UNI-TROL TM GAS CONTROLLER

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1 MODELS: R1G, R2G and R4G UNI-TROL TM GAS CONTROLLER One, Two and Four-Channel Rack-Mount Controller ISO 9001 Certified Company Part Number: MAN-0004 Rev. 1

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3 Copyright 2002 Net Safety Monitoring Inc. Printed in Canada This manual is provided for informational purposes only. Although the information contained in this manual is believed to be accurate, it could include technical inaccuracies or typographical errors. Changes are, therefore, periodically made to the information within this document and incorporated without notice into subsequent revisions of the manual. Net Safety Monitoring Inc. assumes no responsibility for any errors that may be contained within this manual. This manual is a guide for the use of a Gas controller and the data and procedures contained within this document have been verified and are believed to be adequate for the intended use of the controller. If the controller or procedures are used for purposes other than as described in the manual without receiving prior confirmation of validity or suitability, Net Safety Monitoring Inc. does not guarantee the results and assumes no obligation or liability. No part of this manual may be copied, disseminated or distributed without the express written consent of Net Safety Monitoring Inc. Net Safety Monitoring Inc. products, are carefully designed and manufactured from high quality components and can be expected to provide many years of trouble free service. Each product is thoroughly tested, inspected and calibrated prior to shipment. Failures can occur which are beyond the control of the manufacturer. Failures can be minimized by adhering to the operating and maintenance instructions herein. Where the absolute greatest of reliability is required, redundancy should be designed into the system. Net Safety Monitoring Inc., warrants its sensors and detectors against defective parts and workmanship for a period of 24 months from date of purchase and other electronic assemblies for 36 months from date of purchase. No other warranties or liability, expressed or implied, will be honored by Net Safety Monitoring Inc. Contact Net Safety Monitoring Inc. or an authorized distributor for details.

4 Table of Contents Unit I GENERAL INFORMATION DESCRIPTION... 1 FEATURES... 1 SPECIFICATIONS... 1 Figure 3 - Controller Face-Plate... 2 Figure 1 - Controller Dimensions... 2 BASIC OPERATION... 2 FACEPLATE DESCRIPTION... 2 OUTPUTS... 3 Figure 3 - Jumper Selections for an Isolated or Non-isolated Current Output... 3 PROGRAMMING OPTIONS... 4 EXTERNAL RESET... 5 AUTOMATIC DIAGNOSTICS AND FAULT IDENTIFICATION... 5 OPERATING MODES... 5 Unit II SYSTEM INSTALLATION INSTALLATION... 7 SENSOR LOCATIONS... 7 GENERAL WIRING REQUIREMENTS... 8 CONTROLLER WIRING... 8 DIP SWITCH SETTINGS Figure 7a - Relay and Dip Switch Positions ACTIVE CHANNELS CALIBRATION GAS CONCENTRATION POWER-UP TIME DELAY ALARM SETTINGS LATCHING/NON-LATCHING SELECTION ENERGIZED/DE-ENERGIZED SELECTION RELAY SETTINGS Figure 7c - Relay Settings INSTALLATION CHECKLIST Unit III SYSTEM OPERATION MENU AND FUNCTION SELECTION START-UP PROCEDURE MAIN MENU SELECTIONS ERROR CHECK MODE (Err Chc) SET-POINT DISPLAY MODE (SPd) SENSOR CALIBRATION (CAL) SENSOR REPLACEMENT MODE (SrP) SPECIAL FUNCTION MENU SELECTIONS FORCED CURRENT OUTPUTS (FoP) CURRENT CALIBRATION MODE (CuC) ADDRESS SET MODE (Adr Set) (OPTIONAL) CHANNEL DISPLAY(Chd) BYPASS (bps) OPERATING MODES RESET MODE FORCED RESET MODE NORMAL OPERATING MODE FORCED DISPLAY (FdP)... 31

5 Unit IV SYSTEM MAINTENANCE ROUTINE MAINTENANCE MANUAL CHECK OF OUTPUT DEVICES SYSTEM CHECK IN NORMAL MODE SENSOR REPLACEMENT TROUBLESHOOTING Appendix B Record Of Dip Switch Settings Wire Resistance In Ohms SENSOR REPLACEMENT MODE (SrP) SPECIAL FUNCTION MENU SELECTIONS FORCED CURRENT OUTPUTS (FoP) CURRENT CALIBRATION MODE (CuC) ADDRESS SET MODE (Adr Set) (OPTIONAL) CHANNEL DISPLAY (Chd) BYPASS (Bps) OPERATING MODES RESET MODE FORCED RESET MODE NORMAL OPERATING MODE FORCED DISPLAY (FdP) UNIT IV - SYSTEM MAINTENANCE ROUTINE MAINTENANCE MANUAL CHECK OF OUTPUT DEVICES SYSTEM CHECK IN NORMAL MODE SENSOR REPLACEMENT TROUBLESHOOTING DEVICE REPAIR AND RETURN Table 9 - Troubleshooting Guide Appendix A... i Appendix B... ii Appendix C...iii

6 Unit I GENERAL INFORMATION DESCRIPTION The Uni-Trol R1G, R2G and R4G Controllers accept 4-20 ma DC analog input signals from Net Safety Combustible and toxic gas sensors. Controller response includes actuation of relays for direct control of field response devices, 4-20mA outputs and a full array of faceplate indicators. The type of controller and its range can be determined from the model number as shown below: RXG-100-LEL = 0 to 100% LEL controller RXG-100-H2S = 0 to 100ppm H 2 S controller RXG-1000-CO = 0 to 1000ppm CO controller RXG-20-SO2 = 0 to 20ppm SO 2 controller The controller displays the gas concentration in parts per million (p.m.) for all types of gases unless it is a combustible gas controller which shows the gas concentration as % of lower explosive limit (LEL). FEATURES < Controller accepts 4 to 20 ma analog inputs from Net Safety Combustible and toxic gas sensors. < Two digital displays, one bar graph display, and high intensity LEDs indicate important system status. < AutoCal feature provides easy and accurate calibration. < Microprocessor-based controller is easily field programmable. < 4-20mA current outputs to send important system information to other devices. < Relay alarm and fault outputs. SPECIFICATIONS < Operating Voltage: 24 Volts DC. Device can operate between 18 and 32 Volts DC < Power Consumption (Controller only): 2.4 Watts nominal, 4.4 Watts maximum (100 ma nominal, 180 ma maximum at 24 Volts DC) Maximum start-up current is 1.5 Amperes for 10 milliseconds. Power supplies with foldback current limiting are not recommended < Maximum Ripple: Ripple should not exceed 5 Volts peak-to-peak. The sum of DC plus ripple must be $18 Volts DC and #32 Volts DC < Temperature Range: Operating: -40ºC to +85ºC (-40ºF to +185ºF) Storage: -55ºC to +150ºC (-65ºF to +302ºF) < Relay Contacts: Normally open/normally closed contacts rated at 5 Amperes at 30 Volts DC/250 Volts AC - 1 -

7 < Current Outputs: Two 4-20mA DC current, with a maximum external loop resistance of 600S at Volts DC < Dimensions: Refer to Figure 1 < Shipping Weight (approximate): 2 lbs. (0.9 kilograms). < Certification: Designed to meet CSA and FM specifications for ordinary locations. Figure 1 - Controller Dimensions BASIC OPERATION FACEPLATE DESCRIPTION The controller faceplate provides LEDs for identifying status conditions, two digital displays and a bar graph display for indicating the sensor inputs, and MENU/SET and SELECT/RESET push-buttons for programming, calibrating and resetting the system. Refer to Figure 2 for the location of indicators and push-buttons. < Digital Displays - Two digital displays are used to display the sensor inputs in both the Normal and Calibrate Modes; one display indicates the channel and one display indicates the corresponding sensor input. In the event of a fault, it identifies the nature of the fault using an alphanumeric code. In the Normal Operating Mode, each channel is sequentially displayed for 5 seconds. In other operating modes, the digital displays show the alarm set-points, programmed calibration gas concentration, or the communication addresses for the Digital Communication. A negative zero drift condition is indicated by a minus sign in the left-hand digit. Since at least one display is always lit, it also functions as a power indicator Figure 3 - Controller Face-Plate

8 < Bar Graph Display - The common 10-segment bar graph display provides readings of the four sensor inputs in 5% of full range increments (ie. for a 50ppm controller each segment represents 2.5ppm, which is 5% of the full range of 50ppm), from 0% to 50% of full range; all 10 segments are illuminated for 50% of full range and higher gas concentrations. < High Alarm LED (HI) - Flashes in response to a sensor signal that exceeds the high set-point. < Low Alarm LED (LOW) - Flashes in response to a sensor signal that exceeds the low set-point. < Calibrate LED (CAL) - is illuminated while the controller is in the Calibrate Mode. < Fault LED (Fault) - is illuminated upon detection of an overall system fault or a channel related fault. < Channel LEDs - are illuminated when status on the corresponding channel is displayed on the common indicators (digital displays and bar graph). During power-up, a channel LED is on if the channel is selected for operation. < MENU/SET Push-Button - is used for changing the menu display as well as other system programming and calibration functions. < SELECT/RESET Push-Button - is used for menu selection and other system programming, as well as for resetting the controller. OUTPUTS Relay Outputs: The relay outputs have SPDT contacts rated at 5 Amperes at 30 Volts DC or 250 Volts AC. The four relays include an Area 1 low alarm (channels 1 and 2), an Area 2 low alarm (channels 3 and 4), one common high alarm, and a fault alarm. RECOMMENDATION The fault relay output should not be used to activate an automatic shutdown procedure. The fault output indicates a potential problem with the controller, not an alarm condition. Current Outputs: Two 4-20mA DC current outputs for transmitting system information to other devices are also included. The current outputs can be wired for isolated or non-isolated operation by changing the positions of J12 and J18, as shown in Figure 3. Refer to Table 1 for a description of the current output signal levels

