MILLENNIUM
Oxygen Gas Detector
User Manual
Models:
MLP-A/AR/AD-ST1400-25
&
(all available options)
Part Number: MAN-0060 Rev 04
August 2008
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Warranty
IMPORTANT INFORMATION
Net Safety Monitoring Inc., warrants its ST1400 sensor against defective parts
and workmanship for a period of 6 months from date of purchase; other
electronic assemblies for 36 months from date of purchase.
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.
No other warranties or liability, expressed or implied, will be honoured by Net
Safety Monitoring Inc.
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.
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
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.
2721 Hopewell Place NE
Calgary, AB T1Y 7J7
Canada
Telephone: (403) 219-0688 Fax: (403) 219-0694
E-mail: [email protected]
Copyright © 2005 Net Safety Monitoring Inc.
Printed in Canada
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MODBUS Termination ....................................................................................9
Figure 11: Modbus Termination Jumpers ................................................................9
Step 4 — Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TABLE OF CONTENTS
Important Information
Warranty
Figure 12: Controller Functionality ........................................................................10
Table 2: Status LEDs, Display Messages and Current Loop .................................11
RTU Registers .....................................................................................................11
Table 3: RTU Status Register (40002) Read Only (Binary) ..................................11
Calibration Button ...............................................................................................11
Magnetic Reed Switch .........................................................................................12
Power Up .............................................................................................................12
Current Loop Measurement (Test Jacks) .............................................................12
Status LED ...........................................................................................................12
The Main Menu ..............................................................................................12
Accessing the Main Menu ...................................................................................12
Main Menu Functionality ....................................................................................12
Contact Information
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
The Product ...................................................................................................... 1
The Sensor ............................................................................................................. 1
The Controller ....................................................................................................... 1
The Manual ........................................................................................................... 1
Step 1 — Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Locate Controller/Sensor ................................................................................. 2
Figure 1: Locate Sensor/Controller .......................................................................... 2
Figure 2: Dimensional Drawings ............................................................................. 3
Step 2 — Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Step 5 — Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Unpack ............................................................................................................. 3
Figure 3: Components .............................................................................................. 3
Mount .................................................................................................................... 4
Step 3 — Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Calibration Procedure .....................................................................................13
Calibration Procedure ..........................................................................................13
Figure 13: Calibration Procedure ...........................................................................13
Calibration Failure .........................................................................................14
Step 6 — Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Field Installation .............................................................................................. 4
Seal ................................................................................................................... 4
Connecting Wires .................................................................................................. 4
Board Assembly .................................................................................................... 5
Figure 4: Millennium Module Boards ...................................................................... 5
Figure 5: Wiring—Controller and Sensor ................................................................ 6
Sensor and Controller ...................................................................................... 6
Table 1: Controller/Sensor Connections .................................................................. 6
RS-485 Communication ........................................................................................ 6
Sensor Separation ............................................................................................ 7
Figure 6: Wiring—Sensor Separation ...................................................................... 7
Non-Isolated/Isolated Wiring .......................................................................... 8
Terminal Connection ............................................................................................. 8
Figure 7: Non-isolated Terminal Connection .......................................................... 8
Figure 8: Isolated Terminal Connection .................................................................. 8
Current Output ....................................................................................................... 8
Figure 9: Jumper Positions ....................................................................................... 8
Remote Reset ................................................................................................... 9
Figure 10: Remote Reset ......................................................................................... 9
Review Relay Settings ....................................................................................14
Relay Options .................................................................................................15
Table 4: Default Relay Settings ..............................................................................15
Setting Relay Options ..........................................................................................15
Modbus Options .............................................................................................16
Node Address ......................................................................................................16
Baud Rate ............................................................................................................16
Enter Restricted Menu ....................................................................................16
Set Low Power Options - Optional ......................................................................16
Select Display Language ................................................................................17
Alarms ............................................................................................................17
Sensor Fault .........................................................................................................17
Non-standard O2 Levels ......................................................................................17
Sensor Life ...........................................................................................................17
Reset ...............................................................................................................17
Manual Reset .......................................................................................................17
Remote Reset .......................................................................................................17
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Outputs ........................................................................................................... 18
Relays - Optional ................................................................................................. 18
Modbus ................................................................................................................ 18
Current ................................................................................................................. 18
Step 7 — Maintain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Periodic Response Check ............................................................................... 18
Troubleshoot .................................................................................................. 18
How to Return Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Spare Parts/Accessories ................................................................................. 19
Table 5: Part Numbering ........................................................................................ 19
Face Rotation Option ..................................................................................... 19
Figure 14: Non-standard Orientations .................................................................... 19
Rotate PCB Assembly ......................................................................................... 20
Appendix A: Electrostatic Sensitive Device (ESD) . . . . . . . . . . . .20
Appendix B: Resistance Table in OHMS . . . . . . . . . . . . . . . . . . . .21
Appendix C: Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
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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.
