STATUS SCIENTIFIC CONTROLS MCU3 Feuille d'instructions

STATUS SCIENTIFIC CONTROLS LTD.

Hermitage Lane Industrial Estate,

Kings Mill Way,

Mansfield,

Nottinghamshire.

NG18 5ER

England

Tel

Fax

: 01623 651381

: 01623 421063

Environmental Monitoring &

Control Units Types MCU 3 & 4

Installation and Hardware

Configuration Manual

Date:

11.6.2009.

Issue:

STATUS SCIENTIFIC CONTROLS

MCU System Installation and Hardware Configuration Manual

The MCU3 & 4 Manuals

The MCU3 & 4 Environmental Monitoring Systems have a range of manuals covering various

aspects of their operation:

•MCU3 & 4 Installation and Hardware Configuration Manual

This manual covers all of the hardware aspects of the MCU Environmental Monitoring

Systems. Each of the component parts of the system is discussed and hardware

configuration is explained. Dimensional drawings are included.

•MCU3 & 4 Software Configuration and System Calibration Manual

The operation of the MCU system is discussed as well as the software configuration

and calibration procedures.

•‘Mentor PC’ Operators Manual

The Mentor PC software is discussed including:

Software Installation

Hardware Configuration to facilitate downloading logged data and

configuration via a PC.

Displaying, and archiving logged data.

Important

Status Scientific Controls strive to continually improve their products in line with customer’s

requirements and technological advancement. Status Scientific reserve the right to modify

the design of the system at any time.

Due to continual improvement not all of the features described within this manual may be

available on earlier models, contact Status for further details.

This manual covers all MCU Control Units containing Input Boards fitted with jumper switch

configurable options. If the configuration of the Input Boards is set by the removal or fitting

of jumpers then please refer to an Issue 2.0 manual available from Status Scientific

Controls.

STATUS SCIENTIFIC CONTROLS 
 
MCU System Installation and Hardware Configuration Manual 
 
 
 
1Introduction........................................................................................................................ 1-1 
1 MICROCONTROLLER MODULE......................................................................................... 1-5 
2 INPUT MODULE.............................................................................................................. 1-6 
3 DISTRIBUTION BOARD.................................................................................................... 1-7 
3.1 Field Connections ................................................................................................... 1-7 
3.2 Distribution Board - Issues 1 & 2............................................................................ 1-8 
3.3 Distribution Board - Issues 3 and above................................................................. 1-8 
4 COMMON RELAY MODULE.............................................................................................. 1-9 
5 POWER SUPPLY MODULE............................................................................................. 1-10 
6 BATTERY BACKUP........................................................................................................ 1-11 
6.1 Calculation Examples ........................................................................................... 1-12 
6.2 Calculating the backup time for your system........................................................ 1-13 
7 MCU SYSTEM COMMUNICATIONS................................................................................. 1-14 
7.1 MCU System Configuration and Interrogation...................................................... 1-14 
7.2 MCU System Networking...................................................................................... 1-14 
2MCU Installation................................................................................................................. 2-1 
1 SITING THE MCU........................................................................................................... 2-1 
2 ASSEMBLING ................................................................................................................. 2-2 
3 SYSTEM WIRING............................................................................................................ 2-2 
4 POWER SUPPLY INPUT................................................................................................... 2-2 
4.1 A.C. Mains Connection ........................................................................................... 2-2 
4.2 24V DC Connection................................................................................................ 2-3 
5 CABLE ROUTING............................................................................................................ 2-3 
6 CABLE SCREENING........................................................................................................ 2-3 
3Gas Detector Head Installation......................................................................................... 3-4 
1 SITING THE DETECTORS................................................................................................. 3-4 
2 INSTALLATION IN A NON-HAZARDOUS AREA .................................................................... 3-4 
3 INSTALLATION IN A HAZARDOUS AREAS........................................................................... 3-6 
3.1 Hazardous area installation using barrier type FGDIO........................................... 3-7 
3.2 FGDIO Intrinsically Safe Output Module Installation .............................................. 3-9 
3.3 Hazardous area installations using Proprietary Safety Barriers........................... 3-11 
4Input Module Configuration.............................................................................................. 4-1 
1 INPUT CONFIGURATION.................................................................................................. 4-1 
1.1 Status Scientific Controls Gas Detectors................................................................ 4-2 
1.2 Alternative Detector Heads..................................................................................... 4-7 
2 ANALOGUE OUTPUT CONFIGURATION........................................................................... 4-11 
2.1 4-20mA Current Source........................................................................................ 4-12 
2.2 4-20mA Current Sink ............................................................................................ 4-12 
2.3 1-5V Voltage Output ............................................................................................. 4-12 
3 INPUT MODULE INSTALLATION ...................................................................................... 4-13 
5Detector Head Operation & Calibration........................................................................... 5-1 
1 DETECTOR HEAD VARIANTS........................................................................................... 5-1 
2 OPERATION................................................................................................................... 5-1 
2.1 Status Indications.................................................................................................... 5-1 
3 INSPECTION AND MAINTENANCE ..................................................................................... 5-2 
3.1 Calibration Intervals ................................................................................................ 5-2 
3.2 Routine Inspection .................................................................................................. 5-2 
4 CALIBRATION................................................................................................................. 5-2 
5 GAS DETECTOR CONTAMINANTS.................................................................................... 5-2 
5.1 Flammable Gas Detectors...................................................................................... 5-2 
5.2 Oxygen Gas detectors ............................................................................................ 5-3 
5.3 Toxic Gas Detectors ............................................................................................... 5-3 
6 SENSOR DISPOSAL........................................................................................................ 5-4 