9 Figure 3 - Jumper Selections for an Isolated or Non-isolated Current Output Current Output 0mA 1mA 2mA 3mA 4mA to 20mA Situation Open or shorted signal output, or loss of power Fault or Power up Power Fault Sensor Calibration 0 to 100% of full scale Table 1 - Current Outputs PROGRAMMING OPTIONS A set of dip-switches, located on the circuit board, can be used to program various options and set-points, including: < the channels selected for operation, < low and high alarm settings, < calibration gas concentration, < power-up delay time (either 45 or 90 seconds), < latching/non-latching selection, and < energized/de-energized selection The alarm outputs are programmable for either normally energized or normally de-energized operation (programmable as a group only, not individually). The fault output is normally energized. The low alarm outputs are programmable for either latching or non-latching operation. The high alarm output is always latching and the fault output is non-latching. Refer to Table 2. OUTPUT Selectable Normally Open/Closed Selectable Normally Energized/De-Energized Selectable Latching/Nonlatching LOW 1 Y Y 2 Y HIGH Y Y 2 N 3 FAULT Y N 4 N 5 Table 2 - Selectable Output Options Low alarms are programmed together, not individually Programmable together, not individually High alarm relay is always latching Fault relay is normally energized Fault relay is non-latching - 4 -

10 EXTERNAL RESET A normally open, momentary closure switch can be connected between the external reset terminal and the negative power terminal to provide remote reset capabilities. AUTOMATIC DIAGNOSTICS AND FAULT IDENTIFICATION The microprocessor-based controller features self-testing circuitry that continuously checks for problems that could prevent proper system response. When power is applied, the microprocessor automatically tests memory. In the Normal Operating Mode, it continuously monitors the input signals from the sensor/transmitter to ensure proper functioning. In addition, a watchdog timer is maintained to ensure that the program is running correctly. The timer resets the micro-controller if it enters erroneous processor states within a reasonable period of time. If a fault is detected, the Fault LED illuminates, the digital display identifies that a fault has occurred, the fault relay output becomes de-energized, and the current output drops to 1 ma. The nature of the fault can be identified by a numeric code, which can be viewed in the Fault Message Display mode. OPERATING MODES The controller can operate in any of the modes discussed in this section. Operating modes other than Normal are selected by pressing the appropriate MENU/SET and SELECT/RESET buttons located on the controller front panel. Refer to Figure 2 for a diagram of the controller front panel. This section is intended to acquaint the user with the basic operation of the controller. Refer to Unit III for detailed instructions and description. Normal Operating Mode: If no alarms or faults are occurring, the module will be in a Level 1 Display Mode; the bar graph and digital display sequentially indicate the sensor inputs for 5 seconds on each channel, and all the LEDs are off except the appropriate channel LEDs. Relay outputs are in their normal state, and the current outputs correspond to the sensor inputs. If a low alarm condition occurs on any channel, the module will be in a Level 2 Display Mode; the bar graph and digital display will display only the channel that is in alarm. If more than one channel is in alarm, the channel with the highest alarm will be displayed and the channel LED for any other channel(s) in alarm will flash. The low alarm LED will flash, the low alarm relay(s) change state, and the current outputs change to indicate the alarm. If the signal(s) decreases below the low set-point again, the corresponding alarm relays return to their normal state if programmed for non-latching operation and remain unchanged if programmed for latching operation. The current outputs will return to the normal output level. The low alarm LED will still illuminate whenever the channel which had the alarm condition is displayed. If a high alarm condition occurs, the module will be in a Level 3 Display Mode; the bar graph and digital display will cycle through all channels with a high alarm condition. While one channel is displayed, the channel LED for any other channel in a high or low alarm state will flash. When 1 or more channels are in a high alarm condition and 1 or more channels are in a low alarm condition, only the channels in the high alarm condition will be cycled on the display. The channel LED for any channel in the low alarm condition will flash

11 Reset Mode: The Reset Function is entered by pressing the SELECT/RESET button located on the front panel of the controller. (Refer to Figure 2) When the SELECT/RESET button is activated momentarily, all LEDs turn off and all outputs return to their normal condition if no alarms or faults are occurring (basic reset). Forced Reset Mode: If any of the channels receives a reading beyond 100% of full scale, a reset will not clear the alarms, even if the channel has returned to levels below the low alarm set point. The error resulting from this occurrence must be cleared and a forced reset applied. To apply a forced reset, press the SELECT/RESET button for 3 second, the LEDs turn off and the outputs return to their normal condition. The remote reset performs a forced reset. The remote reset performs a reset function only. It cannot be used for other controller functions. Forced Display (FdP): This mode forces a sequential display of all the active channels. It can be used during alarm situations when the digital and bar graph display normally remain on the channel with the highest alarm condition. This function is also useful while in menu functions that do not show the sensor readings. Sensor Replacement Mode (SrP): This mode inhibits all controller outputs to allow replacement of the sensor(s) without removing power from the controller. Alarm set-points and calibration gas concentration are not affected. The upper display will show SrP while in the sensor replace mode. The lower display will show the status of the sensor being replaced ( NoS means no sensor is connected). The fault LED is on and the fault relay is deenergized. The channel LED will be on for the sensor being replaced. All other sensors remain active during sensor replace mode. If an alarm condition occurs on one of the active channels while in this mode, the appropriate channel LED will flash and relays and current outputs will act accordingly. All other display features will be inhibited. In order to exit this mode the SELECT/RESET button must be pressed. The controller will perform a power-up countdown (45 or 90 seconds) for the sensor that was replaced and the affected current output will be 1mA during this time. Sensor Calibration Mode (CAL): The Uni-Trol Controller uses a fully automatic calibration procedure that requires no adjustments by the operator. The controller displays Air on the upper display and the channel status on the lower display while automatically performing the zero adjustments. Next the controller will signal the user to apply the calibration gas by alternating gas and in on the upper display. When the controller detects that the gas has been applied to the sensor, the upper display will read gas. Once the controller has finished the gain adjustments it will alternate Cut and gas on the upper display, telling the user that it is time to remove the calibration gas. Upon completion of the calibration the controller will automatically return to the normal operating mode. If the operator fails to complete the calibration procedure, if an error in the calibration procedure occurs, or if a successful calibration cannot be completed, the microprocessor will automatically return to the Normal Operating Mode and continue to use the previous calibration data. A fault indication will be displayed until a reset occurs. If the microprocessor determines that the sensor is approaching the end of its useful life, a fault code will indicate this

12 While in the calibration mode, all controller outputs for the affected channel are inhibited, the current output is 3mA, and the Cal LED is illuminated. All other channels remain active, however if an alarm condition occurs, the only display indication will be a flashing channel LED, all other display features will be inhibited. Set-Point Display (Spd): In this mode, the digital display sequentially shows the programmed low and high alarm set-points, calibration gas concentration, and communication addresses. Each value is displayed for approximately 2 seconds. Address Set (Adr Set): The communication addresses for Digital Communications are set in this mode, which is found in the main menu. The MENU/SET and SELECT/RESET buttons are used to raise and lower the address. This mode can only be exited by allowing ten seconds to go by without pressing either button. Error Message Display (Err Chc): The microprocessor-based controller features self-testing circuitry that continuously checks for problems that could prevent proper system response. As a diagnostic and troubleshooting tool, identifiable faults are displayed on the digital display, using error codes, during the Error Message Display Mode. The controller will also display an error message after the last channel in the cycling routine. Channel Display (Chd): In this mode, the displays can be forced to monitor only one channel, as long as no alarms are occurring, on other channels. If an alarm occurs on the channel that is being monitored, the controller will remain in the manual display mode. If an alarm occurs on any other channel the controller will automatically return to the Normal Operating Mode. INSTALLATION SENSOR LOCATIONS Unit II SYSTEM INSTALLATION Proper location of the sensors is essential for providing maximum protection. The method for deciding the most effective number and placement of sensors varies depending on the conditions at the job site. The individual performing the installation must rely on experience, common sense, and knowledge of plant operations to determine the number of sensors needed and the best controller locations to protect the area adequately. The following factors are important and should be considered for every installation: < Sensors should be located where they are safe from potential sources of contamination < Refer to sensor application manuals and follow guidelines for sensor installation < Sensors must be accessible for testing and calibration < Exposure to excessive heat or vibration can cause premature failure of electronic devices, and should be avoided if possible - 7 -

