MILLENNIUM
Infrared Combustible
Gas Detector
User Manual
Model:
MLP-A-AR-SIR100
Part Number: MAN-0059-00 Rev 2
October 2003
Net Safety Monitoring Inc
I MPORTANT I NFORMATION
Warranty
This manual is for informational purposes only. Although every effort has been
made to ensure the correctness of the information, technical inaccuracies may
occur and periodic changes may be made without notice. Net Safety
Monitoring Inc., assumes no responsibility for any errors contained within this
manual.
Net Safety Monitoring Inc., warrants its sensors against defective parts and
workmanship for a period of 24 months from date of purchase; other
electronic assemblies for 36 months from date of purchase.
If the products or procedures are used for purposes other than as described in
the manual, without receiving prior confirmation of validity or suitability, Net
Safety Monitoring Inc., does not guarantee the results and assumes no
obligation or liability.
Contact Net Safety Monitoring Inc., or an authorized representative for details.
No other warranties or liability, expressed or implied, will be honoured by Net
Safety Monitoring Inc.
We welcome your input at Net Safety Monitoring. If you have any comments
please contact us at the phone/address below or visit our web site and
complete our on-line customer survey: www.net-safety.com.
No part of this manual may be copied, disseminated or distributed without the
express written consent of Net Safety Monitoring Inc.
Contact Information
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.
2711 39th Ave., N.E.
Calgary, AB T1Y 4T8
Telephone: (403) 219-0688 Fax: (403) 219-0694
www.net-safety.com
E-mail: netsafe@net-safety.com
Copyright © 2003 Net Safety Monitoring Inc.
Printed in Canada
Net Safety Monitoring Inc
TABLE OF CONTENTS
Important Information
Warranty
Contact Information
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
The Product .......................................................................................... 1
Calibration Procedure ......................................................................... 12
Calibration Procedure ..............................................................................12
Calibration Failure ..............................................................................13
Step 6 — Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Review Relay Settings ......................................................................... 13
Set Relay Options ............................................................................... 13
Setting Relay Options ...............................................................................14
The Sensor .................................................................................................1
The Controller ............................................................................................1
The Manual ...............................................................................................1
Select Gas Curve ................................................................................. 14
Select Display Language ..................................................................... 14
Alarms ................................................................................................ 15
Step 1 — Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Sensor Fault .............................................................................................15
Gas Present ..............................................................................................15
Sensor Life ...............................................................................................15
Locate Controller/Sensor ....................................................................... 2
Step 2 — Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Reset ................................................................................................... 15
Unpack ................................................................................................. 3
Manual Reset ...........................................................................................15
Remote Reset ......................................................................................15
External Equipment ....................................................................................3
Mount ........................................................................................................4
Step 3 — Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Field Installation ................................................................................... 4
Seal ...................................................................................................... 4
Connecting Wires ......................................................................................5
Board Assembly .........................................................................................5
Sensor and Controller ........................................................................... 6
Sensor Separation ................................................................................. 7
Non-Isolated/Isolated Wiring ................................................................ 8
Terminal Connection .................................................................................8
Current Output ..........................................................................................8
Remote Reset ........................................................................................ 8
Step 4 — Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Calibration Button ....................................................................................10
Magnetic Reed Switch .............................................................................10
Power Up ................................................................................................10
Current Loop Measurement (Test Jacks) ....................................................11
Status LED ................................................................................................11
The Main Menu .................................................................................. 11
Accessing the Main Menu ........................................................................11
Main Menu Functionality .........................................................................11
Step 5 — Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Outputs ............................................................................................... 15
Relays (Optional) .....................................................................................15
Current .....................................................................................................15
Step 7 — Maintain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Periodic Response Check .................................................................... 16
Troubleshoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
How to Return Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Spare Parts/Accessories ....................................................................... 17
Face Rotation Option .......................................................................... 17
Rotate PCB Assembly ...............................................................................17
Appendix A: Electrostatic Sensitive Device (ESD) . . . . . . . . . . .18
Appendix B: Resistance Table . . . . . . . . . . . . . . . . . . . . . . . . . .19
Appendix C: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Net Safety Monitoring Inc
T ABLE L IST
Table 1: Controller/Sensor Terminal Connections .............................................6
Table 2: Status LEDs, Display Messages and Current Loop ..............................10
Table 3: Default Relay Settings .......................................................................13
Table 4: Part Numbering ................................................................................17
Table 5: Wire Resistance In Ohms .................................................................. 19
F IGURE L IST
Figure 1: Locate Sensor/Controller .................................................................... 2
Figure 2: Dimensional Drawings ......................................................................3
Figure 3: Components ......................................................................................3
Figure 4: Millennium Module Boards ...............................................................5
Figure 5: Wiring—Controller and Sensor ..........................................................6
Figure 6: Wiring—Sensor Separation ................................................................7
Figure 7: Non-isolated Terminal Connection ....................................................8
Figure 8: Isolated Terminal Connection ............................................................8
Figure 9: Jumper Positions ................................................................................8
Figure 10: Remote Reset ..................................................................................8
Figure 11: Controller Functionality ...................................................................9
Figure 12: Calibration Procedure ....................................................................12
Figure 13: Non-standard Orientations ............................................................17
Net Safety Monitoring Inc.
INTRODUCTION
The Millennium series is Net Safety's latest innovation in a line of continuously
evolving industrial gas detectors and sensors. The microcontroller based
system provides fast, accurate and continuous monitoring of gases in extreme
environments.
T HE P RODUCT
The Sensor
The SIR100 digital infrared sensor employs a simple and effective optical design.