Step 1 — PLAN
Step 2 — INSTALL
Step 3 — WIRE
THE PRODUCT
The Sensor
Step 4 — OPERATE
Step 5 — CALIBRATE
Step 6 — MONITOR
Step 7 — MAINTAIN
The electrochemical sensor is a proven design ensuring an accurate and
repeatable response within a detection range of 0 to 25% oxygen.
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 intrusive or non-intrusive calibration.
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.
MLP-A/AR/AD-ST1400-25
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Figure 1: Locate Sensor/Controller
STEP 1 — PLAN
LOCATE CONTROLLER/SENSOR
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.
Conduit to
Controller
• Locate the Controller where it will be accessible and visible.
• Oxygen deficiency can be caused by O2 consumption from such activities as
chemical reactions or combustion and/or displacement by other gases.
• Use redundant systems to enhance protection and reliability.
• Consider air movement patterns within the facility.
• 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.
Controller
About
eye
level
Sensor
Calibration Cup
Option 1
Apply Calibration Gas
Locate Sensor separate from Controller using a certified (Net Safety Muti-propose)
Junction Box.
The Controller is located near eye-level. Conduit is run from the Controller to
the Sensor. The Multi-purpose Junction Box is used to connect the conduit from
the Controller to the Sensor. A Calibration Cup can be attached to the Sensor.
Tubing can be run from the calibration cup to a convenient location accessible
for calibration gas to be injected. Refer to MAN-0081 for Multi-purpose Junction
Box Terminal designations.
TIP: The Calibration Cup allows for tubing to be affixed
to a Sensor mounted in remote locations. The tubing
is directed to a level, usually close to the Controller,
for easy injection of calibration gas.
Option 2
The Sensor is attached directly to the Controller. A Calibration Cup and tubing
may also be used to facilitate calibration as in Option 1 above.
The Calibration Cup can also act as a splash guard,
protecting sensors when mounted low to the ground.
See "Sensor and Controller" on page 6 for detailed instructions.
CCS-1
MLP-A/AR/AD-ST1400-25
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Figure 2: Dimensional Drawings
STEP 2 — INSTALL
5.68”
(144.3 mm)
5.60”
(142.2 mm)
UNPACK
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.
4.06”
5.31”
(134.9 mm)
(103.1 mm)
If you find any components missing or damaged, notify the representative or
Net Safety Monitoring immediately.
10.51”
(267.0 mm)
Figure 3: Components
Controller Housing
Millennium Faceplate
Housing Cover
2.60”
Controller with sensor
(66.0 mm)
2.89”
(73.4 mm)
4.82”
(122.4 mm)
Ribbon connecting
faceplate/controller
9.92”
(252.0 mm)
Sensor Housing
5.10”
(129.5 mm)
External Equipment
It is necessary that reliable monitoring and indicating devices or systems be
connected to the transmitter. These devices must be designed to produce clear
visual and audible danger signals when high signal levels occur.
Multi-purpose Junction Box with sensor
MLP-A/AR/AD-ST1400-25
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Mount
SEAL
• 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.
The Controller is usually mounted near eye-level and be easily accessible for
calibration and maintenance purposes. The Sensor should be placed where O2
may build up or where other gases are likely to build up and displace O2.
Ensure all devices are securely mounted, taking into consideration all
requirements.
• 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.
Use the Face Rotation Option to mount the Millennium
Controller at a different orientation (refer to "Face
Rotation Option" on page 19 for detailed instructions).
• 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'.
STEP 3 — WIRE
FIELD INSTALLATION
WARNING: Wiring codes and regulations may vary. Compliance with
regulations is the responsibility of the installer. Wiring must comply with
applicable regulations relating to the installation of electrical equipment in a
hazardous area. If in doubt, consult a qualified official before wiring the system.
