Operating Instructions

System 57
5704 Control System
MAN0448_Issue 13_01-2010 5704 Control System
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Total Environmental Solutions

Ensure that you read and understand these instructions BEFORE
operating the equipment.

Please pay particular attention to the Safety Warnings.

WARNINGS
The items of equipment covered by this manual are:

1. Not designed or certified for use in hazardous areas.

2. Designed for indoor use only.

3. Not to be exposed to rain or moisture.

CAUTIONS

1. Use only approved parts and accessories with the 5704 Control
System.

2. To maintain safety standards, regular maintenance, calibration

and operation of the 5704 Control System by qualified personnel
is essential.

IMPORTANT NOTICES

1. Honeywell Analytics Limited can take no responsibility for installation

and/or use of its equipment if this is not done in accordance with
the appropriate issue and/or amendment of the manual.

2. The user of this manual should ensure that it is appropriate in all

details to the exact equipment to be installed and/or operated. If
in doubt, the user should contact Honeywell Analytics Limited for
advice.

Honeywell Analytics Limited reserve the right to change or revise

the information supplied in this document without notice and without
obligation to notify any person or organisation of such revision or
change.

If further details are required which do not appear in this manual, contact
Honeywell Analytics Limited or one of their agents.

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Manual Issue Status

The following table indicates the issue status of this manual and of the
individual chapters within the manual

Issue 13, January 2010

Section Pages File Issue

Front Pages 1 to 6 MAN0448A 13

Chapter 1 1-1 to 1-8 MAN0448B 13
Chapter 2 2-1 to 2-26 MAN0448C 13
Chapter 3 3-1 to 3-22 MAN0448D 13
Chapter 4 4-1 to 4-58 MAN0448E 13

Chapter 5 5-1 to 5-20 MAN0448G 13
Chapter 6 6-1 to 6-12 MAN0448H 13
Chapter 7 7-1 to 7-16 MAN0448I 13
Chapter 8 8-1 to 8-14 MAN0448J 13
Chapter 9 9-1 to 9-4 MAN0448K 13
Chapter 10 10-1 to 10-6 MAN0448L 13

Since the 'Front Pages' of a manual contain the above manual issue
status table these pages will always carry the overall issue status of
the manual. The remaining chapter issues will reflect the latest issue of
those chapters at the time of print of a manual, e.g., Issue A, B, C, etc.,
for chapters of provisional information and 1, 2, 3, etc., for chapters of
confirmed information.

Help us to help you

Every effort has been made to ensure the accuracy in the contents
of our documents, however, Honeywell Analytics Limited can assume
no responsibility for any errors or omissions in our documents or their
consequences.
Honeywell Analytics Limited would greatly appreciate being informed
of any errors or omissions that may be found in our documents. To this
end we include the following form for you to photocopy, complete and
return to us so that we may take the appropriate action.

3
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Manual Contents
Chapter

1. SYSTEM CONCEPT

2. SYSTEM DESCRIPTION

3. CONTROLS AND FACILITIES

4. INSTALLATION INSTRUCTIONS

5. COMMISSIONING AND MAINTENANCE INSTRUCTIONS

6. OPERATING INSTRUCTIONS

7. ENGINEER'S OPERATING INSTRUCTIONS

8. SPECIFICATION

9. ORDERING INFORMATION

10. SPECIAL CONDITIONS FOR SAFE USE ACCORDING TO

EC-TYPE EXAMINATION CERTIFICATE BVS 04 ATEX
G 001 X

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User Notes

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Chapter 1 - System Concept

5704 Series

CONTROL SYSTEM

Chapter 1

System Concept

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Chapter 1 - System Concept

Contents

Section Page

1. PRINCIPAL FEATURES 1-3

2. CONSTRUCTION 1-4

Figures
Figure Page

1. 5704 Control System 1-6

2. 5704 Control System Over View 1-7

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Chapter 1 - System Concept

1. Principal Features
The 5704 Series Control System is part of the System 57 family and is
designed to monitor field mounted industrial gas detectors. The principal
features of the system are:

* Provides up to 64 channels of gas detection in a standard 19'' sub-

rack using a 3U card format.

* Provides up to 32 channels of gas detection in a half 19'' sub-rack

using a 3U card format.

* Racking available for both front and rear access field wiring.

* Simple field connections for wire up to 2.5mm2 (14 AWG).

* Four channels per one inch wide card.

* Control cards removable without disturbing other wiring.

* Catalytic bridge or 4 - 20mA input control card versions.

* Alarm change-over relay output options.

* Optional time delayed operation of alarm relays.

* Multi-alarm mode for master, zoned and voted alarms.

* Rising, falling, STEL, LTEL and update alarm outputs.

* Remote inhibit and reset inputs per card.

* Optional 0 - 20mA or 4 - 20mA isolated monitor outputs per

channel.

* Easy to calibrate and operate using a dedicated Engineering

Card.

* EMC compliant.

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Chapter 1 - System Concept

2. Construction
The system consists of individual 1'' (2.54cm) wide cards fitted to a
rigid custom rack designed to fit Euro rack cabinets. Two rack widths
are available:

a. 19 inch with 17 card slots to house up to 16 Four Channel Control

Cards and an Engineering Card.

b. Half 19 inch with nine card slots to house up to eight Four Channel
Control Cards and an Engineering Card.

Each sub-rack contains an Engineering Card and a DC Input Card to

make up the rack system

The system is designed to meet the differing customer wiring

configurations and to achieve this the control functions are split away
from the relays and field wiring connections. Four channels of gas
detection therefore consists of:

a. Four Channel Control Card

Each Four Channel Control Card functions independently and

contains all the necessary electronic circuitry to provide the sensor
drive, alarm detection and gas level display for four channels of gas
detection.

There are two types of Four Channel Control Cards, one for catalytic
inputs and the other for 4 - 20mA inputs.

b. Quad Relay Interface Card

The Quad Relay Interface Card provides the interface connections

between the Control Card and the respective field connected gas
sensors. In addition, it provides four alarm outputs via the field
connections.

c. Relay Interface Assembly

Where additional relay contacts are required, an Expansion Relay

Card is attached to the Quad Relay Interface Card. The new
assembly becomes the Relay Interface Assembly and expands the
alarm relays to 16. This combination occupies two interface card
slots and as a consequence limits the number of control cards that
can be fitted to the rack.

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Chapter 1 - System Concept

In a system where the field wiring is required to be connected to the rear
of the system, the rack is centrally divided into front and rear sections
by a printed circuit board backplane which provides common signal
routeing between individual Four Channel Control Cards. The control
cards are fitted at the front of the rack while Quad Relay Interface Cards
are fitted directly behind the associated Four Channel Control Card at
the rear of the rack. The control cards and their respective interface
cards are interconnected by a plug and socket arrangement.

In a system where the field wiring is required to be connected to the front

of a system, the Four Channel Control Cards and Quad Relay Interface
Cards are mounted one above the other in a 6U rack. The backplane
printed circuit board still provides the common signal routeing between
the individual Four Channel Control Cards, but short cables at the rear
of the cards connect each control card to their respective Quad Relay
Interface Card.

Simple calibration and checking of the system is carried out using push
buttons on the Engineering Card fitted in each rack. More complex
configuration can be carried out using the RS232 link between the
Engineering Card and an external IBM compatible personal computer
running the engineering interface software.

When a Relay Interface Assembly is used, the resultant four channel

control assembly then takes up two card slots.

A mixture of 5704 and 5701 Control Cards may be fitted in the same
System 57 rack.

The 5704 Control System is shown in Figure 1.

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Chapter 1 - System Concept

Sub Rack
Interface Section Control Card Section - RFI Protected

Quad Relay Four Channel

Interface Card * Control Card
Sensors

Quad Relay Four Channel

Interface Card * Control Card
Sensors

Expansion Relay Front Panel

Card Blanking Panel

Optional Alarm
Alarm Update Update Panel
MODBUS or
Printing Output

Option Module
DC Input Card *
Engineering
Card Backplane
8/16-Way
Interface
AC to DC PSU

RS232

* Interconnecting Cable for

Front Access Racks. PC, Printer or
Engineering Key

Figure 1 5704 Control System

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Chapter 1 - System Concept

Front Access
8 or 16-Way

Quad Relay
Interface Card
4 x DC Input Engineering
Sensor Card Card

4 x Relay

Analogue
Output
Modules

MODBUS
Interface
Blank
OR Module
Panels

Relay Interface Master Alarm

Assembly 4 x Update Module
Sensor Event Print Module

16 x Relay

Four
Channel
Control
Cards

Rear Access
8 or 16-Way

Figure 2 5704 Control System Over View

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Chapter 2 - System Description

5704 Series

CONTROL SYSTEM

Chapter 2

System Description

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Chapter 2 - System Description

Contents
Section Page

1. INTRODUCTION 2-3

2. RACKS 2-4

3. CABINETS 2-6

4. FOUR CHANNEL CONTROL CARDS 2-8

4.1 General 2-8

4.2 Control Functions 2-9
4.3 Analogue Output Module 2-9
4.4 Physical Layout 2-10

5. QUAD RELAY INTERFACE CARD AND RELAY
INTERFACE ASSEMBLY 2-11

5.1 General 2-11

5.2 Quad Relay Interface Card 2-11
5.3 Relay Interface Assembly 2-14
5.4 Expansion Relay Card 2-17

6. ENGINEERING CARD 2-18

7. DC INPUT CARD 2-19

7.1 General 2-20

7.2 DC Input Card Rear Access Connections 2-21
7.3 DC Input Card Front Access Connections 2-22

8. AC TO DC POWER SUPPLY UNITS 2-23

8.1 Types of Power Supply Unit 2-23

8.2 Power Supply Unit Upgrades 2-23
8.3 Power Supply Connections 2-23
8.4 8-Way AC to DC Power Supply Unit Layout 2-24
8.5 16-Way AC to DC Power Supply Unit Layout 2-24
8.6 50W Sub-Unit Layout 2-25
8.7 100W Sub-Unit Layout 2-25

9. FRONT PANEL BLANKING PANEL 2-26

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Chapter 2 - System Description

1. INTRODUCTION
The 5704 Series Control System is a microprocessor based system
which displays the reading and status of connected gas detectors.
The system provides complex alarm handling facilities with a full
maintenance capability.

A rack system is fitted with a number of Four Channel Control Cards

each with an associated Quad Relay Interface Card which provides the
necessary sensor input and optional relay output connections. A Relay
Interface Assembly may be used to expand the number of relay outputs
available for each of the Four Channel Control Cards. Simple alarm
handling and operation is provided by each channel control card.

Complex alarm handling is achieved by communication between a

specified number of control cards via the backplane of the rack.

An Engineering Card is fitted to each rack and provides control of

the rack backplane communications, control card interrogation and
facilitates maintenance.

In small systems power supplies, auxiliary power supplies and battery

back up systems can be connected to the rack via a DC Input Card. In
heavily populated installations of more than eight Four Channel Catalytic
Control Cards, power supplies are connected to each individual Four
Channel Catalytic Control Card via its interface card.

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Chapter 2 - System Description

2. Racks
Each rack assembly contains a sub-rack, Engineering Card, DC Input
Card, key kit and where necessary an interconnecting cable.

Dependent upon configuration, the control system is housed in one of

four standard size sub-racks as follows:

a. Full 19 inch wide by 3U high - Part Number 05701-A-0511,

for rear field wiring connections.

b. Full 19 inch wide by 6U high - Part Number 05701-A-0501,

for front field wiring connections.

c. Half 19 inch wide by 3U high - Part Number 05701-A-0512,

for rear field wiring connections.

d. Half 19 inch wide by 6U high - Part Number 05701-A-0502,

for front field wiring connections.

All four versions have two separate chambers. One is sealed against
electromagnetic interference and contains the control cards while the
other chamber contains the relay interface cards. A backplane between
the two chambers provides a path for signal routeing between individual
control cards and the Engineering Card.

Typical Eight Card Rear Access Rack - Front View

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Chapter 2 - System Description

Typical Eight Card Rear Access Rack - Rear View

Typical Eight Card Front Access Rack

(Relay/Interface Chamber Front Cover Removed)

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Chapter 2 - System Description

3. CABINETS
Two wall mounted cabinets are used to house:

a. the full width 16 card front access rack,

(Part Number 05701-A-0451)

b. or the eight card half width front access rack.

(Part Number 05701-A-0452)

A front door on each cabinet provides security and dust protection, while
a clear panel in the door allows the channel card displays to be viewed
when the door is closed. The base of each cabinet contains a selection
of preformed knockout cable gland entries. A removable plate is fixed
to the inside of the cabinet for mounting accessories.

Cabinet

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Chapter 2 - System Description

Eight Card Cabinet Installation

Blanking Panel

8-Way AC to DC Power Supply Unit

Control Cards and Engineering Card

Interface/Relay Cards and DC Input Card

Accessory Plate suitable for mounting DIN rails,

circuit breakers, relays, etc.

16 Card Cabinet Installation

Blanking Panel

16-Way AC to DC
Power Supply Unit

Control Cards
and Engineering Card

Interface/Relay Cards
and DC input Card

Accessory Plate suitable

for mounting DIN rails,
circuit breakers, relays, etc.

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Chapter 2 - System Description

4. FOUR Channel Control Cards
4.1 General

The 5704 Four Channel Control Card provides

control, display and alarm facilities for up to four
connected gas detectors. The front panel backlit
display indicates the gas reading, channel status
and channel number while LEDs are used for
alarms. A push-button is provided for resetting
the alarms and selecting the card for use with
the Engineering Card.

The operation of the control card is microprocessor

controlled and is fully definable for a wide range
of connected gas detectors and application
requirements. The software configuration setup
is stored in an EEPROM.

There are two types of control card depending

on the type of gas detector being fitted to the
system:

a. Four Channel Control Card Catalytic Input

Part Number 05704-A-0144.

b. Four Channel Control Card 4 - 20mA Input

Part Number 05704-A-0145.

Optional Analogue Output Modules which provide

a remote output of the channel card readings can
be plugged into the Four Channel Control Card.
One module is required per channel and different
module types are available to permit either
current source or current sink as required.

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Chapter 2 - System Description

4.2 Control Functions

The Four Channel Control Card carries out the control functions for up
to four loops of gas detection as follows:

a. Provides the necessary voltages and currents to drive the connected

sensors.

b. Processes the incoming sensor signals.

c. Displays the signal levels, one at a time, on the front panel liquid
crystal display.

d. Compares each channel signal level with pre-defined alarm limits.

e. When the pre-defined alarm limits are exceeded, raises the alarms
by lighting up front panel LEDs and operating connected relays.

f. Informs other cards with the alarm status information.

g. Self validates the operation of its circuit components, software

operation and the condition of the sensor.

4.3 Analogue Output Module

Optional Analogue Output Modules may be factory fitted to the Four

Channel Control Card and are used on each channel of gas detection
to provide a current loop output which follows the sensor signal level.
This may be set electronically to produce a 0 - 20mA output or a 4 -
20mA output and can be used to operate a chart recorder, data logger,
PLC, etc. Two versions are available:

a. Analogue Output Module, Current Sink

Part Number 04200-A-0145

b. Analogue Output Module, Current Source

Part Number 04200-A-0146

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Chapter 2 - System Description

4.4 Physical Layout

The physical layout of the Four Channel Control Card is shown below.
Analogue Output Modules, when fitted, plug into channel sockets as
shown:
LK1 fitted to pins 1 - 2 Identification Label

4 CHANNEL
Liquid Crystal CONTROL CARD
Display 05704-A-0144 Iss.
CATALYTIC INPUT

Ser/Batch No.

32-Way Connector (SK2)

To Backplane

LEDs
26-Way D Type Connector (SK1)
To Quad Relay Interface Cards
Reset/Select
Push Button
Switch

Plug-in Sockets for Analogue Output Modules

(From left to right - Channel 1 2 3 4)

LK1 fitted to pins 1 - 2 Identification Label

4 CHANNEL
CONTROL CARD
Liquid Crystal 05704-A-0145 Iss.
Display 4 - 20mA LOOP INPUT

Ser/Batch No.

32-Way Connector (SK2)

To Backplane

LEDs 26-Way D Type Connector (SK1)

To Quad Relay Interface Cards
Reset/Select
Push Button
Switch

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Chapter 2 - System Description

5. Quad Relay Interface Card and Relay
Interface Assembly
5.1 General

The Quad Relay Interface Card provides the interface between a Four
Channel Control Card and the field wiring.

An Expansion Relay Card can also be factory fitted to the Quad Relay
Interface Card and the resultant assembly is then known as the Relay
Interface Assembly. This assembly is used to expand the standard four
relays available for alarms on the Quad Relay Interface to 16 relays.

5.2 Quad Relay Interface Card (Part Number 05704-A-0121)

5.2.1 General

Provides connections between the four sensors and the control card.
In addition, four single pole relays provide voltage free contact outputs
that can be configured for the A1 alarm level, A2 alarm level, A3 alarm
level, fault or inhibit conditions and as individual alarms or master
alarms. Connections for power, remote inputs and analogue outputs
are also provided.

