Monicon Technology Ltd

Intelligent Combustible Gas Sensor

Model S-500 Instruction Manual
 Monicon Technology Ltd
Intelligent Combustible Gas Sensor
Model S-500 Instruction Manual

The information and technical data disclosed in this document

may be used and disseminated only for the purposes and to the
extent specifically authorised by Monicon Technology in writing.
Such information and technical data are proprietary to Monicon
Technology and may not be used or disseminated except as
provided in the foregoing sentence.

Monicon Technology reserves the right to change published specifications and

designs without prior notice.

Monicon Technology Ltd S-500-English-180400-1 Page 2

Monicon Technology Ltd

Represented by:
Warning
Correct functioning of these instruments must be verified by carrying out a calibration
check at least every 6 months but every 3 months is preferable. Install and maintain
all hazardous area equipment in accordance with the relevant regulations and
practices of the country concerned.

Warranty
Monicon Technology warrants all of its products to be free from defects in
workmanship or material under normal use and service within the periods specified in
the individual data sheets.

Monicon Technology will repair or replace without charge any equipment found to be
defective during the warranty period.

Full determination of the nature and responsibility for defective or damaged

equipment will be made by Monicon Technology Personnel.

Defective or damaged equipment must be shipped prepaid to the Monicon

Technology plant or distributor from which shipment was made.

Gas detection elements that have been poisoned by contaminants (e.g. silicone, lead,
chlorine, sulphur or phosphor) are not included in the warranty.

In all cases this warranty is limited to the cost of the equipment supplied by Monicon
Technology.

The customer will assume all liability for the misuse of the said equipment by its
employees or other personnel.

Monicon Technology implements a policy of continuous improvement of all its products.

For an up-to-date specification on this product, please refer to the relevant data sheet
published by Monicon Technology.

Monicon Technology Ltd S-500-English-180400-1 Page 3

 Contents
General Information
1-1 On Receipt Of Equipment
1-2 Controller Installation
1-3 Installation Of Detector Head
1-4 Detector Locations
1-5 Detector Field Cables
1-6 Caution Note
1-7 Initial Power-up
1-8 Maintenance
1-9 Storage

Operating Instructions
2-1 CAL Magnetic Switch
2-2 SET Magnetic Switch
2-3 é Magnetic Switch
2-4 ê Magnetic Switch
2-5 STATUS Display
2-6 %LEL Display
2-7 General Operation

System Setup
3-1 Entering System Setup Mode
3-2 A1 Alarm Setpoint
3-3 A2 Alarm Setpoint
3-4 A3 Alarm Setpoint
3-5 ZERO setting
3-6 SPAN setting
3-7 Alarm Relays Energised/de-Energised
3-8 RS485 Address
3-9 Hardware Adjustments
3-10 Overrange Latching
3-11 Factory Default settings
3-12 Saving System Variables

Trouble Shooting and System Diagnostics

4-1 Error: Supply Voltage Low
4-2 Error: Sensor Signal Low
4-3 Error: Sensor Current Low
4-4 Error: Electronic Component Fault
4-5 Error: EEPROM Write
4-6 Error: Software

Monicon Technology Ltd S-500-English-180400-1 Page 4

S-500 Terminations
5-1 Power Supply Connections (+24V, COM)
5-2 Analogue Output (AO+, COM)
5-3 RS485 Connections (DA, DB)
5-4 Alarm 1 Relay Contact (A1 Relay)
5-5 Alarm 2 Relay Contact (A2 Relay)
5-6 Sensor Connections (REF, JNC, ACT)

RS485 Communications Interface

6-1 General Description
6-2 Timing Sequences
6-3 Command Codes
6-4 Fault Flags
6-5 CAL Status Registers
6-6 Magnetic Switch Register
6-7 ASCII Character Codes for Digits #1 to #4
6-8 Status Register Flags
6-9 C Serial Interface Function
6-10 BASIC Serial Interface Subroutine

System Specification
7-1 Environmental Specification
7-2 Mechanical Specification
7-3 Electrical Specification
7-4 Cable Specification

User Information
8-1 Wiring Diagram
8-2 Dimensional Diagram

Monicon Technology Ltd S-500-English-180400-1 Page 5

1-1 On Receipt Of Equipment
All items of equipment shipped by Monicon Technology are pre-packed in stout
containers and enclosed in a shock-absorbing filling which affords a considerable
degree of protection against physical damage.