Note: Seals are not required for all Class 1 Division 2 locations in Canada.
However, to fully avoid any exposure, the use of seals are still
recommended, especially for installations that use high-pressure or
steam cleaning devices in proximity to the controller and/or sensor.
• 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 (refer to " Resistance Table in OHMS" on page 21).
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.
• When developing a RS-485 chain of devices, the last device in the chain
requires end of line termination.
• RS-485 connection 2-wire, multipoint serial line.
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Board Assembly
There are three different fixed boards, two optional relay boards and an optional Modbus board which make up the PCB Assembly. Depending upon requirements,
either a Electromechanical or Solid State Relay Board module can be used. Boards are field replaceable. Simply loosen the three locking standoffs, remove one
board, insert the other board and tighten screws.
Note: Boards are susceptible to ESD. Refer to Appendix A, "Electrostatic Sensitive Device (ESD)", on page 20.
Figure 4: Millennium Module Boards
Solid State Relay Board
+
Fault
-
+
Low
-
+
High
-
Terminal
Board
Option Board
Sensor
Electromechancial Relay Board
Board
FNO
FCOM
FNC
LNO
LCOM
LNC
HNO
HCOM
HNC
normally open
common
normally closed
normally open
common
normally closed
normally open
common
Modbus Terminals
A
B
COM
Shld
normally closed
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Figure 5: Wiring—Controller and Sensor
SENSOR AND CONTROLLER
WARNING:
Power to the unit must be OFF before wiring.
Terminal Board
Note: The Sensor may be factory installed to the Controller. If so, you need
only connect the Power Terminals.
RST
+24V
COM
4-20
ISO
1. Remove the Controller’s Housing Cover.
2. Connect the Sensor to the Sensor Terminals (if necessary) and the Output
Terminals to the output signal wires.
Power
Terminals
RST
+24V
COM
4-20
Table 1: Controller/Sensor Connections
Sensor Board Terminals
Terminal Board Power
Sensor
Controller
Controller
Power
ISO
A
Red
Blk
-
Wire
Red
(Sensor Board)
(Terminal Board)
Connections
B
Red+
= Red (+24 V)
= Blk (Sig)
RST
= Remote Reset
= Power (+)
= Power (-)
Modbus RTU
Sensor
Terminals
Blk
Terminals
to PLC
COM
-
Black
+24V
COM
4-20
-
Shld
-
-
= Current Loop
Shld
Output
Shield
= Shld
ISO
= +24 V isolated
4-20 power
Note: For Sensor Separation instructions, see Figure 6, "Wiring—Sensor
Separation", on page 7.
3. Replace the Controller’s Housing Cover.
4. Turn Controller On.
Sensor Board
5. 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.
Sensor
Wires
RS-485 Communication
Connect devices in a chain via the Modbus terminals. The last device in the
chain requires end of line termination (refer to "MODBUS Termination" on
page 9).
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/AD-ST1400-25
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SENSOR SEPARATION
Figure 6: Wiring—Sensor Separation
Terminal Board
Power
Terminals*
To designated terminal board
and oxygen sensor. See MAN-0081
Multi-purpose Junction Box manual
RST
+24V
COM
4-20
ISO
Red
Blk
Modbus RTU
Terminals
to PLC*
Shld
Sensor
Terminals*
Sensor Board
As the Sensor must be located in one location and the Controller in a location
where it can be easily reached, it is often necessary to “separate” the Controller
and Sensor.
Ensure that the appropriate wire is used for Class 1/Division 1 hazardous
applications.
Note: If the 4-20 mA signal is not used, connect a jumper between the 4-20
The Sensor separation kit (SEP) is composed of a junction box and terminal
strip. Refer to the Net Safety Multi-purpose Junction Box manual (MAN-0081)
for terminal designation when wiring for sensor separation.
terminal and the COM terminal on the Terminal Board.
Shielded copper instrument wire (minimum 18 AWG) should be used for
separations up to 500 feet. Shielded copper instrument wire (minimum
16 AWG) should be used for separations up to 2000 feet. Consult the factory if a
greater separation distance is required.
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Current Output
NON-ISOLATED/ISOLATED WIRING
To set an isolated current output, simply move the Jumper (shorting jack) to the
isolated current position (refer to Figure 9, "Jumper Positions", on page 8).
Terminal Connection
Figure 7: Non-isolated Terminal Connection
Note: Unless otherwise specified, all models ship with non-Isolated current
output.