The front and rear access connections are shown in Sections 5.2.2 and
5.2.3 respectively while the physical layout is shown below:

Expansion
Relay Card
Connector J1

26-Way D Type
Connector (SK1)
To Four Channel
Control Cards

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Chapter 2 - System Description

5.2.2 Quad Relay Card Rear Access Connections
RL1-NC (Master Fault) 1 2 RL1-NO (Master Fault)

Slot Location Label

RL1-COM (Master Fault) 3 4 RL2-COM (Master A1)

RL2-NC (Master A1) 5 6 RL2-NO (Master A1)
RL3-NC (Master A2) 7 8 RL3-NO (Master A2)
RL3-COM (Master A2) 9 10 RL4-COM (Master A3)
RL4-NC (Master A3) 11 12 RL4-NO (Master A3)
Ground 13 14 Ground
Channel 1 (S) 15 16 Channel 2 (S)
Channel 1 (01) 17 18 Channel 2 (01)
Channel 1 (NS) 19 20 Channel 2 (NS)
Channel 3 (S) 21 22 Channel 4 (S)
Channel 3 (01) 23 24 Channel 4 (01)
Channel 3 (NS) 25 26 Channel 4 (NS)
Analogue 24V 27 28 Analogue 0V
Analogue CH1 29 30 Analogue CH2
Analogue CH3 31 32 Analogue CH4
Remote Reset 33 34 Remote Inhibit
+24V Input 35 36 0V Input

Label for
User Terminal
Reference

1. NC = Normally Closed. NO = Normally Open. COM = Common.

2. Relay contact conditions refer to the no power state of the relay.

3. The functions shown for terminals 1 to 12 are the default functions for
relays RL1 to RL4 only. For other configurations - refer to the configuration
printout.

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Chapter 2 - System Description

5.2.3 Quad Relay Card Front Access Connections

Label for
User Terminal
Reference

0V Input 36 35 +24V Input

Remote Inhibit 34 33 Remote Reset
Analogue CH4 32 31 Analogue CH3
Analogue CH2 30 29 Analogue CH1
Analogue 0V 28 27 Analogue 24V
Channel 4 (NS) 26 25 Channel 3 (NS)
Channel 4 (01) 24 23 Channel 3 (01)
Channel 4 (S) 22 21 Channel 3 (S)
Channel 2 (NS) 20 19 Channel 1 (NS)
Channel 2 (01) 18 17 Channel 1 (01)
Channel 2 (S) 16 15 Channel 1 (S)
Ground 14 13 Ground
RL4-NO (Master A3) 12 11 RL4-NC (Master A3)
RL4-COM (Master A3) 10 9 RL3-COM (Master A2)
RL3-NO (Master A2) 8 7 RL3-NC (Master A2)
RL2-NO (Master A1) 6 5 RL2-NC (Master A1)
RL2-COM (Master A1) 4 3 RL1-COM (Master Fault)
RL1-NO (Master Fault) 2 1 RL1-NC (Master Fault)

Slot Location Label

1. NC = Normally Closed. NO = Normally Open. COM = Common.

2. Relay contact conditions refer to the no power state of the relay.

3. The functions shown for terminals 1 to 12 are the default functions for
relays RL1 to RL4 only. For other configurations - refer to the configuration
printout.

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Chapter 2 - System Description

5.3 Relay Interface Assembly (Part Number 05704-A-0131)

5.3.1 General

The following diagrams show the Expansion Relay Card fitted to the
Quad Interface Relay Card to form a Relay Interface Assembly:

Rear Access Front Access Front Access

Front View Front View Top View

Expansion Quad Relay Quad Relay Expansion Expansion Quad Relay

Relay Interface Interface Relay Relay Interface
Card Card Card Card Card Card

1. For details of the Quad Interface Card, see Section 5.2.

2. For details of the Expansion Relay Card, see Sections 5.4.

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Chapter 2 - System Description

5.3.2 Relay Interface Assembly Rear Access Connections

Expansion Quad Relay

Card Card

Slot
Location
Label
Expansion Card Quad Relay Card

Left Left Right

Right
1 RL1-NC (Master Fault) 2 RL1-NO (Master Fault)
3 RL1-COM (Master Fault) 4 RL2-COM (Master A1)
1 RL5-NC (CH1 Fault) 2 RL5-NO (CH1 Fault)
5 RL2-NC (Master A1) 6 RL2-NO (Master A1)
3 RL5-COM (CH1 Fault) 4 RL6-COM (CH2 Fault)
7 RL3-NC (Master A2) 8 RL3-NO (Master A2)
5 RL6-NC (CH2 Fault) 6 RL6-NO (CH2 Fault)
9 RL3-COM (Master A2) 10 RL4-COM (Master A3)
7 RL7-NC (CH3 Fault) 8 RL7-NO (CH3 Fault)
11 RL4-NC (Master A3) 12 RL4-NO (Master A3)
9 RL7-COM (CH3 Fault) 10 RL8-COM (CH4 Fault)
13 Ground 14 Ground
11 RL8-NC (CH4 Fault) 12 RL8-NO (CH4 Fault)
15 Channel 1 (S) 16 Channel 2 (S)
13 RL9-NC (CH1 A1) 14 RL9-NO (CH1 A1)
17 Channel 1 (01) 18 Channel 2 (01)
15 RL9-COM (CH1 A1) 16 RL10-COM (CH2 A1)
19 Channel 1 (NS) 20 Channel 2 (NS)
17 RL10-NC (CH2 A1) 18 RL10-NO (CH2 A1)
21 Channel 3 (S) 22 Channel 4 (S)
19 RL11-NC (CH3 A1) 20 RL11-NO (CH3 A
23 Channel 3 (01) 24 Channel 4 (01)
21 RL11-COM (CH3 A1) 22 RL12-COM (CH4 A1)
25 Channel 3 (NS) 26 Channel 4 (NS)
23 RL12-NC (CH4 A1) 24 RL12-NO (CH4 A1)
27 Analogue 24V 28 Analogue 0V
25 RL13-NO (CH1 A2) 26 RL13-COM (CH1 A2)
29 Analogue CH1 30 Analogue CH2
27 RL14-NO (CH2 A2) 28 RL14-COM (CH2 A2)
31 Analogue CH3 32 Analogue CH4
29 RL15-NO (CH3 A2) 30 RL15-COM (CH3 A2)
33 Remote Reset 34 Remote Inhibit
31 RL16-NO (CH4 A2) 32 RL16-COM (CH4 A2)
35 +24V Input 36 0V Input
33 Ground 34 Ground
35 Not Used 36 Not Used

Label for
User Terminal
Reference

1. NC = Normally Closed. NO = Normally Open. COM = Common.

2. Relay contact conditions refer to the no power state of the relay.

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Chapter 2 - System Description

5.3.3 Relay Interface Assembly Front Access Connections

Quad Relay Expansion

Card Card

Label for
User Terminal
Reference

Quad Relay Card Expansion Card

Left Right
Left Right
36 0V Input 35 +24V Input 36 Not Used 35 Not Used

34 Remote Inhibit 33 Remote Reset 34 Ground 33 Ground

32 Analogue CH4 31 Analogue CH3 32 RL16-COM (CH4 A2) 31 RL16-NO (CH4 A2)

30 Analogue CH2 29 Analogue CH1 30 RL15-COM (CH3 A2) 29 RL15-NO (CH3 A2)

28 Analogue 0V 27 Analogue 24V 28 RL14-COM (CH2 A2) 27 RL14-NO (CH2 A2)

26 Channel 4 (NS) 25 Channel 3 (NS) 26 RL13-COM (CH1 A2) 25 RL13-NO (CH1 A2)

24 Channel 4 (01) 23 Channel 3 (01) 24 RL12-NO (CH4 A1) 23 RL12-NC (CH4 A1)

22 Channel 4 (S) 21 Channel 3 (S) 22 RL12-COM (CH4 A1) 21 RL11-COM (CH3 A1)

20 Channel 2 (NS) 19 Channel 1 (NS) 20 RL11-NO (CH3 A1) 19 RL11-NC (CH3 A1)

18 Channel 2 (01) 17 Channel 1 (01) 18 RL10-NO (CH2 A1) 17 RL10-NC (CH2 A1)

16 Channel 2 (S) 15 Channel 1 (S) 16 RL10-COM (CH2 A1) 15 RL9-COM (CH1 A1)

14 Ground 13 Ground 14 RL9-NO (CH1 A1 13 RL9-NC (CH1 A1)

12 RL4-NO (Master A3) 11 RL4-NC (Master A3) 12 RL8-NO (CH4 Fault) 11 RL8-NC (CH4 Fault)

10 RL4-COM (Master A3) 9 RL3-COM (Master A2) 10 RL8-COM (CH4 Fault) 9 RL7-COM (CH3 Fault)

8 RL3-NO (Master A2) 7 RL3-NC (Master A2) 8 RL7-NO (CH3 Fault) 7 RL7-NC (CH3 Fault)

6 RL2-NO (Master A1) 5 RL2-NC (Master A1) 6 RL6-NO (CH2 Fault) 5 RL6-NC (CH2 Fault)

4 RL2-COM (Master A1) 3 RL1-COM (Master Fault) 4 RL6-COM (CH2 Fault) 3 RL5 - COM (CH1 Fault)

2 RL1-NO (Master Fault) 1 RL1-NC (Master Fault) 2 RL5-NO (CH1 Fault) 1 RL5-NC (CH1 Fault)

Slot
Location
Label

1. NC = Normally Closed. NO = Normally Open. COM = Common.

2. Relay contact conditions refer to the no power state of the relay.

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5.4 Expansion Relay Card

The Expansion Relay Card provides relay expansion for a Four Channel
Control Card and the Quad Relay Interface Card. The Expansion Relay
Card is connected to the Quad Relay Interface Card and provides 12
additional relays, eight of which are single pole changeover and four
are single pole single throw. The relays can be configured for A1, A2,
A3, fault or inhibit alarms and as individual or master outputs.

When the Expansion Relay Card is connected to the Quad Relay

Interface Card, the pair of cards take up two slots of the rack. For this
reason a blank panel has to be fitted to the rack front panel adjacent
to the associated Four Channel Control Card.

The front and rear access connections are shown in Sections 5.3.2 and
5.3.3 respectively while the physical layout is shown below:

Quad Relay Card

Connector J1

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Chapter 2 - System Description

6. Engineering Card Part Number (05701-A-0361)
The Engineering Card is used on a System 57 rack to provide a common
interface that enables the user to perform all the required functions to
commission and operate each fitted control card.

The front panel is fitted with a series of tactile push-buttons for the
operation of various functions, LEDs to provide rack power and
communications status and a mini DIN socket for the connection of a
serial printer, computer or an engineering key. The Engineering Key
is used to unlock functions that can alter the operation of a control
card.

The Engineering Card is always fitted into the right-hand slot of the
rack and provides:
a. Routeing of the 24V dc input from the DC Input
Card to the backplane of the rack.

b. A backplane serial communications controller and

monitor.
c. A time and date reference.
d. An RS232 external engineering interface.
PRINT
e. Depending upon the security level, the operation
of the following rack facilities:
Catalytic sensor head current monitoring and
adjustment.
BEAD mA ALARMS Alarm set point checking, adjustment and
testing.
ZERO SIGNAL
Sensor signal zero adjustment.
SPAN 1ST SPAN
Sensor signal span adjustment and setting of
INHIBIT
sensor life monitoring values.
CLOCK

Sensor line monitoring.

Enabling of control card alarm inhibit.
Checking and adjustment of the system
clock.
f. Self validation of the operation of its circuit
components, software operation and the
backplane communications.
g. A socket for the addition of special modules that
expand the System 57 capabilities.

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One of four optional modules may be fitted to the Engineering Card:

a. Master Alarm Update Module

This facility provides an indication when a new alarm occurs on

any channel in the rack, even if a previous alarm condition already
exists.

b. Event Printing Module

This facility provides time stamped reporting of alarm and fault

events as they occur and system status at predetermined regular
intervals.

c. Modbus Interface Module RS422/485

This facility provides for digital communication between the

System 57 Control System and an external computer system using
the RS422/485 serial data format and the Modbus communication
protocol.

d. Modbus Interface Module RS232

This facility provides for digital communication between the System 57

Control System and an external computer system using the RS232
serial data format and the Modbus communication protocol.

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7. DC Input Card (Part Number 05701-A-0325)
7.1 General

The dc power to the rack can enter the sub-rack via the DC Input Card.
This power may be supplied by the user from an external nominal 24V
dc supply. The dc supply is routed through the Engineering Card and
sub-rack back plane to all cards in the rack and is protected by a fuse on
the DC Input Card. There is a two part terminal block, TB1, to aid removal
of the card without disconnecting each of the connected wires.

To prevent excessive current flow along the rack backplane in

installations where more than eight 5704 Catalytic Cards are used, it is
recommended that the Control Cards are powered via their associated
Quad Relay Interface Card and the DC Input Card used to power the
Engineering Card only.

If required, a stand-by backup battery supply may also be connected

to the auxiliary dc input connections.

The PSU and AUX connections are isolated from each other by
diodes.

The DC Input Card also provides RFI filtering and reverse polarity
protection.

In addition, the DC Input Card provides an interface to the Engineering

Card plug-in modules via TB2. The functions of the six terminals will
vary dependent upon the module fitted. For full details refer to:

a. 05701-M-5006 System 57 Control System

Modbus Interface Option RS485/422

b. 05701-M-5007 System 57 Control System

Event Printing Option RS232

c. 05701-M-5009 System 57 Control System

Alarm Update Option

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7.2 DC Input Card Rear Access Connections

Label for
User Terminal
Reference

TB1
12 +24V In (PSU 1)
11 0V In (PSU 1)
10 +24V In (PSU 2*) or +24V Out (PSU 1)
9 0V In (PSU 2) or 0V Out (PSU 1)
8 +24V In (AUX 1)
7 0V In (AUX 1)
6 +24V In (AUX 2*) or +24V Out (AUX 1)
5 0V In (AUX 2) or 0V Out (AUX 1)
4 +24V Out (Fused)
3 0V Out (Fused)
2 Ground
1 Ground
TB2
6
5
4 For Engineering Card Modules
3 (Functions will vary)
2
1

Slot Location Label

* PSU 1 and PSU 2 (and AUX 1 and AUX 2) must be

compatible with parallel connection.

Note: For 5704 systems with more than eight catalytic control cards, it
is recommended that the dc power is connected direct to each
channels' Quad Relay Card.

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7.3 DC Input Card Front Access Connections

Slot Location Label

TB2
1
2
3 For Engineering Card Modules
(Functions will vary)
4
5
6
TB1
1 Ground
2 Ground
3 0V Out (Fused)
4 +24V Out (Fused)
5 0V In (AUX 2) or 0V Out (AUX 1)
6 +24V In (AUX 2*) or +24V Out (AUX 1)
7 0V In (AUX 1)
8 +24V In (AUX 1)
9 0V In (PSU 2) or 0V Out (PSU 1)
10 +24V In (PSU 2*) or +24V Out (PSU 1)
11 0V In (PSU 1)
12 +24V In (PSU 1)

Label for
User Terminal
Reference

* PSU 1 and PSU 2 (and AUX 1 and AUX 2) must be

compatible with parallel connection.

Note: For 5704 systems with more than eight catalytic control cards, it
is recommended that the dc power is connected direct to each
channels' Quad Relay Card.

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8. AC To DC Power Supply Units
8.1 Types of Power Supply Unit

There are two types of AC to DC power supply units:

a. 8-Way AC to DC Power Supply Unit (Part Number 05701-A-0406)

A 1U high half width 19 inch rack mounted unit that contains a single
50W Switched Mode AC to DC Power Supply Module.

b. 16-Way AC to DC Power Supply Unit (Part Number 05701-A-

0405)

A 1U high 19 inch rack mounted unit that contains a single 50W

Switched Mode AC to DC Power Supply Module.

Both power supply units will operate from an 85V to 264V, 47Hz to 440Hz
ac supply, or a 110V to 340V dc supply (Refer to Zellweger Analytics
for information on dc supplies).

8.2 Power Supply Unit Upgrades

Both power supply units are provided with internal connections to enable
a power upgrade to 100W by the addition of a second 50W Switched
Mode AC to DC Power Supply Module (Part Number 05701-A-0440).

A second sub-unit (Part Number 05701-A-0441) can be fitted to the

basic 16-way power supply unit if more than 100W is required to operate
the system. The additional sub-unit will contain a 50W Switched Mode
AC to DC Power Supply Module as standard and will therefore give an
additional 50W of available power. If required a further 50W Switched
Mode AC to DC Power Supply Module (Part Number 05701-A-0440)
can be added to this second sub-unit to bring the power availability up
to 200W.

The switched mode power supply modules used are fully overload
protected and are designed to be connected together.

8.3 Power Supply Connections

The input ac power supply is connected via a three core cable at the
rear of each unit.

The nominal 24V dc output supply is connected via a twin core cable
at the rear of each unit.

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8.4 8-Way AC to DC Power Supply Unit Layout

Front View

Top View

Rear View

Input ac 24V dc Output Voltage.

Supply Voltage 50W per Fitted Module

8.5 16-Way AC to DC Power Supply Unit Layout

Optional Sub Unit

Input ac 24V dc Output Voltage. Input ac 24V dc Output Voltage.