There are no mirrors to be fogged, fouled, misaligned or cleaned. The entire
optical path is protected from airborne contaminates such as mist, dust and oil
and de-fogging heaters are not required.
The Controller
The Millennium Controller has an explosion-proof Housing, rated Class 1,
Division 1, Groups B, C, and D for hazardous applications. It was designed for
either a 1-man, intrusive calibration or 2-man non-intrusive calibration.
Step 1 — PLAN
Step 2 — INSTALL
Step 3 — WIRE
Step 4 — OPERATE
Step 5 — CALIBRATE
Step 6 — MONITOR
Step 7 — MAINTAIN
The Controller has convenient user interface functionality to make installation,
operation and maintenance easy.
The Manual
The manual has been designed to make installation of the Millennium product
easy. To ensure proper installation, follow the steps outlined in the following
pages. If you encounter problems during operation, consult the
troubleshooting section or contact your sales representative.
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STEP 1 — PLAN
Figure 1: Locate Sensor/Controller
L OCATE C ONTROLLER /S ENSOR
Prior to the installation process, a location plan for placing the Controller and
Sensor should be developed. Although there are no absolute rules for
determining the quantity and location of a sensor or controller, the following
points should be considered when planning the installation.
•
•
•
•
•
•
Locate the Controller where it will be accessible and visible.
Carefully locate Sensor in an area where gases may potentially accumulate.
Use redundant systems to enhance protection and reliability.
Light gases tend to rise; heavy gases tend to accumulate in low areas.
Consider air movement patterns within the facility.
Consider the construction of the facility (such as trenches where heavy
gases may accumulate or peaks where light gases may accumulate).
• Seek advice from experts knowledgeable about the primary gas to be
detected.
• Use common sense and refer to various regulatory publications that discuss
general guidelines for your industry.
The two most common installation options are as follows.
Conduit to Controller
Controller
Side Calibration Fitting
Option 1
Sensor is located lower to the ground to detect heavy gases
The Sensor is attached directly to the Controller. A Calibration Cover is
slipped onto the bottom of the Sensor and the calibration gas is attached to
the side calibration fitting.
Tubing for Calibration Gas
See "Wiring—Controller and Sensor" on page 6 for detailed instructions.
Option 2
Locate Sensor separate from Controller using a Junction Box.
The Controller is located near eye-level. Conduit is run from the Controller to
the Sensor. A Junction Box is used to connect the conduit from the Controller
to the Sensor. A Calibration Cover is slipped onto the Sensor to concentrate
the gas. Tubing can be run from the side calibration fitting on the Sensor to a
convenient location accessible for calibration gas to be injected.
SIR100
Sensor
Calibration Cover
TIP:
The Calibration Cover (CC-SIR100-SEP) prevents air circulation
affecting the Calibration process and concentrates the gas during
calibration.
See "Sensor Separation" on page 7 for detailed instructions.
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STEP 2 — INSTALL
Figure 2: Dimensional Drawings
5.60”
6.58”
U NPACK
Carefully remove all components from the packaging. Check components
against the enclosed packing list and inspect all components for obvious
damage such as broken or loose parts.
13.27”
If you find any components missing or damaged, notify the representative or
Net Safety Monitoring immediately.
4.06”
Figure 3: Components
Controller Housing
Millennium Faceplate
Junction Box*
2.60”
2.95”
Housing Cover
13.14”
3/4” NPT
Ribbon connecting
faceplate/controller
SIR100 Sensor
External Equipment
* A Junction Box is used only when Sensor and Controller are separated.
Refer to "Sensor Separation" on page 7 for instructions.
MLP-A-AR-SIR100
It is necessary that reliable monitoring and indicating devices or systems be
connected to the detector. These devices must be designed to produce clear
visual and audible danger signals when high signal levels occur.
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Mount
STEP 3 — WIRE
The Controller should be mounted near eye-level and be easily accessible for
calibration and maintenance purposes. The Sensor should be placed where gas
is likely to accumulate.
F IELD I NSTALLATION
Ensure all devices are securely mounted, taking into consideration all
requirements.
Use the Face Rotation Option to mount the Millennium
Controller at a different orientation (refer to "Face
Rotation Option" on page 17 for detailed instructions).
WARNING:
Wiring codes and regulations may vary. Wiring must
comply with applicable regulations relating to the installation of electrical
equipment in a hazardous area and is the responsibility of the installer. If in
doubt, consult a qualified official before wiring the system.
• If the 4-20 mA signal is not used, connect a jumper between the 4-20
terminal and the Common terminal.
• The use of shielded cable is highly recommended for signal, input, output and
power wires to protect against interference caused by extraneous electrical
or electromagnetic 'noise'.
• In applications where the wiring cable is installed in conduit, the conduit
must not be used for wiring to other electrical equipment.
• The maximum distance between the Sensor and Controller is limited by the
resistance of the connecting wiring, which is a function of the gauge of the
wire being used.
S EAL
• Water-proof and explosion-proof conduit seals are recommended to
prevent water accumulation within the enclosure.
• Seals should be located as close to the device as possible and not more than
18 inches (46 cm) away.
• Explosion-proof installations may require an additional seal where conduit
enters a non-hazardous area. Ensure conformity with local wiring codes.
• When pouring a seal, use a fibre dam to assure proper formation of the seal.
Seals should never be poured at temperatures below freezing.
• The jacket and shielding of the cable should be stripped back to permit the
seal to form around the individual wires. This will prevent air, gas and water
leakage through the inside of the shield and into the enclosure.