STATUS SCIENTIFIC CONTROLS

MCU System Installation and Hardware Configuration Manual

5.6.1 Oxygen Sensors ..................................................................................................... 5-4

5.6.2 Toxic Gas Sensors.................................................................................................. 5-4

5.6.3 Flammable Gas Sensors ........................................................................................ 5-4

6Trouble Shooting ............................................................................................................... 6-1

6.1 COMMON FAULTS .......................................................................................................... 6-1

7Service ................................................................................................................................ 7-1

7.1 WARRANTY ................................................................................................................... 7-1

7.2 COMMISSIONING AND SERVICE....................................................................................... 7-1

7.3 SENSOR REPLACEMENT................................................................................................. 7-1

7.4 ROUTINE SERVICING...................................................................................................... 7-2

7.4.1 Routine Inspection .................................................................................................. 7-2

8Appendix............................................................................................................................. 8-1

8.1 INSTALLATION OF SAFE AREA SOUNDERS AND BEACONS................................................. 8-1

8.2 INSTALLATION OF INTRINSICALLY SAFE SOUNDERS AND BEACONS ................................... 8-2

8.3 EXAMPLE OF CONNECTION TO A STATUS SCIENTIFIC CONTROLS TRAFFIC LIGHT UNIT ...... 8-3

8.4 MOUNTING DETAILS FOR MCU3 CONTROL UNIT............................................................. 8-4

8.5 MOUNTING DETAILS FOR MCU4 CONTROL UNIT............................................................. 8-5

8.6 MOUNTING DETAILS FOR FGD2 DETECTOR HEADS......................................................... 8-6

8.7 MOUNTING DETAILS FOR FGD3 DETECTOR HEADS......................................................... 8-7

8.8 FGD DETECTOR HEAD CALIBRATION ‘LOOK-UP’TABLE................................................... 8-8

9Specifications..................................................................................................................... 9-1

9.1 MCU3 &4CONTROL UNITS........................................................................................... 9-1

9.2 I.S. BARRIER TYPE FGDIO............................................................................................ 9-2

9.3 SPECIFICATION FOR FGD DETECTOR HEADS.................................................................. 9-3

9.3.1 FGD Flammable Heads.......................................................................................... 9-3

9.3.2 FGD O2/Toxic Heads .............................................................................................. 9-3

Please Note:

Page numbers within this manual are of the form:

Section –Page

e.g. ‘Page 2-3’ refers to Section 2, Page 3

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1 INTRODUCTION

The MCU3 & 4 are environmental Monitoring Control Units (MCU) that provide facilities to monitor

a wide variety of industry standard environmental and other sensors.