Supply Voltage 50W per Fitted Module Supply Voltage 50W per Fitted Module

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8.6 50W Sub-Unit Layout

The 50W Sub-unit is fitted with a single 50W Switched Mode AC to DC

Power Supply Module as shown below:

Top View 50W Switched Mode

(with cover AC to DC Power
removed) Supply Module

This type of unit is identified on the identification label as follows:

Indicates
50W Unit
POWER SUPPLY UNIT 05700-A-0405 Iss. 2
INPUT = 85 - 264V AC OUTPUT = 24V DC
47 - 440Hz POWER = 50W
OR 110 - 340V DC = 100W

8.7 100W Sub-Unit Layout

The 100W Sub-unit is a 50W Sub-unit with an additional 50W

Switched Mode AC to DC Power Supply Module fitted as shown
below:
Top View 50W Switched Mode
(with cover AC to DC Power
removed) Supply Module

Additional 50W
Switched Mode AC
to DC Power Supply
Module

This type of unit is identified on the identification label as follows:

Indicates
POWER SUPPLY UNIT 05700-A-0405 Iss. 2 100W Unit
INPUT = 85 - 264V AC OUTPUT = 24V DC
47 - 440Hz POWER = 50W
OR 110 - 340V DC = 100W

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9. Front Panel Blanking Panel
Matching blank front panels are available for fitting to the rack in all
unused control card spaces.

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Notes

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Chapter 3 Controls and Facilities

5704 Series

CONTROL SYSTEM

Chapter 3

Controls and Facilities

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Chapter 3 Controls and Facilities

Contents
Section Page

1. Introduction 3-3

2. Four Channel Control Card 3-8

2.1 General 3-8

2.2 Liquid Crystal Display 3-8
2.3 Status LEDs 3-11
2.4 Reset/Select Push-button 3-14
2.5 Extraction Slot 3-15
2.6 Display Label and Cover 3-15

3. Engineering Card 3-17

3.1 General 3-17

3.2 LED Indicators 3-17
3.3 Engineering Push-buttons 3-18
3.4 Engineering Serial Port 3-21

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1. Introduction
The 5704 Series Control System is equipped to provide the operational
and engineering facilities necessary to fully maintain a system of gas
detection equipment.

Each control card within a rack system displays a sensor reading, alarm
status condition and channel reading number.

Further information can be gathered and, depending on the security

status, certain settings can be adjusted by means of an Engineering
Card fitted to the rack.

The relay outputs of the system are configured to provide a range of

output alarm functions as follows:

a. Fault Alarm

The fault alarm activates when a fault is detected in the control

channel or associated sensor and is not user configurable. In addition
the FAULT LED will be illuminated as described in Section 2.3.1a.

b. Inhibit Alarm

The inhibit alarm activates when the system alarms are inhibited for
any reason and is not user configurable. In addition the INHIBIT
LED will be illuminated as described in Section 2.3.1b.

c. A1, A2 and A3 Level Alarms

The A1, A2 and A3 level alarms are activated when the level of
gas being measured crosses the preconfigured alarm threshold. In
addition the relevant LED will be illuminated as described in Section
2.3.1c, d and e.

d. STEL Alarm (Short Term Exposure Limit).

The STEL alarm will be activated when the time weighted average
concentration of a toxic gas, usually averaged over 10 or 15 minutes,
crosses a preconfigured threshold. The control card alarm LED,
associated during setup to the STEL alarm, will be illuminated as
described in Section 2.3.1f and the message display will show
STEL.

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e. LTEL Alarm (Long Term Exposure Limit).

The LTEL alarm will be activated when the time weighted average
concentration of a toxic gas, usually averaged over 8 hours, crosses
a preconfigured threshold. The control card alarm LED, associated
during setup to the LTEL alarm, will be illuminated as described in
Section 2.3.1f and the message display will show LTEL.

f. Individual Alarm

An individual alarm is caused by the input to an individual control

channel crossing a preconfigured threshold and is not related to
any other control channel. The relevant LED (A1, A2, A3, Fault,
Inhibit) will illuminate on the control card with the alarm condition
as described in Section 2.3.1.

CAUTION*

Depending upon the configuration, control cards configured for the

following Zoned, Master or Voted alarms may not give indvidual alarm
outputs.

g. Zoned Alarm*

A zoned alarm is caused by the input to any control channel, from a

sensor in a designated area, crossing a preconfigured threshold. The
relevant LED (A1, A2, A3, Fault, Inhibit) will illuminate as described
in Section 2.3.1 on the control card with the alarm condition and the
message display of the control card designated Zone Master Card
will show ZONE.

h. Master Alarm*

A master alarm is caused by the input to any designated control

channel within a single rack crossing a preconfigured threshold. The
relevant LED (A1, A2, A3, Fault, Inhibit) will illuminate as described
in Section 2.3.1 on the control card with the alarm condition and the
message display of the control card designated the Master Control
Card will show MSTR.

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i. Voted Alarm*

A voted alarm is caused by the simultaneous presence of an identical
alarm on more than one control channel within a preconfigured
group. The relevant LED (A1, A2, A3, Fault, Inhibit) will illuminate
as described in Section 2.3.1 on the control cards with the alarm
conditions and the message display of the control card designated
the Vote Master Card will show VOTE.

Vote compensation may be applied to the voted alarm output

operation by selecting one of the following configurations:

a. No compensation.
b. Faults counted as alarms.
c. Faults and inhibits counted as alarms.
d. Vote count reduction on faults.
e. Vote count reduction on faults and inhibit.

Vote compensation is useful to ensure that sensors in fault (or inhibit)

do not prevent voted alarm outputs.

Note: Vote compension should not be used with software Version

1V5 or earlier.

j. Update Alarm

The update alarm facility provides a common alarm indication

whenever a new alarm occurs, even if a previous alarm condition
exists. The update alarm can be configured to operate on a single
card or on a grouped alarm e.g. master or zoned. The update alarm
is especially useful in systems configured with only master or group/
zone relays, where the occurrence of subsequent alarms will not
cause further relay output compared to that caused by the initial
alarm. The relevant LED (A1, A2, A3, Fault, Inhibit) will illuminate
on the control card with the alarm condition as described in Section
2.3.1. The ATTN LED will also illuminate as described in Section
2.3.2b and the message display will show the cause of the update
alarm, e.g., -FT-, -IN-, -A1-, etc.

When relays are used for signalling update alarms, no other alarms
or messages must be allocated to them.

Note: Update alarms should not be used with software Version 1V5 or
earlier.

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k. Rising Alarm

A rising alarm is caused by a rising level of the parameter being

measured crossing a preconfigured threshold. This will also cause
the associated alarm LED to illuminate as described in Section
2.3.1.

l. Falling Alarm

A falling alarm is caused by a falling level of the parameter being

measured crossing a preconfigured threshold. This will also cause
the associated alarm LED to illuminate as described in Section
2.3.1.

m. Latched Alarm

A latched alarm is an alarm that will remain active even though the
level monitored no longer crosses the alarm threshold. The alarm
LED will remain lit until the alarm reset is operated.

n. Non-latched Alarm

A non-latched alarm is an alarm that only remains active while the

level being monitored crosses the alarm threshold. The alarm LED
will remain lit while the alarm level remains but will automatically
be reset when the level monitored no longer crosses the alarm
threshold.

o. Normally Energised

A normally energised relay is activated when the power is removed

from it, (eg. in the event of a system power failure). The LEDs will
illuminate when an alarm or fault condition occurs irrespective of
the relay configured state.

p. Normally De-energised

A normally de-energised relay is activated when the power is applied

to it, (eg. in the event of an alarm condition). The LEDs will illuminate
when an alarm or fault condition occurs irrespective of the relay
configured state.

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q. Time Delay Alarms

The operation in response to alarm events of certain relays may

be modified by applying a delay function to the relays. Time delay
functions are available to delay the activation of a relay for a short
period after an alarm event occurs and/or to maintain relay activation
for a period after the alarm event has cleared. The time delay facilities
are available for:

i. Relays 1 to 4 if the Quad Relay Interface Card is fitted.

ii. Relays 1 to 8 if the Relay Interface Assembly is fitted.

The time delay function is useful to prevent spurious alarms and to

ensure appropriate minimum operating times for external electrical
apparatus connected to the relay.

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2. Four Channel Control Card

2.1 General
The Four Channel Control Card provides the necessary power
supplies to the associated sensors and conditions the incoming sensor
signals. The received sensor
signals are then processed by the
microprocessor and the resultant
values and any necessary alarm
action, depending on the channel
configuration, is carried out.

The channel card front panel can

be subdivided into five areas:
//////////
//////////
//////////
//////////
//////////
//////////
//////////
//////////
//////////

Display Label and Cover.

LCD Display.

Status LEDs.

Reset/Select Push-button.

Extraction Slot.

2.2 Liquid Crystal Display

2.2.1 General

The backlit LCD provides a display of the selected sensor reading and
its status, or if maintenance is being carried out on a sensor, information
on the sensor set points and calibration data.
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The method of displaying each channels

information can be selected from one of the
following:

a. Automatic sequencing.
b. Highest reading.

c. Combination of automatic sequencing and 5704

highest reading.
d. Manually selected. % LEL
100
80
The display can be divided into four parts: 60
40
Analogue Display. //////////
//////////
20
////////// 0
///////////
Message Display //////////

Digital Display.

Icon Display.

2.2.2 Analogue Display

This consists of 25 segments providing an
indication of the sensor gas reading in the form % LEL
100
of an analogue bargraph which covers the sensor 80
range between -10% and +110% fsd. 60
40
There are two possible modes of operation: //////////
//////////
20
0

a. Solid in which the segments fill the area

between zero and the actual gas reading. % LEL
100
80
b. Single Line in which a single segment 60

indicates the actual gas reading. 40

20

Each of these modes can be operated as either 0

a rising or falling display.

% LEL
100
A peak reading facility is available which maintains 80
a segment at the highest, or lowest, gas value 60

obtained by the sensor since the previous peak 40

reading reset. This is a useful recording tool for ///////// 20

/////////
0
the behaviour of the connected sensor.
% LEL
100
80
60
40
20
0

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The default mode of operation is a rising solid bar current gas reading
display with a peak reading facility, and with a combination of automatic
sequencing between channels and highest reading.

2.2.3 Digital Display

The digital display is a four character, seven segment display which

provides either an indication of the sensor gas reading or a value relating
to a function selected from the Engineering Card.

Depending on the sensor range and the configuration setting, the digital
display shows a gas value to either no decimal place (the default setting)
or to one or two decimal place.

2.2.4 Message Display

The message display consists of a four character, 14 segment display

which provides intelligent reporting of the sensor status or information
on a selected engineering function. Fot control cards fitted with the
high integrity relay outputs performing master, zone or voted alarms
the alarm state will also be indicated as follows:

BEAM - Beamed Block Alarm

MSTR - Master Alarm
ZONE - Zoned Alarm
VOTE - Voted Alarm

In the case of an update alarm, the cause of the alarm is indicated

as follows:
-FT- - Fault Alarm
-IN- - Inhibit Alarm
-A1- - A1 Alarm
-A2- - A2 Alarm
-A3- - A3 Alarm
-ST- - STEL Alarm
-LT - LTEL Alarm

2.2.5 Icon

The icon provides a simple indication that the display is functioning

and changes when the channel card is selected for operation with the
Engineering Card.

Normal Operation Selected

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2.3 Status LEDS

2.3.1 CHL (Channel) LEDs

The four CHL alarm LEDs on the front panel of the control card provide
multi status indications for each channel. These LEDs indicate as
follows:

a. FAULT ALARM- Flashing Amber CHL LED

The fault condition is shown by the CHL LED flashing amber as

shown below:

////////////////////////////////////// //////////////////////////////////////
////////////////////////////////////// //////////////////////////////////////
////////////////////////////////////// //////////////////////////////////////
////////////////////////////////////// //////////////////////////////////////

1 second 1 second 1 second 1 second

This provides an indication in the event of a sensor hardware failure,

if the sensor signal is outside pre-defined limits or if the channel card
has detected a channel hardware or software fault.

b. INHIBIT ALARM - Steady Amber CHL LED

The inhibit condition is shown by the CHL LED in a steady on amber

condition as shown below:
/////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////
/////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////
/////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////
/////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////

1 second 1 second 1 second 1 second

This indicates when the channel is in the inhibit condition. This

condition can be selected manually and remotely, or occurs
automatically:

during start-up for a pre-defined period of typically 30

seconds,

when carrying out certain engineering functions such as zero,

span, 1st span and alarm test.

During the inhibit condition, the channel card will continue to read
the gas sensor reading, however, no action is taken in the event of
an alarm condition being exceeded.
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c. A1 ALARM - Flashing Red CHL LED

The A1 channel alarm condition is shown by the associated CHL

LED flashing red once per period as shown below:

//////////// //////////// ////////////

//////////// //////////// ////////////
//////////// //////////// ////////////

0.2s 0.8s 0.2s 0.8s 0.2s 0.8s

This indicates that the preset first level gas alarm for that channel
has been exceeded. This alarm will not function in the event of either
a fault or inhibit condition being active.

d. A2 ALARM - Flashing Red CHL LED

The A2 channel alarm condition is shown by the associated CHL

//////////// //////////// //////////// //////////// //////////// ////////////

//////////// //////////// //////////// //////////// //////////// ////////////
//////////// //////////// //////////// //////////// //////////// ////////////

0.2s 0.1 0.2s 0.5s 0.2s 0.1 0.2s 0.5s 0.2s 0.1 0.2s 0.5s

LED flashing red twice per period as shown below:

This indicates that the preset second level gas alarm for that channel
has been exceeded. This alarm will not function in the event of either
a fault or inhibit condition being active.

e. A3 ALARM - Flashing Red CHL LED

The A3 channel alarm condition is shown by the associated CHL
LED flashing red three times per period as shown below:

//////////// //////////// //////////// //////////// //////////// //////////// //////////// //////////// ////////////

//////////// //////////// //////////// //////////// //////////// //////////// //////////// //////////// ////////////
//////////// //////////// //////////// //////////// //////////// //////////// //////////// //////////// ////////////

0.2s 0.1 0.2s 0.1 0.2s 0.2s 0.2s 0.1 0.2s 0.1 0.2s 0.2s 0.2s 0.1 0.2s 0.1 0.2s 0.2s

This indicates that the preset third level gas alarm for that channel
has been exceeded. This alarm will not function in the event of either
a fault or inhibit condition being active.

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f. Special Alarm (STEL and LTEL)

Slow Flashing Red CHL LED.

///////////////////////////////////// /////////////////////////////////////
///////////////////////////////////// /////////////////////////////////////
///////////////////////////////////// /////////////////////////////////////
///////////////////////////////////// /////////////////////////////////////

1 second 1 second 1 second 1 second

A slow flashing red CHL LED indicates that a STEL or LTEL alarm
level has been exceeded.

2.3.2 ATTN (Attention) LED

The amber ATTN LED provides a common indication for the card as
follows:

a. HARDWARE OR SOFTWARE FAULT

///////////////////////////////////// /////////////////////////////////////
///////////////////////////////////// /////////////////////////////////////
///////////////////////////////////// /////////////////////////////////////
///////////////////////////////////// /////////////////////////////////////

1 second 1 second 1 second 1 second

Slow Flashing Amber ATTN LED

A slow flashing amber ATTN LED indicates that there is a card

hardware or software fault.

b. UPDATE ALARM CONDITION

Fast Flashing Amber ATTN LED

//////// //////// //////// //////// //////// //////// //////// //////// //////// ////////
//////// //////// //////// //////// //////// //////// //////// //////// //////// ////////
//////// //////// //////// //////// //////// //////// //////// //////// //////// ////////

1 second 1 second

A fast flashing amber ATTN LED indicates that there is an update

alarm condition. Update alarms can be configured for a card, or a
number of cards, and for each A1, A2, A3, Fault and/or Inhibit.

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c. ALARM TEST

Steady Amber ATTN LED

////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////
////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////
////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////

1 second 1 second

A steady amber ATTN LED indicates control card is in the alarm test
mode.

2.4 Reset/Select Push-button

The front panel RESET/SELECT push-button provides five functions

depending upon how it is operated:

a. Alarm Reset using the General Reset

The RESET/SELECT push-button, when pressed momentarily,

resets any latched non active alarms, faults, warning or information
messages, display peak reading indicator, attention lamp and will
acknowledge an update if such a condition is present.

b. Card Select

The RESET/SELECT push-button, when pressed for approximately

1.5 seconds, selects the control card for operations controlled
from the Engineering Card. (The required channel is subsequently
selected by the Engineering Card ( ) and ( ) keys).

c. Extended Reset

When a channel is not selected, the RESET/SELECT push-button,

when pressed continuously for five seconds:

i. Clears all maximum and minimum gas readings.

ii. Resets any active short term (STEL) and long term (LTEL)
exposure alarms clearing the timer to zero.

iii. For active time delay functions, activates any relay with
impending trigger and clears any relay being held.

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d. Channel Deselect

The RESET/SELECT push-button, when pressed momentarily

while a control card is selected, deselects the control card from the
Engineering Card functions.