• It is recommended that explosion-proof drains and conduit breathers be
used. In some applications, alternate changes in temperature and barometric
pressure can cause 'breathing' which allows moist air to enter and circulate
inside the conduit. Joints in the conduit system are seldom tight enough to
prevent this 'breathing'.
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Connecting Wires
1. Use a small screw driver to gently press down and hold the spring
connector open.
2. Insert appropriate wire into open connector hole.
3. Release screw driver to secure wire.
Figure 4: Millennium Module Boards
Solid State Relay Board
Fault
Low
High
+
+
+
-
Terminal
Board
Board Assembly
There are three different fixed boards and two optional relay boards which
make up the PCB Assembly. Depending upon requirements, either a
Electromechanical or Solid State Relay Board module can be used in the
Millennium Controller. Simply loosen the three locking standoffs, remove one
board, insert the other board and tighten screws.
Option Board
Sensor
Board
Note: Boards are susceptible to ESD. Refer to Appendix A, "Electrostatic
Sensitive Device (ESD)", on page 18.
HIGH
LOW
FAULT
Electromechancial Relay Board
FNO
normally open
FCOM
common
FNC
normally closed
LNO
normally open
LCOM
common
LNC
normally closed
HNO
normally open
HCOM
common
HNC
normally closed
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S ENSOR
Figure 5: Wiring—Controller and Sensor
RST
Power
Terminals
RST
+24V
COM
4-20
ISO
COM
4-20
ISO
Wht+
Blu
Sensor
Terminals
Red
Blk
C ONTROLLER
WARNING:
Power to the unit must be OFF before wiring.
Terminal Board
+24V
AND
Wht
Blu
Red
Blk
Shld
Shld
Note: The Sensor may be factory installed to the Controller. If so, you need
only connect the Power Terminals.
4. Remove the Controller’s Housing Cover.
5. Connect the Sensor to the Sensor Terminals (if necessary) and the Output
Terminals to the output signal wires.
Table 1: Controller/Sensor Terminal Connections
Sensor Terminals
Sensor
Controller
Wire
(Sensor Board)
White = Wht (+)
Blue
= Blu (Sig A)
Red
= Red (Sig B)
Black
= Blk (-)
Shield
Sensor Board
Sensor
Wires
SIR100 Sensor
Shld
Power Terminals
Controller
Power
(Terminal Board)
Connections
RST
= Remote Reset
+24V
= Power (+)
COM
= Power (-)
= Current Loop
4-20
Output
= +24 V isolated
ISO
4-20 power
Note: For Sensor Separation instructions, see Figure 6, "Wiring—Sensor
Separation", on page 7.
6. Replace the Controller’s Housing Cover.
7. Turn Controller On.
8. Ensure display reads Start Delay, Status LED is Red Slow Flash and
current output displays 3.0 mA. This is the start-up delay sequence which
will last approximately 90 seconds.
Note: If the 4-20 mA signal is not used, connect a jumper between the 4-20
terminal and the COM terminal on the Terminal Board.
MLP-A-AR-SIR100
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S ENSOR S EPARATION
Figure 6: Wiring—Sensor Separation
Cut Shield
Terminal Board
RST
+24V
Power
Terminals
COM
Internal Ground
(Green Wire)
4-20
ISO
Wht+
Sensor
Terminals
Blu
Red
Sensor
Input
to
Junction Box
Blk
Shield
Shld
Sensor Board
SIR100 Sensor
As the Sensor must be located where gas is likely to accumulate and the
Controller where it can be easily reached, it is often necessary to “separate”
the Controller and Sensor.
(minimum 16 AWG) should be used for separations up to 2000 feet. Consult
the factory if a greater separation distance is required.
The Sensor separation kit (SEP) is composed of a junction box and terminal
strip. Refer to Option 1, Figure 1, "Locate Sensor/Controller", on page 2 for an
example.
Note: Refer to Table 1, "Controller/Sensor Terminal Connections", on
page 6 for Terminal definitions.
Ensure that the appropriate wire is used for Class 1/Division 1 hazardous
applications.
Shielded copper instrument wire (minimum 18 AWG) should be used for
separations up to 500 feet. Shielded copper instrument wire
Note: If the 4-20 mA signal is not used, connect a jumper between the 4-20
terminal and the COM terminal on the Terminal Board.
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Net Safety Monitoring Inc
N ON -I SOLATED /I SOLATED W IRING
Current Output
Terminal Connection
To set an isolated current output, simply move the Jumper (shorting jack) to
either the isolated or non-isolated current position (refer to Figure 9, "Jumper
Positions", on page 8).
Figure 7: Non-isolated Terminal Connection
Note: Unless otherwise specified, all models ship with non-Isolated current
output.
Terminal Board
Power Terminal
Figure 9: Jumper Positions
Jumper—Position Jumper
(shorting jack) over pins to
set power source for
current output.
Terminal Board
RST
Power
Supply
+24V
COM
Position 3 & 2 =
Non-isolated (default)
4-20
ISO
Position 1 & 2 = Isolated
to Monitor
Figure 8: Isolated Terminal Connection
RS-485 Terminator—
Jumper must remain
installed over pins 1 & 2.
Terminal Board
Power Terminal
Sensor Board
RST
Power
Supply
+24V
COM
4-20
ISO
to Monitor
R EMOTE R ESET
The Millennium can be set for remote reset. A normally open Push Button
Switch must be connected between the RST and the COM terminals on the
Terminal Board and the Relay Option Latch Status must be set to Latching.