Terminal Board
Power Terminal Strip
Figure 9: Jumper Positions
Jumper—Position Jumper
Terminal Board
(shorting jack) over pins to
set power source for current
output.
RST
+24V
COM
4-20
ISO
Power
Supply
Position 3 & 2 =
Non-isolated (default)
Position 1 & 2 = Isolated
to Monitor
Termination Jumper—Is non-
functional in this application
and can be placed in any
position or removed
Figure 8: Isolated Terminal Connection
Terminal Board
Power Terminal Strip
entirely.
Sensor Board
RST
+24V
COM
4-20
ISO
Power
Supply
to Monitor
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REMOTE RESET
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
+24V
Terminal Board
PowerTerminal Strip
COM
4-20
ISO
MODBUS TERMINATION
Devices are networked in a daisy chain. The device located at the end of the
chain requires end of line termination. Place both jumpers over the pins, as
shown in Figure 11, "Modbus Termination Jumpers", on page 9, for end of line
termination.
Figure 11: Modbus Termination Jumpers
MLP-A/AR/AD-ST1400-25
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STEP 4 — OPERATE
The Controller faceplate contains most functional elements of the user interface. Below is a description of that functionality.
Figure 12: Controller Functionality
Scrolling 8-character display -
provides various status messages and
prompts. Refer to "Status LEDs,
Display Messages and Current
Loop" on page 11.
Magnetic Reed Switch - provides non-intrusive access for
Pull Here knob - unscrew the two
programming, calibrating and resetting.
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) for less than one
second to initiate a basic system reset (clear a latched alarm) and
make selections.
-Place magnet against Housing (where
indicated) and hold to program, view
current settings and calibrate.
Pull
Here
Refer to "Magnetic Reed Switch" on page 12
for further information.
Status Light (Red and Green) -
indicates status of unit. Refer to
"Status LEDs, Display Messages and
Current Loop" on page 11 for
Status
Red
Slow Flash:
Gas present
Flast flash :
Cal or Fault
Solid:
Calibration/Setup
-Hold Cal/Reset or
On
Overrange
magnet until countdown
is zero (~10 sec)
-Follow instruction on
display
detailed explanation of states/status.
Green
Short Blips:
Normal
operation.
No gas
present
ON/OFF Switch - used to turn Controller on and
off. Housing must be removed to access.
Off
Power
Current O/P Check
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.
Calibration Button - provides intrusive
access for programming, calibrating and
resetting.
Pull
Here
Connect current probes
to meter jacks and
read mA output
-Push for less than one second to initiate a
basic system reset (clear a latched gas
alarm) and make selections.
Current Test Jacks - to take current loop measurements use the following procedure:
-Insert your current meter leads into the Test Jacks.
-Push and hold to program, view current
settings and calibrate.
-Set external devices to bypass, if necessary, to avoid unwanted alarm response
-Review current loop measurements.
Refer to "Calibration Button" on page 11
for further information.
Refer to "Current Loop Measurement (Test Jacks)" on page 12 and Table 2, "Status LEDs, Display
Messages and Current Loop", on page 11.
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RTU Registers
Table 2: Status LEDs, Display Messages and Current Loop
Register 40001 = % output (read only)
Register 40002 = RTU Status (read only)
Register 40101 = Reset latched relays (write)
Status LED
Current O/P RED or GREEN
State
Options
Review/Settings
Display
3.0 mA
n/a
n/a
Table 3: RTU Status Register (40002) Read Only (Binary)
Standard level of
Oxygen present
Blip/
blink
Slow
flash
RTUstat_fault
0x0001 (fault sensor...)