The contents should be carefully removed and checked against the enclosed
packing slip.

Any discrepancies between the contents and the packing slip must be reported to
Monicon Technology within ten days of receipt of the shipment. Monicon
Technology cannot be held responsible for shortages not reported within this
period.

Damage to the contents of a shipment should be brought to the attention of the

carrier immediately and a claim filed.

All subsequent correspondence with Monicon Technology must specify the

equipment part number and serial numbers.

1-2 Controller Installation

The controller should be subjected to a minimum of shock and vibration.

Although the controller is, to a great extent, immune to electromagnetic

interference, it should not be mounted in close proximity to radio transmitters or
similar equipment.

The controller requires free air circulation in order to avoid excessive heat build-up
inside the enclosure. Controllers should not be mounted in close proximity to
heaters or any device that might cause excessive heat build-up inside the
controller.

1-3 Installation Of Intelligent Gas Detector

The assemblies should be installed in the hazardous areas in accordance with the
relevant regulations and practices of the country concerned.

The mounting should be as free from shock and vibration as possible, and must
be accessible for calibration purposes.

Detectors should always be mounted pointing down, so as to avoid accumulation

of moisture and particulate deposits.

Various detector accessories are available to minimise the effects of rain, wind
and particulate matter.

Monicon Technology Ltd S-500-English-180400-1 Page 6

1-4 Detector Locations
There are many variables involved in defining the optimum location for a detector.
Obvious though it may sound, the most important rule is:

ð A detector will not detect a gas leak unless that gas actually reaches the
detector!

In addition, the following should be borne in mind:

ð Ensure that the detector is accessible for maintenance and calibration.

ð Ensure that accessories, if required, have sufficient clearance when

fitted.

ð Ensure that prevailing air currents contain maximum gas concentration.

ð Consider possible gas dispersion patterns, bearing in mind the weight of

the gas with respect to air but also that this may not be the only factor
determining dispersion patterns.

ð Any potential leak point should be well covered.

ð Compare the actual environment with the Environmental Specifications

for the particular detector being used.

ð Ensure that detectors are located away from any source of R. F. or any
electromagnetic interference.

1-5 Detector Field Cables

The detector cable should be a three-core (or 3-core plus “twisted pair” if the
RS485 interface is used) stranded, screened cable complying with local
standards. The screen should be enclosed in a suitable insulating outer jacket,
and should be grounded only at the controller end of the cable. Additional cabling
will be required if the voltage free relay contacts are being used. A second cable
entry is provided for relay connections. The correct cable gland should be used
for the entries provided.

Care should be taken, particularly at the detector end, that the screen does not
come into contact with any metal conduit or junction box. Avoid running detector
cables close to high power cables, radio transmission lines or cables subject to
pulses of high current.

If the detector is being installed in a hazardous environment, the relevant

requirements for hazardous area apparatus must be observed at all times.

Monicon Technology Ltd S-500-English-180400-1 Page 7

1-6 Caution Note
Caution should be exercised when working on the terminations of a "live" system
as externally applied high voltages may be present on the relay terminations.

1-7 Initial Power Up

On initial application of power, the controller will initialise its "Power-Up" mode for
a period as determined by the user-selectable Power-Up variable. Power-Up
mode is indicated by the STATUS display displaying "PU" while the %LEL display
indicates the time remaining (in seconds).

The Power-Up display appears as follows:

When the Power-Up period has expired The STATUS display should change to
"OK" and the %LEL display will indicate gas concentration.
The “OK” display appears as follows:

When the Power-Up period has expired, should the STATUS display not indicate
"OK", a possible fault condition exists and this should be investigated.

1-8 Maintenance
When installed correctly, systems require very little maintenance other than
regular calibration and inspection.

Monicon Technology recommends that the system be re-calibrated 3 weeks after

installation and then at least every 6 months and even more frequent calibration
may be desirable.

ð The entire system, including any peripheral circuitry, should be checked

at least annually. An annual check should include at least the following
and individual plant layout will dictate exact checkout procedure.