Figure 10: Remote Reset
RST
Terminal Board
Power Terminal Strip
+24V
COM
4-20
ISO
MLP-A-AR-SIR100
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Net Safety Monitoring Inc.
STEP 4 — OPERATE
The Controller faceplate contains most functional elements of the user interface. Below is a description of that functionality.
Figure 11: Controller Functionality
Magnetic Reed Switch - provides non-intrusive access for
programming, calibrating and resetting.
-Place magnet against Housing (where indicated) for less than one
second to initiate a basic system reset (clear a latched alarm) and
make selections.
Scrolling 8-character display provides various status messages and
prompts. Refer to "Status LEDs,
Display Messages and Current
Loop" on page 10.
Pull Here knob - unscrew the two
screws and gently pull to remove
faceplate. Removal allows access to
terminal boards. The faceplate remains
attached by the ribbon cable.
-Place magnet against Housing (where
indicated) and hold to program, view
current settings and calibrate.
Refer to "Magnetic Reed Switch" on page 10
for further information.
Pull
Here
Ca
l/R
e
Ma set
On gnet
Sid
e
Status
Red
Calibration/Setup
On
ON/OFF Switch - used to turn Controller on
and off. Housing must be removed to access.
Pull Here knob - unscrew the two screws
and pull to remove faceplate. Removal
allows access to PCBs. The faceplate
remains attached by the ribbon cable.
-Hold Cal/Reset or
magnet until countdown
is zero (~10 sec)
-Follow instruction on
display
Off
Power
Slow Flash:
Gas present
Flast flash :
Cal or Fault
Solid:
Overrange
Green
Short Blips:
Normal
operation.
No gas
present
Status Light (Red and Green) indicates status of unit. Refer to "Status
LEDs, Display Messages and Current
Loop" on page 10 for detailed explanation
of states/status.
Current O/P Check
Pull
Here
Connect current probes
to meter jacks and
read mA output
Current Test Jacks - to take current loop measurements use the following procedure:
-Insert your current meter leads into the Test Jacks.
-Set external devices to bypass, if necessary, to avoid unwanted alarm response
-Review current loop measurements.
Calibration Button - provides intrusive access
for programming, calibrating and resetting.
-Push for less than one second to initiate a basic
system reset (clear a latched gas alarm) and make
selections.
-Push and hold to program, view current settings
and calibrate.
Refer to "Calibration Button" on page 10 for
further information.
Refer to "Current Loop Measurement (Test Jacks)" on page 11 and Table 2, "Status LEDs, Display
Messages and Current Loop", on page 10.
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Net Safety Monitoring Inc
Calibration Button
Table 2: Status LEDs, Display Messages and Current Loop
Status LED
State
Current O/P
Calibrate Sensor
Set Relay Options
Review Settings
3.0 mA
Normal operation
4.0 mA
Start-up delay (90 sec)
3.0 mA
Access Main Menu
3.0 mA
RED or GREEN Display
n/a
Blip/
blink
Slow
flash
n/a
00 %LEL
Start Delay
n/a
Switch On 10-0
Memory Error (contact
2.5 mA
factory)
Slow
flash
Memory Error
White, Blue, Red or
2.5 mA
Black Sensor lead open
Slow
flash
Sensor Fault
Auto zero set
3.0 mA
Apply calibration gas
3.3 mA
Solid
Fast
flash
The Calibration Button provides access to the Millennium’s Main Menu, which
in turn allows calibration and options to be reviewed and set. Refer to
Figure 11, "Controller Functionality", on page 9 for more information.
• Press and hold the Calibration Button to Calibrate and access Main Menu.
• Briefly press to make a selection (select YES?).
WARNING:
Opening the Controller’s Housing should be avoided when the
presence of gas is possible (when in a hazardous environment). Do
not power up the system, with the Housing removed, unless the
area has been de-classified.
Magnetic Reed Switch
Setting zero
The Magnetic Reed Switch is provided to avoid opening the Housing in an
environment where gas may be present. The Magnetic Reed Switch functions
in the same manner as the Calibration Button but in a non-intrusive manner.
Refer to Figure 11, "Controller Functionality", on page 9 for more information.
Apply 50% Span
Attached to the side of the Controller is a magnet:
Span is set, remove gas 3.6 mA
Solid
Remove gas
Return to normal
operation
• Place and hold the magnet to the Controller’s Housing (10 o’clock
position) to Calibrate and access Main Menu.
3.6 mA
Solid
Cal. Complete
Gas present
>4.0-20.0 mA
Blip/
blink
• Briefly place the magnet to the Controller’s Housing (10 o’clock position)
to make a selection (select YES?).
1 to 100% full
Scale
Power Up
Calibration procedure
failed/Sensor failed
3.0 / 3.3 mA
Flash
Flash
Fail Cal
Turn power switch On. A 90 second warm-up routine will begin. The display
reads Start Delay Millennium Net Safety, Status LED is Red Slow Flash and
current output displays 3.0 mA.
When power is applied, the system is automatically tested to ensure proper
functionality.
After warm-up, the Controller will enter normal operation, the display reads
00 %LEL, Status LED will Green Blip/blink and analog output will change to 4.0
mA.
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Current Loop Measurement (Test Jacks)
Accessing the Main Menu
Use a standard meter to measure current loop during various states. The
Controller’s Housing cover must be removed to access the Test Jacks.
There are two ways to access the Main Menu:
Refer to Table 2, “Status LEDs, Display Messages and Current Loop,” on
page 10 for a detailed list and Figure 11, "Controller Functionality", on page 9
for more information.