13 GENERAL WIRING REQUIREMENTS The wiring procedures in this manual are intended to ensure proper functioning of the device under normal conditions. However, because of the many variations in wiring codes and regulations, total compliance to these ordinances cannot be guaranteed. Be certain that all wiring complies with applicable regulations that relate to the installation of electrical equipment in a hazardous area. If in doubt, consult a qualified official before wiring the system. The use of shielded cable is highly recommended for any signal wires to protect against interference caused by extraneous electrical 'noise'. This includes power and current outputs; relay outputs do not require shielded cable. In applications where the wiring cable is installed in conduit, the conduit must not be used for wiring to other electrical equipment. Water will damage electronic devices. Moisture in the air can condense within electrical conduit and drain into the enclosure, therefore, water-proof and explosion-proof conduit seals are recommended to prevent water accumulation within the enclosure. Seals should be located as close to the device as possible and not more than 18 inches (46 cm) away. Explosion-proof installations may require an additional seal where conduit enters a non-hazardous area. Conform to local wiring codes. When pouring a seal, use a fibre dam to assure proper formation of the seal. The seals should never be poured at temperatures below freezing. The jacket and shielding of the cable should be stripped back to permit the seal to form around the individual wires. This will prevent air, gas and water leakage through the inside of the shield and into the enclosure. It is recommended that explosion-proof drains and conduit breathers be used. In some applications, alternate changes in temperature and barometric pressure can cause 'breathing' which allows moist air to enter and circulate inside the conduit. Joints in the conduit system are seldom tight enough to prevent this 'breathing'. CONTROLLER WIRING The controller contains semiconductor devices that are susceptible to damage by electrostatic discharge. An electrostatic charge can build up on the skin and discharge when an object is touched. Therefore, use caution when handling, taking care not to touch the terminals or electronic components. For more information on proper handling, refer to the Appendix. The Uni-Trol controllers can be wired for isolated or non-isolated current outputs by changing the positions of J12' and J18', as shown in Figure 3. Figures 4a, 5a, and 6a show the terminal proper wiring of the controller for non-isolated current outputs with 2 and 3 wire sensors. Figures 4b, 5b and 6b show the proper wiring of the controller for isolated current outputs with 2 and 3 wire sensors. If local wiring codes permit, and if a ground fault monitoring system is not being used, the minus side of the DC power source can be connected to chassis (earth) ground. Alternatively, a 0.47 microfarad, 100 Volt capacitor can be installed (negative side of power supply terminal 13, to chases ground, terminal 8)

14 R1G-XXXX CONTROLLER NON-ISOLATED CURRENT OUTPUT ALARM RELAY CONTACTS ARE JUMPER SELECTABLE AS N.O. OR N.C. FAULT RELAY COIL IS NORMALLY ENERGIZED J16 1 FAULT RELAY 2 FAULT RELAY 3 HIGH ALARM RELAY 4 HIGH ALARM RELAY 5 AREA 1 LOW ALARM RELAY 6 AREA 1 LOW ALARM RELAY 7 NOT USED 8 NOT USED 24Vdc TO USER EQUIPMENT mA LOOP J17 1 CAN - 2 CAN + 3 REMOTE RESET 4 NOT USED 5 NOT USED 6 NOT USED 7 NOT USED 8 CHASIS GROUND 9 SENSOR INPUT 1 10 NOT USED 11 NOT USED 12 NOT USED 13-24Vdc SYSTEM POWER Vdc SYSTEM POWER 15 AREA 1 CURRENT OUTPUT 16 NOT USED 17 EXTERNAL POWER FOR CURRENT OUTPUT 18 SYSTEM COMMON 19 SYSTEM COMMON 20 SENSOR POWER (+24Vdc) 21 SENSOR POWER (+24Vdc) CUT SHIELD SHIELD TO SYSTEM COMMON J17 (18,19) SENSOR POWER 24Vdc. J17 (20 OR 21) SENSOR INPUT 1. J17 (9) SYSTEM COMMON. J17 (18,19) SENSOR INPUT 1. J17 (9) SENSOR POWER 24Vdc. J17 (20 OR 21) SHIELD TO SYSTEM COMMON J17 (18,19) CUT SHIELD SENSOR CONTROLLER CONTROLLER SENSOR WHT WHT TX-LEL-C-24 TRANSMITTER OR JB AND TERMINAL BOARD SC1100 LEL SENSOR ST1200 H2S SENSOR OR OTHER 2 WIRE SENSOR TRANSMITTER Figure 4a - Wiring for R1G with Non-Isolated Current Output - 9 -

15 R1G-XXXX CONTROLLER ISOLATED CURRENT OUTPUT J16 ALARM RELAY CONTACTS ARE JUMPER SELECTABLE AS N.O. OR N.C. FAULT RELAY COIL IS NORMALLY ENERGIZED FAULT RELAY FAULT RELAY HIGH ALARM RELAY HIGH ALARM RELAY AREA 1 LOW ALARM RELAY AREA 1 LOW ALARM RELAY NOT USED NOT USED J17 1 CAN - 2 CAN + 3 REMOTE RESET 4 NOT USED 5 NOT USED NOT USED NOT USED CHASIS GROUND 9 SENSOR INPUT 1 10 NOT USED 11 NOT USED 12 NOT USED 24Vdc Vdc SYSTEM POWER Vdc SYSTEM POWER 15 AREA 1 CURRENT OUTPUT 24Vdc TO USER EQUIPMENT mA LOOP 16 NOT USED 17 EXTERNAL POWER FOR CURRENT OUTPUT 18 SYSTEM COMMON 19 SYSTEM COMMON 20 SENSOR POWER (+24Vdc) 21 SENSOR POWER (+24Vdc) CUT SHIELD SHIELD TO SYSTEM COMMON J17 (18,19) SENSOR POWER 24Vdc. J17 (20 OR 21) SENSOR INPUT 1. J17 (9) SYSTEM COMMON. J17 (18,19) SENSOR INPUT 1. J17 (9) SENSOR POWER 24Vdc. J17 (20 OR 21) SHIELD TO SYSTEM COMMON J17 (18,19) CUT SHIELD SENSOR CONTROLLER CONTROLLER SENSOR WHT WHT TX-LEL-C-24 TRANSMITTER OR JB AND TERMINAL BOARD SC1100 LEL SENSOR ST1200 H2S SENSOR OR OTHER 2 WIRE SENSOR TRANSMITTER Figure 4b - Wiring for R1G with Isolated Current Output

16 R2G-XXXX CONTROLLER NON-ISOLATED CURRENT OUTPUT J16 ALARM RELAY CONTACTS ARE JUMPER SELECTABLE AS N.O. OR N.C. FAULT RELAY COIL IS NORMALLY ENERGIZED FAULT RELAY FAULT RELAY HIGH ALARM RELAY HIGH ALARM RELAY AREA 1 LOW ALARM RELAY AREA 1 LOW ALARM RELAY AREA 2 LOW ALARM RELAY AREA 2 LOW ALARM RELAY J17 1 CAN - 2 CAN + 3 REMOTE RESET 4 NOT USED 5 NOT USED NOT USED NOT USED CHASIS GROUND 9 SENSOR INPUT 1 10 SENSOR INPUT 2 11 NOT USED 12 NOT USED 24Vdc Vdc SYSTEM POWER Vdc SYSTEM POWER 15 AREA 1 CURRENT OUTPUT TO USER EQUIPMENT 4-20mA LOOP 16 AREA 2 CURRENT OUTPUT 17 EXTERNAL POWER FOR CURRENT OUTPUT 18 SYSTEM COMMON 19 SYSTEM COMMON 20 SENSOR POWER (+24Vdc) 21 SENSOR POWER (+24Vdc) CUT SHIELD SHIELD TO SYSTEM COMMON J17 (18,19) SENSOR POWER 24Vdc. J17 (20 OR 21) SENSOR INPUT 1. J17 (9) OR SENSOR INPUT 2 J17 (10) SYSTEM COMMON. J17 (18,19) SENSOR INPUT 1. J17 (9) OR SENSOR INPUT 2 J17 (10) SENSOR POWER 24Vdc. J17 (20 OR 21) SHIELD TO SYSTEM COMMON J17 (18,19) CUT SHIELD SENSOR CONTROLLER CONTROLLER SENSOR WHT WHT TWO (2) TX-LEL-C-24 TRANSMITTER OR TWO (2) JB AND TERMINAL BOARD SC1100 LEL SENSOR ST1200 H2S SENSOR OR OTHER 2 WIRE SENSOR TRANSMITTER Figure 5a - Wiring for R2G with Non-Isolated Current Output