Note: The control card may also be deselected by pressing the key.
This will override any sequential display scanning and continuously
display the previously selected channel.

e. Extended Channel Reset

While a channel is selected, the RESET/SELECT push-button when

pressed continuously for five seconds, clears the short term (STEL)
and the long term (LTEL) exposure calculations and sets the timer
to zero.
Note: This operation only affects the selected channel.
2.5 Extraction Slot
An extraction tool is used in conjunction with the extraction slot, just
below the select push-button, to remove the card from the rack. The
extraction tool is provided as part of the Key Kit (05701-A-0550) supplied
with each rack assembly.
The card is removed by first unscrewing the two card securing screws,
one at the top of the card and the other at the bottom of the card, and
then hooking the extraction tool into the extraction slot and then gently
pulling the card out of the rack.
2.6 Display Label and Cover
A clear perspex cover clips to the front panel and retains the label which
provides identification of the control card type, sensor scale, LED and
push-button functions.
Two different label colours are used:

a. Grey/Blue - Four Channel Control Card, Catalytic Sensor

Input

b. Violet - Four Channel Control Card, 4 - 20mA Sensor Input

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Extraction Hole
The perspex cover is removed by
first removing the control card from 5704
the rack and then locating a small PPM

hole on the inside of the front panel

50
40

just above the LCD display. A blunt

30
20

object, such as a screwdriver, is then

10
0

pushed through the hole to unclip the

perspex cover. & &
A small recess in the perspex cover CHL 4

allows a label to be inserted to CHL 3

indicate the channel tag name or CHL 2

gas type.
CHL 1

ATTN

RESET/SELECT

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Chapter 3 Controls and Facilities

3. Engineering Card

3.1 General

The Engineering Card provides facilities to allow each control card

channel to be interrogated and to allow normal maintenance functions
such as calibration to be carried out. It also acts as a connecting point
for the engineering interface software which allows each card to be
configured.

3.2 LED Indicators

Two indicators at the top of the front panel of the

Engineering Card indicate the operational status of
the card:

3.2.1 - Green LED

A continuously illuminated LED indicates that the

correct dc power is connected to the rack via the
DC Input Card.
PRINT
A flashing LED at approximately two second
intervals, indicates a low dc power input level.

A flashing LED at approximately 0.5 second intervals,

indicates a hardware fault.
BEAD mA ALARMS
3.2.2 - Red LED
ZERO SIGNAL
Provides an indication of the operation of the
Engineering Card communications status as SPAN 1ST SPAN
follows:
INHIBIT CLOCK
Off: Engineering Card functioning correctly
and the engineering functions are locked.
Operators functions are operational to
allow the checking of various control card
channel settings.

On: Engineering Card functioning correctly

and the engineering functions are
unlocked enabling changes to be made
to the operation of a selected control card
channel.

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Flashing: Indicates that a control card has been withdrawn from the rack,
there is a communications error or that an external PC running
the engineering interface software is communicating with the
control cards.

Note: To reset the indication, insert the Engineering Key momentarily

and then remove again.

3.3 Engineering Push-buttons

3.3.1 General

The Engineering Card push-buttons control various functions depending

on the type of control card fitted and whether the Engineering Key is
fitted.

3.3.2 Up Push-button ( )

When the up push-button ( ) is operated, it increases the value of

those functions that can be adjusted. With no engineering functions
selected, this push-button is used to select a particular channel of a
selected control card.

3.3.3 Down Push-button ( )

When the down push-button ( ) is operated, it decreases the value

of those functions that can be adjusted. With no engineering functions
selected, this push-button is used to select a particular channel of a
selected control card.

3.3.4 Operation of the Up and Down Push-buttons

Simultaneously

This operation can only be used if a serial printer is connected to the

rack. When the up ( ) and down ( ) push-buttons are operated
simultaneously a print out command is selected of the control card
configuration and status.

3.3.5 Accept Push-button ( )

When the accept push-button ( ) is operated during any of the

engineers functions, this button confirms adjustments that have been
made and then cancels that function.

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3.3.6 Reject Push-button ( )

When operated during any of the engineers functions and providing the
accept ( ) push-button has not been operated, the reject push-button (
) cancels adjustments that have been made. This push-button is also
used to deselect a selected function and for manual channel display
selections.

3.3.7 BEAD mA Push-button

When the BEAD mA push-button is operated, the display of the selected

Catalytic Control Card provides an indication of the selected channels
sensor head current.

Adjustments to this current can also be made if the Engineering Key is

fitted to the Engineering Card.

3.3.8 ALARMS Push-button

When the ALARMS push-button is operated, the display of the selected

control card provides an indication of the selected channels level and
type (rising or falling) of each alarm level (A1, A2, A3), and the STEL/
LTEL levels

If the Engineering Key is fitted to the Engineering Card, adjustments can

be made to the alarm levels, within pre-defined limits, and additional test
facilities become available. This facility allows each alarm operation to be
checked and, if required, its associated output relay to be exercised.

3.3.9 SIGNAL Push-button

When the SIGNAL push-button is operated, the display of the selected

control card provides an indication of the selected channels sensor
signal as follows:

a. 4 - 20mA Control Card - Loop current in mA.

b. Catalytic Control Card - Catalytic bridge output (sensitivity) in

mV.

3.3.10 ZERO Push-button

The ZERO push-button can only be used when the Engineering Key is
fitted to the Engineering Card and is used to calibrate the zero point of
the selected control card channel.

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3.3.11 SPAN Push-button

The SPAN push-button can only be used when the Engineering Key is
fitted to the Engineering Card and is used to calibrate the span point
of the selected control card channel.

3.3.12 1ST SPAN Push-button

The 1ST SPAN push-button can only be used when the Engineering
Key is fitted to the Engineering Card and is used to calibrate the span
point of a new catalytic sensor fitted to a selected catalytic control card
channel.

This function is used to provide an indication, in conjunction with

subsequent normal span adjustments, of the output sensitivity of a
catalytic sensor and to automatically indicate poisoning or loss of sensor
performance.

3.3.13 CLOCK Push-button

When the CLOCK push-button is operated, the display of the selected

control card provides an indication of the time and date of the rack
clock.

The rack clock is located in the Engineering Card, however since the
Engineering Card has no display, a control card must be selected to
enable the time and date to be displayed. It does not matter which
control card or channel is selected.

If the Engineering Key is fitted to the Engineering Card, the time and
date can be adjusted.

3.3.14 INHIBIT Push-button

When the INHIBIT push-button is operated, the selected control card

channel is placed in the inhibit mode. This prevents the operation of
any configured relay output alarm functions.

Inhibit can only be used if the Engineering Key is fitted to the Engineering
Card, however, if the Engineering Key is subsequently removed the
selected control card channel remains in the inhibit mode.

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3.4 Engineering Serial Port

The Engineering Serial Port is a miniature DIN socket which provides

three functions:

a. Connection point for the Engineering Key to unlock the engineers

functions.

b. Connection point for the External Engineering Interface which allows

each control card to be configured by an external PC running the
engineering interface configuration software.

c. Connection point for a serial printer which can be used to provide

a hard copy of the control card configuration data and status.

The Engineering Serial Port and its Engineering Key are shown below:

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5704 Series

Control System

Chapter 4

Installation Instructions

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Chapter 4 - Installation Instructions

WARNING

For installations in the EU, refer to EN 60079-14, ‘Explosive atmospheres

- Electrical installations design, selection and erection.'

Additionally, the code of practice regarding Selection, installation, use

and maintenance of apparatus for the detection and measurement
of combustible gases or oxygen must be complied with. Refer to
EN 60079-29-2.

The above standards apply to the System 57 since the sensors

may be installed in potentially hazardous atmospheres.

In addition, appropriate local or national regulations shall be used.”

IMPORTANT NOTICES

1. Honeywell Analytics Limited can take no responsibility for installation

and/or use of its equipment if this is not done in accordance with
the appropriate issue and/or amendment of the manual.

2. The user of this manual should ensure that it is appropriate in all

details to the exact equipment to be installed and/or operated.
If in doubt, the user should contact Honeywell Analytics Limited
for advice.

3. The System 57 cards contain no user serviceable parts. Refer all

servicing to qualified service personnel.

4. When inserting or removing system components ensure that the

power is switched off. Failure to do this may result in damage to
the system.

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Contents
Section Page

1. INTRODUCTION 4-5

2. UNPACKING 4-5

3. LOCATION 4-6

4. CABLING 4-7

5. POWER REQUIREMENTS 4-7

6. VENTILATION 4-9

7. PRELIMINARIES 4-9

8. CABINET INSTALLATION 4-10

9. PANEL INSTALLATION 4-12

10. RACK INSTALLATION 4-14

11. SENSOR INSTALLATION 4-15

11.1 General 4-15

11.2 Sensor Line Resistance 4-16
11.3 Cable Resistance Guide 4-17
11.4 Catalytic Sensors 4-17
11.5 4 - 20mA Loop Powered Sensors 4-18
11.6 4 - 20mA Transmitters 4-18

12. SENSOR CONNECTIONS 4-19

12.1 General 4-19

12.2 Catalytic Sensor Connections 4-19
12.3 4 - 20mA Loop Powered Sensor Connections 4-23
12.4 4 - 20mA Transmitter Connections 4-25
12.5 IS Series 2000 Toxic Transmitter Connections 4-39

13. OUTPUT CONNECTIONS 4-41

13.1 Relay Output 4-41

13.2 Analogue Output 4-42

14. REMOTE INPUT CONNECTIONS 4-47

15. DC POWER CONNECTIONS 4-49

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15.1 General 4-49

15.2 Individually Powered Control Cards 4-50
16. AC TO DC POWER SUPPLY UNIT CONNECTIONS 4-51

17. UPGRADING THE AC TO DC POWER SUPPLY UNITS 4-53

17.1 General 4-53

17.2 8-Way and 16-Way AC to DC Power Supply Unit
Upgrade to 100W 4-56
17.3 16-Way AC to DC Power Supply Unit Upgrade
to 150W or 200W 4-57

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1. INTRODUCTION
A summary of the System 57 controller installation procedures is shown
below:

a. Unpack and check the equipment.

b. Identify a suitable location and check the cabling requirements.

c. Confirm the power supply requirements.

d. Install the Cabinet, 19" Mounting Frame or Panel Cutout as

required.

e. Fit the System 57 rack into the Cabinet, 19" Mounting Frame or
Panel Cutout.

f. Install the sensors and wire back to the System 57.

g. Check, and if necessary reconfigure, the Four Channel Control

Cards.

h. Wire the sensors to the Quad Relay Interface Card terminal

blocks.

i. Wire the outputs from the Quad Relay Interface Card terminal blocks
or from the Relay Interface Assembly if used.

j. Wire the power supply to the DC Input Card.

k. In individually powered applications, wire the power supply to each

Quad Relay Interface Card.
After installation is complete perform the commissioning procedures
outlined in Chapter 5.

The following sections of this chapter provide a detailed explanation of

the installation operations.

2. UNPACKING
On receipt:

a. Carefully unpack the equipment observing any instructions printed

on or contained in the packaging.

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b. Check the contents for transit damage and against the packing note
for deficiencies.

c. Locate the configuration sheet supplied with the unit and confirm
that each channel card type and settings are compatible with the
proposed sensors.

3. LOCATION
The control system must be installed in a safe area such as a control
or equipment room. It must be installed in a vibration-free environment
away from sources of heat, with adequate ventilation and protected
from the weather.

There are two different System 57 rack configurations to accommodate

either front or rear field wiring entry. Each configuration is available in
half or full 19" width. The three most common mounting methods are:

a. 19" Mounting Frame

The System 57 19" 6U front and 3U rear access racks are compatible
with the standard 19" (483mm) sub-rack format and may therefore
be fitted into any suitable 19" mounting frame.

b. Cabinet

Wall mounting cabinets are available in two sizes to accommodate

the 19" and half 19" 6U front access rack assemblies.

c. Panel

Alternatively all the racks are suitable for fitting directly into a panel
cutout aperture.

Power supply units are available, in both 19" and half 19" 1U formats,
for applications where an ac input power source is to be used. It is
recommended that the power supply units are mounted directly above
the System 57 rack.

Caution

3U rear access racks should always be supported at the rear of

the unit to prevent distortion and excessive loading of the front
flange plates.

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4. CABLING
The field terminals on the Quad Relay Interface and Relay Interface
Assembly accept single or multi-stranded wire up to 2.5mm˝ (14 AWG).
Cables should be routed carefully to avoid physical and environmental
hazards such as mechanical stress and high temperatures.

Sensor wiring should consist of a cable with an earthed outer shield

and should be routed away from sources of interference such as ac
power cables, motors, machinery etc. All sensor cabling is subject to a
maximum cable length that is dependant upon the cable line resistance
and sensor types.

The current ratings of the power and relay cables should always be
higher than the worst case maximum load requirement.

All sensor field cables must be screened in order to ensure correct

operation of the system and to meet European Standards for RFI and
EMC. The cable screen of each sensor should be connected to a
GROUND terminal at the cabinet entry or the ground terminal of the
appropriate Quad Relay Interface Card or another suitable ground
point.

5. POWER REQUIREMENTS
The System 57 operates from a nominal 24V (18V to 32V) dc power
supply input which may be derived from various sources including the
mains ac, via a separate ac to dc power supply unit, local plant dc
supply and/or battery backup dc supply.

The power supply may be applied to the System 57 backplane, via the
DC Input Card, where the maximum backplane current is limited to 8A.
The DC Input Card terminal blocks allow flexible power connections
and diode isolation for two separate power supply inputs.

Where the number of Four Channel Control Cards fitted and the type
of sensors used would cause a backplane current in excess of the
8A maximum, it is necessary to connect the power supply to each
individual control card via its Quad Relay Interface Card. As a general
rule, individually powered cards are required where more than eight
catalytic control cards are fitted.

See Section 17 for connection details.

The power supply rating required is dependent upon the sensor types,
number of channels and configuration of the System 57. Table 1, the
Power Budget Calculation Sheet, allows for a quick and easy calculation
of the worst case power requirement for the system. In many cases a
lower power rating can be used, however, a more detailed power budget

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Table 1 Power Budget Calculation Sheet
To calculate the power requirement:
(1) Enter the number of devices of each type used in the system in column B.
(2) Multiply by the unit power shown in column C.
(3) Enter the result in column D.
(4) Add up column D to calculate the total power required.

Device or Sensor Type Number Unit Total

in Rack Requirement Power
(W) (W)

A B x C = D
System 57 DEVICES:

Four Channel Control Card,

Catalytic (includes bridge drive
at 200mA) ____ 12.8 ____
Four Channel Control Card,
4 - 20mA (includes loop power) ____ 8.3 ____
Engineering Card 1 1.5 1.5
DC Input Card 1 0 0
Modbus Interface 232 ____ 0.75 ­­­____
Modbus Interface 422/485 ____ 1.50 ­­­____
Event Printing ____ 0.75 ­­­____
Alarm Update ____ 0.25 ­­­____
Update Panel ____ 0.20 ­­­____
Quad Relay Interface Card* ____ 1.7 ____
Relay Interface Assembly* ____ 6.5 ____
Analogue Output Modules (4 off)
(includes loop power) ____ 4.0 ____

Allowance for Transmitters & Sensors

powered from System 57 PSU:
Searchline ____ 5.0 ____
Searchline Excel Receiver ____ 8.0 ____
Searchline Excel Transmitter (S/R) ____ 6.5 ____
Searchline Excel Transmitter (L/R) ____ 7.5 ____
Searchline Excel Cross Duct TX & RX ____ 13.0 ____
Searchpoint 500 ____ 10.0 ____
Searchpoint Optima ____ 4.2 ____
Searchpoint Optima plus ____ 4.5 ____
Series 2000 Toxic ____ 0 0
Series 2000 Combustible
(incl UL) ____ 3.8 ____
Digi-Chem ____ 0.6 ____
Digi-Cat (includes sensor) ____ 2.0 ____
Digi-Ana Toxic ____ 0.6
Digi-Optima ____ 4.80 ____
Life Line ____ 0 ____
Others (refer to manufacturers
data for column (C) ____ x ____
Apex Toxic* 4.0
Apex Combustible* 5.5
Opus/Lifeline II Toxic* 2.4
Opus/Lifeline II Combustible* 2.9

TOTAL SYSTEM POWER REQUIREMENT = W

* All relays energised.

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analysis should be performed to confirm the exact requirement.
The 8-Way AC to DC Power Supply Units can provide a 50W dc supply
or a 100W dc supply depending upon whether one or two switch mode
modules are incorporated in the power supply unit.
Similarly, the 16-Way AC to DC Power Supply Units can provide a
50W, 100W, 150W and 200W dc supplies depending upon whether
one, two, three or four switch mode modules are incorporated in the
power supply unit.
6. Ventilation
The 5704 Control System provides the facility for a large number of
channels in a very small space. In heavily populated racks, especially
those with many catalytic input control cards or relays configured for
normally energised operation, it is possible for the heat dissipation to
cause a significant rise in temperature both within the rack and in an
area close to the rack.

As such, careful consideration must be given to thermal planning. To

achieve most from the convection cooling, always ensure that the air
can flow freely through the rack and power supply. Do not obstruct the
air vent holes in the top and bottom of the rack and if possible space
the control cards evenly within the rack.

It is recommended that during commissioning the operating temperature

of the rack is checked to ensure that the maximum operating temperature
of 55oC is not exceeded. In some cases the addition of forced air
ventilation may be required.

Maximum power supply configuration allowed without provision for

additional ventilation is 100w for 8 way cabinet and 200w for 16 way
cabinet.
7. PRELIMINARIES
Ensure that each control card is compatible with the proposed sensor/
transmitter to be connected to that control card.
Ensure that where an AC to DC Power Supply Unit is to be used, this
is compatible with the local mains ac supply voltage and that the PSU
power rating is adequate for its individual system load.

Note: The model 05701-A-0405 and 05701-A-0406 AC to DC Power

Supply Units operate, without the requirement of input voltage
adjustments, from an 85V to 264V, 47Hz to 440Hz ac supply
inputs.

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8. CABINET INSTALLATION
Two cabinets are available, an 8-way to accommodate the 8-way front
access rack and a 16-way to accommodate the 16-way front access
rack.
The cabinet must be secured to a wall, or other suitable vertical surface,
as follows:

(1) Knock out the bottom gland-plate entries as appropriate for the
system cabling and fit the glands before mounting the cabinet.
(2) Attach the four mounting brackets provided to the cabinet.