Status LED
The Status LED will remain solid, flash, blip and/or blink, in either Red or
Green, to indicate various states. Refer to Table 2, “Status LEDs, Display
Messages and Current Loop,” on page 10 for a detailed list.
T HE M AIN M ENU
The Main Menu provides access to various functional settings and viewing of
current settings.
• Calibrate Sensor.
• Review Relay Settings (optional) - Review the current Fault, Low and High
alarm settings. This is a read only section.
• Set Relay Options (optional) - Set the Low and High alarm settings.
• Select Gas Curve (methane or propane).
• Select a display language - English, Spanish or French.
• Calibration Button found on the faceplate (the Housing cover must be
removed to access)
• Magnetic Reed Switch (a magnet must be used to activate)
Main Menu Functionality
1. Ensure that the Controller has been turned on and no fault is present.
2. Hold the magnet against the Reed Switch or press and hold the Calibration
Button until the message Switch On displays and the countdown (10 to 0)
finishes.
3. An option will scroll across the display followed by the prompt YES?.
4. To select an option, momentarily place the magnet to the Reed Switch or
press the Calibration Button at the YES? prompt.
5. If you do not wish to select that option wait until the next option appears
and then select YES?.
6. A selection is acknowledged with a flashing YES.
7. If no option is selected, the Controller returns to 00 %LEL (normal
operation).
Note: The current output will drop to 3.0 mA while in the Main Menu.
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STEP 5 — CALIBRATE
C ALIBRATION P ROCEDURE
WARNING:
The calibration procedure requires about 5 minutes to complete. If gas is not applied at the appropriate time, a calibration failure may occur
(refer to "Calibration Failure" on page 13 for specific information).
For accurate performance, the Millennium should be calibrated using 50% span of the specific gas of concern. The concentration of gas, corresponding to 100% of
full scale, is converted to a linear 4 to 20 mA output signal which can be powered from the primary dc supply of the instrument. Power up the unit for at least 4
hours BEFORE first calibration.
Note: Air movement, drafts and wind can cause dilution of calibration gas flow which can cause an erroneous calibration and inaccurate performance. To avoid
this, use a Calibration Cover to cover the slots on the Sensor. The cover MUST be removed for normal operation. When slots are covered, inject
calibration gas at a rate of 1.0 litre per minute or greater; when not covered, ensure area is free of drafts/wind and inject calibration gas at a rate of
3.0 litres per minute or greater.
The following calibration procedure should be followed to ensure an accurate correlation between the 4 to 20 mA output signal and the gas concentration.
Calibration Procedure
1. Confirm successful power up of Controller—LED Green Blip/blink every 2 seconds; no fault indicated.
2. Flow certified ZERO AIR at a rate of 1.0 litre per minute through the side calibration fitting when using the Calibration Cover (if separated or not using the
Calibration Cover, a rate of at least 3.0 litres per minute is recommended).
3. Press and hold the Calibration Button or use the Reed Switch to access the Main Menu and wait for countdown (10-0) to complete.
4. When Calibrate Sensor YES? displays, use the Calibration Button or Reed Switch to select YES?
Selection will be confirmed by a flashing YES.
5. When Setting Zero displays apply clean air.
6. Wait for Apply 50% Span to display and apply specific gas. If in windy conditions and using a Calibration Cover, apply at a rate of 1.0 litre per minute
otherwise 3.0 litres per minute is recommended.
7. The display will show Calibrating as gas detected.
8. Remove span gas when the message Remove Gas displays (Status LED Green solid and 3.6 mA output).
9. The message Cal Complete will display when calibration is complete.
10. Apply zero gas (clean air) again to purge system.
Note: Always apply test gas after calibration to verify operation.
Figure 12: Calibration Procedure
Display
Shows
Calibrate
Sensor YES?
Setting Zero
Apply 50% Span
Action
Select YES?
Apply clean (zero air)
Apply specific gas
MLP-A-AR-SIR100
Calibrating
Remove Gas
Cal Complete
Remove gas
Apply clean air to purge
system
12
Net Safety Monitoring Inc.
Calibration Failure
If the calibration procedure fails, the display shows Fail Cal, the Status LED
alternates Red/Green flashes and the analog output changes back and forth
from 3.0 to 3.3 mA.
STEP 6 — MONITOR
The unit remains in a failed state until manually reset. After the Manual Reset,
the unit will return to normal operation based on previous calibration values.
See "Manual Reset" on page 15 for instructions.
This is a read-only mode; changes cannot be made.
R EVIEW R ELAY S ETTINGS
Step 1:
Press and hold the Calibration Button or the magnet to the Reed
Switch to enter the Main Menu; wait for the countdown, from 10
to 0, to end.
Step 2:
When Review Relay Settings displays press the Calibration
Button or use the Reed Switch to select.
The flashing YES confirms the selection.
Step 3:
The Fault Alarms are fixed (Energized / Non-Latching) and
display first. Then the Low Alarm level, coil and latch status display,
followed by the High Alarm level, coil and latch status.
Step 4:
At this point, the option to Set Relay Options YES? is displayed.
S ET R ELAY O PTIONS
Use to set the alarm level, coil status and latch status for the Low and High
relays (Fault Alarm is fixed).
