)
The m icroprocessor-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 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 norm ally energized fault output is de-energized,
<
the Fault LED is illum inated, and
<
if no alarm is occurring and the controller is sequentially displaying each sensor input, the
m essage ‘Err’ ‘Fnd’ (left and right displays) will be displayed after each sequence.
To view the fault code, enter the Main Menu, then m om entarily activate the SELECT/RESET reed
switch when ‘Err’ is displayed on The right digital display. Next, activate the MENU/SET reed
switch repeatedly; the left digital display will sequentially show:
‘SYS’ - system faults
‘CH1' - channel 1 faults
‘CH2' - channel 2 faults
‘CH3' - channel 3 faults
‘CH4' - channel 4 faults
‘Clr’ - clear faults
NOTE
If no errors exist, this function is hidden and can not be accessed.
To select the fault to be displayed, m om entarily activate the SELECT/RESET reed switch when
the required fault is being displayed on the left digital display. The left digital display will show the
channel (or system ) and the right digital display will show the fault code, for 5 seconds then m ove
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 autom atically reset except the 9X, 20, and 10 faults. After the fault condition has been
corrected, the fault output autom atically switches to the norm al (energized) state, the DC current
output returns to norm al, and the Fault LED turns off. Clearing 9X faults requires rem oving
operating power from the controller for approxim ately 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 M ODE (SPd)
1
In this m ode, the digital displays sequentially display the low and high alarm and
calibration gas concentration autom atically. This function is used to check the
present alarm and calibration gas set-point values.
2
To enter the Set-point Display Mode, enter the Main Menu, activate the
MENU/SET reed switch repeatedly until ‘Spd’ is displayed on the right digital
display, then m om entarily activate the SELECT/RESET reed switch
3
The Low LED goes on, ‘LoA’ is shown on the left digital display, and the low
alarm set-point is shown on the right digital display for 2 seconds
4
The Low LED goes out, the High LED goes on, ‘HiA’ is shown on the left digital
display, and the high alarm set-point is shown on the right display for 2 seconds
5
The High LED goes out, the Cal LED goes on, ‘CAL’ is shown on the left display,
and the calibration gas concentration (in percent LEL) is shown on the right
display for 2 seconds
6
The Cal LED goes out, ‘Adr’ is shown on the left display and the right digital
display shows the com m unication address for the CAN interface for 2 seconds.
Address setting is not used
7
Finally, the controller returns to the norm al operating m ode (it is no longer in the
m ain m enu)
If adjustm ents to the set-points are required, the settings on the program m ing dip
switches m ust be changed; Refer to ‘DIP SW ITCH SETTINGS’ in the ‘SYSTEM
INSTALLATIONS’ section of this m anual for instructions. W hen the set-point
levels are acceptable, record this inform ation for future reference and proceed to
‘CALIBRATION.’
8
NOTE
IT IS VERY IMPORTANT THAT POWER TO THE CONTROLLER IS RECYCLED
AFTER ANY DIP SWITCH CHANGES, TO MAKE THE CHANGES TAKE EFFECT!
STATUS
E90
CONDITION
W HAT TO DO
Dip Switch Configuration error
Check dip switch settings and recycle
power
-25-
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
start-up
Consult the Factory
E97
EEPROM failure
Consult the Factory
E98
Duplicate CAN address.
Check CAN address and change to a
vacant address
E99
Lost com m unication.
Check com m unication wiring, disconnect
controller, and re-connect it. If this does
not help, contact the factory
CHx E80
Sensor output is m ore than 26 m A
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 transm itter) input failure;
input is below 1 m A.
Check wiring and signal output from
sensor.
CHx E30
Negative zero drift; sensor (or
transm itter) is -9% full scale or lower.
Calibrate transm itter.
CHx E20
Tim e ran out while waiting for the user
to apply gas to the sensor.
Restart calibration procedure.
CHx E21
Sensor (or transm itter) output is too
low; enough offset to get an accurate
calibration is not being generated.
Calibrate transm itter or replace sensor.
CHx E22
Sensor can not be calibrated.
Calibrate transm itter or replace sensor.
CHx E23
Sensor is too sensitive for the detector
to read 100% full scale.
Calibrate transm itter or replace sensor.