0x0002 low alarm tripped
0x0004 high alarm tripped
0x0008 low alarm latched
0x0010 high alarm latched
0x0080 power up delay
0x0100 calibration cycle in progress
0x0200
0x0400
0x0800
0x1000
0x2000
20.9 %O2
17.4 mA
RTUstat_low_alarm
RTUstat_high_alarm
RTUstat_low_alarm_latched
RTUstat_high_alarm_latched
RTUstat_powerUp
Start Delay
Start-up delay (90 sec) 3.0 mA
Switch On
10-0
Access Main Menu
3.0 mA
2.5 mA
n/a
Memory Error (contact
factory)
Black or Red Sensor
lead open
Slow
flash
Slow
flash
Memory Error
Sensor Fault
RTUstat_cal_cycle
RTUstat_zeroing
2.5 mA
3.0 mA
RTUstat_apply_span_gas
RTUstat_calibrating
RTUstat_remove_gas
RTUstat_cal_complete
RTUstat_mem_error
Apply Clean
Air
Auto zero set
Solid
Fast
flash
Apply 20.9%
O2
Apply calibration gas 3.3 mA
Span is set, remove
0x4000 memory error
Remove gas
3.6 mA
gas
Solid
Flash
XX Low Alarm
XX High Alarm
Low alarm set point
High alarm set point
Non-standard levels of >17.4 mA or Blip/
Oxygen present
Calibration procedure
failed/Sensor failed
Over 25% Range
-
-
Flash
Flash
Calibration Button
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 12,
"Controller Functionality", on page 10 for more information.
% O2 shown left
side display
<17.4 mA
3.0 / 3.3 mA
20 mA
blink
Flash
Solid
Fail Cal
• Press and hold the Calibration Button to Calibrate and access Main Menu.
• Briefly press to make a selection (select YES? ).
<25%O2
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.
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Magnetic Reed Switch
THE MAIN MENU
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 12, "Controller Functionality", on page 10 for more information.
The Main Menu provides access to various functional settings and viewing of
current settings.
• Calibrate Sensor - Calibrate sensor.
• Review Relay Settings - Review the current Fault, Low and High alarm
settings. This is a read only section.
Attached to the side of the Controller is a magnet:
• Set Relay Options - Set the Low and High alarm settings.
• Select Modbus Options.
• Place and hold the magnet to the Controller’s Housing (10 o’clock position)
to Calibrate and access Main Menu.
• Restricted Menu - Select low power options.
• Select a display language - English, Spanish or French.
• Briefly place the magnet to the Controller’s Housing (10 o’clock position) to
make a selection (select YES? ).
Note: The current output will drop to 3.0 mA while in the Main Menu.
Accessing the Main Menu
Power Up
Turn power switch On. A 90 second warm-up routine will begin. The display
There are two ways to activate the Main Menu:
reads Start Delay Millennium Net Safety
, Status LED is Red Slow Flash and
• Calibration Button found on the faceplate (the Housing cover must be
removed to access)
• Magnetic Reed Switch (a magnet must be used to activate)
current output displays 3.0 mA.
When power is applied, the system is automatically tested to ensure proper
functionality.
Main Menu Functionality
After warm-up, the Controller will enter normal operation, the display reads
%O2, Status LED will Green Blip/blink and analog output will change to
4.0 mA.
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 0 (normal operation).
Current Loop Measurement (Test Jacks)
Use a standard meter to measure current loop during various states. The
Controller’s Housing cover must be removed to access the Test Jacks.
Refer to Table 2, “Status LEDs, Display Messages and Current Loop,” on
page 11 for a detailed list and Figure 12, "Controller Functionality", on page 10
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 11 for a detailed list.
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STEP 5 — CALIBRATE
CALIBRATION PROCEDURE
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 14 for specific information).
For accurate performance, the concentration of gas, corresponding to 0 to 25% oxygen 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.
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 0.5 litres per minute through the calibration cup for 1 minute to ensure clean air environment.
3. Use the Calibration Button or Reed Switch to access the Main Menu and wait for countdown 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 Apply Clean Air
displays apply clean air.
6. When Apply 20.9% O2 displays, apply O2 at a rate of 0.5 litres per minute using the calibration cup.
7. The display will show Calibrating as the internal settings are being modified (current loop 3.3 mA).
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 13: Calibration Procedure
Apply 20.9%
O2
Apply Clean
Air
Calibrate
Sensor YES?
Display
Shows
Remove Gas
Calibrating
Cal Complete
Select YES?
Remove gas
Apply O2
Apply clean
(zero air)
Action
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Calibration Failure
If the calibration procedure fails, the display shows Fail Cal , the Status LED
alternates Red and Green flashes and the analog output changes back and forth
from 3.0 to 3.3 mA.
STEP 6 — MONITOR
REVIEW RELAY SETTINGS
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.
Refer to "Manual Reset" on page 17 for instructions.
This is a read-only mode; changes cannot be made.
Step 1:
Step 2:
Step 3:
Step 4:
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.
When Review Relay Settings displays press the Calibration
Button or use the Reed Switch to select.