Table 3: Default Relay Settings
MLP-A-AR-SIR100
MLP-A-(AR)
20%
40%
Fault
Energ./Non-latching
*
De-energized
High
Energized
Low
Non Latching
Millennium
Model Number
Coil Status
Latching
Alarm Levels
*
13
Net Safety Monitoring Inc
Setting Relay Options
S ELECT G AS C URVE
There are two settings for Relay Options: Low and High. The Fault Relay is
fixed as Energized/Non-latching and cannot be changed. The low alarm level,
coil energization and latch status for low alarm are set first; high alarm level,
coil energization and latch status for high alarm are then set. All ranges are in
%LEL.
The Millennium can be set to detect methane or propane.
Step 1:
Step 2:
Step 3:
When Set Relay Options YES? displays press the Calibration
Button or use the Reed Switch to select.
The flashing YES confirms the selection.
The message Set Low displays. Low Alarm set-points are then
displayed in increments of 5 (5 to 95).
When the required level displays, press the Calibration Button or
use the Reed Switch to select.
The level selected will flash to confirm the selection.
Step 4:
The message Coil Status displays. The display then shows
Energized YES? and then De-Energized YES?.
Step 5:
Press the Calibration Button or use the Reed Switch to select.
The flashing YES confirms the selection. If no selection is made,
Coil Status option is repeated.
Note: The default curve is set in the factory based on the gas ordered.
Step 1:
When the message Select Gas Curve YES? displays press the
Calibration Button or use the Reed Switch to select.
The flashing YES confirms the selection.
Step 2:
The message Methane %LEL Yes? displays. Use the Calibration
Button or use the Reed Switch to select or wait for Propane %LEL
Yes? to display and select.
Step 3:
The flashing YES confirms the selection and will continue to flash
for a few seconds. The Millennium display will shortly return to
normal operation 00 %LEL.
Note: If the gas curve is modified, the Millennium must be recalibrated (refer
to "Calibration Procedure" on page 12).
S ELECT D ISPLAY L ANGUAGE
Step 1:
When Select Display Language YES? displays press the
Calibration Button or use the Reed Switch to select.
The flashing YES confirms the selection.
When the required language displays (English, Espanol, Francais)
press the Calibration Button or use the Reed Switch to select.
The flashing YES confirms the selection.
Step 6:
The message Latch Status displays. The display then shows
Latching YES? and then Non-Latching YES?.
Step 2:
Step 7:
Press the Calibration Button or use the Reed Switch to select.
The flashing YES confirms the selection. If no selection is made,
Latch Status option is repeated.
Note: Factory default is English.
Step 8:
The message Set High displays.
The High Alarm level cannot be set to a value lower than the Low
Alarm level (as set in Step 3), nor higher than the maximum of
100% LEL. The High Alarm level is displayed in increments of 5
greater than the Low Alarm level (as set in Step 3).
Step 9:
Repeat Steps 3 through 7 to complete the High Alarm level, coil
and latch status settings.
Note: If no selection is made, a 5 minute timer expires, in which case the unit
returns to normal operation.
MLP-A-AR-SIR100
14
Net Safety Monitoring Inc.
A LARMS
R ESET
Sensor Fault
Manual Reset
WARNING:
The fault detection circuitry does not monitor the operation of external
response equipment or the external wiring to these devices. It is important
that these devices be checked periodically to ensure they are operational.
Self-testing circuitry continuously checks for problems that could prevent
proper response. When power is applied, the microcontroller automatically
tests the system to ensure that it is functioning properly. During normal
operation, it continuously monitors the signal from the internal sensor source.
In addition, a "watchdog" timer is maintained to ensure the program is running
correctly. When a system fault is detected, the Status LED will Red Slow flash,
the displays shows Sensor Fault and analog output changes to 2.5 mA.
Gas Present
When gas is present, 1 to 100% Full Scale will display, the analog output
switches to between 4 and 20 mA and the Status LED Blip/blinks Red.
Sensor Life
Depending on various factors, sensor response may slowly deteriorate over a
period of years. If calibration becomes impossible for any reason, the display
will show Fail Cal, the analog output will switch repeatedly between 3.0 mA
and 3.3 mA and the Status LED alternates Red and Green flashes.
A Manual Reset is required after a calibration failure or to clear a latched relay
alarm. Simply place and hold the magnet against the Reed Switch or press and
hold the Calibration Button for 3-5 seconds. The unit will return to normal
operation using previous calibration values.
Remote Reset
If Relay Option is set to Latching (refer to "Setting Relay Options" on
page 14) and an open Push Button Switch is connected between the RST
terminal and the COM terminal on the Terminal Board, Remote Reset is
possible. Also refer to "Remote Reset" on page 8 for details.
O UTPUTS
Relays (Optional)
Note: The fault relay output is not used to activate an automatic shutdown
procedure. The fault output indicates a potential problem with the
Controller not an alarm condition.
Standard electro-mechanical relay outputs have Form C SPDT contacts rated
5 Amps at 30 V dc/ 250 V ac. Three relay outputs are available; one for Fault;
one for Low alarm; and one for High alarm. All relays have normally open and
normally closed contacts available at the output terminals.
The fault relay is set for normally energized operation and is non-latching. If a
system fault is detected, the fault relay becomes de-energized. The fault relay is
factory set and cannot be altered. The Low alarm and High alarm relays can be
selected for either normally energized or normally de-energized operation and
latching/non-latching.
Current
A 4-20 mA dc current output is used to transmit the alarm status and fault
codes to other devices. This output can be wired for isolated or non-isolated
operation. A 4.0 mA output indicates normal operation; a 4.0 - 20.0 mA output
indicates the presence of gas. Current output of 2.5 mA indicates the presence
of a system fault.