ð Ensure that detector heads are always positioned effectively with respect
to surrounding plant, equipment and potential sources of gas leaks.

ð Ensure that detector heads have not been contaminated by any foreign
matter.

ð Ensure that detector accessories have not been damaged or

contaminated.

ð Ensure that cables and connections are intact and in good condition.

ð Ensure that the complete system will operate as it would be expected to

in a real gas leak situation including peripheral alarm circuitry
annunciators and backup battery (if fitted).

Monicon Technology Ltd S-500-English-180400-1 Page 8

 Operating Instructions

2-1 CAL Magnetic Switch

The CAL magnetic switch is positioned under the word CAL on the front panel
decal. It is activated by placing a magnet over the word CAL. Activating the CAL
magnetic switch places the S-500 in calibration mode. In calibration mode, the
alarm relays are inhibited, the analogue output is set to 2mA and the CAL bit is set
on the status register. In calibration mode, the STATUS display indicates “CA” as
follows:

2-2 SET Magnetic Switch

The SET magnetic switch is positioned under the word SET on the front panel
decal. It is activated by placing a magnet over the word SET. Activating the SET
magnetic switch in calibration mode causes the system to enter SYSTEM SETUP
mode and allows for the setting of various parameters. For further details, please
refer to section 3.

2-3 é Magnetic Switch

The é magnetic switch is positioned under the é symbol on the front panel decal.
It is activated by placing a magnet over the é symbol. Activating the é magnetic
switch increments variables in SYSTEM SETUP mode.

2-4 ê Magnetic Switch

The ê magnetic switch is positioned under the ê symbol on the front panel decal.
It is activated by placing a magnet over the ê symbol. Activating the ê magnetic
switch decrements variables in SYSTEM SETUP mode.

2-5 STATUS Display

The STATUS display is a 2-digit display used in conjunction with the %LEL display
to indicate instrument status in its various modes.

2-6 %LEL Display

The %LEL display is used primarily as a readout of gas concentration.
Additionally, the %LEL display is also used to display various parameters being
set during system setup (refer to System Setup section) and also as a fault
indicator in the event of a system error (refer to Trouble Shooting section).

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2-7 General Operation
In normal operation, the STATUS display will indicate "CH" to indicate "Channel
Healthy", while the %LEL display will indicate the gas concentration at the sensor,
in % LEL, (i.e. % Lower Explosive Level) as follows:

If the concentration of gas at the sensor reaches 100% LEL, the STATUS display
will change to "OR" (Over-Range) and the %LEL display will indicate "99":

To comply with the requirements of various international standards (including

BS6020 and EN50057), this over-range condition will latch. This latched condition
will be maintained until the CAL switch is activated.

ð A latched over-range should not be reset until it is verified that the gas
concentration has dropped below 100% LEL.

Monicon Technology Ltd S-500-English-180400-1 Page 10

 Section 3 System Setup
3-1 Entering System Setup Mode
System Setup provides the facility to change certain system variables. System
Setup Mode is accessed as an extension on CAL Mode. CAL Mode is accessed
by momentarily activating the CAL magnetic switch. In CAL Mode the %LEL
display flashes. CAL Mode merely inhibits the Alarm relays and provides for
easier calibration by displaying negative values preceded with a "-" symbol.

While in CAL Mode, System Setup Mode may be invoked by momentarily

activating the SET magnetic switch under the front panel.

3-2 A1 Alarm Setpoint

Activating the SET magnetic switch presents the A1 Alarm setpoint variable. The
STATUS display indicates A1 while the %LEL display indicates the current A1
alarm setpoint, for example:

This setpoint can be incremented by activating the é magnetic switch or

decremented by activating the ê magnetic switch.

3-3 A2 Alarm Setpoint

Activating the SET magnetic switch presents the A2 Alarm setpoint variable. The
STATUS display indicates A2 while the %LEL display indicates the current A2
alarm setpoint, for example:

This setpoint can be incremented by activating the é magnetic switch or

decremented by activating the ê magnetic switch.