17 R2G-XXXX CONTROLLER ISOLATED CURRENT OUTPUT J16 ALARM RELAY CONTACTS ARE JUMPER SELECTABLE AS N.O. OR N.C. FAULT RELAY COIL IS NORMALLY ENERGIZED FAULT RELAY FAULT RELAY HIGH ALARM RELAY HIGH ALARM RELAY AREA 1 LOW ALARM RELAY AREA 1 LOW ALARM RELAY AREA 2 LOW ALARM RELAY AREA 2 LOW ALARM RELAY J17 1 CAN - 2 CAN + 3 REMOTE RESET 4 NOT USED 5 NOT USED NOT USED NOT USED CHASIS GROUND 9 SENSOR INPUT 1 10 SENSOR INPUT 2 11 NOT USED 12 NOT USED 24Vdc Vdc SYSTEM POWER 13-24Vdc SYSTEM POWER 15 AREA 1 CURRENT OUTPUT 24Vdc mA LOOP TO USER EQUIPMENT 16 AREA 2 CURRENT OUTPUT 17 EXTERNAL POWER FOR CURRENT OUTPUT 18 SYSTEM COMMON 19 SYSTEM COMMON 20 SENSOR POWER (+24Vdc) 21 SENSOR POWER (+24Vdc) CUT SHIELD SHIELD TO SYSTEM COMMON J17 (18,19) SENSOR POWER 24Vdc. J17 (20 OR 21) SENSOR INPUT 1. J17 (9) OR SENSOR INPUT 2 J17 (10) SYSTEM COMMON. J17 (18,19) SENSOR INPUT 1. J17 (9) OR SENSOR INPUT 2 J17 (10) SENSOR POWER 24Vdc. J17 (20 OR 21) SHIELD TO SYSTEM COMMON J17 (18,19) CUT SHIELD SENSOR CONTROLLER CONTROLLER SENSOR WHT WHT TWO (2) TX-LEL-C-24 TRANSMITTER OR TWO (2) JB AND TERMINAL BOARD SC1100 LEL SENSOR ST1200 H2S SENSOR OR OTHER 2 WIRE SENSOR TRANSMITTER Figure 5b - Wiring for R2G with Isolated Current Output

18 R4G-XXXX CONTROLLER NON-ISOLATED CURRENT OUTPUT J16 ALARM RELAY CONTACTS ARE JUMPER SELECTABLE AS N.O. OR N.C. FAULT RELAY COIL IS NORMALLY ENERGIZED FAULT RELAY FAULT RELAY HIGH ALARM RELAY HIGH ALARM RELAY AREA 1 LOW ALARM RELAY AREA 1 LOW ALARM RELAY AREA 2 LOW ALARM RELAY AREA 2 LOW ALARM RELAY J17 1 CAN - 2 CAN + 3 REMOTE RESET 4 NOT USED 5 NOT USED NOT USED NOT USED CHASIS GROUND 9 SENSOR INPUT 1 10 SENSOR INPUT 2 11 SENSOR INPUT 3 12 SENSOR INPUT 4 24Vdc Vdc SYSTEM POWER 13-24Vdc SYSTEM POWER 15 AREA 1 CURRENT OUTPUT TO USER EQUIPMENT 4-20mA LOOP 16 AREA 2 CURRENT OUTPUT 17 EXTERNAL POWER FOR CURRENT OUTPUT 18 SYSTEM COMMON 19 SYSTEM COMMON 20 SENSOR POWER (+24Vdc) 21 SENSOR POWER (+24Vdc) SHIELD TO SYSTEM COMMON J17 (18,19) SENSOR POWER 24Vdc. J17 (20 OR 21) SENSOR INPUT 1. J17 (9) OR SENSOR INPUT 2 J17 (10) OR SENSOR INPUT 3 J17 (11) OR SENSOR INPUT 4 J17 (12) SYSTEM COMMON. J17 (18,19) SENSOR INPUT 1. J17 (9) OR SENSOR INPUT 2 J17 (10) OR SENSOR INPUT 3 J17 (11) OR SENSOR INPUT 4 J17 (12) SENSOR POWER 24Vdc. J17 (20 OR 21) SHIELD TO SYSTEM COMMON J17 (18,19) CUT SHIELD CUT SHIELD SENSOR CONTROLLER CONTROLLER SENSOR WHT WHT FOUR (4) TX-LEL-C-24 TRANSMITTER OR FOUR (4) JB AND TERMINAL BOARD SC1100 LEL SENSOR ST1200 H2S SENSOR OR OTHER 2 WIRE SENSOR TRANSMITTER Figure 6a - Wiring for R4G with Non-Isolated Current Output

19 R4G-XXXX CONTROLLER ISOLATED CURRENT OUTPUT J16 ALARM RELAY CONTACTS ARE JUMPER SELECTABLE AS N.O. OR N.C. FAULT RELAY COIL IS NORMALLY ENERGIZED FAULT RELAY FAULT RELAY HIGH ALARM RELAY HIGH ALARM RELAY AREA 1 LOW ALARM RELAY AREA 1 LOW ALARM RELAY AREA 2 LOW ALARM RELAY AREA 2 LOW ALARM RELAY J17 1 CAN - 2 CAN + 3 REMOTE RESET 4 NOT USED 5 NOT USED NOT USED NOT USED CHASIS GROUND 9 SENSOR INPUT 1 10 SENSOR INPUT 2 11 SENSOR INPUT 3 12 SENSOR INPUT 4 24Vdc Vdc SYSTEM POWER 13-24Vdc SYSTEM POWER 15 AREA 1 CURRENT OUTPUT 24Vdc mA LOOP TO USER EQUIPMENT 16 AREA 2 CURRENT OUTPUT 17 EXTERNAL POWER FOR CURRENT OUTPUT 18 SYSTEM COMMON 19 SYSTEM COMMON 20 SENSOR POWER (+24Vdc) 21 SENSOR POWER (+24Vdc) SHIELD TO SYSTEM COMMON J17 (18,19) SENSOR POWER 24Vdc. J17 (20 OR 21) SENSOR INPUT 1. J17 (9) OR SENSOR INPUT 2 J17 (10) OR SENSOR INPUT 3 J17 (11) OR SENSOR INPUT 4 J17 (12) SYSTEM COMMON. J17 (18,19) SENSOR INPUT 1. J17 (9) OR SENSOR INPUT 2 J17 (10) OR SENSOR INPUT 3 J17 (11) OR SENSOR INPUT 4 J17 (12) SENSOR POWER 24Vdc. J17 (20 OR 21) SHIELD TO SYSTEM COMMON J17 (18,19) CUT SHIELD CUT SHIELD SENSOR CONTROLLER CONTROLLER SENSOR WHT WHT FOUR (4) TX-LEL-C-24 TRANSMITTER OR FOUR (4) JB AND TERMINAL BOARD SC1100 LEL SENSOR ST1200 H2S SENSOR OR OTHER 2 WIRE SENSOR TRANSMITTER Figure 6b - Wiring for R4G with Isolated Current Output

20 DIP SWITCH SETTINGS See Table 4 for a list of the standard factory settings. It is essential that the controller be properly programmed before applying power to the system. There are three banks of dip switches located on the controller. Each switch bank has eight individual switches that can be set to an on or off position. The dip switches are located on the circuit board. The switch banks are numbered from bottom to top as numbers SW3, SW4, and SW5. Refer to Figure 7a. Individual switches are referenced as X.Y, where X refers to the bank number and Y refers to the switch number on X bank. For example, switch 3.4 (SW3.4) is switch number four on bank number three. Switches are set as either OFF or ON. Refer to Figure 7b. Figure 7a - Relay and Dip Switch Positions Figure 7b - Dip Switch IT IS VERY IMPORTANT THAT POWER TO THE CONTROLLER IS RECYCLED AFTER ANY DIP SWITCH CHANGES, TO MAKE THE CHANGES TAKE EFFECT! ACTIVE CHANNELS Switches for setting the active channels (the channels that are to have sensors/transmitters attached) can be found on Switch Bank 3, switches 1 to 4 (SW3.1 through SW3.4). Set the designated switch to OFF if the channel is to be connected (sensor attached), and ON if the channel is not to be used. SW3.1: OFF: ON: SW3.2: OFF: ON: SW3.3: OFF: ON: SW3.4: OFF: ON: channel 1 connected channel 1 not connected channel 2 connected channel 2 not connected channel 3 connected channel 3 not connected channel 4 connected channel 4 not connected

21 CALIBRATION GAS CONCENTRATION Calibration gas concentration for all channels are set together using the dip switches on the circuit board. To select the calibration gas concentration of 50% of full scale, set SW3.5 to OFF. If a selectable value (from 20% to 99% of full scale) is required, set SW3.5 to ON; SW4.1 through SW4.7 must then be used to select the calibration gas concentration. SW3.5: OFF: calibration gas set to 50% (ignore SW4.1 - SW4.7) ON: calibration gas selectable (set SW4.1 - SW4.7) If SW3.5 is set to ( ON ), it is very important to accurately set SW4.1 to SW4.7. If the selectable option is chosen, the calibration gas concentration must be set. This is done on Switch Bank 4, switches 1 through 7 (SW4.1 to SW4.7). The required calibration gas concentration must be set with these switches using the binary counting system. ON selects the value listed below; OFF selects a zero. SW4.1: ON: 1% SW4.2: ON: 2% SW4.3: ON: 4% calibration SW4.4: ON: 8% gas SW4.5: ON: 16% concentration SW4.6: ON: 32% SW4.7: ON: 64% The switches can be used in combination to select concentrations from 20% to 99% of full scale. Combustible Gas Controller Example: SW4.1: OFF SW4.2: OFF SW4.3: ON SW4.4: ON SW4.5: ON SW4.6: ON SW4.7: OFF calibration gas concentration = 60% LEL 1000ppm Toxic Gas Controller Example: SW4.1: OFF SW4.2: OFF SW4.3: ON SW4.4: ON SW4.5: ON SW4.6: ON SW4.7: OFF calibration gas concentration = 600ppm