CHx E24
Zero point is m ore than 6% below
standard value
Calibrate transm itter
CHx E25
Zero point is m ore than 6% above
standard value
Calibrate transm itter
CHx E10
Calibration was successful, but sensor
reaching end of life or tim e to change
jum per position on transm itter
Be prepared to calibrate transm itter or
replace sensor at next calibration tim e
CHx goP
Over-range error (reading greater than
100% of full range)
Insure area has been de-contam inated
then perform a forced reset
Table 8 - System Status Codes
(Chx = Channel number)
SENSOR CALIBRATION (CAL)
General Information
-26-
Various factors affect the interval between periodic calibrations. Exposure to certain
contam inants in the air, accum ulation of contam inants on the filter, or an extended period of
norm al operation can cause changes in sensitivity. Since each application is different, the length
of tim e between regularly scheduled calibrations can vary from one installation to the next. In
general, the m ore a system is checked, the greater the reliability. A calibration must be
perform ed:
<
<
<
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 autom atic calibration procedure that requires no adjustm ents by the
operator. The controller perform s the zero adjustm ents, then signals the operator when to apply
and when to rem ove the calibration gas.
W hile in the Sensor Calibrate Mode, all controller outputs are inhibited, the current output is 3m A,
and the Cal LED is illum inated.
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 m inim um of 4 hours, although it is
best to allow 24 hours for the sensor to stabilize.
2
Be certain that the controller is properly program m ed for the gas concentration
being used for calibration. (Refer to ‘SET-POINT DISPLAY MODE’ to check
program m ed value.) Reprogram the controller if required. (Refer to ‘DIP
SW ITCH SETTINGS.’) Failure to do so will greatly im pair 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 m icroprocessor begins
taking zero readings im m ediately 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, activate the MENU/SET reed switch repeatedly until ‘CAL’
is shown on the right digital display, then m om entarily activate the
SELECT/RESET reed switch.
5
Once in the sensor calibrate m ode, the right digital display will continue to show
‘CAL’ and the left digital display will show ‘Chn’. Activate the MENU/SET reed
switch repeatedly until the desired channel is shown on the left digital display,
then m om entarily activate the RESET/SELECT reed switch.
-27-
6
Once the required channel has been selected, the controller will autom atically
start taking zero readings. The left digital display will show ‘Air’ and the right
display will flash a value close to zero. W hen the zero calculations are com plete
(30 seconds m inim um ), the right digital display stops flashing and reads '00'; the
left display will now alternately display ‘gAS’ and ‘in’.
7
Apply the calibration gas to the sensor. The right 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 left display will show ‘gAS’.
8
W hen the m icroprocessor has com pleted the gain adjustm ents (30 seconds
m inim um ), the right digital display stops flashing and the left display will
alternately display ‘Cut’ and ‘gAS’.
9
Rem ove the calibration gas. W hen the gas level falls to half the low alarm
set-point, the controller autom atically returns to the norm al operating m ode.
10
If another sensor m ust also be calibrated, return to step 1.
If the operator fails to com plete the calibration procedure or if the sensitivity of the sensor has
deteriorated to the extent that calibrations cannot be successfully com pleted, a calibration fault
(‘E2X’ status) will be generated. The system will autom atically revert to the form er calibration
settings (after 10 m inutes or when the gas level drops below the lowest set-point). If a successful
calibration cannot be accom plished, replace the sensor and calibrate (refer to the
transm itter/sensor m anual, as som e transm itters will have gain jum pers which need to be
changed and the sensor m ay still be useful).
If the m icroprocessor determ ines that the sensor is approaching the end of its useful life or the
gain jum per on the transm itter needs to be changed, ‘E10' will be indicated on the digital display.
This does not indicate a system m alfunction, but is intended to notify the operator of this condition.
A successful calibration can still be perform ed, but the operator should be prepared to change the
sensor at the tim e of the next calibration. Activate SELECT/RESET after com pleting calibration to
clear the display.
SENSOR REPLACEM ENT M ODE (SrP)
This m ode inhibits all controller outputs to allow replacem ent of the sensor(s) without rem oving
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 m ode. The right display will show the
status of the sensor being replaced (‘NoS’ m eans 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 rem ain active during sensor replace m ode. If an alarm condition occurs on one
of the active channels while in this m ode, the appropriate channel LED will flash and relays will act
accordingly. All other display features will be inhibited. In order to exit this m ode the
SELECT/RESET reed switch m ust be activated. 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 1m A.
SPECIAL FUNCTION MENU SELECTIONS
FORCED CURRENT OUTPUTS (FoP)
-28-
The forced current output m ode 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 m ode, enter the special function m enu. W hen ‘FoP’ is shown
on the right display, activate the SELECT/RESET reed switch. Upon successful entry into this
m ode the left display will flash ‘gPn’. Activate the MENU/SET reed switch until the desired area
output is reached (‘GPA’ = Area 1 and ‘GPb’ = Area 2), then activate the SELECT/RESET reed
switch.