The flashing YES confirms the selection.
The Fault Alarm is fixed (Energized Non-Latching ) and
/
displays first. Then the Low Alarm level, coil and latch status
display, followed by the High Alarm level, coil and latch status.
At this point, the option to Set Relay Options YES? is
displayed.
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RELAY OPTIONS
Setting Relay Options
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 10
to 25%. Low Alarm levels and High Alarm levels will display if reached.
Use to set the alarm level, coil status and latch status for the Low and High
relays (Fault Alarm is fixed).
The following table describes the default settings for the sensor.
Table 4: Default Relay Settings
Step 1:
When Set Relay Options YES? displays press the Calibration
Button or use the Reed Switch to select.
The flashing YES confirms the selection.
Relay Coil
Alarm Levels
Status
Millennium
Model Number
Step 2:
Step 3:
The message Set Low
displays. Low alarm set-points are displayed
in increments of 1, beginning at 10 and cannot be set above 20.
Low High
Fault
When the required level displays, press the Calibration Button or
use the Reed Switch to select.
The level chosen will flash to confirm the selection.
MLP-A/AR/AD-
ST1400
(25%range)
Step 4:
Step 5:
The message Coil Status
displays. The display then shows
Energized
/Non-latching
20% 22%
*
*
Energized YES? and then De-Energized YES?
Press the Calibration Button or use the Reed Switch to select.
The flashing YES confirms the selection. If no selection is made, the
Coil Status option is repeated.
Step 6:
Step 7:
The message Latch Status
displays. The display then shows
Latching YES? and then Non-Latching YES?
Press the Calibration Button or use the Reed Switch to select.
The flashing YES confirms the selection. If no selection is made, the
Latch Status option is repeated.
Step 8:
The message Set High displays.
The High Alarm level must be set between 21 and 25. The High
Alarm level is displayed in increments of 1 beginning at the Low
Alarm set-point (as set in Step 3).
Step 9:
Repeat Steps 4 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.
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MODBUS OPTIONS
ENTER RESTRICTED MENU
The digital RS-485 Modbus RTU protocol is used. There are two Modbus
options: Node Address and Baud Rate.
The Restricted Menu allows you to set the Low Power Options.
Step 1:
Step 2:
Step 3:
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.
Node Address
Each device connected to the chain must be assigned a unique node address (1-
255). The last number in the address is selected first.
When Enter restricted menu YES? displays press the
Calibration Button or use the Reed Switch to select.
The flashing YES confirms the selection.
Step 1:
When Modbus Setup? YES? displays press the Calibration Button
or use the Reed Switch to select.
The flashing YES confirms the selection.
When Are you sure? YES? displays press the Calibration Button
or use the Reed Switch to select.
The flashing YES confirms the selection.
Step 2:
Step 3:
The current node address will display Node: 000
.
and press the Calibration
Wait for the prompt New Address? YES?
Set Low Power Options - Optional
Button or use the Reed Switch to select.
Two optional low power features are available to reduce overall power
consumption. Use this option to:
Step 4:
Use the Calibration Button or Reed Switch to select each of three
numbers in the new address:
- select the last number in the address first: 0 thru 9.
- select the next number in the address: 0 thru 9.
- select the first number in the address last: 0 1 2 .
• Dim the LED display although display will still be visible in most lighting
conditions (default setting)
• Disable the 4 to 20 mA analog output for applications requiring only relay
output (default setting)
Baud Rate
Step 1:
Step 2:
Enter the Restricted Menu (refer to "Modbus Options" on page 16).
The transmission speed must be defined.
When Set Low Power Options YES? displays press the Calibration
Button or use the Reed Switch to select.
The flashing YES confirms the selection.
Step 1:
When Modbus Setup? YES? displays press the Calibration Button
or use the Reed Switch to select.
The flashing YES confirms the selection.
Step 3:
Step 4:
When Lower Display Brightness YES? displays press the
Calibration Button or use the Reed Switch to select or wait until
Display Full Brightness YES? displays and select.
Step 2:
Step 3:
Step 4:
Step 5:
Step 6:
After setting the Node Address, the current Baud Rate will display
XX.X BPS
.
Wait for the prompt New Baud Rate? YES? and press the
Calibration Button or use the Reed Switch to select.
The flashing YES confirms the selection.