22 100ppm Toxic Gas Controller Example: SW4.1: OFF SW4.2: OFF SW4.3: ON SW4.4: ON SW4.5: ON SW4.6: ON SW4.7: OFF calibration gas concentration = 60ppm 50ppm Toxic Gas Controller Example: SW4.1: OFF SW4.2: OFF SW4.3: ON SW4.4: ON SW4.5: ON SW4.6: ON SW4.7: OFF calibration gas concentration = 30ppm 25ppm Toxic Gas Controller Example: SW4.1: OFF SW4.2: OFF SW4.3: ON SW4.4: ON SW4.5: ON SW4.6: ON SW4.7: OFF calibration gas concentration = 15ppm 20ppm Toxic Gas Controller Example: SW4.1: OFF SW4.2: OFF SW4.3: ON SW4.4: ON SW4.5: ON SW4.6: ON SW4.7: OFF calibration gas concentration = 12ppm If a calibration gas concentration greater than 99% or less than 20% of full scale is programmed, the controller will give a configuration error (E90) when power is applied. POWER-UP TIME DELAY SW3.6 is used to select the power-up time delay. SW3.6: OFF: 45 seconds ON: 90 seconds SW3.7 and SW3.8 are not used

23 ALARM SETTINGS Switch bank 4, switch 8 (SW4.8) is used to set the low and high alarm to a default or selectable value. If SW4.8 is ( OFF ) the low alarm will be set to 20% of the full scale and the high alarm to 40% of full scale. If SW4.8 is ( ON ), the low and high alarm are selectable, using SW5.3 to SW5.8. SW4.8: OFF: ON: low 20% full scale high 40% full scale (ignore SW5.3 - SW5.8) selectable alarm (set SW5.3 - SW5.8) If SW4.8 is set to ( ON ), it is very important to accurately set SW5.3 to SW5.8. If the selectable option is chosen, the alarms must be set with SW5.3 to SW5.8. The low alarm can be set from 5% to 40% of full scale and the high alarm is automatically set at twice the low alarm value. The low alarm value is set using the binary counting system. ( ON ) selects the value listed below; ( OFF ) selects a zero. SW5.3: ON: 1% SW5.4: ON: 2% SW5.5: ON: 4% SW5.6: ON: 8% SW5.7: ON: 16% SW5.8: ON: 32% The switches can be used in combination to select low alarm settings from 5% to 40% of full scale. If a low alarm level less than 5% or greater than 40% of full scale is programmed, the controller will give a configuration error (E90) upon power up. Combustible Gas Controller Example: SW5.3: OFF SW5.4: OFF SW5.5: ON SW5.6: ON SW5.7: OFF SW5.8: OFF low alarm 12% LEL high alarm 24% LEL 1000ppm Toxic Gas Controller Example: SW5.3: OFF SW5.4: OFF SW5.5: ON SW5.6: ON SW5.7: OFF SW5.8: OFF low alarm 120ppm high alarm 240ppm

24 100ppm Toxic Gas Controller Example: SW5.3: OFF SW5.4: OFF SW5.5: ON SW5.6: ON SW5.7: OFF SW5.8: OFF low alarm 12ppm high alarm 24ppm 50ppm Toxic Gas Controller Example: SW5.3: OFF SW5.4: OFF SW5.5: ON SW5.6: ON SW5.7: OFF SW5.8: OFF low alarm 6ppm high alarm 12ppm 25ppm Toxic Gas Controller Example: SW5.3: OFF SW5.4: OFF SW5.5: ON SW5.6: ON SW5.7: OFF SW5.8: OFF low alarm 3ppm high alarm 6ppm 20ppm Toxic Gas Controller Example: SW5.3: OFF SW5.4: OFF SW5.5: ON SW5.6: ON SW5.7: OFF SW5.8: OFF low alarm 2.4ppm high alarm 4.8ppm IT IS VERY IMPORTANT THAT POWER TO THE CONTROLLER IS RECYCLED AFTER ANY DIP SWITCH CHANGES, TO MAKE THE CHANGES TAKE EFFECT! LATCHING/NON-LATCHING SELECTION Switch Bank 5, switch 1 is used to set the low alarm relays for latching or non-latching operation; the high alarm is always latching and the fault is always non-latching. SW5.1: OFF: ON: low alarm relay latching operation low alarm relay non-latching operation ENERGIZED/DE-ENERGIZED SELECTION Switch Bank 5, switch 2 (SW5.2) is used to set the high and low alarm relays for normally energized or normally de-energized operation; the fault relay is always normally energized. SW5.2: OFF: ON: alarm relays normally energized alarm relays normally de-energized

25 IT IS VERY IMPORTANT THAT POWER TO THE CONTROLLER IS RECYCLED AFTER ANY DIP SWITCH CHANGES, TO MAKE THE CHANGES TAKE EFFECT! Refer to Table 3, at the end of this unit, for a summary of the dip switch settings and Table 4 for the standard factory settings. RELAY SETTINGS There are four relays on the controller circuit board that can be set up for normally open or normally closed operation by changing the positions of the FAULT, J2', J3' and J4' which are located beside the relays. See Figure 7a for the location of the relays on the circuit board and Figure 7c for the correct settings. Figure 7c - Relay Settings INSTALLATION CHECKLIST The following checklist is provided as a means of double checking the system to be sure that all phases of system installation are complete and have been performed correct. T T T T T T T T T Controller is securely mounted and sensor is oriented correctly All cable shields are properly grounded at one end only Explosion-proof conduit seals have been installed at all conduit entries (if conduit is being used) Sensor to controller wiring is correct Power wiring to the controller is installed and power source is operational External loads are properly connected to the controller Controller is programmed as needed. Record this information for future reference. A table is provided in the appendix for this purpose Controller is properly installed in the housing Proper ventilation is provided to prevent overheating of the controller

26 SWITCH OPEN OFF CLOSED ON SW3.7 & SW3.8 NOT USED SW3.1 Channel 1 connected Channel 1 not connected SW3.2 Channel 2 connected Channel 2 not connected SW3.3 Channel 3 connected Channel 3 not connected SW3.4 Channel 4 connected Channel 4 not connected SW3.5 Calibration gas concentration is set to 50% of full scale (ignore SW4.1 to Calibration gas concentration is selectable using SW4.1 to SW4.7 SW4.7) SW3.6 Power-up time delay is 45 seconds Power-up time delay is 90 seconds SW4.1 - SW4.7 Set calibration gas concentration from 20% to 99% of full scale SW4.8 LOW 20% of full scale/high 40% of full scale (ignore SW5.3 to SW5.8) Selectable alarm settings using SW5.3 to SW5.8 (LOW = 5% to 40% of full scale; HIGH = 2 x LOW) SW5.1 LOW alarm relay is latching LOW alarm relay is non-latching SW5.2 LOW and HIGH alarm relays normally energized LOW and HIGH alarm relays normally de-energized SW5.3 - SW5.8 Set LOW alarm settings from 5% to 40% of full scale (HIGH alarm is twice the LOW alarm setting) Table 3 - Summary of Dip Switch Settings Switch LEL 100ppm H 2 S 50ppm H 2 S 20ppm SO OFF OFF OFF OFF 3.2 OFF OFF OFF OFF 3.3 OFF OFF OFF OFF 3.4 OFF OFF OFF OFF 3.5 OFF OFF ON ON 3.6 OFF ON ON ON 3.7 NOT USED NOT USED NOT USED NOT USED 3.8 NOT USED NOT USED NOT USED NOT USED 4.1 OFF OFF OFF OFF 4.2 OFF OFF OFF ON 4.3 OFF OFF OFF OFF 4.4 OFF OFF ON OFF 4.5 OFF OFF OFF ON 4.6 OFF OFF ON ON 4.7 OFF OFF OFF OFF 4.8 OFF ON ON ON 5.1 ON ON ON ON 5.2 ON ON ON ON 5.3 OFF OFF OFF ON