(3) Using the dimensions shown mark the position of the mounting holes
on the mounting surface.
(4) Drill and wall plug the mounting holes as necessary.
Note: The mounting brackets will accept up to a 10mm ( 0.4'' ) diameter
screw.
(5) Secure the cabinet in position using appropriate mounting screws.

(6) Fit the System 57 Rack and AC to DC Power Supply Unit (if required)
into the cabinet in the positions as shown:

(7) Pass cables through the gland adjacent to field terminal blocks,
where possible keeping the sensor cable(s) separate from the other
wiring.

(8) Prepare and connect the cable ends to Quad Relay Interface and
Expansion Relay Card terminals. For terminal identification see
Chapter 2.

(9) Ensure that the cabinet is properly earthed by connecting a suitable

earth cable to the earth stud located in the bottom panel of the
cabinet.

(10) Close and lock the cabinet.

CAUTION
Do not apply power to the System 57 until the commissioning
procedure has been read and understood. See Section 5.

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Cabinet Dimensions:

630

8 way 337
268
16 way 540

All dimension shown in mm.

Wall Mounting Bracket Hole Locations Cabinet Mounting Brackets

8 way 367
16 way 57

100

430

27
15

100
9

15 15

36
All dimension shown in mm.

10.2

10

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Eight Card Cabinet Installation
Blanking Panel 8-Way AC to DC
Power Supply Unit

Control Cards Engineering Card

Interface/Relay DC Input Card

Cards

Accessory Plate
(suitable for mounting
DIN rails, circuit
breakers, relays, etc.)

16 Card Cabinet Installation

Blanking Panel 16-Way AC to DC

Power Supply Unit

Control Cards Engineering Card

Interface/Relay DC Input Card

Cards

Accessory Plate
(suitable for mounting
DIN rails, circuit
breakers, relays, etc.)

9. PANEL INSTALLATION
All racks and the AC to DC Power Supply Units are suitable for panel
installation and are installed as follows:

(1) Cut out a suitable aperture to accommodate the System 57 rack and
power supply unit (where required) using the dimensions shown:

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A

(holes 6mm
diameter)

C E

A
B

(holes 6mm
diameter)

C E

Rack Table of Sizes (mm)

Rack Assembly A B C D E Depth

8 Way Rear Access 279.4 261.9 57.0 37.8 132.5 287.6

8 Way Front Access 279.4 261.9 190.5 37.8 266.0 217.6

16 Way Rear Access 482.6 465.1 57.0 37.8 132.5 287.6

16 Way Front Access 482.6 465.1 190.5 37.8 266.0 217.6

Panel Cut-out Clearance

8 Way Width: 247 Height as column E

16 Way 450 as column E

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A

8.4 B

43.6 31.8
5.9

AC to DC PSU Table of Sizes (mm)

PSU Assembly A B Clearance

Width Height Depth

8 Way 279.4 261.9 222 41 190

16 Way 482.6 465.1 443 41 190

(2) Insert the rack into the aperture and secure using M6, or similar
bolts, through the four mounting holes located upon the front flange
plates.

(3) Ensure adequate support at the rear of rear access racks.

(4) Prepare and connect the cable ends to Quad Relay Interface and
Expansion Relay Cards terminals. For terminal identification see
Chapter 2. Where possible keep sensor cables separate from the
other wiring.

(5) Ensure that the rack is properly earthed by connecting a suitable

earth cable to the earth stud located at the rear of the rack.

CAUTION

Do not apply power to the System 57 until the commissioning

procedure has been read and understood. See Chapter 5.

10. RACK INSTALLATION

The 16-way 3U high rear access and 6U high front access racks are
suitable for mounting in standard 19" (483mm) wide Mounting Frames.
These are fitted as follows:

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(1) Insert the rack into the 19" Mounting Frame and secure using M6
or similar bolts through the four mounting holes located on the front
flange plates.
(2) Ensure adequate support at the rear of rear access racks.

(3) Prepare and connect the cable ends to Quad Relay Interface and
Expansion Relay Card terminals. For terminal identification see
Chapter 2. Where possible keep sensor cables separate from the
other wiring.

(4) Ensure that the rack is properly earthed by connecting a suitable

earth cable to the earth stud located at the rear of the rack.

CAUTION

Do not apply power to the System 57 until the commissioning

procedure has been read and understood. See Chapter 5.

11. SENSOR INSTALLATION

11.1 General

Always install the sensors in accordance with the Sensor Operating

Instructions.

In general, sensors for lighter than air gasses should be located at a

high level and sensors for heavier than air gasses should be located
at a low level.

Do not install the sensors:

a. Where the normal air flow may be impeded.

b. In corners of rooms where static air pockets may exist.

c. Near sources of heat such as convector heaters.

Do install the sensors:

a. As close as possible to the potential source of gas to be detected

in order to give the maximum possible warning.

b. So that they are accessible for maintenance work.

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11.2 Sensor Line Resistance
Sensors should be located such that the line resistance of cable does
not exceed the maximum permitted. The table below gives a quick guide
to the maximum cable lengths permitted for specific sensors, when
connected by stranded copper conductor cables of various sizes to a
System 57 running at the minimum dc input voltage.
Maximum Cable Length (m)

Device or Sensor Type Conductor Cross Sectional Area

AWG 21 19 18 16 14
mm˝ 0.50 0.75 1.00 1.50 2.50
704/705 500 750 1000 1500 2500
780 (at 200mA bridge current) 500 750 1000 1500 2500
811 5600 8400 11200 16800 28000
910 (Single pair at 200mA) 480 720 960 1400 2400
910 (2 pair at 200mA) 230 340 460 690 1100
911 5600 8400 11200 16800 28000
SensePoint Flam. LEL/ppm 500 750 1000 1500 2500
SensePoint Toxic 3200 4800 6400 9600 16000
SignalPoint Flamable 500 750 1000 1500 2500
SignalPoint Toxic 2000 3000 4000 6000 10000
Digi-Cat 400 570 800 1150 1850
Digi-Chem 1000 1500 2000 3100 4800
Digi-Ana 1000 1500 2000 3100 4800
Digi-Optima 180 260 360 540 860
Life Line 3200 4600 6500 9750 15000
Searchline
(minimum dc supply 21V) 60 90 120 180 300
Searchpoint 500 32 48 64 96 160
Searchpoint OPTIMA
(minimum dc supply 19V) 180 270 360 540 900
Series 2000 Flammable 450 670 900 1300 2200
Series 2000 Toxic 1600 2400 3200 4800 8000
Searchline Excel Receiver
(Minimum dc supply 21V) 90 135 179 271 449
Searchline Excel Transmitter
(S/R) (Minimum dc supply 21V) 141 211 282 425 704
Searchline Excel Transmitter
(L/R) (Minimum dc supply 21V) 94 141 188 283 998
Searchline Excel Cross Duct
Transceiver assembly
(Minimum dc supply 21V) 55 82 109 165 274
Searchpoint Optima Plus 159 237 315 476 787
Apex - Toxic 180 270 360 540 900
Apex - Combustible/Thick Film 130 195 260 390 650
Opus/LLII - Toxic 300 450 600 900 1500
Opus/LLII - Combustible 250 375 500 750 1250
The figures in the table above provide a useful reference guide to
maximum cable lengths, however, in many circumstances longer cable
runs can be used. eg. Where the dc input voltage is higher than the
minimum. In these circumstances a more detailed analysis is required
to determine maximum line resistance.
WARNING
It is required that verification by testing that cable faults (open circuit and
short circuit) at the transmitter’s side are correctly detected by the control
card. The control card shall indicate ER81, ER87 or ER88 in this case.
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The following sections outline how to calculate the maximum line
resistance for catalytic sensors, loop powered sensors and transmitters
powered from the System 57. See Section 11.3 for a guide on cable
selection.

11.3 Cable Resistance Guide

A guide to the resistance of various copper cable sizes is given below:

Solid Copper Conductor

Cross Sectional Area Maximum resistance at 20°C

(mm˝) AWG (ohm/km)

0.50 21 36.8
0.75 19 24.5
1.00 18 18.4
1.50 16 12.3
2.50 14 7.4

Stranded Copper Conductor

Cross Sectional Area Maximum resistance at 20°C

(mm˝) AWG (ohm/km)

0.50 21 36.8
0.75 19 24.5
1.00 18 17.6
1.50 16 11.7
2.50 14 7.4

11.4 Catalytic Sensors

The maximum line resistance of cabling for a catalytic sensor varies with
the current and voltage requirements of the type of sensor installed. It is
also subject to a maximum of 10V permitted across terminals S and NS
at the Quad Relay Interface Card.
Maximum line loop resistance is calculated as follows:

10 - Vs
RL =
Is

Where: RL = Total Line Resistance (ohms). Including sensor.

Vs = Sensor Voltage (V)
Is = Sensor Current (A)

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11.5 4 - 20mA Loop Powered Sensors:

The maximum line resistance of cabling for a 4 - 20mA loop powered

sensor varies with the voltage drive requirements of the type of sensor
installed. It is also subject to a 24V maximum loop drive voltage.

Maximum line loop resistance is calculated as follows:

24 - Vs
RL =
0.025

Where: RL = Total Line Resistance (ohms)

V s = Minimum Sensor Operating Voltage (V)

11.6 4 - 20mA Transmitters

The maximum line resistance of cabling for a 4 - 20mA transmitter

powered from the System 57 varies with the voltage and current
requirements of the transmitter. It is also subject to the minimum supply
voltage available from the System 57.

Maximum line loop resistance is calculated as follows:

Vr - Vs
RL =
Is

Where: RL = Total Line Resistance (ohms)

Vr = Minimum DC Supply to System 57 (V)
Vs = Sensor Voltage (V)
Is = Sensor Current (A)

Making the above calculation using a Vr of 18V will accommodate the

worst case low dc supply situation.

The maximum resistance per core can be calculated from the above
configurations as follows:

RL
Maximum Resistance of Core = ohms
2

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12. Sensor Connections
12.1 General
WARNING
Incorrect connection of the sensor wires may cause damage to
both the sensor and System 57.
CAUTION
The sensors connections must always be made with the System
57 unit in an unpowered state. Isolate power supplies at their
source before making connections.
Ensure that any external dc backup battery supply is also
disabled.
IMPORTANT
In order to ensure the correct operation of the system and to meet
European Standards for RFI and EMC, all sensor field cables
must be screened. The cable screen of each sensor should be
connected to the cabinet protective earth.

Connect the cabling to sensors in accordance with the Sensor Operating

Instructions and run the field cables back to the System 57 unit. The
sensor cables should be routed away from sources of interference such
as ac power cables, motors, machinery etc.

Use the information on the configuration sheet provided with the unit to
decide which sensor to connect to each channel. The following sections
describe the sensor connections for the Catalytic and 4 ‑ 20mA input
Four Channel Control Cards.
12.2 Catalytic Sensor Connections
Catalytic sensors require a three wire connection and the sensor
documentation will indicate three connections S, 01 and NS, which are
usually brown, white and blue respectively.

At the System 57 end of the field cable, the three sensor wires should
each be connected to the respective matching S, 01 or NS terminal
of the appropriate channel on the Quad Relay Interface Card that is
attached to the required Four Channel Control Card.

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The sensor cable screen or steel wire armour (or braid), as appropriate,
should be connected to the system (protective) earth. This can be
achieved where the cable enters the cabinet by using a metal cable
gland, or by other suitable means, and avoiding any screen 'tails' within
the cabinet.
Where the cable consists of a separate screen sheath and wire armour
(or braid), the armour should be connected, at the cabinet entry, to the
protective earth and the screen sheath should be connected to the
GROUND terminal of the Quad Relay Interface Card or to a suitable
instrument earth point.

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Quad Relay Interface Card
05704-A-0121

Junction Box
Terminal
Junction
Block Separate Screen Sheath
Box
(If Fitted)

GND

S 13
15
S 01 17
01
NS 19
NS
Brown
White
Blue
Green/Yellow Screened/Armoured
Cable
Protective
Earth Terminal
Earth
780 Series
910 704/705 Cabinet
980 Sensors

Notes: 1. Where a sensor is earthed locally, either to an Earth Stud or

through the sensor casing or mounting, to avoid earth loops
the screen sheath of the cable should only be connected at
one end.

2. The above diagram shows the sensor connections for Channel

1. Channels 2, 3 and 4 connections are similar and their pin
connection numbers are shown below:

Channel Sensor Connection

S 01 NS Ground

Quad Relay 1 15 17 19 13
Interface Connections 2 16 18 20 14
3 21 23 25 13
4 22 24 26 14

Combustible Sensor, Junction Box and Terminal Block

Connections

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Chapter 4 - Installation Instructions

Notes: 1. Where a sensor is earthed locally, either to

an Earth Stud or through the sensor casing
or mounting, to avoid earth loops the screen
sheath of the cable should only be connected
at one end.

2. The above diagram shows the sensor

connections for Channel 1. Channels 2, 3
and 4 connections are similar and their pin
connection numbers are shown below:

Channel Sensor Connection

S 01 NS Ground

Quad Relay 1 15 17 19 13
Interface Connections 2 16 18 20 14
3 21 23 25 13
4 22 24 26 14

SensePoint Combustible Sensor, Junction Box and Terminal

Block Connections

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12.3 4 - 20mA Loop Powered Sensor Connections

Loop powered sensors require a two wire connection and the sensor
documentation will indicate the positive and negative loop connections,
usually brown and blue respectively.

At the System 57 end of the field cable the two sensor wires should
be connected to the S (positive) and 01 (negative) terminals of the
appropriate channel on the Quad Relay Interface Card that is attached
to the required Four Channel Control Card.

The sensor cable screen or steel wire armour (or braid), as appropriate,
should be connected to the system (protective) earth. This can be
achieved where the cable enters the cabinet by using a metal cable
gland, or by other suitable means, and avoiding any screen 'tails' within
the cabinet.
Where the cable consists of a separate screen sheath and wire armour
(or braid), the armour should be connected, at the cabinet entry, to the
protective earth and the screen sheath should be connected to the
GROUND terminal of the Quad Relay Interface Card or to a suitable
instrument earth point.

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Quad Relay Interface Card
Junction Box 05704-A-0121

Junction Terminal Block

Box Arrows Indicate
Direction of Loop
Current Flow
S
01 S 15
17
+-
01

Brown
Blue
Green/Yellow Screened Cable
Earth Terminal Protective
811, 911 ECC,
Earth
S2000 Toxic
Sensor
Cabinet

Notes: 1. Where a sensor is earthed locally, either to an Earth Stud or through the sensor
casing or mounting, to avoid earth loops the screen sheath of the cable should only
be connected at one end.
2. The above diagram shows the sensor connections for Channel 1. Channels 2, 3 and
4 connections are similar and their pin connection numbers are shown below:
Channel Sensor Connection
S 01

Quad Relay 1 15 17
Interface Connections 2 16 18
3 21 23
4 22 24
Loop Powered Sensor (Measuring Resistance in Supply Return)

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12.4 4 - 20mA Transmitter Connections

Transmitters require either three or four wire connections and the sensor
documentation will indicate the 0V and +24V power connections and
the positive and negative loop connections.

At the System 57 end of the field cable the sensor loop signal wires
should be connected to the S, 01, NS terminals on the Quad Relay
Interface Card that is attached to the required Four Channel Control
Card. The exact terminals used vary depending upon whether three or
four wire topology is used, the requirement for a loop current source
configuration and the channel to be connected to.

The transmitter power connection +24V and 0V should be connected

to a suitable dc supply.

Note: Terminals 35 and 36 on the Relay Interface Card are input terminals
only and cannot be used to power the transmitter.

The sensor cable screen or steel wire armour (or braid), as appropriate,
should be connected to the system (protective) earth. This can be
achieved where the cable enters the cabinet by using a metal cable
gland, or by other suitable means, and avoiding any screen 'tails' within
the cabinet.
Where the cable consists of a separate screen sheath and wire armour
(or braid), the armour should be connected, at the cabinet entry, to the
protective earth and the screen sheath should be connected to the
GROUND terminal of the Quad Relay Interface Card or to a suitable
instrument earth point.

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Opus/Lifeline II Transmitter
Quad Relay Interface Card
05704-A-0121

Arrows Indicate
6 J4 Direction of Loop
Current Flow +24V*
J5

01 17
NS 19
1 3

0V*
Screen to
cable gland Screened
Cable Protective
Earth

Cabinet

* 24V supply may be obtained

from either the cabinet or a
separate field supply

Notes: 1. Where the sensor is earthed locally, either to the stud or through
the sensor casing or mounting, to avoid earth loops the screen
sheath should only be connected at one end, i.e. the sensor
or at the relay/interface card.

2. The above diagram shows the sensor connections for Channel

1. Channels 2, 3 and 4 connections are similar and their pin
connection numbers are shown below:

Channel Sensor Connection

01 NS

Quad Relay 1 17 19
Interface Connections 2 18 20
3 23 25
4 24 26

Three Wire Control Card Current Sink, Transmitter Current

Source Connection for Opus/Lifeline II
(Signal Returned to 0V)

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Quad Relay Interface Card

Opus/Lifeline II Transmitter 05704-A-0121
Arrows Indicate
Direction of Loop
Current Flow +24V*

6 J4 S
5
15
J5 17
01

1 3 Cabinet
Screen to 0V*
cable gland Screened
Cable

* 24V supply may be obtained Protective

from either the cabinet or a Earth
separate field supply

Notes: 1. Where the sensor is earthed locally, either to the stud or through
the sensor casing or mounting, to avoid earth loops the screen
sheath should only be connected at one end, i.e. the sensor
or at the relay/interface card.