When Disable 4 - 20mA O/P YES? displays press the Calibration
Button or use the Reed Switch to select or wait until Enable 4 -
20mA O/P YES? displays and select.
The available baud rates will display: 2400s , 4800s , 9600s,14.4s
19.2s , 28.8s , 38.4s , 57.6s .
Use the Calibration Button or use the Reed Switch to select baud
rate when it displays.
,
The flashing YES confirms the selection.
The flashing YES confirms the selection.
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Non-standard O2 Levels
SELECT DISPLAY LANGUAGE
When levels >20.9 or <20.9 are detected, the display shows the oxygen level, in
percent, on the left side of the display and the LED will blip green. Current output
will vary, depending on the O2 level.
Step 1:
After the Restricted Menu the option Select Display Language
YES? displays. Press the Calibration Button or use the Reed Switch
to select.
The flashing YES confirms the selection.
If an alarm set-point is reached, the %O2 still displays to the left but a High
Alarm or Low Alarm message will scroll to the right and the LED will blip/
blink red. Current output will vary, depending on the O2 level.
Step 2:
When the required language displays (English , Espanol ,
press the Calibration Button or use the Reed Switch to
Francais
select.
)
Over range is reached if the O2 level exceeds 25%. The display shows
<25%O2, the LED goes solid red and 20 mA is delivered.
The flashing YES confirms the selection.
Note: Factory default is English.
Sensor Life
ALARMS
Depending on various factors, sensor response may slowly deteriorate over
time. 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.
Sensor Fault
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.
RESET
Manual Reset
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
display show Sensor Fault and analog output change to 2.5 mA.
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 15) 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 9 for details.
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OUTPUTS
STEP 7 — MAINTAIN
Relays - Optional
PERIODIC RESPONSE CHECK
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.
We recommend a typical response check or calibration is performed on the
Millennium 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
12% oxygen is applied, the response is expected to be between 10.4 mA (10%
O2) and 12.96 mA (14% O2). An additional consideration is the accuracy
tolerance of the calibration gas which may be + or - a few percent.
Standard electro-mechanical relay outputs have Form C SPDT contacts rated
5 Amperes 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.
TROUBLESHOOT
Modbus
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 13 for calibration instructions.
Digital RS-485 Modbus RTU protocol is used.
Register 40001 = % output (read only)
Register 40002 = Status (read only)
Register 40101 = Reset latched alarms (write)
• Excess negative drift is indicated by 2.5 mA current output
• Sensor or transmitter is connected or disconnected
• Long term exposure or high concentration exposure to gas
Note: Many registers are used by the controller. Please do not write outside
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 19 for detailed instructions.
the three registers.
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 17.4 mA output indicates normal operation; a value >17.4 or <17.4 mA out-
put indicates an abnormal amount of oxygen. Current output of 2.5 mA indi-
cates the presence of a system fault.
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SPARE PARTS/ACCESSORIES
HOW TO RETURN EQUIPMENT
Table 5: Part Numbering
Description
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.
Net Safety Part Number
THSG-FULL-O2-SS
THSG-FULL-O2
Oxygen Sensor housing(light blue)
Oxygen Sensor housing(light blue)
Oxygen (O2) Sensor
If you are required to return equipment, include the following information:
ST1400-25
PCBA-0252E
FRO-001
CCS-1
Terminal Connector Board
90 Degrees Rotation Plate
Calibration Cup
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.
Magnet-1
Magnet assembly
3. A company name, contact name and telephone number.
4. A Purchase Order, from your company, authorizing repairs or request for
quote.
Transmitter for MLP series
ML7-TX100
c/w Display, Terminal & Input board
Mechanical Relay Board for
MLP series
Option Board c/w connectors
for Mechanical Relay board
Electromechanical Relay Board
c/w Option board
5. Ship all equipment, prepaid to:
ML7RS305
ML7OP100
Net Safety Monitoring Inc
2721 Hopewell Place NE
Calgary, Alberta, Canada
T1Y 7J7
ML7-ORL305
ML7-MB100
ML7 Modbus Output Board
6. Mark all packages: RETURN for REPAIR
FACE ROTATION OPTION
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.
Waybills, for shipments from outside Canada, must state:
Equipment being returned for repair
All charges to be billed to the sender
Figure 14: Non-standard Orientations
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 aluminum-
backed cardboard as protection from electrostatic discharge.