W hen an area has been chosen for forced current output, the left display will alternate between
‘GPX’ and ‘FoP’ and the right 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 reed switch down until ‘rtn’ is shown on the right display. Release the reed
switch, and the controller will return to the norm al operating m ode in 10 seconds if no reed
switches are pushed.
CURRENT CALIBRATION M ODE (CuC)
The next selection in the special function m enu is the current calibration m ode. This m ode 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 left display will alternate between
‘CuC’ and the area that is being calibrated (‘GPX’). The right 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
m illiam p m etre between the Area current output and system com m on. Use the m agnetic reed
switches to raise and right the current. Once the current m easured is as close to 4m A as
possible, do not activate any reed switches for 10 seconds and the constant shown on the right
display will change to a m uch higher num ber. This tells the operator that it is tim e to calibrate the
higher end of the current output range. Use the magnetic reed switches to bring the current level
as close as possible to 20m A. Do not activate any reed switches for 10 seconds and the constant
shown on the display will change to a lower num ber. Now it is tim e to calibrate the current output
to 3m A for when the controller is in the calibration m ode. Once this current level is set, do not
activate any reed switches for 10 seconds and the controller will return to the norm al operating
m ode.
ADDRESS SET M ODE (Adr Set) (Do not use)
Do not use the next selection in the special function menu. It is the address set m ode, used
to set the controllers address for the CAN system . W hen the left display shows ‘Adr’ and the right
display shows ‘SEt’ activate the SELECT/RESET reed switch. The left display will alternate
between ‘Adr’ and ‘SEt’ and the right display will show the current address. Use the m agnetic
reed switches to raise and lower the address. Once the address is correct, do not activate any
reed switches for 10 seconds and the controller will return to the norm al operating m ode.
CHANNEL DISPLAY(Chd)
In this m ode, the displays can be forced to m onitor only one channel, as long as no alarm s are
occurring. If any alarm occurs, the controller will return back to the Norm al Operating Mode for
the situation when an alarm is occurring.
Enter the Special Function Menu, activate the MENU/SET reed switch repeatedly until ‘Chd’ is
displayed on the right digital display, then m om entarily activate the SELECT/RESET reed switch.
The left digital display will show ‘Chn’. Activate the MENU/SET reed switch repeatedly to toggle
through the channels (CH1, CH2, CH3, or CH4). To select a channel, m om entarily activate the
-29-
SELECT/RESET reed switch when the required channel is displayed, on the left digital display.
The displays will now only display the inform ation for the chosen channel.
To return to the norm al operating m ode, enter the m anual display m ode again and instead of
selecting a single channel, select ‘ALL’.
BYPASS (bPS)
The bypass m ode is entered through the special functions m enu. Enter the special functions
m enu and activate the MENU/SET reed switch repeatedly until ‘bPS’ is shown on the right digital
display, then m om entarily activate the SELECT/RESET reed switch. The right digital display will
still show ‘bPS’ and the left display will show ‘gPn’. Select the group to put in bypass m ode by
activating the MENU/SET reed switch repeatedly until the desired group is shown, then activate
the SELECT/RESET reed switch m om entarily.
W hile in bypass m ode, the alarm outputs for the selected group(s) are inhibited. The HIGH alarm
relay is com m on to both groups, and is inhibited even if the unselected group has an alarm
condition. CAUTION SHOULD BE USED W HILE IN BYPASS M ODE.
To exit the bypass m ode, activate the SELECT/RESET reed switch m om entarily.
OPERATING MODES
RESET M ODE
The Reset Function is entered by activating the SELECT/RESET reed switch located on the front
panel of the controller. (Refer to Figure 2.) W hen the SELECT/RESET reed switch is activated
momentarily, all LEDs turn off and all outputs return to their norm al condition if no alarm s or
faults are occurring.
FORCED RESET M ODE
If any of the channels gets a reading beyond 100% of full scale, a reset will not clear the alarm s,
even if the channel has returned to levels below the low alarm set point. The error resulting from
this occurrence m ust be cleared in the error check m ode and then a forced reset m ust be 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. Rem ote reset perform s a forced reset.
NOTE
The remote reset performs a reset function only. It cannot be used for other controller
functions.
NORM AL OPERATING M ODE
The following discussion covers the situation where no fault condition is occurring. Refer to
‘FAULT IDENTIFICATION’ for a discussion on faults.