2. The above diagram shows the sensor connections for

Channel 1. Channels 2, 3 and 4 connections are similar and
their pin connection numbers are shown below:

Channel Transmitter Connection

S 01

Quad Relay 1 15 17
Interface Connections 2 16 18
3 21 23
4 22 24

Four Wire Isolated Signal Input, Transmitter Connection for

Opus/Lifeline II

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Chapter 4 - Installation Instructions

Apex Transmitter Quad Relay Interface Card
05704-A-0121

Arrows Indicate Direction of

Loop Current Flow
+24V*
+24V
4 - 20mA(-) 01 17
0V NS 19

0V* Cabinet
Screened
Cable
Protective
Earth
Apex Link
1
2
Settings:
3
4
5 J4
6
7
J5
SK4
(Comms
and
Power) * 24V supply may be obtained
from either the cabinet or a
separate field supply

Apex

Notes: 1. The Apex Transmitter should be earthed locally. The transmitter is earthed through
the Earth Stud, to avoid earth loops the screen sheath of the cable should only be
connected at the transmitter.

2. The above diagram shows the sensor connections for Channel 1. Channels 2, 3 and
4 connections are similar and their pin connection numbers are shown below:

Channel Transmitter Connection

01 NS

Quad Relay 1 17 19
Interface Connections 2 18 20
3 23 25
4 24 26
Three Wire Control Card Current Sink, Transmitter Current
Source Connection for Apex (Signal Returned to 0V Supply)

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Chapter 4 - Installation Instructions

Apex Transmitter Quad Relay Interface Card
05704-A-0121
Arrows Indicate
Direction of Loop
Current Flow +24V*
+24V
4 - 20mA(-) S
15
4 - 20mA(+) 17
01
0V

Cabinet
0V*
Screened
Cable

Protective
Earth
Apex Link
1 Settings:
2
3
4 J4
5
6
7 J5
SK4
(Comms * 24V supply may be obtained
and
Power) from either the cabinet or a
separate field supply

Apex

Note: 1. The Apex Transmitter should be earthed locally. The

transmitter is earthed through the Earth Stud, to avoid
earth loops the screen sheath of the cable
should only be connected at the transmitter.

2. The above diagram shows the sensor connections for

Channel 1. Channels 2, 3 and 4 connections are similar and
their pin connection numbers are shown below:

Channel Transmitter Connection

S 01

Quad Relay 1 15 17
Interface Connections 2 16 18
3 21 23
4 22 24
Four Wire Isolated Signal Input, Transmitter Connection for
Apex
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Quad Relay Interface Card

05704-A-0121
Series 2000
Flammable
Arrows Indicate
Direction of Loop
Current Flow +24V*

11 +24V
4 4 - 20mA (-) 01 17
9 0V NS 19
2
3
GND
0V*

Link fitted for Screened Cable

Transmitter Source
Protective
Earth Stud Earth

Cabinet

* 24V supply may be obtained

from either the cabinet or a
separate field supply

Notes: 1. Where a sensor is earthed locally, either to an Earth Stud or

through the sensor casing or mounting, to avoid earth loops
the screen sheath of the cable should only be connected at
one end.

2. The above diagram shows the sensor connections for Channel

1. Channels 2, 3 and 4 connections are similar and their pin
connection numbers are shown below:

Channel Sensor Connection

01 NS

Quad Relay 1 17 19
Interface Connections 2 18 20
3 23 25
4 24 26

Three Wire Control Card Current Sink, Transmitter Current

Source Connection for Series 2000 Flammable
(Signal Returned to 0V)

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Chapter 4 - Installation Instructions

Quad Relay Interface Card
05704-A-0121
Connections using a
Searchline Excel Receiver DVC100 Junction Box
Current Source
Field Connections Cabinet
4 1
Arrows Indicate

2
3

4
BLUE B Direction of Loop

6
Current Flow +24V*

36 34 32 30 28 26 24 22 20 18 16 14 12 10 8
ORANGE A

35 33 31 29 27 25 23 21 19 17 15 13 11 9
BLACK 0V 28
1 0V DC Supply NS
WHITE 4-20mA 4-20mA Output 01 17
4 +24V DC Supply 19
RED 24V
GND
GRN/YEL GND 0V*

Receiver Connections
Connections using a
DX100 Junction Box Screened Cable
BLUE B

ORANGE A * 24V supply may be obtained from either

Control Cabinet the cabinet or a separate field supply Protective
Connections Earth
4 TB1 1
+24V DC Supply Rx (+24V)
(Instrument
or Clean
4-20mA Output Rx (SIG)
Earth)
0V DC Supply Rx (0V)
IS EARTH IS EARTH

1 TB2 4
Cable
Earth Shield
Terminal
Earth

RED +24V
Instrument Earth
WHITE 4-20mA
BLACK 0V
GRN/YEL GND

Notes: 1. Where a sensor is earthed locally, either to an Earth Stud or

through the sensor casing or mounting, to avoid earth loops
the screen sheath of the cable should only be connected at
one end.

2. The above diagram shows the sensor connections for Channel

1. Channels 2, 3 and 4 connections are similar and their pin
connection numbers are shown below:

Channel Sensor Connection

01 NS

Quad Relay 1 17 19
Interface Connections 2 18 20
3 23 25
4 24 26

Three Wire Control Card Current Sink, Transmitter Current

Source Connection for Searchline Excel
(Signal Returned to 0V)

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Chapter 4 - Installation Instructions

Notes: 1. Where a sensor is earthed locally, either to an Earth Stud or

through the sensor casing or mounting, to avoid earth loops
the screen sheath of the cable should only be connected at
one end.

2. The above diagram shows the sensor connections for Channel

1. Channels 2, 3 and 4 connections are similar and their pin
connection numbers are shown below:

Channel Sensor Connection

01 NS Ground

Quad Relay 1 17 19 13
Interface Connections 2 18 20 14
3 23 25 13
4 24 26 14

Three Wire Control Card Current Sink, Transmitter Current Source Connection
for Searchline Excel Cross Duct (Signal Returned to 0V)

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Chapter 4 - Installation Instructions

Notes: 1. Where a sensor is earthed locally, either to an Earth Stud or

through the sensor casing or mounting, to avoid earth loops
the screen sheath of the cable should only be connected at
one end.

2. The above diagram shows the sensor connections for Channel

1. Channels 2, 3 and 4 connections are similar and their pin
connection numbers are shown below:

Channel Sensor Connection

01 NS Ground

Quad Relay 1 17 19 13
Interface Connections 2 18 20 14
3 23 25 13
4 24 26 14

Three Wire Control Card Current Sink, Transmitter Current Source Connection
for Searchline Excel Cross Duct (Signal Returned to 0V)

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Terminal Quad Relay Interface Card
Block 05704-A-0121
Junction
Searchpoint Optima Box
(Configured for current Arrows Indicate
source using hybrid Direction of Loop
module 04200-A-0146) Current Flow +24V*
SHC1
+24V

4 - 20mA (-) 01 17
- 0V NS 19
GND

0V*
Screened Cable
Earth Green/Yellow - Ground
Terminal Black - 0V DC Supply Protective
White - 4 - 20mA Output Earth
Red - +24V Supply
Cabinet
Blue Communications
Orange Link to SHC1
* 24V supply may be obtained
from either the cabinet or a
separate field supply

Notes: 1. Where a sensor is earthed locally, either to an Earth Stud or

through the sensor casing or mounting, to avoid earth loops
the screen sheath of the cable should only be connected at
one end.

2. The above diagram shows the sensor connections for Channel

1. Channels 2, 3 and 4 connections are similar and their pin
connection numbers are shown below:

Channel Sensor Connection

01 NS

Quad Relay 1 17 19
Interface Connections 2 18 20
3 23 25
4 24 26

Three Wire Control Card Current Sink, Transmitter Current

Source Connection for Searchpoint Optima
(Signal Returned to 0V)

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Chapter 4 - Installation Instructions

Quad Relay Interface Card
Terminal 05704-A-0121
Junction Block
Box
Searchpoint Optima Plus Arrows Indicate
Configured for current Direction of Loop
source Current Flow +24V*
SHC1
+24V
01 17
4 - 20mA (-)
- 0V NS 19
GND

0V*
Screened Cable
Earth Green/Yellow - Ground
Terminal Black - 0V DC Supply Protective
White - 4 - 20mA Output Earth
Red - +24V Supply
Cabinet
Blue Communications
Orange Link to SHC1
* 24V supply may be obtained
from either the cabinet or a
separate field supply

Notes: 1. Where a sensor is earthed locally, either to an Earth Stud or

through the sensor casing or mounting, to avoid earth loops
the screen sheath of the cable should only be connected at
one end.

2. The above diagram shows the sensor connections for Channel

1. Channels 2, 3 and 4 connections are similar and their pin
connection numbers are shown below:

Channel Sensor Connection

01 NS

Quad Relay 1 17 19
Interface Connections 2 18 20
3 23 25
4 24 26

Three Wire Control Card Current Sink, Transmitter Current

Source Connection for Searchpoint Optima Plus
(Signal Returned to 0V)

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Chapter 4 - Installation Instructions

Quad Relay Interface Card
05704-A-0121

Arrows Indicate Direction of

Loop Current Flow
Digi Series +24V*

+24V
4 - 20mA(+) 01 17
0V NS 19

See Table for Cabinet

0V*
Sensor Wiring
Screened Cable

4-20mA(+) * 24V supply may be obtained

from either the cabinet or a Protective
1 LK2 Fitted separate field supply Earth
2
3
4
(For Current Source)
0V

Block Sensor Connections

+24
Wiring Digi-Cat Digi-Chem Digi-Ana
Catalytic ECC Analogue
Terminal
Signal Colour Signal Colour Signal Colour

1 GND - GND - - -
2 NS Blue C Brown 01 Brown*
Sensors: 704 705 3 C/T White R White 0V/NS Blue*
783 811 4 S Brown W Blue +24V
910 911
* Valid for 811 and 911. For other sensors, see sensor documentation.

Notes: 1. Where a sensor is earthed locally, either to the Earth Stud or through the sensor
casing or mounting, to avoid earth loops the screen sheath of the cable should only
be connected at one end.

2. The above diagram shows the sensor connections for Channel 1. Channels 2, 3 and
4 connections are similar and their pin connection numbers are shown below:

Channel Transmitter Connection

01 NS

Quad Relay 1 17 19
Interface Connections 2 18 20
3 23 25
4 24 26
Three Wire Control Card Current Sink, Transmitter Current
Source Connection for Digi Series (Signal Returned to 0V
Supply)
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Chapter 4 - Installation Instructions

Quad Relay Interface Card
05704-A-0121
Arrows Indicate
Direction of Loop
Digi Series +24V*
Current Flow
+24V
4 - 20mA(-) S
15
17
4 - 20mA(+) 01
0V
GND
See Table for Sensor Wiring Cabinet
0V*
4-20mA(-) Screened Cable

4-20mA(+) * 24V supply may be obtained

from either the cabinet or a Protective
1
2 separate field supply Earth
3
4
Do not fit LK2 or LK3

0V
+24 Block Sensor Connections

Wiring Digi-Cat Digi-Chem Digi-Ana

Catalytic ECC Analogue
Terminal
Signal Colour Signal Colour Signal Colour

Sensors: 704 705 1 GND - GND - S -
2 NS Blue C Brown 01 Brown*
783 811 3 C/T White R White 0V Blue*
910 911 4 S Brown W Blue +24V

* Valid for 811 and 911. For other sensors, see sensor documentation.

Note: The above diagram shows the sensor connections for Channel
1. Channels 2, 3 and 4 connections are similar and their pin
connection numbers are shown below:

Channel Transmitter Connection

S 01

Quad Relay 1 15 17
Interface Connections 2 16 18
3 21 23
4 22 24

Four Wire Isolated Signal Input, Transmitter Current Sink

Connection for Digi Series

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Quad Relay Interface Card

05704-A-0121
Series 2000 UL
Sensor Arrows Indicate
Terminal Block Direction of Loop Cabinet
Current Flow
Barrier Safety Ground

+24V
No +24V
Links S
4 - 20mA (+)
15
17
4 - 20mA (-) 01

0V

0V
Screened
Cable

Protective
Earth

Note: The above diagram shows the sensor connections for Channel
1. Channels 2, 3 and 4 connections are similar and their pin
connection numbers are shown below:

Channel Sensor Connection

S 01

Quad Relay 1 15 17
Interface Connections 2 16 18
3 21 23
4 22 24

Four Wire Floating Signal Input, Transmitter Current Sink

Connection

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12.5 IS Transmitter Connections

If the measuring resistance is in the negative supply line, a double

safety barrier must be used. Quad Relay Interface
Card
IS Series 2000 05704-A-0121
Toxic Sensor Arrows Indicate
Terminal Block Direction of Loop
Current Flow
Double IS
Safety Barrier
1 S 15

17
2 x3 01
19
x3
GND
NS

Two Core Screened Cable Protective

Earth Stud Earth

Cabinet

Note: The above diagram shows the sensor connections for Channel 1.
The connections for Channels 2, 3 and 4 are similar and their pin
connection numbers are shown below:

Channel Sensor Connection

S 01 0V

Quad Relay 1 15 17 19
Interface Connections 2 16 18 20
3 21 23 25
4 22 24 26

IS Series 2000 Toxic Sensor With Double Safety Barrier

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If the measuring resistance is in the negative supply line, a double
safety barrier must be used.

Note 1: *To ensure that the input circuit is properly referred to the safety
barrier it is necessary to connect the isolated 0V to the barrier
ground.

2: The above diagram shows the sensor connections for Channel

1. The connections for Channels 2, 3 and 4 are similar and
their pin connection numbers are shown below:

Channel Sensor Connection

S 01 0V

Quad Relay 1 15 17 19
Interface Connections 2 16 18 20
3 21 23 25
4 22 24 26

IS Lifeline Sensor With Double Safety Barrier

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13. OUTPUT CONNECTIONS
13.1 Relay Outputs

Note: The FAULT relay is permanently configured for normally

energised operation in the non-fault condition.

Caution
When mains ac is connected to the relay contacts:

a. The ac supply should be fused at 5A maximum.

b. A safety earth connection should be made to the ground

terminal of the relay card.
There are two relay card types providing different levels of alarm relay
capability (See Chapter 2 Section 5).

The cabling to the relays should where possible be kept away from the
sensor cabling, especially those cables carrying mains supplies. The
following figure shows the relay contact connections as shown on the
terminal block.

Com
Energised
Contact NO
Position
NC

Com
De-energised
Contact NO
Position
NC

De-energised and Energised Relays Showing Contact Positions

The alarm relays may be configured for either normally de-energised or

normally energised operation. Check the configuration sheet supplied
with the system to determine the operating mode of the relays on each
channel. The energisation mode of the relays can be reconfigured easily
using a computer attached to the Engineering Port. Contact Honeywell
Analytics or your local agent for more information.

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13.2 Analogue Output

Analogue Output Modules, when fitted, plug into the Four Channel
Control Card as shown below:

Plug-in Sockets for Analogue Output Modules:

04200-A-0145 Sink
04200-A-0146 Source
(From left to right - Channel 1 2 3 4)

CAUTION
Connecting the analogue output to a loop voltage in excess of 40V
may cause permanent damage to the analogue output module.
The Analogue Output Modules provides a current loop output that
follows each sensor signal level. The loop output is isolated from the
control card supply and provides:

a. fully isolated operation per card when powered from an external

supply.
b. Non-isolated operation when powered from the System 57 power
supply.

The analogue outputs can be configured for 0 - 20mA or 4 - 20mA

output modes. Check the configuration sheet supplied with the system
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to determine the factory configured operating mode. The operating
mode can be reconfigured easily using a computer attached to the
Engineering Port. Contact Honeywell Analytics or your local agent for
more information.
Note: With software versions prior to 1V6, the analogue output signal
may not properly reflect the sensor signal when the sensor signal
is outside the normal measuring range.
The analogue outputs can be connected to voltage input device (eg.
chart recorders) by including an external sense resistor in series with
each loop and connecting the device input in parallel with the resistor.
ie. Use a 100 ohm resistor and select an input range of 2V on the chart
recorder.