3-4 A3 Alarm Setpoint

Activating the SET magnetic switch presents the A3 Alarm setpoint variable. The
STATUS display indicates A3 while the %LEL display indicates the current A3
alarm setpoint, for example:

This setpoint can be incremented by activating the é magnetic switch or

decremented by activating the ê magnetic switch.

Monicon Technology Ltd S-500-English-180400-1 Page 11

3-5 ZERO setting
Activating the SET magnetic switch again presents the ZERO variable. To correct
the ZERO variable, first ensure that the sensor is in clean air.

Then if the %LEL display does not indicate 0, the reading can be incremented by
activating the é magnetic switch or decremented by activating the ê magnetic
switch.

3-6 SPAN setting

Activating the SET magnetic switch again presents the SPAN variable. To correct
the SPAN variable, first apply 50% LEL gas to the sensor.

Then if the %LEL display does not indicate 50, the reading can be incremented
by activating the é magnetic switch or decremented by activating the ê magnetic
switch.

3-7 Alarm Relays Energised/de-Energised

Activating the SET magnetic switch again presents the Alarm Relays
Energised/deEnergised variable. The STATUS display indicates "AR" while the
%LEL display indicates the current setting. Activating the ê switch selects
normally Energised relays as follows:

Activating the é switch selects normally deEnergised relays as follows:

The Alarm Relay contacts are Normally Open (NO) contacts. If deEnergised is
selected for the Alarm Relays, the relay contacts will be open circuit if there is no
gas alarm and will be short circuit if there is a gas alarm. The reverse will apply if
Energised Alarm Relays are selected.

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3-8 RS485 Address
Activating the SET magnetic switch again presents the RS485 address variable.
Each S-500 on a loop must have a unique address. This address may be
between 0 and 99. The STATUS display indicates “AD” while the %LEL display
indicates the current RS485 address. Activating the é switch increments the
RS485 address while activating the ê switch decrements the RS485 address:

⇒ It should be noted that the RS485 address should not be changed

remotely but should only be changed locally via the magnetic switches.

⇒ It should also be noted that the same RS485 address must not be used
on two S-500’s sharing the common RS485 interface. If the RS485
address is not unique, bus contention will occur and remote access will
not be possible, however, local operation will not be affected.

3-9 Hardware Adjustments

During routine checking and re-calibration, it is not necessary to make any
hardware adjustments on the S-500. In fact, it is not even necessary to remove
the cover of the S-500 as the S-500’s microprocessor can be instructed to make
the necessary calibration changes by activating the magnetic switches through the
glass panel.
However, if it becomes necessary to replace the sensor, certain hardware
adjustments may be necessary. On PCB CA0C05, the V-SENS potentiometer
allows the sensor voltage to be adjusted to 2.05V ±0.05V. The ZERO and SPAN
potentiometers allow hardware pre-setting of the ZERO and SPAN parameters
respectively. This is only necessary when replacing the sensor or re-calibrating
for a different gas. Activating the SET switch again displays the actual hardware
value:

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3-10 Overrange Latching
To comply with the requirements of British Standard BS6020 and European Norm
EN50057, an Overrange Latching facility has been incorporated in the S500
(Refer to section 2-7 for further details). However, under certain circumstances it
may be desirable to disable the Overrange Latching facility.
It must be cautioned that disabling the Overrange Latching facility will
render the S500 non-compliant with BS6020 and EN50057 and is not
recommended. No responsibility can be accepted for the consequences of
disabling the Overrange Latching facility.
Activating the SET switch again displays the current Overrange Latching status.
Activating the é switch turns the Overrange Latch facility ON:

Activating the ê switch turns the Overrange Latch facility OFF:

3-11 Factory Defaults

Persons who are not familiar with the S500 may, in the process of familiarising
themselves with the S500, inadvertently change the factory default settings. A
facility has been incorporated to allow the novice to restore the factory default
settings easily. Activating the SET switch again displays the status of the Factory
Default settings.
Activating the é switch turns the Factory Default settings ON:

Activating the ê switch turns the Factory Default settings OFF:

3-12 Saving System Variables

Saving system variables in non-volatile memory is accomplished by simply
activating the CAL switch in CAL mode. If no variables were changed, the old
settings are retained. The display indicates saving as follows:

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 Section 4 Trouble Shooting/System Diagnostics
The S-500’s advanced software continually monitors the system's performance
and functionality. In fact, a self check is performed twice every second. The self
check examines the integrity of the systems electronic circuitry, system software
and sensor. The supply voltage is also monitored. The system even verifies the
system variables when they are written to non-volatile memory.