The MCU3 provides up to 8 monitoring channels.

The MCU4 provides up to 16 monitoring channels.

The MCU range has been designed primarily for environmental monitoring. However, the

versatility of the range extends its application to other aspects of industry where monitoring of

remotely connected sensors is required. The specification allows the use of any sensor that can

produce a voltage or current output within a specified range.

The versatile design allows a monitoring system to be initially installed using the minimum

number of required channels and then, as the monitoring environment changes, more channels

can be added, or alternative detector heads can be used as required.

Data logging is provided as a standard function. Data is stored within the systems’ non-volatile

memory thereby providing reliable storage without the risk of losing data in the event of total

power loss (mains and battery backup failure). Logged data can be viewed via the LCD display

situated on the front panel in either numerical or graphical form, or alternatively the data may be

transferred to a P.C. (running the Mentor PC Software) via the RS232 output. This provides the

system with an unlimited storage and data-logging medium.

Care has been taken with the design of the MCU housings and internal chassis to facilitate ease

of connection and wire termination. All on-site wiring to the system is via removable screw

terminal connectors.

A monitoring system consists of, as a minimum, an MCU3 Control Unit and 1 detector head. The

MCU Control Unit houses all of the components required to implement a sophisticated and

reliable monitoring system (battery back-up, alarm relays etc).

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•MCU3 Control Unit.

The MCU3 can monitor up to eight channels.

Channels 1-4 are located on a lower platform whilst channels 4-8 are located on a hinged

upper level. This allows easy access to all hardware configurable options whilst maintaining

its compact size.

It is supplied with interchangeable gland plates located on its upper and lower face. The

lower plate has seventeen holes suitable for 20mm compression glands, or ½” NPT Conduit

entries (other gland plate configurations are available on request), whilst the upper plate is

blank.

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•MCU4 Control Unit

The MCU4 contains two MCU3 systems giving the system the ability to monitor up to sixteen

channels.

The MCU4 is supplied with interchangeable gland plates located on its upper and lower

face. The lower plate has seventeen holes suitable for 20mm compression glands, or ½”

NPT Conduit entries (other gland plate configurations are available on request), whilst the

upper plate is blank.

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The diagram above shows a pictorial representation of the various module positions within the

MCU3 and MCU4 Control Units.

The power supply is situated beneath the main chassis and is not visible when the unit is

assembled, however the four system fuses (FS1 –4) are easily accessible. The mains input

connector and FS1 are sited beneath a cover to avoid inadvertent user contact during normal

operation. The standby batteries are also located beneath the main chassis.

Channels 5-8 are mounted on a hinged platform positioned above channels 1-4. This design

allows easy access to channel 1-4 situated below.

The microcontroller module and LCD display are not shown on the above diagram. These are

mounted on the rear of the hinged front panel of the MCU3 and MCU4 Control units.

Mains Input to PSU (situated

beneath main chassis)

Fuse FS1 (Mains Input)

RL3a RL3b RL4a RL4b

RL2b RL2a RL1b RL1a

Distribution

Board

Common Relay

Module

Fuse FS4 (int./ext. battery)

Fuse FS3 (24V for ext. outputs)

Fuse FS2 (24V)

Detector Head

Connections

Analogue

Output

Relay 3

Relay 2

Relay 1

CHANNEL 4

24V

L N E

Detector Head

Connections

Analogue

Output

Relay 3

Relay 2

Relay 1

CHANNEL 2

Detector Head

Connections

Analogue

Output

Relay 3

Relay 2

Relay 1

CHANNEL 3

Detector Head

Connections

Analogue

Output

Relay 3

Relay 2

Relay 1

CHANNEL 1

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1.1 Microcontroller Module

Situated within the MCU Control Unit front panel is the Microcontroller Module. This module

communicates with all Input Modules connected to the system via an I2C serial bus. The

Microcontroller Module also communicates with the Distribution Board and Relay Module as well

as providing a user interface in the form of a back lit 240 x 64 dot LCD graphical display and an

eight button multifunction keypad.