The recommended connections are:

Channel Analogue Power Supply

Output 0V 24V

Quad Relay 1 29 28 27
Interface Connections 2 30 28 27
3 31 28 27
4 32 28 27

Quad Relay Interface Card 05704-A-0121

Programmable Four Channel Control Card Fitted with:

Logic
Controller Analogue Output Module (Sink) 04200-A-0145

+24V
(18V to 40V)
Analogue 24V

28
27
Analogue Channel 1
29

Analogue OV

0V

Isolated Analogue Output Connection with Power Sourced from

Programmable Logic Controller Using Sink Module

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Chapter 4 - Installation Instructions

Channel Analogue Power Supply

Output 0V 24V

Quad Relay 1 29 28 27
Interface Connections 2 30 28 27
3 31 28 27
4 32 28 27

Quad Relay Interface Card 05704-A-0121

Four Channel Control Card Fitted with:

Analogue Output Module (Source) 04200-A-0146

Programmable
Logic
Controller

+24V
(18V to 40V)
Analogue 24V 28
27

29
Analogue Channel 1

Analogue OV

0V

Isolated Analogue Output Connection with Power Sourced from

Programmable Logic Controller Using Source Module

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Quad Relay Interface Card 05704-A-0121

Four Channel Control Card Fitted with:

Analogue Output Module (Sink) 04200-A-0145

+24V
(18V to 40V)

Anlogue 24V

Current 28
Sense 27
Analogue Channel 1
29

Analogue 0V

0V

Non-isolated Analogue Output Connection with Power from

System 57 Using Sink Module

Quad Relay Interface Card 05704-A-0121

Four Channel Control Card Fitted with:

Analogue Output Module (Source) 04200-A-0146

+24V
(18V to 40V)

28
Analogue 24V 27
Analogue Channel 1

Current 29
Sense Analogue 0V

0V

Non-isolated Analogue Output Connection with Power from

System 57 Using Source Module

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Quad Relay Interface Card 05704-A-0121

Four Channel Control Card Fitted with:

Analogue Output Module (Sink) 04200-A-0145

+24V
(18V to 40V)

Anlogue 24V
Chart
+
Recorder R = 100 28
Input Analogue Channel 1 27
-
29

Analogue 0V

0V

Analogue Output Connection with 100 Ohm Sense Resistor and

Parallel Chart Recorder Using Sink Module
Quad Relay Interface Card 05704-A-0121

Four Channel Control Card Fitted with:

Analogue Output Module (Source) 04200-A-0146

+24V
(18V to 40V)

28
Analogue Channel 1 Analogue 24V 27

Chart +
29
Recorder R = 100
Input
-
Analogue 0V

0V

Analogue Output Connection with 100 Ohm Sense Resistor and

Parallel Chart Recorder Using Source Module

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14. REMOTE INPUT CONNECTIONS

CAUTION

Connecting voltages in excess of 32V to the remote inputs may

cause permanent damage to the Four Channel Control Card.

There are two remote inputs, RESET and INHIBIT, which are individually
configurable for active high or active low operating modes. Each input
is common to all four channels of the Four Channel Control Card.
Check the configuration sheet supplied with the system to determine
the factory configured operating modes. The operating mode can be
reconfigured easily using a computer attached to the Engineering Port.
Contact Honeywell Analytics or your local agent for more information.

The switching level of the remote input pins (when enabled) is

approximately +2V with respect to the dc system 0V. The inputs require
less than 5mA drive current and irrespective of configuration are
internally pulled down to system 0V.

Active high remote inputs may be left unconnected or can be connected

to +24V via a normally open contact. The remote input will operate
whenever the contact closes.

Active low remote inputs may be connected to +24V via a normally

closed contact. The remote input will operate whenever the contact
opens. Do not leave active low inputs unconnected.

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Four Channel Control Card Configured for active

05704-A-0145 4 - 20mA high remote inputs
05704-A-0144 Catalytic

Quad Relay Interface Card

05704-A-0121

Normally Open Contact

+24V
(18V to 32V)

RESET Remote Reset 33 34

+24V

INHIBIT Remote Inhibit

Active High Remote Input Connected via Normally Open Voltage

Free Contact to +24V

Four Channel Control Card Configured for active

05704-A-0145 4 - 20mA low remote inputs
05704-A-0144 Catalytic

Quad Relay Interface Card

05704-A-0121

+24V
Normally Closed Contact (18V to 32V)

RESET Remote Reset 33 34

+24V

Remote Inhibit
INHIBIT

Active Low Remote Input Connected via Normally Closed

Voltage Free Contact to +24V

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Chapter 4 - Installation Instructions

15. DC POWER CONNECTIONS
15.1 General
CAUTION
The ratings of power supplies should be checked by calculating a
system power budget as outlined in Section 5.
IMPORTANT
The System 57 must be earthed
DC power is connected to the System 57 via the DC Input Card terminal
block TB1 and via the Quad Relay Interface Cards.
The DC Input Card provides diode isolation to permit the connection
of two separate power supplies. eg. A mains derived dc power supply
and battery backup dc supply. Note that current will be drawn from
the supply input with the highest voltage and in some circumstances
current will be shared between the two inputs. Each of the two inputs
have twin +24V and 0V terminals for easy through power connection
or paralleling of input sources.
A fused +24V output, which is the combination of both dc inputs, is
provided for powering ancillary devices.
TB1

12
Site PSU
24V DC Nominal 11
10
Site PSU
Through Wiring 9
8
Aux Battery
24V DC Supply 7
FS1
6 10A
Aux Battery
Through Wiring 5
4
24V Output to
Ancillary Equipment 3
2
1

System Earth

Site DC Supply and Auxiliary Battery Backup DC Power Supply

Connections, With Through Wiring

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15.2 Individually Powered Control Cards

Notes: 1. In individually powered control systems a DC connection is

still required to the DC Input Card in order to provide power
to the Engineering Card.

2. The supply to each control card must be externally fuse rated

at 2A maximum.

Individually powered control cards may be required for two reasons:

a. Where the local or other regulations dictate individual connections

in order to achieve the highest integrity for power distribution.

b. In densely populated racks to reduce the current load on the

backplane.

The System 57 DC Input Card supply is fused at 10A and to ensure

reliable operation of the system, the maximum continuous current flow
in the rack backplane should be less than 8A. In 16 channel racks,
substantially populated with four channel catalytic control cards, this
backplane current can be exceeded, especially where long sensor
cable runs are present. Therefore, as a general rule, where more than
eight catalytic control cards are used in a single rack, these should be
powered using the individually powered scheme.

Individual powering of a four channel control card is easily achieved

as follows:

(1) On the Four Channel Control Card, remove the link LK1 from
position 1 - 2 and refit in position 2 - 3 as shown below:
LK1
1 2 3

+24V
(18V to 32V)

External
Fuse 2A
Maximum
35 36

Four Channel Control Four Channel Control 0V

Card Catalytic Input Card 4 - 20mA Input

(2) Wire the +24V DC power supply to the respective Quad Relay
Interface Card terminals 35 (+24V) and 36 (0V) as shown above:

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Chapter 4 - Installation Instructions

16. AC TO DC POWER SUPPLY UNIT CONNECTIONS

Warning

The AC to DC Power Supply Unit must be earthed.

The input supply to the AC to DC Power Supply Unit may be:

a. an ac supply of 85V to 264V at 47Hz to 440Hz.

b. a dc supply of 110V to 340V (Refer to Honeywell Analytics for

information on dc supplies).

The supply must be fused at 6A maximum at the supply source. eg. At

the distribution panel. Where additional cabling is used this must be
mains rated for a minimum of 6A.

Two cables emerge from the rear of the AC to DC Power Supply

Unit:

a. AC Input

The ac supply cable connections are colour coded BROWN - LIVE,

BLUE - NEUTRAL and YELLOW/GREEN - EARTH. If necessary,
these wires should be connected to the ac supply via a suitable
intermediate mains rated terminal block.

b. DC Output

The dc output cable connections are colour coded RED - +24V and
BLACK - 0V. These should be connected to the appropriate DC Input
Card terminals.

It is recommended that the AC to DC Power Supply Unit is connected

to the system earth using the earth stud provided at the rear of the unit.
For additional electrical safety a Residual Current Device (RCD) type
circuit breaker should be used at the supply source.

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AC to DC PSU AC to DC PSU
50W Sub-Unit 50W Sub-Unit

Earth Earth
AC Input Stud System
Stud
Supply Earth

Brown
L
Blue
N
Green/Yellow
E
DC Input Card
L Brown TB1
Blue Red
N 12
Green/Yellow Black
E 11
Red
Black 10
9
Intermediate
Auxiliary 24V DC Supply 8
Terminal
Block (eg. Battery Backup) 7
6
5
24V Output to Ancillary 4
Equipment
3
2
1
System
Earth

Twin Sub-Unit AC to DC Power Supply Connections to AC Supply, Earth and DC

Input Card, Together with Auxiliary Battery Backup Supply

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17. UPGRADING The AC TO DC POWER SUPPLY
UNITS

WARNING

High voltages exist within the AC to DC Power Supply Unit.

Disconnect from the ac supply for a period of at least five minutes
before removing the top cover and carrying out any maintenance
or upgrade operation.

17.1 General

There are two types of AC to DC Power Supply Unit, an 8-Way 50W

and 16-Way 50W. The 8-way unit may be upgraded to 100W with the
addition of a second 50W Switched Mode Module. The 16-way unit
may be upgraded to 100W, 150W or 200W with the addition of 50W
Switched Mode Module(s) and if necessary a 50W Sub Unit.

Front View

Top View
50W Switched Mode AC to DC
Power Supply Module

Rear View

Input AC 24V 50W DC Earth

Supply Voltage Output Stud

8-Way AC to DC Power Supply Unit (50W)

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Front View

50W Switched Mode AC to DC

Power Supply Module

Top View

50W Switched Mode AC to DC

Power Supply Module

Rear View

Input AC 24V 100W DC Earth

Supply Voltage Output Stud

8-Way AC to DC Power Supply Unit (100W)

Front View

Top View 50W Switched Mode AC to DC

Power Supply Module

Rear View

Input AC 24V 50W DC Earth

Supply Voltage Output Stud

16-Way AC to DC Power Supply Unit (50W)

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Front View

50W Switched Mode AC to DC

Power Supply Module

Top View
50W Switched Mode AC to DC
Power Supply Module

Rear View

Input AC 24V 100W DC Earth

Supply Voltage Output Stud

16-Way AC to DC Power Supply Unit (100W)

Front View

50W Switched Mode AC to DC

Power Supply Module

Top View 50W Switched Mode AC to DC 50W Switched Mode AC to DC

Power Supply Module Power Supply Module

Rear View

Input AC 24V 100W DC Input AC 24V 50W DC

Supply Voltage Output Supply Voltage Output
Earth Earth
Stud Stud

16-Way AC to DC Power Supply Unit (150W)

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Front View

50W Switched Mode AC to DC 50W Switched Mode AC to DC

Power Supply Module Power Supply Module

Top View
50W Switched Mode AC to DC 50W Switched Mode AC to DC
Power Supply Module Power Supply Module

Rear View

Input AC 24V 100W Input AC 24V 100W

Supply Voltage DC Output Supply Voltage DC Output
Earth Earth
Stud Stud

16-Way AC to DC Power Supply Unit (200W)

17.2 8-Way and 16-Way AC to DC Power Supply Unit Upgrade

to 100W

To upgrade the 8-Way or 16-Way AC to DC Power Supply Units to

100W proceed as follows:

(1) Remove and retain the screws securing the top cover of the power
supply unit and lift the cover clear.

(2) Cut and remove the retaining straps that secure the unused ac and
dc connecting cables to the sub-unit chassis.

(3) On the 50W Switched Mode Module to be added to the 50W Sub-
Unit, remove and discard the four packing screws from the underside
of the module, however, retain the long nuts and washers.

(4) On the 50W Switched Mode Module to be added to the 50W Sub-
Unit, ensure that the spacers under the printed circuit board are
correctly located.

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(5) Insert the module, with the same orientation as the already fitted
module, into the vacant position inside the 50W Sub Unit and secure
using the washers and long nuts retained in Step (3).

(6) Connect the 50W Sub Unit second ac input and 24V dc output cable
connectors to the ac input terminal CN1 and dc output terminal CN2
respectively on the added 50W Switched Mode Module as shown
below:

CN2 CN1
DC Output AC Input

(7) Refit the top cover.

17.3 16-Way AC to DC Power Supply Unit Upgrade to 150W or

200W

To upgrade the 16-Way AC to DC Power Supply Unit to 150W or 200W

proceed as follows:

(1) Fit a second 50W Sub unit, containing a 50W Switched Mode
Module, to the 16-way AC to DC Power Supply Unit front panel
using the fixings supplied.

(2) When an upgrade to 200W is required, fit a further 50W Switched

Mode Module into the new 50W Sub unit as indicated in Section
17.2.

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User NotesInstructions

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Chapter 5 - Commissioning and

Maintenance Instructions

5704 Series

Control System

Chapter 5

Commissioning and Maintenance

Instructions

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Chapter 5 - Commissioning and

Maintenance Instructions

Contents
Section Page

1. General 5-3

2. Start Up Procedure 5-3

3. Calibration 5-5

4. Maintenance 5-6

5. Error Codes 5-7

5.1 General 5-7

5.2 Start-up Hardware Faults 5-8
5.3 Run Time Errors 5-10
5.4 Calibration Errors 5-13
5.5 System Errors 5-16
5.6 Miscellaneous Errors 5-17

6. FAULT FINDING 5-18

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Chapter 5 - Commissioning and

Maintenance Instructions
WARNING

High ac mains voltages may be present at the system power supply

unit and at the relay terminals of the interface cards. Appropriate
safety precautions must be taken when commissioning or servicing
the system.

IMPORTANT

Commissioning and maintenance of the system should be carried out

by trained authorised personnel only.

1. General
The following guide to commissioning and maintenance should be used
in conjunction with the relevant instructions issued with the sensors
being used.

2. Start Up Procedure
A detailed check of the system wiring should be carried out prior to this
start-up procedure.

Start-up the system as follows:

(1) Ensure that the system power supply is switched off.

(2) Disconnect the power supply connections to the DC Input Card by

removing the two part connector TB1 and TB2 if fitted.

(3) Unscrew the two retaining screws used to secure the control cards
and then, using the extraction tool, partially remove the cards from
the rack so that there is no electrical connection between the control
cards and the backplane.

(4) Switch on the system power supply.

(5) Check that a voltage of between 18V and 32V dc exists at the
terminal block TB1 (and for individually power systems on each of
the Quad Relay Interface Card terminals 35 and 36).

(6) Switch off the power supply.

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Chapter 5 - Commissioning and

Maintenance Instructions
(7) Reconnect the terminal block TB1 to the DC Input Card.

(8) Switch on the system power supply.

(9) Check that a voltage of between 18V and 32V dc still exists at the
terminal block TB1.

(10) Check that the Engineering Card front panel power on ( ) green
LED is illuminated and the unlocked ( ) LED is flashing.

(11) Push the control card in slot 1 fully into the rack so that it makes
connection with the backplane and secure with the two securing
screws.

(12) Check that the display operates and that the INHIBIT LED on the
control card front panel is illuminated.

(13) Check that after the pre-defined start up inhibit period, typically 30
seconds, the INHIBIT LED are extinguished.

(14) Check the operation of each connected sensor by checking the

BEAD mA and mV SIGNAL for a catalytic sensor or the mA SIGNAL
for a 4 - 20mA sensor.

(15) Repeat Steps (11) to (14) for the remaining control cards in the
rack.

(16) Reconnect the terminal block TB2 to the DC Input Card and test the
optional Engineering Card module in accordance with the relevant
operating manual instructions.

(17) Verify the alarm configuration for each channel using the relay test
procedure outlined in Chapter 7 Section 6.

(18) Verify that the System 57 Control Cards and power supply are
operating within the maximum specified operating temperature of
55oC.

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Maintenance Instructions
3. Calibration
Leave the connected sensors to stabilise for a period as specified in
the sensor manual.

Adjust the sensor head current of catalytic sensors as described in

Chapter 7 Section 7 to the required value as indicated in the sensor
operating instructions.

Using the procedures specified for the type of sensors being used,
follow the zero and 1st span operational guide in Chapter 7 Sections
8 and 10, and calibrate each channel.

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Chapter 5 - Commissioning and

Maintenance Instructions
4. Maintenance
To ensure that the system functions correctly, maintenance should be
carried out on a regular basis as dictated by the site regulations and
instructions for the type of sensor being used. For installations in the
EU, EN 60079-29-2 should be followed.”
The system should be maintained in a clean condition and kept free
from dust and grease. The following checks should be made annually,
or more frequently if required by local regulations or procedures:

(1) Check and if necessary tighten all terminations to the DC Input Card,
Quad Relay Interface Cards and if fitted to the Expansion Relay
Card.

(2) Check that the Engineering Card power on ( ) green LED is

illuminated and all other LEDs are extinguished.

(3) Check the display of each channel in use, of every control card,
indicates a normal reading with no error messages.

(4) Select each channel of every control card, in turn, and check
that channels sensor signal reading and, if a catalytic sensor is
connected, the sensor bridge current.

(5) With the Engineering Key fitted to the Engineering Card, select
each channel of every control card in turn and enter the alarms test
function.

(6) Check the alarm levels, alarm LED operation alarm relay operation
and display operation for each channel.

(7) Check the operation of all fault and inhibit relays.

(8) Check that, with the sensor in a gas free atmosphere, the display
indicates zero. If appropriate adjust the zero reading using the ZERO
function.

Note: For oxygen applications the zero function should only be operated in
an oxygen free atmosphere. Under normal atmosphere conditions
the display should indicate 21% ± 0.5% v/v, this can be adjusted
by using the SPAN function.
The System 57 control cards and engineering cards carry out continual
self checking of the integrity of the hardware, software and sensor
operation. In the event of a problem, and depending on the type of
problem, the control card will indicate either an error message on the
LCD display or will operate the fault LED and relay output.