MLP-A-AR-SIR100
15
Net Safety Monitoring Inc
STEP 7 — MAINTAIN
P ERIODIC R ESPONSE C HECK
We recommend the Millennium be verified or calibrated every 3 months. A
typical response check involves the application of calibration gas to the sensor,
then the observation of the response LEDs, analog output, display and external
monitoring equipment. Be sure to prevent unwanted response of external
monitoring devices and equipment during this procedure. If the Millennium
response to calibration gas is within its specified accuracy then it is not
necessary to perform a calibration. For example, when 50% of full scale is
applied, the response is expected to be between 11.5 mA (47% of full scale)
and 12.5 mA (53% of full scale). An additional consideration is the accuracy
tolerance of the calibration gas which may be + or - a few percent. If the
calibration gas is + or - 10% of full scale then the reading may be from 10.7 mA
(42% of full scale) to 13.3 mA (58% of full scale).
TROUBLESHOOT
Response to the input should be checked and, if necessary, calibration should
be performed whenever any of the following occur. Refer to "Calibration
Procedure" on page 12 for calibration instructions.
HOW TO RETURN EQUIPMENT
A Material Return Authorization number is required in order to return
equipment. Please contact Net Safety Monitoring at (403) 219-0688 before
returning equipment or consult our Service Department to possibly avoid
returning equipment.
If you are required to return equipment, include the following information:
1. A Material Return Authorization number (provided over the phone to you
by Net Safety).
2. A detailed description of the problem. The more specific you are regarding
the problem, the quicker our Service department can determine and
correct the problem.
3. A company name, contact name and telephone number.
4. A Purchase Order, from your company, authorizing repairs or request for
quote.
5. Ship all equipment, prepaid to:
Net Safety Monitoring Inc
3rd Floor, 2711 39th Ave., N. E.
Calgary, Alberta, Canada
T1Y 4T8
• Sensor or transmitter is connected or disconnected
6. Mark all packages: RETURN for REPAIR
• Gas Curve is modified
Waybills, for shipments from outside Canada, must state:
The Millennium is not designed to be repaired in the field. If a problem should
develop, first calibrate the device and carefully check for faulty wiring. If it is
determined that the problem is caused by an electronic failure, the device must
be returned to the factory for repair. Refer "How to Return Equipment" on
page 16 for detailed instructions.
Equipment being returned for repair
All charges to be billed to the sender
Also, please ensure a duplicate copy of the packing slip is enclosed inside the
box indicating item 1-4 along with the courier and account number for
returning the goods.
All Equipment must be Shipped prepaid. Collect shipments will not
be accepted.
Pack items to protect them from damage and use anti-static bags or aluminumbacked cardboard as protection from electrostatic discharge.
MLP-A-AR-SIR100
16
Net Safety Monitoring Inc.
S PARE P ARTS /A CCESSORIES
Rotate PCB Assembly
Table 4: Part Numbering
1.
2.
3.
4.
Description
Net Safety Part Number
Calibration Cover for windy conditions
CC-SIR100-SEP
Separation Kit
SEP
F ACE R OTATION O PTION
In some applications, it is necessary for the Millennium Controller to be
mounted in a non-standard orientation. To accommodate such installations
and ensure that the display will appear at the correct angle for viewing, the
PCB Assembly can be rotated inside the Controller.
Figure 13: Non-standard Orientations
5.
6.
7.
8.
9.
10.
11.
12.
Remove the Controller’s Housing Cover.
Turn the power to the detector off.
Unscrew both the knobs marked "Pull Here".
Lift Controller faceplate from Housing and allow to hang from ribbon
cable.
Unscrew the two metal standoffs.
Carefully remove the PCB Assembly from the Housing.
The Rotator plate is secured to the bottom of the Housing and is
accessible after the PCB Assembly has been removed.
Rotate the PCB Assembly to desired position and line up the standoffs
with the mounting holes.
Insert standoffs in the appropriate horizontal or vertical mounting holes.
Tighten standoffs to secure PCB Assembly.
Replace faceplate and tighten "Pull Here" knobs.
Return power to detector and replace Housing Cover.
Vertical Mounting Holes
(Insert Standoffs)
Horizontal Mounting
Holes
(Insert Standoffs)
Note: Ensure orientation allows for connections and excess wire within Controller
Housing.
Ribbon cable
Standoffs
PCB Assembly
Faceplate
WARNING:
See Appendix A, "Electrostatic Sensitive Device (ESD)", on
page 18 for handling instructions of electronic components.
MLP-A-AR-SIR100
17
Net Safety Monitoring Inc
Appendix A:
ELECTROSTATIC SENSITIVE DEVICE (ESD)
Electrostatic discharge (ESD) is the transfer, between bodies, of an
electrostatic charge caused by direct contact or induced by an electrostatic
field.
The most common cause of ESD is physical contact. Touching an object can
cause a discharge of electrostatic energy—ESD! If the charge is sufficient and
occurs near electronic components, it can damage or destroy those
components.
In some cases, damage is instantaneous and an immediate malfunction occurs.
However, symptoms are not always immediate—performance may be marginal
or seemingly normal for an indefinite period of time, followed by a sudden
failure.
To eliminate potential ESD damage, review the following guidelines:
• Handle boards by metal shields—taking care not to touch electronic
components
• Wear grounded wrist or foot straps, or ESD shoes or heel grounders to
dissipate unwanted static energy
• Prior to handling boards, dispel any charge in your body or equipment
• Enure components are transported and stored in static safe packaging
• When returning boards, carefully package in the original carton and static
protective wrapping
• Ensure ALL personnel are educated and trained in ESD Control Procedures
In general, exercise accepted and proven precautions normally observed when
handling electrostatic sensitive devices.