All of this checking is done automatically in a manner that is fully transparent to

the operator. However, in the unlikely event of a problem, the system enters a
special diagnostic mode with a user-friendly diagnostic display to identify the
nature of the fault.

To assist the operator in identifying a potential problem, the STATUS display

indicates an error by displaying "ER" while the %LEL display indicates the nature
of the fault.

The following is an explanation of the possible problems that the system may
identify:

4-1 Error: Supply Voltage Low

If the supply voltage goes below a safe level for the instrument to function
correctly, the following display indication appears:

4-2 Error: Sensor Signal Low

If the sensor signal goes below a predefined level, the following display indication
appears:

This error indication may be due to any of several causes as follows:

Ø Negative zero drift on sensor

Ø Faulty sensor
Ø Sensor connection fault

4-3 Error: Sensor Current Low

If the sensor signal goes below a predefined level, the following display indication
appears:

Monicon Technology Ltd S-500-English-180400-1 Page 15

4-4 Error: Electronic Component Fault
As previously mentioned, the S-500 is continually self-checking its own
electronics, software and sensor. In the unlikely event of the failure of a key
electronic component failure, the operator may be alerted with a display indication
of "ER EL" as follows:

4-5 Error: EEPROM Write

The S-500 runs three memory systems in parallel. The system program is stored
in ROM (Read Only Memory). This information cannot be altered by the operator
as it is permanently stored by Monicon Technology at the factory. Another type of
memory, RAM (Random Access Memory) is used by the microprocessor as short
term storage for data that is constantly changing. However, RAM 'forgets' its
contents if the power is removed.

A third type of memory is also used by the S-500. This is called EEPROM
(Electrically Erasable Programmable Read Only Memory). EEPROM provides
permanent data storage but the data can be erased and new information written.
EEPROM is used to store the system variables during system setup. However,
EEPROM is very slow and the software required to store and retrieve information
from EEPROM is very complex. Because of this, certain occurrences of electrical
interference may corrupt the data while it is in the process of being written to the
EEPROM.

To ensure 100% data integrity, after the S-500 writes information to the EEPROM,
it reads it back again to verify that the stored information is correct. If the
information read back differs from the information written, then the display
indicates "ER EP" as follows:

If this error occurs, simply activate the CAL switch twice and the S-500 will make a
further attempt to write the system variables to the EEPROM.

4-6 Error: Software

As previously mentioned, the S-500 checks its software. In the unlikely event that
a software error is discovered, the display indicates "ER SO" as follows:

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 Section 5 S-500 Terminations

DB DA COM AO+ +24V

A1 Relay A2 Relay

REF JNC ACT

5-1 Power Supply Connections (+24V, COM)

The S-500 operates from a nominal 24VDC supply. This voltage may be in the
range 20VDC - 35VDC. The +24VDC is applied to the B+ terminations while the
return (0V) is applied to the 0V terminations

5-2 Analogue Output (AO+, COM)

The analogue output terminations provide an "industry standard" 4-20mA current
signal proportional to gas concentration. 4.0mA equates to zero gas while
20.0mA equates to full scale. Calibration or System Setup modes are indicated by
a 2.0mA signal while a fault is indicated by a 0.0mA Signal. The tolerance on the
analogue output signal is ±0.3mA. The maximum load resistance is 500Ω.

5-3 RS485 Connections (DA, DB)

The S-500’s RS485 interface connections appear on terminals DA and DB. When
connecting these to the common twisted pair, care should be taken to ensure that
DA and DB are not transposed. They are antiphase signals and are not
interchangeable. It is not essential to fit termination resistors. DA and DB may be
connected to the common RS485 twisted pair by a 2-core screened cable if
desired. Alternatively, the entire RS485 bus may be a 2-core screened cable.