27 Switch LEL 100ppm H 2 S 50ppm H 2 S 20ppm SO OFF ON OFF OFF 5.5 OFF OFF ON OFF 5.6 OFF ON OFF ON 5.7 OFF OFF ON ON 5.8 OFF OFF OFF OFF CH1 CONNECTED CH2 CONNECTED CH3 CONNECTED CH4 CONNECTED LOW ALARM = 20% HIGH ALARM = 40% CAL. GAS = 50% 45 Sec. POWER UP RELAYS: Non-latching Normally De-energized Table 4 - Factory Dip Switch Settings CH1 CONNECTED CH2 CONNECTED CH3 CONNECTED CH4 CONNECTED LOW ALARM = 10PPM HIGH ALARM = 20PPM CAL. GAS = 50PPM 45 Sec. POWER UP RELAYS: Non-latching Normally De-energized Unit III SYSTEM OPERATION CH1 CONNECTED CH2 CONNECTED CH3 CONNECTED CH4 CONNECTED LOW ALARM = 10PPM HIGH ALARM = 20PPM CAL. GAS = 20PPM 45 Sec. POWER UP RELAYS: Non-latching Normally Deenergized CH1 CONNECTED CH2 CONNECTED CH3 CONNECTED CH4 CONNECTED LOW ALARM = 5PPM HIGH ALARM = 10PPM CAL. GAS = 10PPM 45 Sec. POWER UP RELAYS: Non-latching Normally Deenergized MENU AND FUNCTION SELECTION The controller has various functions and menus that can be entered by pressing the MENU/SET (and SELECT/RESET) buttons for a specified amount of time. Table 5 indicates how to enter the various menus and functions. BUTTON TIME FUNCTION OR MENU SELECT/RESET < 0.5 sec Basic Reset SELECT/RESET 3 sec Forced Reset MENU/SET 2 sec Forced Display [FdP] MENU/SET 5 sec Main Menu MENU/SET & SELECT/RESET 20 sec Special Function Menu Simultaneously Table 5 - Menu and Function Selection

28 Further explanation on how to enter the functions will be given in the following discussion. The Main Menu has five functions within it (See Table 6) and the Special Function Menu has five functions (See Table 7). To enter the Main Menu, press the MENU/SET button for approximately 5 seconds, until Err Chc or SPd is displayed, then release it. Once in the Main Menu, the next selection can be brought up by pressing the MENU/SET button. The SELECT/RESET button is used to accept a currently displayed selection. Failure to activate any buttons for a period of 10 seconds will result in the controller returning to the Normal Operating Mode. Selecting the Return function will also return the controller to the Normal Operating Mode. When rtn is on the lower digital display, momentarily press the SELECT/RESET button. Summary of Main Menu: Enter Main Menu: Find Desired Function: Select Function: Next Function: Exit Main Menu: MENU/SET for 5 sec. MENU/SET SELECT/RESET MENU/SET no buttons for 10 sec. or Select RETURN function UPPER DIGITAL DISPLAY LOWER DIGITAL DISPLAY FUNCTION Chc Err Error Check (hidden if no errors) blank SPd Set Point Display blank CAL Calibration blank SrP Sensor Replacement blank rtn Return Table 6 - Main Menu Selection UPPER DIGITAL DISPLAY LOWER DIGITAL DISPLAY FUNCTION 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 Table 7 - Special Function Menu Selection START-UP PROCEDURE 1 Output loads that are normally actuated by the system should be secured. Remove power from all of the output devices to prevent undesired activation. 2 Check all external wiring for proper connections. Be sure that the sensor has been wired properly. 3 Before installing the controller, inspect it to verify that it has not been physically damaged in shipment. Check the dip switches on the controller for proper programming

29 4 Apply power to the system. The controller has a 45 or 90 second delay (as programmed), before beginning normal operation, after power is applied to the system. During this time the outputs are inhibited, the Fault LED is illuminated, the upper digital display cycles through the active channels, and the lower digital display counts down from 45 or 90. This delay allows time for the sensors to stabilize before beginning normal operation. 5 Put the controller in the Set-point Display Mode to check the present alarm set-points and calibration gas concentration. If changes are required, refer to the Dip Switch Setting section of the manual. 6 Calibrate the sensor(s); refer to the Sensor Calibration Procedure. 7 Remove mechanical blocking devices (if used) and restore power to the output loads. MAIN MENU SELECTIONS ERROR CHECK MODE (Err Chc) The microprocessor-based controller features self-testing circuitry that continuously checks for problems that could prevent proper system response. As a diagnostic and troubleshooting tool, identifiable faults are displayed on the digital display during the Error Message Display Mode. Two types of faults are identified: system faults and channel faults. Table 7 lists the codes and the corresponding conditions. If a fault should occur: < the normally energized fault output is de-energized, < the Fault LED is illuminated, and < if no alarm is occurring and the controller is sequentially displaying each sensor input, the message Err Fnd (upper and lower displays) will be displayed after each sequence. To view the fault code, enter the Main Menu, then momentarily press the SELECT/RESET button when Err is displayed on the lower digital display. Next, press the MENU/SET button repeatedly; the upper digital display will sequentially show: SYS - system faults CH1' - channel 1 faults CH2' - channel 2 faults CH3' - channel 3 faults CH4' - channel 4 faults Clr - clear faults If no errors exist, this function is hidden and can not be accessed. To select the fault to be displayed, momentarily press the SELECT/RESET button when the required fault is being displayed on the upper digital display. The upper digital display will show the channel (or system) and the lower digital display will show the fault code, for 5 seconds then move to the next channel

30 Faults that affect the actual function of the controller (50, 60, 70, 9X) can impair the ability of the controller to maintain an alarm output. All faults automatically reset except the 9X, 20, and 10 faults. After the fault condition has been corrected, the fault output automatically switches to the normal (energized) state, the DC current output returns to normal, and the Fault LED turns off. Clearing 9X faults requires removing operating power from the controller for approximately one second. Clearing 20 and 10 requires a reset. CAUTION The fault detection circuitry does not monitor the operation of external response equipment or the external wiring to these devices. It is important that these devices be checked periodically to ensure that they are operational. SET-POINT DISPLAY MODE (SPd) In this mode, the digital displays sequentially display the low and high alarm, calibration gas concentration, and communication address, automatically. This function is used to check the present alarm and calibration gas set-point values, and the communications address. 1 To enter the Set-point Display Mode, enter the Main Menu, press the MENU/SET button repeatedly until Spd is displayed on the lower digital display, then momentarily press the SELECT/RESET button. 2 The Low LED goes on, LoA is shown on the upper digital display, and the low alarm set-point is shown on the lower digital display for 2 seconds. 3 The Low LED goes out, the High LED goes on, HiA is shown on the upper digital display, and the high alarm set-point is shown on the lower display for 2 seconds. 4 The High LED goes out, the Cal LED goes on, CAL is shown on the upper display, and the calibration gas concentration (in percent LEL) is shown on the lower display for 2 seconds. 5 The Cal LED goes out, Adr is shown on the upper display and the lower digital display shows the communication address for the CAN interface for 2 seconds. 6 Finally, the controller returns to the normal operating mode (it is no longer in the main menu). 7 If adjustments to the set-points are required, the settings on the programming dip switches must be changed; Refer to DIP SWITCH SETTINGS in the SYSTEM INSTALLATIONS section of this manual for instructions. If adjustments are required for the communication addresses, refer to the Address Set procedure. When the set-point levels are acceptable, record this information for future reference and proceed to CALIBRATION. IT IS VERY IMPORTANT THAT POWER TO THE CONTROLLER IS RECYCLED AFTER ANY DIP SWITCH CHANGES, TO MAKE THE CHANGES TAKE EFFECT!

31 STATUS CONDITION WHAT TO DO E90 Dip Switch Configuration error Check dip switch settings and recycle power. E91 RAM or processor failure Consult the Factory. E94 Set-point and calibration data lost Consult the Factory. E95 Internal 5 volt supply failure during start-up Consult the Factory. E96 External 24 volt supply failure during startup Consult the Factory. E97 EEPROM failure Consult the Factory. E98 Duplicate Communication address. Check Communication address and change to a vacant address. E99 Lost communication. Check communication wiring, disconnect controller, and re-connect it. If this does not help, contact the factory. CHx E80 Sensor output is more than 26 ma Check wiring and signal output from sensor. CHx E70 External reset switch has been activated for 15 seconds or longer. Self clearing when Check external reset switch for a short, or faulty operation. switch is released. CHx E40 Sensor (or transmitter) input failure; input is Check wiring and signal output from sensor. below 1 ma. CHx E30 Negative zero drift; sensor (or transmitter) is Calibrate transmitter. -9% full scale or lower. CHx E20 Time ran out while waiting for the user to Restart calibration procedure. apply gas to the sensor. CHx E21 Sensor (or transmitter) output is too low; Calibrate transmitter or replace sensor. enough offset to get an accurate calibration is not being generated. CHx E22 Sensor can not be calibrated. Calibrate transmitter or replace sensor. CHx E23 Sensor is too sensitive for the detector to Calibrate transmitter or replace sensor. read 100% full scale. CHx E24 Zero point is more than 6% below standard Calibrate transmitter. value. CHx E25 Zero point is more than 6% above standard value. Calibrate transmitter. CHx E10 Calibration was successful, but sensor reaching end of life or time to change jumper position on transmitter. CHx gop Over-range error (reading greater than 100% of full range). Table 8 - System Status Codes (Chx = Channel number) SENSOR CALIBRATION (CAL) General Information: Be prepared to calibrate transmitter or replace sensor at next calibration time. Insure area has been de-contaminated then perform a forced reset. Various factors affect the interval between periodic calibrations. Exposure to certain contaminants in the air, accumulation of contaminants on the filter, or an extended period of normal operation can cause changes in sensitivity. Since each application is different, the length of time between regularly scheduled