Note: Ensure orientation allows for connections and excess wire within Controller
Housing.
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Rotate PCB Assembly
Appendix A:
1. Remove the Controller’s Housing Cover.
2. Turn the power to the detector off.
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.
3. Unscrew both the knobs marked "Pull Here".
4. Lift Controller faceplate from Housing and allow to hang from ribbon
cable.
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.
5. Unscrew the two metal standoffs.
6. Carefully remove the PCB Assembly from the Housing.
7. The Rotator plate is secured to the bottom of the Housing and is accessible
after the PCB Assembly has been removed.
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.
8. Rotate the PCB Assembly to desired position and line up the standoffs with
the mounting holes.
9. Insert standoffs in the appropriate horizontal or vertical mounting holes.
10. Tighten standoffs to secure PCB Assembly.
11. Replace faceplate and tighten "Pull Here" knobs.
12. Return power to detector and replace Housing Cover.
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
• Ensure 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
Vertical Mounting Holes
(Insert Standoffs)
Horizontal Mounting
Holes
(Insert Standoffs)
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.
Ribbon cable
Standoffs
PCB Assembly
Faceplate
WARNING:
See Appendix A, "Electrostatic Sensitive Device (ESD)", on
page 20 for handling instructions of electronic components.
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Appendix B: RESISTANCE TABLE IN OHMS
Distance (Feet)
100
AWG #20
1.02
AWG #18
0.64
AWG #16
0.40
AWG #14
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
AWG #12
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
AWG #10
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
AWG #8
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
200
2.03
1.28
0.80
300
3.05
1.92
1.20
400
4.06
2.55
1.61
500
5.08
3.20
2.01
600
6.09
3.83
2.41
700
7.11
4.47
2.81
800
8.12
5.11
3.21
900
9.14
5.75
3.61
1000
1250
1500
1750
2000
2250
2500
3000
3500
4000
4500
5000
5500
6000
6500
7000
7500
8000
9000
10 000
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
6.39
7.99
9.58
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
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
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
Note: Resistance shown is one way. This figure should be doubled when determining closed loop resistance.
MLP-A/AR/AD-ST1400-25
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Appendix C: SPECIFICATIONS
SENSOR SPECIFICATIONS
SENSOR ELEMENT
Operating Temperature Range
Range of Detection
Response Time
Oxygen O2 (ST1400)
-20°C to +50°C (-4F to +122F)
0 to 25%
<15 seconds to T95
Span Drift
<5% of signal loss / year
Enclosure Material
Anodized / powder coated aluminum (optional stainless steel)
CSA and NRTL/C certified for hazardous locations. Class I, Division 1, Groups C and D.
IEC Rating Ex d IIB T6 NEMA 3R (Class 1, Zone 1, Grp IIB T6)
Certifications
Weight
0.5 Kg (1.0 lb)
CONTROLLER SPECIFICATION
MILLENNIUM
ANALOG
ANALOG/RELAY
ANALOG/DIGITAL
Operating Temperature Range
Power Consumption @ 24 V dc
-20°C to +50°C (-4F to +122F)
Nom 68 mA / 1.63 W
Max 90 mA / 2.16 W
Nom 75 mA / 2.0 W
Max 108 mA / 2.6 W
Nominal 125 mA/3.01 W
Maximum 155mA/3.73 W
Humidity Range
0 to 99% relative humidity, non-condensing
10.5 to 32.0 V dc
Operating Voltage Range
Enclosure Material
Certifications
Powder coated Copper Free Cast Aluminum (optional stainless steel)
CSA and NRTL/C certified for hazardous locations. Class I, Division 1, Groups B, C and D. NEMA 4X.
IEC Rating Ex d IIB+H2 T5
Note: With any Type 4 enclosure (electronics only-sensor remotely mounted in Class I, Division 1 area with seals between
sensor and electronics), CSA and NRTL/C certified for hazardous locations, Class 1, Division 2, Groups A, B, C and D.
Weight
3.2 Kg (7.0 lb)
- 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.
- Premium version - 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.
Outputs
Low Power Version - Form A contacts rated.2.5 Amps at 60 V ac/dc. 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.
- Digital RS 485 Modbus RTU Protocol
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2721 Hopewell Place NE
Calgary, Alberta, Canada T1Y 7J7
Telephone: (403) 219-0688 Fax: (403)
E-mail: [email protected]
219-0694
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