Monicon Technology Ltd S-500-English-180400-1 Page 17

5-4 Alarm 1 Relay Contact (A1 Relay)
In the event of Alarm 1 activation, the A1 relay contact will operate. The A1 relay
may be normally de-energised or normally energised as programmed during
System Setup mode. The A1 relay contact is rated 500mA @ 125VAC and is
open when de-energised and closed when energised. The Alarm 1 relay contacts
are Normally Open (NO).

5-5 Alarm 2 Relay Contact (A2 Relay)

In the event of Alarm 2 activation, the A2 relay contact will operate. The A2 relay
may be normally de-energised or normally energised as programmed during
System Setup mode. The A2 relay contact is rated 500mA @ 125VAC and is
open when de-energised and closed when energised. The Alarm 2 relay contacts
are Normally Open (NO).

5-6 Sensor Connections (REF, JNC, ACT)

The S-500 has been designed to operate with the Monicon CGS500 combustible
gas sensor. The terminals REF, JNC and ACT coincide with the nomenclature of
the CGS500 sensor leads as follows:

Terminal Colour
REF Black
JNC Grey
ACT Red

ð Special conditions for safe use

The sensor assembly does not incorporate an external earthing facility. lt is
the responsibility of the user to ensure adequate earth bonding via the
mounting arrangements.

The flying leads must be protected against mechanical damage and be

terminated in an enclosure suitable for the conditions of use.

Monicon Technology Ltd S-500-English-180400-1 Page 18

 Section 6 RS485 Communication Interface
6-1 General Description
The S-500’s RS485 communication interface allows the S-500 to be interrogated
and some options programmed by a remote computer. Up to 100 S-500’s may be
connected to the same RS485 interface.

Each S-500 operates in polled slave mode. This means that the S-500 cannot
initiate a communication, it can only respond when addressed by the master
computer. The master computer broadcasts an address, a command code, a
variable field and a checksum. The addressed S-500 then responds with its
identification, a response identifier, a variable field and a checksum.

To reduce the effect of interference from external electrical signals the RS485
interface uses a differential signal over a “twisted pair” cable. To further reduce
the effects of interference, a low Baud rate of 2400 Baud is used. Finally, each
communication is accompanied by a checksum. The use of a checksum ensures
that if data corruption does occur, the information is disregarded and the
information is transmitted again.

6-2 Timing Sequences

The following timing diagram indicates the computer broadcast sequence:

The following timing diagram indicates the S-500 broadcast sequence:

It will be noted that D7 is always set on the address frame but always cleared on
other frames. This allows the S-500 to differentiate between address frames and
other frames.

The checksum is derived from the arithmetic sum (truncated to the least
significant 7 bits) of the previous data.

Computer CKS = (ADDD0-D6) +(CMDD0-D6) + (VARD0-D6)

S-500 CKS = (IDD0-D6) +(RESD0-D6) + (VARD0-D6)

Monicon Technology Ltd S-500-English-180400-1 Page 19

6-3 Command Codes
The following chart indicates command and response codes.

Status Hex Dec Description Range

ü 00 00 Report gas concentration 0-99
ü 01 01 Report A1 setpoint 0-99
ü 02 02 Report A2 setpoint 0-99
ü 02 03 Report A3 setpoint 0-99
ü 04 04 Report FAULT flags, frame #1 D0-D6
û 05 05 Report FAULT flags, frame #2 D0-D6
û 06 06 Report CAL status register 0-127
û 07 07 Report magnetic switch register D0-D3
û 08 08 Report analogue output register 0-127
û 09 09 Report digit #1 register ASCII 0-127
û 0A 10 Report digit #2 register ASCII 0-127
û 0B 11 Report digit #3 register ASCII 0-127
û 0C 12 Report digit #4 register ASCII 0-127
û 0D 13 Report sample rate 0-127
û 0E 14 Report maximum memory register 0-99
û 0F 15 Report power up register 0-127
ü 10 16 Report supply voltage register 0-127
û 11 17 Report status register #1 D0-D6
û 12 18 Report status register #2 D0-D6
û 13 19 Reserved -
û 14 20 Reserved -
ü 20 32 Set A1 setpoint absolute 0-99
ü 21 33 Set A2 setpoint absolute 0-99
ü 22 34 Set A3 setpoint absolute 0-99
û 23 35 Set CAL status register D0-D6
û 24 36 Override analogue output register 0-127
û 25 37 Override digit #1 register ASCII 0-127
û 26 38 Override digit #2 register ASCII 0-127
û 27 39 Override digit #3 register ASCII 0-127
û 28 40 Override digit #4 register ASCII 0-127
û 29 41 Set sample rate 0-127
û 2A 42 Set timeout 0-127
û 2B 43 Set status register #1 D0-D6
û 2C 44 Set status register #2 D0-D6