32 calibrations can vary from one installation to the next. In general, the more a system is checked, the greater the reliability. A calibration must be performed: < when a new system is initially put into service, < when the sensor is replaced, or < when a controller is replaced. IMPORTANT To ensure adequate protection, the detection system must be calibrated on a regularly scheduled basis. The Controller uses a fully automatic calibration procedure that requires no adjustments by the operator. The controller performs the zero adjustments, then signals the operator when to apply and when to remove the calibration gas. While in the Sensor Calibrate Mode, all controller outputs are inhibited, the current output is 3mA, and the Cal LED is illuminated. If the sensor is being replaced, refer to the 'Sensor Replacement' section (under 'Maintenance') in this manual for information regarding replacement and calibration of the sensor. Calibration Procedure: 1 The sensor should be allowed to stabilize for a minimum of 4 hours, although it is best to allow 24 hours for the sensor to stabilize. 2 Be certain that the controller is properly programmed for the gas concentration being used for calibration. (Refer to SET-POINT DISPLAY MODE to check programmed value.) Reprogram the controller if required. (Refer to DIP SWITCH SETTINGS. ) Failure to do so will greatly impair system response. IT IS VERY IMPORTANT THAT POWER TO THE CONTROLLER IS RECYCLED AFTER ANY DIP SWITCH CHANGES, TO MAKE THE CHANGES TAKE EFFECT! 3 Be sure that only clean air is present at the sensor. The microprocessor begins taking zero readings immediately upon entering the Calibrate Mode. If the possibility of background gases exists, purge the sensor with clean air to assure an accurate calibration. 4 Enter the Main Menu, press the MENU/SET button repeatedly until CAL is shown on the lower digital display, then momentarily press the SELECT/RESET button. 5 Once in the sensor calibrate mode, the lower digital display will continue to show CAL and the upper digital display will show Chn. Press the MENU/SET button repeatedly until the desired channel is shown on the upper digital display, then momentarily press the RESET/SELECT button. 6 Once the required channel has been selected, the controller will automatically start taking zero readings. The upper digital display will show Air and the lower display will flash a value close to zero. When the zero calculations are complete (30 seconds minimum), the lower digital display stops flashing and reads '00'; the upper display will now alternately display gas and in. 7 Apply the calibration gas to the sensor. The lower digital display starts to flash, and the value indicated on the display rises. The bar graph display also indicates the level of gas at the sensor, but does not flash. The upper display will show gas

33 8 When the microprocessor has completed the gain adjustments (30 seconds minimum), the lower digital display stops flashing and the upper display will alternately display Cut and gas. 9 Remove the calibration gas. When the gas level falls to half the low alarm set-point, the controller automatically returns to the normal operating mode. 10 If another sensor must also be calibrated, return to step 1. If the operator fails to complete the calibration procedure or if the sensitivity of the sensor has deteriorated to the extent that calibrations cannot be successfully completed, a calibration fault ( E2X status) will be generated. The system will automatically revert to the former calibration settings (after 10 minutes or when the gas level drops below the lowest set-point). If a successful calibration cannot be accomplished, replace the sensor and calibrate (refer to the transmitter/sensor manual, as some transmitters will have gain jumpers which need to be changed and the sensor may still be useful). If the microprocessor determines that the sensor is approaching the end of its useful life or the gain jumper on the transmitter needs to be changed, E10' will be indicated on the digital display. This does not indicate a system malfunction, but is intended to notify the operator of this condition. A successful calibration can still be performed, but the operator should be prepared to change the sensor at the time of the next calibration. Press SELECT/RESET after completing calibration to clear the display. SENSOR REPLACEMENT MODE (SrP) This mode inhibits all controller outputs to allow replacement of the sensor(s) without removing power from the controller. Alarm set-points and calibration gas concentration are not affected. The upper display will show SrP while in the sensor replace mode. The lower display will show the status of the sensor being replaced ( NoS means no sensor is connected). The fault LED is on and the fault relay is deenergized. The channel LED will be on for the sensor being replaced. All other sensors remain active during sensor replace mode. If an alarm condition occurs on one of the active channels while in this mode, the appropriate channel LED will flash and relays will act accordingly. All other display features will be inhibited. In order to exit this mode the SELECT/RESET button must be pressed. The controller will perform a power-up count down (45 or 90 seconds) for the replaced sensor, and the affected current output will drop to 1mA. SPECIAL FUNCTION MENU SELECTIONS FORCED CURRENT OUTPUTS (FoP) The forced current output mode is used to check the current output calibration and the operation of any devices connected to the current outputs. To enter the forced current output mode, enter the special function menu. When FoP is shown on the lower display, press the SELECT/RESET button. Upon successful entry into this mode the upper display will flash gpn. Press the MENU/SET button until the desired area output is reached ( GPA = Area 1 and GPb = Area 2), then press the SELECT/RESET button. When an area has been chosen for forced current output, the upper display will alternate between GPX and FoP and the lower display will show what type of current output (in gas concentration) is being placed on the current output line. The push-button switches are used to change the current output. To exit this function, hold the SELECT/RESET button down until rtn is shown on the lower display. Release the button, and the controller will return to the normal operating mode in 10 seconds if no buttons are pushed

34 CURRENT CALIBRATION MODE (CuC) The next selection in the special function menu is the current calibration mode. This mode is selected to calibrate the current outputs. The Area output to calibrate is chosen as in the Forced Current Output Mode. Once an area has been selected, the upper display will alternate between CuC and the area that is being calibrated ( GPX, where X indicates group A or B). The lower display will show a constant which will rise and fall as the current is adjusted (does not show the current on the outputs). Place a milliamp metre between the Area current output and system common. Use the push-buttons to raise and lower the current. Once the current measured is as close to 4mA as possible, do not press any buttons for 10 seconds and the constant shown on the lower display will change to a much higher number. This tells the operator that it is time to calibrate the higher end of the current output range. Use the push-buttons to bring the current level as close as possible to 20mA. Do not press any buttons for 10 seconds and the constant shown on the display will change to a lower number. Now it is time to calibrate the current output to 3.3mA for when the controller is in the calibration mode. Once this current level is set, do not press any buttons for 10 seconds and the controller will return to the normal operating mode. ADDRESS SET MODE (Adr Set) (OPTIONAL) The next selection in the special function menu is the address set mode, used to set the controllers address for the Digital Communication system. When the upper display shows Adr and the lower display shows SEt press the SELECT/RESET button. The upper display will alternate between Adr and SEt and the lower display will show the current address. Use the push-buttons to raise and lower the address. Once the address is correct, do not press any buttons for 10 seconds and the controller will return to the normal operating mode. CHANNEL DISPLAY(Chd) In this mode, the displays can be forced to monitor only one channel, as long as no alarms are occurring. If any alarm occurs, the controller will return back to the Normal Operating Mode for the situation when an alarm is occurring. Enter the Special Function Menu, press the MENU/SET button repeatedly until Chd is displayed on the lower digital display, then momentarily press the SELECT/RESET button. The upper digital display will show Chn. Press the MENU/SET button repeatedly to toggle through the (Channel Display Cont) channels (CH1, CH2, CH3, or CH4). To select a channel, momentarily press the SELECT/RESET button when the required channel is displayed, on the upper digital display. The displays will now only display the information for the chosen channel. To return to the normal operating mode, enter the manual display mode again and instead of selecting a single channel, select ALL. BYPASS (bps) The bypass mode is entered through the special functions menu. Enter the special functions menu and press the MENU/SET button repeatedly until bps is shown on the lower digital display, then momentarily press the SELECT/RESET button. The lower digital display will still show bps and the upper display will show gpn. Select the group to put in bypass mode by pressing the MENU/SET button repeatedly until the desired group is shown, then press the SELECT/RESET button momentarily. While in bypass mode, the alarm outputs for the selected group(s) are inhibited. The HIGH alarm relay is common to both groups, and is inhibited even if the unselected group has an alarm condition. CAUTION SHOULD BE USED WHILE IN BYPASS MODE