In the Norm al 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 m ore channels are
active, the displays will sequentially display the channels, for 5 seconds each. The left
digital display will indicate the channel (CH1, CH2, CH3, or CH4) and the right digital
display will indicate the sensor reading.
The Channel LEDs will indicate which channel the digital display is referring to.
-30-
<
<
<
All other LEDs are off.
Alarm relays are in their norm al state, energized or de-energized as program m ed.
Fault relay is energized.
In the Norm al 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 m ore 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.
W hen the signal decreases below the low set-point:
<
<
<
<
The digital display and bar graph display continue to track the sensor input.
W ith latching operation program m ed, low alarm relays will not change.
W ith non-latching operation program m ed, low alarm relays will return to their norm al
state.
Low Alarm LEDs are on steady, while the affected channel is displayed, until reset.
If a high alarm condition occurs, the m odule 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
W hen 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 norm al operating m ode with no alarm s occurring, the digital and bar graph displays will
sequentially display each of the channel sensor readings. If an alarm condition occurs, the
displays will rem ain on the channel with the alarm (or ‘highest’ alarm if m ore than one channel is
in an alarm condition). In this situation, the forced display m ode can be used to tem porarily view
the sensor readings of the other channels.
To enter the Forced Display Mode, activate the MENU/SET reed switch for 2 seconds, until the
right digital display shows ‘FdP’. Mom entarily activate the SELECT/RESET reed switch to select
this function. The digital displays will then sequentially display each of the active channels once
before returning to the Norm al Operating Mode autom atically.
Unit V
SYSTEM MAINTENANCE
-31-
ROUTINE MAINTENANCE
To ensure reliable protection, it is im portant to check and calibrate the detection system on a
regularly scheduled basis. The frequency of these checks is determ ined by the requirem ents of
the particular installation.
M ANUAL CHECK OF OUTPUT DEVICES
Fault detection circuitry continuously m onitors for problem s that could prevent proper system
response. It does not m onitor external response equipm ent or the wiring to these devices. It is
im portant that these devices be checked initially when the system is installed, and periodically
during the ongoing m aintenance program .
SYSTEM CHECK IN NORM AL M ODE
The system m ust be checked periodically in the Norm al Operating Mode to ensure that those
item s 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.
SENSOR REPLACEM ENT
The area m ust be declassified or power to the sensor m ust be rem oved prior to replacing the
sensor in a hazardous area.
11
Enter the Main Menu; m om entarily activate the SELECT/RESET reed switch
once the m essage ‘SrP’ appears on the right digital display
12
Once in the sensor replace m ode, the right digital display will continue to show
‘SrP’ and the left 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,
m om entarily activate the SELECT/RESET reed switch to select that channel. If
the first channel displayed is not the required channel, activate the MENU reed
switch; the left digital display will sequentially display the operational channels
each tim e the MENU/SET reed switch is activated. Activate the SELECT/RESET
reed switch, once the required channel is displayed.
13
Once the required channel has been selected, the display reads '00' and the
Channel LED and Fault LED are illum inated. The controller is in the Sensor
Replacem ent Mode.
Once in the Sensor Replacem ent Mode follow the instructions in the sensor m anual for
replacem ent.
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.
-32-
An adequate supply of spare sensors should be kept on hand for field replacem ent. For m axim um
protection against contam ination and deterioration, they should not be rem oved from the original
protective packaging until the tim e of installation.
TROUBLESHOOTING
Table 10 is intended to serve as an aid in locating the cause of a system m alfunction. If this table
is not helpful, contact an authorized repair person.
REPLACEMENT PARTS
The Uni-Trol™ Controller is not designed to be repaired by the custom er in the field. If a problem
should develop, first carefully check for proper wiring, program m ing and calibration. If it is
determ ined that the problem is caused by an electronic defect, the device m ust be returned to the
factory for repair.
NOTE
W hen 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. W hen calibration can no longer be properly perform ed,
the sensor m ust be replaced. The frequency of replacem ent will be determ ined by the am ount and
type of contam ination present at the particular installation. An adequate supply of spare sensors
should be kept on hand for field replacem ent. Always calibrate the sensor after it has been
replaced.
DEVICE REPAIR AND RETURN
The electronics are under full warranty for THREE years (from date of purchase) and the sensors
are under warranty for 2 years. Net Safety Monitoring Inc. supplies all distributors with advance
replacem ent units. These units are available to the user during the warranty period. This allows
Net Safety Monitoring Inc. to take the tim e to repair the unit com pletely while custom ers keep their
operations running sm oothly with the advance replacem ent unit.