The Status column indicates valid commands for the S-500 by the symbol ü.
Invalid commands for the S-500 are indicated by the symbol û. The complete
command set has been listed for compatibility with other instruments in the range
and for future extensions to the software.

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6-4 Fault Flags
The following charts list the S-500 fault flags:

Fault Flags, Frame #1

Flag Set Clear
D0 Supply voltage low Supply voltage OK
D1 Sensor signal fault Sensor signal OK
D2 Analogue output fault Analogue output OK
D3 Electronic component fault Electronic components OK
D4 EEPROM fault EEPROM OK
D5 Software fault Software OK
D6 Sensor current fault Sensor current OK

Fault Flags, Frame #2

Flag Set Clear
D0 RS485 framing error RS485 framing OK
D1 RS485 checksum error RS485 checksum OK
D2 RS485 CRC error RS485 CRC OK
D3 RS485 parity error RS485 parity OK
D4 RS485 command error RS485 command OK
D5 RS485 value out of range RS485 value OK
D6 Reserved Reserved

6-5 CAL Status Register

The following chart lists the S-500 CAL status register values:

CAL Status Register Values

Value Description
00 Normal mode (i.e. not in CAL mode)
01 Setting A1 setpoint
02 Setting A2 setpoint
03 Setting A3
04 Setting ZERO
05 Setting SPAN
06 Setting relay energy status
07 Viewing hardware readings
08 Setting RS485 address
09 Reserved
10 Reserved
11 Reserved
12 Reserved
13 Reserved
14 Reserved
15 Reserved

Monicon Technology Ltd S-500-English-180400-1 Page 21

6-6 Magnetic switch register
The following chart lists the magnetic switch status register:

Magnetic Switch Status Register

Flag Set Clear
D0 SET magnetic switch inactive SET magnetic switch active
D1 é magnetic switch active é magnetic switch inactive
D2 CAL magnetic switch active CAL magnetic switch inactive
D3 ê magnetic switch active ê magnetic switch inactive
D4 Reserved Reserved
D5 Reserved Reserved
D6 Reserved Reserved

6-7 ASCII character codes for digits #1 to #4

The following chart lists the ASCII character HEX codes for digits #1 to #4:

LS
MS 0 1 2 3 4 5 6 7 8 9 A B C D E F
0 ì é è ê ç ¿ à Ø ø ò ù Ñ ç ê É é
1 è Æ æ Å å Ä ä Ö ö Ü ü °C °F ß £ ¥
2 ! “ # $ % & ‘ ( ) * + , - . /
3 0 1 2 3 4 5 6 7 8 9 : ; < = > ?
4 @ A B C D E F G H I J K L M N O
5 P Q R S T U V W X Y Z [ \ ] ^ _
6 ` a b c d e f g h I j k l m n o
7 p q r s t u v w x y z { | } ~

6-8 Status Register Flags

The following chart lists the S-500 status register flags:

Status Register Flags, Frame #1

Flag Set Clear
D0 A1 Alarm On (read only) A1 Alarm Off (read only)
D1 A2 Alarm On (read only) A2 Alarm Off (read only)
D2 A3 Alarm On (read only) A2 Alarm Off (read only)
D3 Alarm Relays Energised Option Alarm Relays de-Energised Option
D4 A1 Enrichment Option A1 Deficiency Option
D5 A2 Enrichment Option A2 Deficiency Option
D6 A3 Enrichment Option A3 Deficiency Option