Note: I2C is a trademark of Phillips Semiconductors.

Three LED indications are provided directly by the Microcontroller Module and these are visible

via MCU front panel:

➢Green LED indication of power on.

➢Red LED indication of alarm condition.

➢Yellow LED indication of fault condition.

An Audible signal is also provided by a sounder mounted within Microcontroller module. This

provides an audible intermittent tone during alarm or fault conditions.

Note:

This sounder is not intended for use as a main indication of alarm conditions. It is strongly

advised that a more substantial sounder and/or beacon be connected to this system (e.g. Status

sounder type SS367 or SS368)

The Microcontroller Module also provides the user with many configuration and interrogation

facilities via the LCD display and keypad. These facilities include:

➢Setting of the Real Time Clock.

•The system has a battery backed 24Hr clock as a standard feature.

➢Sensor Configuration.

•Allows adjustment of Sensor type and range (e.g. Flammable 100%LEL).

➢Calibration of the system.

•This allows each channel to be calibrated independently. The sensor zero point and

span can both be set via this function.

•Calibration of the retransmitted output for each channel.

➢Common Relay Configuration.

•There are four relays situated on the ‘Relay Module’. These relays can be configured

as normally energised or de-energised, and they have several triggering options

dependent on the application.

➢Input Module Relay Configuration.

•Each Input Module contains three relays. These relays can be configured normally

energised or de-energised as required. The levels at which the relays operate are

also engineer configurable.

➢Changing of display modes.

•The LCD has a variety of display modes dependent on the application or maybe the

personal preference of the engineer.

➢Interrogation of logged data.

•The data for any channel can is displayed numerically and graphically.

The microcontroller module contains all of the software required to communicate with up to eight

detecting channels. The addition of extra Input Modules therefore requires only a simple software

configuration change to monitor the additional channels.

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From the rear of the MCU front panel, access can be gained to a 9-way D-type connector labelled

‘Programming and Configuration’ (see section 1.7). With the aid of an interconnecting cable

supplied by Status Scientific the following functions can be performed:

•Programming and Configuration of the MCU system via a P.C.

•Networking of MCU Control Units.

•Downloading of logged data.

A reset button is also located on the Microcontroller Module to allow the system to be reset locally

in the event of an irretrievable fault. This will ‘reboot’ the Microcontroller but will not erase

configuration data or logged data stored within the system.

1.2 Input Module

The input module monitors the status of an externally attached sensor and interfaces the signals

that it receives to the microcontroller module.

The input module is designed to accommodate virtually all sensor configurations currently

available. It can be connected to any sensor (Environmental or otherwise) that supplies it status

signal in any of the following formats:

(a) Current Loop 4 –20mA from 24V source.

(b) Current Loop 4 –20mA to ground.

(d) Voltage Input.

Note:

Option (d) requires hardware configuration that should be made at the factory prior to dispatch.

Please request this option at time of ordering.

In addition the input module can re-transmit the signals for use by external equipment (e.g. chart

recorders). The transmitted signal can be configured using jumpers to provide one of three

output options:

•4 –20mA Current Source proportional to detected signal.

•4 –20mA Current Sink proportional to detected signal.

•0-5V Voltage Output proportional to detected signal.

Up to eight input modules can be located within an MCU3 Control Unit; up to sixteen can be

located within an MCU4.

Situated on each Input Module are 3 Double Pole Change-Over Relays, each relay having

contacts rated at 5A (240V AC). These relays operate at Low, Intermediate and High alarm levels

when enabled. Status Scientific Controls are able to implement modifications to the software to

meet a customer’s specific requirement. Contact Status for further information.

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