A warning label is placed on the packaging, identifying product using
electrostatic sensitive semiconductor devices.
MLP-A-AR-SIR100
18
Net Safety Monitoring Inc.
Appendix B: RESISTANCE TABLE
Table 5: Wire Resistance In Ohms
Distance (Feet)
AWG #20
AWG #18
AWG #16
AWG #14
AWG #12
AWG #10
AWG #8
100
200
300
400
500
600
700
800
900
1000
1250
1500
1750
2000
2250
2500
3000
3500
4000
4500
5000
5500
6000
6500
7000
7500
8000
9000
10 000
1.02
2.03
3.05
4.06
5.08
6.09
7.11
8.12
9.14
10.20
12.70
15.20
17.80
20.30
22.80
25.40
30.50
35.50
40.60
45.70
50.10
55.80
61.00
66.00
71.10
76.10
81.20
91.40
102.00
0.64
1.28
1.92
2.55
3.20
3.83
4.47
5.11
5.75
6.39
7.99
9.58
11.20
12.80
14.40
16.00
19.20
22.40
25.50
28.70
32.00
35.10
38.30
41.50
44.70
47.90
51.10
57.50
63.90
0.40
0.80
1.20
1.61
2.01
2.41
2.81
3.21
3.61
4.02
5.03
6.02
7.03
8.03
9.03
10.00
12.00
14.10
16.10
18.10
20.10
22.10
24.10
26.10
28.10
30.10
23.10
36.10
40.20
0.25
0.51
0.76
1.01
1.26
1.52
1.77
2.02
2.27
2.53
3.16
3.79
4.42
5.05
5.68
6.31
7.58
8.84
10.00
11.40
12.60
13.91
15.20
16.40
17.70
19.00
20.20
22.70
25.30
0.16
0.32
0.48
0.64
0.79
0.95
1.11
1.27
1.43
1.59
1.99
2.38
2.78
3.18
3.57
3.97
4.76
5.56
6.35
7.15
7.94
8.73
9.53
10.30
11.10
12.00
12.70
14.30
15.90
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.09
1.25
1.50
1.75
2.00
2.25
2.50
3.00
3.50
4.00
4.50
5.00
5.50
6.00
6.50
7.00
7.49
7.99
8.99
9.99
0.06
0.13
0.19
0.25
0.31
0.38
0.44
0.50
0.57
0.63
0.79
0.94
1.10
1.26
1.41
1.57
1.88
2.21
2.51
2.82
3.14
3.46
3.77
4.08
4.40
4.71
5.03
5.65
6.28
Note: Resistance shown is one way. This figure should be doubled when determining closed loop resistance.
MLP-A-AR-SIR100
19
Appendix C: SPECIFICATIONS
S ENSOR S PECIFICATIONS
•
•
•
•
•
•
•
•
Operating Temperature Range:
Weight:
Enclosure Material:
Range of Detection:
Accuracy:
Response Time:
Linearity/Repeatability:
Certification:
C ONTROLLER S PECIFICATIONS
-40°C to +75°C (-40F to +167F)
0.9 Kg (2.0 lb)
Powder Coated or Anodized Aluminum (optional stainless steel)
0 to100% LEL methane/propane
±3% LEL up to 50% LEL
±5% LEL above 50% LEL
<5 seconds to T20
<7 seconds to T40
±3% LEL / ±2% LEL
CSA and NRTL/C certified for hazardous locations. Class I, Division 1, Groups B, C and D. IEC Rating Ex d IIB+H2 T5.
Performance certified to CSA C22.2 No. 152.
MILLENNIUM
4-20 mA ANALOG OUTPUT
Operating Temperature Range
-40°C to +85°C (-40F to +185F)
Power Consumption
24 V dc @ 50 Span
Nominal 3.02 W
Maximum 3.38 W
Humidity Range
0 to 100% Relative humidity, non-condensing
Operating Voltage Range
10.5 to 32.0 V dc
Enclosure Material
Powder coated Copper Free Cast Aluminum
Certifications
CSA and NRTL/C certified for hazardous locations. Class I, Division 1, Groups B, C and D. Temperature Code T5. Rating
Ex d IIB+H2 T5 (Class1, Zone 2, Group IIB+H2T5). Maximum operating ambient of 85°C. Enclosure Type 4X.
Note: Electronics only-CSA and NRTL/C certified for hazardous locations Class I, Division 2 Groups A, B, C and D.
Weight
3.5 Kg (7.7 lb)
(1) Current Output
Yes
(2) Relay Output
4-20 mA with RELAY OUTPUT MODULE
Nominal 3.36 W
Maximum 4.5 W
Yes
Yes
8-digit alpha-numeric display
Yes
Non-intrusive Calibration
Yes
(1) 4 to 20 mA - Into a maximum loop impedance of 800 Ohms at 32 V dc or 150 Ohms at 10.5 V dc. Isolated or non-isolated loop supply.
(2) Form C contacts rated 5 Amps at 30 V dc / 250 V ac. Selectable energized / de-energized, latching/non-latching configurable low and high alarms. Fault relay
is factory set as energized, non-latching and cannot be modified.
Distributed by:
Net Safety Monitoring Inc.,
3rd Floor, 2711 39th Avenue N.E.
Calgary, Alberta, Canada T1Y 4T8
Telephone: (403) 219-0688 Fax: (403) 219-0694
E-mail: netsafe@net-safety.com
www.netsafety.com