Monicon Technology Ltd S-500-English-180400-1 Page 22

 Section 7 System Specification
7-1 Environmental Specification
Power-up variation: <3% FSD within 5 minutes
Storage temperature: -40°C to + 66°C
Operating temperature: -18°C to + 66°C
Temperature variation : <5% FSD
Humidity Range: 20 to 90% RH (non-condensing)
Humidity variation: <3% FSD (20 to 90% RH)
Pressure Variation: <3% FSD from 950mB to 1100mB

7-2 Mechanical Specification

Diameter: 100mm (Excluding sensor and cable gland)
Depth: 100mm
Weight: 1.8kg (including sensor)
Mounting Holes: 2 holes, Ø8.0mm, spaced at 82.5mm

7-3 Electrical Specification

Supply voltage: 20 - 35 V DC
Power consumption: 2.0W normal, 2.3W maximum
RS485 comm parameters: HDX, 2400-N-8-1
Max. units on RS485 loop: 100
Unit interrogation time: 40mS
Relay contacts: SPST, 125V @ 0A5 (30V DC @ 1A) each for A1 & A2
Analogue Output: 4-20mA into max. 500 Ohms
Full-Scale range: 0 - 100% LEL
Stabilisation time: 30 seconds
Transient Protection: PCB mounted, 7 Joule, Metal Oxide Varistor
Terminations: Detachable terminal blocks to accept 1.5mm2 cable
Resolution: 1%
Accuracy: 5%

7-4 Cable Specification

Depending on facilities required, various cable types may be used. The maximum
permissible power cable resistance is 10Ω per line (i.e. 20Ω loop resistance). This
would result in cable runs as outlined in the following chart:

Cable Size Maximum Cable Length

0.75mm2 365 Meters
1.00mm2 475 Meters
1.50mm2 735 Meters
2.50mm2 1350 Meters

A screened, multicore cable may be user to carry power, analogue output and
RS485 signals. For power and analogue output a 3-core screened cable will be
required. For power, analogue output and RS485 a 5-core screened cable will be
required. Ideally, the RS485 should be a twisted pair or alternatively should be
separately screened.

Monicon Technology Ltd S-500-English-180400-1 Page 23

Section 8: User Information
8-1 Wiring Diagram
RS485 Twisted Pair (or Screened Pair)

Chart Recorder
0V
PSU
+24V

DB DA COM AO+ +24V

A1 Relay A2 Relay

REF JNC ACT

Load Load
125V AC Max 125V AC Max
500mA Max Black
500mA Max
Grey

Red

CGS500

8-2 Dimensional Drawing

Monicon Technology Ltd S-500-English-180400-1 Page 24

 Monicon Technology Ltd

Gas Sensor, Model CGS500

Installation Instructions and Conditions for Safe Use

This Gas Sensor carries the following Hazardous Area approvals

EEx d IIC T6
II 2 G BAS00ATEX2246X
It is designated Category 2 Equipment and is suitable for installation in Zone 1 Hazardous
Areas with Apparatus Group II. The sensor carries a Temperature Classification (T Rating) of
T6, which means that no surface temperature of the sensor will exceed 85ºC when in service.

The sensor must be fitted into an appropriately rated terminal box or conduit and must not be
removed while the connected circuits are energised.

The sensor assembly does not incorporate an external earthing facility. lt is the responsibility
of the user to ensure adequate earth bonding via the mounting arrangements. The flying
leads must be protected against mechanical damage and be terminated in an enclosure
suitable for the conditions of use.

The sensor has 3 flying leads identified by colour as follows:

Wire Colour Description Abbreviation
Red Active element connection ACT
Grey Junction connection JNC
Black Reference element connection REF

The maximum voltage for safe operation is 3V while the maximum current for safe operation
is 400mA. Note that the maximum operating voltages and currents may be lower. The
following table lists values for the more common elements.

Element type Maximum Maximum

Operating voltage operating current
300P 2.05V 300mA
300N 2.05V 300mA
CAT16 2.70V 200mA
VQ41 2.05V 300mA

The sensor does not contain any user serviceable parts or adjustments. Under no
circumstances should the sensor assembly be opened.

M42 x 1.5 thread

M25 x 1.5 thread

Red (ACT)
Grey (JNC)
Black (REF)

Registration No. 131229 VAT No. IE4766556J

CGS500-INST-REV02