Prior to returning devices or com ponents, contact the nearest local distribution office so that an
RMI (Return Material Identification) num ber can be assigned. A written statem ent describing the
m alfunction m ust accom pany the returned device or com ponent to expedite finding the cause of
the failure, thereby reducing the tim e and cost of the repair to the custom er. Pack the unit or
com ponent properly. Use sufficient packing m aterial in addition to an anti-static bag or alum inum backed cardboard as protection from electrostatic discharge.
-33-
PROBLEM
POSSIBLE CAUSE
No Faceplate
indicators illum inated.
<
<
W iring to external power source.
Input power failure.
FAULT LED on, digital
display blank.
<
<
Power-up tim e delay (45 seconds).
If condition continues after 45 seconds, repeat power-up. If a
problem continues, check dip switches or replace detector.
E90 to E97 Status
<
Initialization failure. Repeat power-up. If successful, reprogram and re-calibrate. If not, replace detector.
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 transm itter wiring
and calibration.
Faulty sensor. Replace and calibrate.
Faulty transm itter. Replace and calibrate.
E30 Status
<
<
<
Negative zero drift. Calibrate sensor.
Faulty sensor. Replace and calibrate.
Faulty transm itter. Replace and calibrate.
E20, E21 Status
<
Calibrate error. Re-calibrate.
E22, E23 Status
<
Sensor sensitivity out of tolerance. Calibrate transm itter. If
problem continues, replace sensor and calibrate.
E10 Status
<
Sensor reaching end of life - no problem at present tim e. Be
prepared to replace sensor at next calibration (calibration
attem pt m ight fail).
Table 10 - Troubleshooting Guide
Appendix A
-34-
Net Safety Monitoring Inc.
Electrostatic Sensitive Device Handling Procedure
W ith the trend toward increasingly widespread use of m icroprocessors and a wide variety of other
electrostatic sensitive sem iconductor devices, the need for careful handling of equipm ent
containing these devices deserves m ore attention than it has received in the past.
Electrostatic dam age can occur in several ways. The m ost fam iliar 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 m agnitude, a spark will also be visible. This voltage is often m ore than
enough to dam age som e electronic com ponents. Som e devices can be dam aged without any
physical contact. Exposure to an electric field can cause dam age if the electric field exceeds the
dielectric breakdown voltage of the capacitive elem ents within the device.
In som e cases, perm anent dam age is instantaneous and an im m ediate m alfunction is realized.
Often, however, the sym ptom s are not im m ediately observed. Perform ance m ay be m arginal or
even seem ingly norm al for an indefinite period of tim e, followed by a sudden and m ysterious
failure.
Dam age caused by electrostatic discharge can be virtually elim inated if the equipm ent 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. m odules that
m ight be dam aged by static electricity are carefully wrapped in a static protective m aterial before
being packaged. Foam packaging blocks are also treated with an anti-static agent. If it should
ever becom e necessary to return the m odule, it is highly recom m ended that it be carefully
packaged in the original carton and static protective wrapping.
Since a static safeguarded work area is usually im practical in m ost field installations, caution
should be exercised to handle the m odule by its m etal shields, taking care not to touch electronic
com ponents or term inals.
In general, always exercise all of the accepted and proven precautions that are norm ally observed
when handling electrostatic sensitive devices.
A warning label is placed on the packaging, identifying those units that use electrostatic sensitive
sem iconductor devices.
*P ublished in Accordance with E1A
standard 471
-35-
Appendix B
Record Of Dip Switch Settings
DIP SW ITCH
ON
SW 3.1
SW 3.2
SW 3.3
SW 3.4
SW 3.5
SW 3.6
SW 3.7
SW 3.8
SW 4.1
SW 4.2
SW 4.3
SW 4.4
SW 4.5
SW 4.6
SW 4.7
SW 4.8
SW 5.1
SW 5.2
SW 5.3
SW 5.4
SW 5.5
SW 5.6
SW 5.7
SW 5.8
-36-
OFF
Appendix C
Wire Resistance In Ohms
Distance
(Feet)
AW G #20
AW G #18
AW G #16
AW G #14
AW G #12
AW G #10
AW G #8
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
NOTE: RESISTANCE SHOW N IS ONE W AY. THIS FIGURE SHOULD BE DOUBLED W HEN
DETERMINING CLOSED LOOP RESISTANCE.
-37-
DISTRIBUTED BY:
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Calgary, Alberta, Canada, T1Y 7J7