35 To exit the bypass mode, press the SELECT/RESET button momentarily. OPERATING MODES RESET MODE The Reset Function is entered by pressing the SELECT/RESET button located on the front panel of the controller. (Refer to Figure 2.) When the SELECT/RESET button is pressed momentarily, all LEDs turn off and all outputs return to their normal condition if no alarms or faults are occurring. FORCED RESET MODE If any of the channels gets a reading beyond 100% of full scale, a reset will not clear the alarms, even if the channel has returned to levels below the low alarm set point. The error resulting from this occurrence must be cleared in the error check mode and then a forced reset must be applied. To apply a forced reset, press the SELECT/RESET button for 3 seconds, the LEDs turn off and the outputs return to their normal condition. Remote reset performs a forced reset. The remote reset performs a reset function only. It cannot be used for other controller functions. NORMAL OPERATING MODE In Normal Operating Mode with no alarm: < The digital and bar graph displays are on and indicate the sensor(s) input(s). If only one channel is active, then the displays will stay on that channel; if two or more channels are active, the displays will sequentially display the channels, for 5 seconds each. The upper digital display will indicate the channel (CH1, CH2, CH3, or CH4) and the lower digital display will indicate the sensor reading. < The Channel LEDs will indicate which channel the digital display is referring to. < All other LEDs are off. < Alarm relays are in their normal state, energized or de-energized as programmed. < Fault relay is energized. In the Normal Operating Mode with a low alarm(s) condition occurring: < Digital and bar graph displays indicate the sensor input(s) as outlined above. < If one channel is in alarm, the system will stay at that channel. < If more than one channel is in alarm, the channel with the highest alarm condition will be displayed. The channel LED of other channels will flash to notify that an alarm condition exists. To force the display of a channel with a lower alarm, go into the Forced Display Mode, as outlined in the next section. < Low LED flashes. < Low alarm relay changes state. < Fault relay is energized and fault LED is off. When the signal decreases below the low set-point: < The digital display and bar graph display continue to track the sensor input. < With latching operation programmed, low alarm relays will not change. < With non-latching operation programmed, low alarm relays will return to their normal state. < Low Alarm LEDs are on steady, while the affected channel is displayed, until reset

36 If a high alarm condition occurs, the module will be in a Level 3 Display Mode; the bar graph and digital display will cycle through all channels with a high alarm condition. While one channel is displayed, the channel LED for any other channel in a high or low alarm state will flash. When 1 or more channels are in a high alarm condition and 1 or more channels are in a low alarm condition, only the channels in the high alarm condition will be cycled on the display. The channel LED for any channel in the low alarm condition will flash. If one or more channels reach an over-range (>100% of full scale) condition, the error must be cleared in the error check mode and then a forced reset must be performed once the channel has returned to normal. A basic reset will not clear an over-range error. FORCED DISPLAY (FdP) In the normal operating mode with no alarms occurring, the digital and bar graph displays will sequentially display each of the channel sensor readings. If an alarm condition occurs, the displays will remain on the channel with the alarm (or highest alarm if more than one channel is in an alarm condition). In this situation, the forced display mode can be used to temporarily view the sensor readings of the other channels. To enter the Forced Display Mode, press the MENU/SET button for 2 seconds, until the lower digital display shows FdP. Momentarily press the SELECT/RESET button to select this function. The digital displays will then sequentially display each of the active channels once before returning to the Normal Operating Mode automatically. Unit IV SYSTEM MAINTENANCE ROUTINE MAINTENANCE To ensure reliable protection, it is important to check and calibrate the detection system on a regularly scheduled basis. The frequency of these checks is determined by the requirements of the particular installation. MANUAL CHECK OF OUTPUT DEVICES Fault detection circuitry continuously monitors for problems that could prevent proper system response. It does not monitor external response equipment or the wiring to these devices. It is important that these devices be checked initially when the system is installed, and periodically during the ongoing maintenance program. SYSTEM CHECK IN NORMAL MODE The system must be checked periodically in the Normal Operating Mode to ensure that those items not checked by the controller diagnostic circuitry (such as output relays) are functioning properly. CAUTION Be sure to secure all output devices actuated by the system to prevent unwanted activation of this equipment, and remember to place these same output devices back into service when the checkout is complete

37 SENSOR REPLACEMENT The area must be declassified or power to the sensor must be removed prior to replacing the sensor in a hazardous area. 1 Enter the Main Menu; momentarily press the SELECT/RESET button once the message SrP appears on the lower digital display. 2 Once in the sensor replace mode, the lower digital display will continue to show SrP and the upper digital display will show a channel selection: CH1, CH2, CH3, or CH4. If the channel that is first displayed corresponds to the senor to be replaced, momentarily press the SELECT/RESET button to select that channel. If the first channel displayed is not the required channel, press the MENU button; the upper digital display will sequentially display the operational channels each time the MENU/SET button is pressed. Press the SELECT/RESET button, once the required channel is displayed. 3 Once the required channel has been selected, the display reads '00' and the Channel LED and Fault LED are illuminated. The controller is in the Sensor Replacement Mode. Once in the Sensor Replacement Mode follow the instructions in the sensor manual for replacement. If power was removed from the controller during the sensor replacement procedure, the controller will automatically return to the Normal Mode when power is restored (after a 45 or 90 second time delay). To prevent the possibility of alarms, allow the system to warm up in the Sensor Replacement Mode.. An adequate supply of spare sensors should be kept on hand for field replacement. For maximum protection against contamination and deterioration, they should not be removed from the original protective packaging until the time of installation. TROUBLESHOOTING Table 9 is intended to serve as an aid in locating the cause of a system malfunction. If this table is not helpful, contact an authorized repair person. The Uni-Trol Controller is not designed to be repaired by the customer in the field. If a problem should develop, first carefully check for proper wiring, programming and calibration. If it is determined that the problem is caused by an electronic defect, the device must be returned to the factory for repair. When replacing a controller, remove power before removing the device from the enclosure or installing the replacement unit. The sensor is not intended to be repaired. When calibration can no longer be properly performed, the sensor must be replaced. The frequency of replacement will be determined by the amount and type of contamination present at the particular installation. An adequate supply of spare sensors should be kept on hand for field replacement. Always calibrate the sensor after it has been replaced

38 DEVICE REPAIR AND RETURN The unit is under full warranty for THREE YEARS (from date of purchase). Net Safety Monitoring Inc. supplies all distributors with advance replacement units. These units are available to the user during the warranty period. This allows Net Safety Monitoring Inc. to take the time to repair the unit completely while customers keep their operations running smoothly with the advance replacement unit. Prior to returning devices or components, contact the nearest local distribution office so that an RMI (Return Material Identification) number can be assigned. A written statement describing the malfunction must accompany the returned device or component to expedite finding the cause of the failure, thereby reducing the time and cost of the repair to the customer. Pack the unit or component properly. Use sufficient packing material in addition to an anti-static bag or aluminum-backed cardboard as protection from electrostatic discharge. PROBLEM No Faceplate indicators illuminated. FAULT LED on, digital display blank. POSSIBLE CAUSE < Wiring to external power source. < Input power failure. < Power-up time delay (45 seconds). < If condition continues after 45 seconds, repeat power-up. If a problem continues, check dip switches or replace controller. E90 to E97 Status < Initialization failure. Repeat power-up. If successful, re-program and re-calibrate. If not, replace controller. E96 Status < Input power problem. Check operation of power source and power wiring. E70 Status < External reset activated for over 15 seconds. Check external switch and wiring. E40 Status < Sensor input problem. Check sensor and/or transmitter wiring and calibration. < Faulty sensor. Replace and calibrate. < Faulty transmitter. Replace and calibrate. E30 Status < Negative zero drift. Calibrate sensor. < Faulty sensor. Replace and calibrate. < Faulty transmitter. Replace and calibrate. E20, E21 Status < Calibrate error. Re-calibrate. E22, E23 Status < Sensor sensitivity out of tolerance. Calibrate transmitter. If problem continues, replace sensor and calibrate. E10 Status < Sensor reaching end of life - no problem at present time. Be prepared to replace sensor at next calibration (calibration attempt might fail). Table 9 - Troubleshooting Guide

39 Appendix A Net Safety Monitoring Inc. Electrostatic Sensitive Device Handling Procedure With the trend toward increasingly widespread use of microprocessors and a wide variety of other electrostatic sensitive semiconductor devices, the need for careful handling of equipment containing these devices deserves more attention than it has received in the past. Electrostatic damage can occur in several ways. The most familiar is by physical contact. Touching an object causes a discharge of electrostatic energy that has built up on the skin. If the charge is of sufficient magnitude, a spark will also be visible. This voltage is often more than enough to damage some electronic components. Some devices can be damaged without any physical contact. Exposure to an electric field can cause damage if the electric field exceeds the dielectric breakdown voltage of the capacitive elements within the device. In some cases, permanent damage is instantaneous and an immediate malfunction is realized. Often, however, the symptoms are not immediately observed. Performance may be marginal or even seemingly normal for an indefinite period of time, followed by a sudden and mysterious failure. Damage caused by electrostatic discharge can be virtually eliminated if the equipment is handled only in a static safeguarded work area and if it is transported in a package or container that will render the necessary protection against static electricity. Net Safety Monitoring Inc. modules that might be damaged by static electricity are carefully wrapped in a static protective material before being packaged. Foam packaging blocks are also treated with an anti-static agent. If it should ever become necessary to return the module, it is highly recommended that it be carefully packaged in the original carton and static protective wrapping. Since a static safeguarded work area is usually impractical in most field installations, caution should be exercised to handle the module by its metal shields, taking care not to touch electronic components or terminals. In general, always exercise all of the accepted and proven precautions that are normally observed when handling electrostatic sensitive devices. A warning label is placed on the packaging, identifying those units that use electrostatic sensitive semiconductor devices. *Published in Accordance with E1A standard 471 i

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