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Maintenance Instructions
5. ERROR CODES
5.1 General
Operating errors within the system are indicated on the LCD message
display as an error code. The error codes used and their meaning are
listed in the following sections. These sections also contain appropriate
information pertaining to the likely cause of the error message being
displayed and an indication on how the error affects the operation of
the channel card.
Error Code: This relates to the error code message ERxx displayed
on the LCD message display. If more than one error is
present simultaneously, the error with the highest code
number is displayed
Card Status: This refers to the condition of the control card
operation.
Active means that the card is still processing signals
from the connected sensor and, in the event of the
sensor detecting gas, will still activate any configured
alarm outputs.
Non active means that it is not possible for the control
card to generate any alarms in response to the sensor
detecting gas.
Fault Signal: This refers to the indication of the fault condition in
response to the error condition.
Yes means that the appropriate channel front panel fault
LED and any configured fault relay will be operated.
No means that no fault indication is given. The error
condition that causes these general warning messages
is of a minor nature and the channel card will continue
to operate. The condition should however still be
investigated.
Latch: This refers to the condition of the error message and
the associated fault signal.
Yes means that the control card will continue to display
the error message until the condition causing the
error has cleared and the reset push-button has been
operated.
No means that the error message will clear automatically
once the condition causing the error message has
cleared.
Conf. means that the latch/non-latch condition
is configurable using the Engineering Interface
Software.
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5.2 Self Test Faults

Note: In addition to some of the following fault codes that may be

displayed, the control card ATTN LED will flash one second on
one second off should a hardware or software fault be detected
on the control card.
Error Error Code Meaning Software Card Fault Latch
Code Version Status Signal

99 RAM Failure. All Non Yes Yes

Active
RAM stores the working values during
operation.

The RAM failure message is displayed if there

are errors in the read/write byte test during
the system start-up or periodicself test.

This is a serious card failure and, as such, the

card needs to be replaced.

98 ROM Failure. All Non Yes Yes

Active
The ROM stores the channel card program.

The ROM failure message is displayed if

there are errors in the read byte test during
the system start-up or periodic self test.

This is a serious card failure and, as such, the

card needs to be replaced.

97 EEPROM Failure.
All Non Yes Yes
The EEPROM holds the application Active
configuration data.

The EEPROM failure message is displayed if

there is a checksum difference or it has been
impossible to carry out a checksum test during
start-up or periodic self test.

This is a serious card failure and, as such, the

card needs to be replaced.

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Error Error Code Meaning Software Card Fault Latch
Code Version Status Signal

96 No Vps. All Non Yes Yes

Active
Vps is a voltage which is used to set the
absolute value reference for the reading scaling
factor.
The no Vps message is only displayed on
a channel card that has not been factory
tested.
This is a serious card failure and, as such, the
card needs to be replaced.

95 Not used.

94 Not used.

93 Configuration Fault All Non Yes Yes

Active
The configuration fault message is displayed
during start-up if the channel card has no
configuration information or the configuration
is not valid..

This is a serious card failure and, as such, the

card needs to be replaced.

92 Not used.

91 Power Fail Error

The power fail error message is displayed if the 1V5 Non Yes No
system supply voltage falls below approximately Active
16V dc.
1V6 Non Yes Conf*
or Active
The error latches* if the power failure delay is later
not enabled.

Check the operation of the power supply. When

the power is restored, check the operation of the
system.

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5.3 Run Time Errors
Error Error Code Meaning Software Card Fault Latch
Code Version Status Signal

89 Hardware Fault All Non Yes Yes

Active
The hardware fault message is displayed
if the channel card detects a fault in its
operation or a fault with a sensor input.
Check the sensor connections. Remove the
channel card and insert it into a compatible
working channel and check its operation
(ER86 may appear during this operation
- this is normal). If the card still indicates
a fault, it must be replaced. If the card is
working, the sensor should be replaced.
88 Under Range Fault All Non Yes Conf
Active
The under range fault message is displayed
when the sensor signal reading is less than
the predetermined level held within the
channel configuration data.
Typically this is due to either the sensor or
the sensor cable installation being open
circuit.
87 Over Range Fault All Non Yes Conf.
Active
The over range fault message will appear
when the sensor signal reading is above the
predetermined level held within the channel
configuration data.
Typically, this is due to either the sensor
or the sensor cable installation being short
circuit. Alternatively, the sensor may be
detecting a very high level of gas.
The reset of a latched signal overrange fault
condition should only be carried out after
checking that the sensor is in clean (non
target gas) air.

86 Card In Wrong Slot All Non Yes No.

Active
The card in wrong slot message is displayed
if a channel card has been moved to a
different slot from the one that it had been
calibrated for.

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Error Error Code Meaning Software Card Fault Latch
Code Version Status Signal

This allows cards to be moved to alternative

slot locations for fault finding purposes.
This message may also be displayed when
fitting a new channel card or fitting a spare
replacement. The message can be cleared by
calibrating the channel card to the new slot
location and connected sensor.

Depending on the alarm configuration,

moving channel cards to alternative slots may
compromise the generation of alarms. The
alarm operation should be checked after the
card has been moved and calibrated.

85 Not used

84 Datasum Changed All Non Yes No

Active
The datasum changed message is displayed
if there is a failure in the channel card RAM
during normal operation.

The card should be reset by removing the

power to the card. This is achieved by
removing the card from the rack slot and
then replacing the card back into the rack
slot. If the error message persists the card
needs replacing.

83 Bead Current Fault 1V6 Non Yes Yes

or Active
The current setting fault message is later
displayed when the control card is unable to
set or maintain the correct operating current
for a catalytic sensor.

Check the cable sensor connection and cable

line lengths to ensure that the maximum line
impedance has not been exceeded.

82 Lifetime Expired All Active No No

The lifetime expired message is displayed if
the catalytic sensor sensitivity falls to below
50% of its original value.

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Error Error Code Meaning Software Card Fault Latch
Code Version Status Signal

The lifetime is calculated on the difference

between the sensitivity measured during 1st
SPAN and that measured during subsequent
normal SPANs, and is only updated during
the SPAN function.
This is a warning that the sensor output is
becoming unacceptably low and may be due
to age or due to the sensor being 'poisoned'
by the presence of silicones, sulphur and
lead compounds.
The sensor should be replaced.

81 Signal Under Range All Non Yes Conf

Active
The signal under range message is displayed
when the sensor signal reading is less than a
predetermined level held within the channel
configuration data. This predetermined level
is below the normal operating range.

This is typically due to the sensor signal

drifting below the normal zero operating
point. This could, depending on the sensor
type, be due to large changes in climatic
conditions, loose terminal connections, the
sensor being poisoned or an early indication
of the failure of the sensor.

In some instances this error can be caused

by short circuits in the sensor or cabling.

The channel card should be calibrated and

its operation checked

80 Signal Over Range All Active No Conf

The signal over range warning message is

displayed when the sensor signal reading
is more than a predetermined level held
within the channel configuration data.This
predetermined level is above the operating
range.

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Error Error Code Meaning Software Card Fault Latch
Code Version Status Signal

This provides a warning that the sensor is

detecting a level of gas exceeding the set
operating range of the channel.

IMPORTANT

If configured for latching, the display

and analogue output may not indicate
the true gas concentration when
the measuring range is exceeded.
The reset of a latched signal overrange
warning condition should only be carried
out after checking that the sensor is in
clean (non target gas) air.

5.4 Calibration Errors

Error Error Code Meaning Software Card Fault Latch

Code Version Status Signal

79 Uncalibrated All Non No No

Active
The uncalibrated message is displayed for
new channel cards that have never been
calibrated.

The channel card should be calibrated and

its operation checked.

78 Calibration Overdue All Active No No

The calibration overdue message is
displayed when the pre-configured
calibration interval has expired.

This is a warning message that the sensor

is due for calibration. Once the calibration
has been completed the message will
clear.

If required, this function can be disabled

using the Engineering Interface Software
configuration program.

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Error Error Code Meaning Software Card Fault Latch
Code Version Status Signal

77 Zero Signal Too Low

The zero signal too low message is displayed

during calibration when the sensor zero
signal is below the pre-configured levels and
a zero calibration can not be achieved. All Active No No

For catalytic sensors this would typically

signify there is a large imbalance between
the two detecting elements of the sensor.
The sensor installation should be checked
for loose wires or the sensor replaced.

For mA sensors this would typically signify
that the mA output from the sensor requires
calibrating.

76 Zero Signal Too High

The zero signal too high message is

displayed during calibration when the
sensor zero signal is above the pre-
configured levels and a zero calibration can All Active No No
not be achieved.

This is typical of the sensor detecting its

target gas and zero gas should be applied
to the sensor. Alternatively, for catalytic
sensors, this would typically signify there
is a large imbalance between the two
detecting elements of the sensor. The
sensor installation should be checked for
loose wires or the sensor replaced.

For mA sensors this would typically signify

that the mA output from the sensor requires
calibrating.

75 Calibration Signal Too Low

The calibration signal too low message

is displayed during calibration when the
sensor span signal is below the pre-
configured levels and a span calibration can All Active No No
not be achieved.

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Error Error Code Meaning Software Card Fault Latch
Code Version Status Signal

This indicates that the output from the

sensor is too low due to either:

a. a faulty sensor which may be poisoned

or damaged.

b. the calibration gas is incorrect. Check

the calibration gas bottle certificate
and age.

c. sticky gas such as chlorine or ammonia

is not reaching the sensor.

Note: With software version 1V5, Error 75

may be generated while setting
zero. In this case see Error 77.

74 Calibration Signal Too High
All Active No No
The calibration signal too high message
is displayed during calibration when the
sensor span signal is above the pre-
configured levels and a span calibration
can not be achieved.

This indicates that the output from the

sensor is too high due to either:

a. a faulty sensor, bad cabling or wrong

sensor defaults in configuration.

b. the calibration gas is incorrect. Check

the calibration gas bottle certificate
and age.

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5.5 System Errors

Error Error Code Meaning Software Card Fault Latch

Code Version Status Signal

69 Invalid Sub-Channel All Active No No

Indicates a request has been received for
an invalid sub-channel address.

68 Printer Not Ready All Active No No

Indicates that the serial device attached to
the engineering port is not able to accept
data.

67 Invalid Request All Active No No

Indicates that an invalid request number

has been received.

66 Serial Communications Timeout All Active No No

Serial communications has timed out.

Reset card by removing power to the card.

If problem persists, replace the card.

65 Failed Error All Active No No

Failed to receive command or card

selected.

Reset card by removing power to the card.

If problem persists, replace the card.

64 Timeout Error All Active No No

Backplane command timed out.

Reset card by removing power to the card.

If problem persists, replace the card.

63 Slot Inactive Error All Active No No

Backplane command sent to empty slot.

Reset card by removing power to the card.

If problem persists, replace the card.

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Error Error Code Meaning Software Card Fault Latch
Code Version Status Signal

62 Communications Error All Active Yes No

A participant in a complex alarm

function hosted by this card has stopped
communicating.

Check all cards within the participant

group are fully inserted into the rack and
are functioning correctly.

5.6 Miscellaneous Errors

Error Error Code Meaning Software Card Fault Latch

Code Version Status Signal

07 Divide By Zero All Active No No

Internal calculation error.

Reset card by removing power to the

card. If problem persists, replace the
card.

01 Invalid Command All Active No No

A serial command has been received

that is not valid for this card.

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6. Fault Finding
The following table provides a guide to diagnosing various conditions
within the operation of System 57.

Note: In addition to some of the following fault codes that may be

displayed, the control card ATTN LED will flash one second on/one
second off should a hardware or software fault be detected on the
control card.

Fault Action

The Engineering Card front Disconnect TB1 and measure the

panel power on ( ) green voltage between the +24V dc and
LED extinguished. 0V terminals.

If the voltage is correct, remove the

DC Input Card and check the fuse
FS1.

If the voltage is not correct, check

the system power supply unit.

The Engineering Card front The dc input voltage is too low.

panel power on ( ) green
LED flashes at approximately Check dc voltage at the DC Input
two second intervals. Card terminals.

The Engineering Card front There is a hardware fault.

panel power on ( ) green
LED flashes at approximately Switch power of and then on again.
0.5 second intervals. If problem persists, check the
diagnostic printout for error codes

No dc voltage output from Check that the ac mains voltage is

Power Supply Unit. between 85V and 264V at the power
supply ac connection wires.

If yes, replace the 50W Power

Supply Module.

No readings on a control card Check that power is being applied to

display. the control card from the backplane
or Quad Interface Card as applicable
and the display still does not read,
replace the control card.

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Fault Action

An error message is Check the error code tables in
displayed. Section 5 for explanation.

A CHL LED indicates a fault Check the message display for

condition by flashing amber an error code. See Section 5 for
(one second on/one second explanation of error codes.
off).
Check channel sensor connection
and operation.

A CHL LED indicates an Wait for at least 255 seconds to see

inhibit condition by showing if the LED extinguishes.
continuous amber.
Insert the Engineers Key into the
Engineering Card and then operate
the INHIBIT push-button. This
should toggle the inhibit LED on
and off, otherwise check the remote
inhibit level.

The unlocked ( ) LED is Remove the Engineering Key from

illuminated. the Engineering Card.

The unlocked ( ) LED is Check that all the control cards are
flashing. fitted to the rack and are working.

If a card has been removed

deliberately, fit the Engineering Key
into the Engineering Card socket
and then remove the key again.

Select each control card in turn

and, using one of the Engineering
Card functions, check that
communications exist between
the selected control card and
Engineering Card.

Check that the dc power supply is

more than 16V.

The CHL LED indicates an

alarm condition by flashing Press the RESET/SELECT push-
red but no gas reading button momentarily to remove the
indicated. latched alarm condition.

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Fault Action
There is no relay operation Check to see if the channel is in the
and a CHL LED indicates inhibited condition and if necessary
either: remove the inhibit.
a. an alarm condition by Check to see that the type of relay
flashing red. interface card fitted can support the
OR expected alarm.
b. slow red flash one Check the channel card configuration
second on/one second to see that the relay is configured for
off. the expected operation.
OR
Swop the relay interface card with
c. a fault condition by another of the same type and test
flashing amber one relay action by using the Engineering
second on/one second Card alarm test function.
off.
OR
d. an inhibit condition by
showing continuous
amber.
symbol showing on the Engineering Card has no
message display. Engineering Key fitted.

If key is fitted but the unlocked

( ) LED is not illuminated check
the condition of Engineering Key and
replace if necessary.

XXXX is displayed on the The function selected is not available

message display when an on the channel hardware present.
engineering function has
been selected.

The engineering push- Select a channel card.

buttons have no effect.
Check that the Engineering Card
power on ( ) LED is illuminated.

The ATTN LED flashes Press the RESET/SELECT push-

rapidly but no gas reading button momentarily to remove
is indicated. latched update alarm conditions.

The ATTN LED is Check whether a channel has been

continuously on. left in the alarm test mode and
remove test mode.

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5704 Series

Control System

Chapter 6

Operating Instructions

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Chapter 6 - Operating Instructions

Contents
Section Page

1. GENERAL 6-3

2. USER OPERATING ROUTINES 6-3

3. CONTROL CARD 6-4

3.1 Reset 6-4

3.2 Extended Reset 6-4
3.3 Channel Reset - TWA Calculations 6-5
3.4 Card and Channel Select 6-5
3.5 Deselect 6-6

4. ENGINEERING CARD 6-6

4.1 General 6-6

4.2 Timeout 6-7
4.3 Bargraph Display 6-7
4.4 Catalytic Sensor Bridge Current 6-7
4.5 View Alarm Level Settings 6-7
4.6 Sensor Signal Monitoring 6-8
4.7 View Clock/Calendar 6-9
4.8 Maintenance Record Printout 6-10

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1. GENERAL
These operating instructions refer to the facilities available for general
operation and interrogation of the system without the Engineering Key
fitted.

Facilities that may effect the way the system operates are covered in
the Engineer's Operating Instructions Chapter 7 which refers to facilities
available when the Engineering Key is fitted.

2. USER OPERATING ROUTINES

Depending upon which keypad function push-buttons are operated, the
following user operating routines may be performed:

Channel reset.

Channel select.

View alarm levels.

Catalytic sensor current check.

Sensor signal monitoring.

Accept an update alarm

View clock/calendar.

Initiate a maintenance record printout.

Channel reset and select are performed by the channel card RESET/
SELECT push-button while the remaining functions are performed,
when a channel control card is selected using the Engineering Card
push-button controls.

Only one channel card can be selected at any one time and while
selected its microprocessor monitors the Engineering Card push-button
functions to determine what action should take place.

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3. CONTROL CARD
3.1 Reset

To reset a channel control card, briefly push and release its front panel
RESET/SELECT push-button.

This will:

a. Reset all latched non-active alarms or faults associated with each

channel of the control card.

b. Cancel all latched and non-active warning or information

messages.

c. Reset the peak reading display.

d. When active, acknowledge any update function .

e. Clear the attention lamp indication.

3.2 Extended Reset

Pressing the RESET/SELECT push-button continuously for

approximately five seconds will perform an extended card reset. During
this period the selected icon will flash on and off, and when the flashing
stops the reset will be complete.

The extended reset performs the following functions:

a. Maximum and Minimum Readings

The maximum and minimum gas readings available via the

engineering printout facility are cleared.

b. TWA Alarms

When exposure alarms are configured, the active short term (STEL)
or long term (LTEL) exposure alarms are cleared and the exposure
timer is reset.

Note: Only channels with active alarms are affected by the extended
reset. The exposure calculations on other channels may be reset
using the procedure outlined in Section 3.3.

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c. Relay Time Delays

When time delay relay functions are configured, the extended reset
will immediately:

i. Activate any inactive relay where an alarm condition is present

but a relay trigger delay is in progress.

ii. Clear any relay where the alarm condition is not present but
the relay is still active due to a relay hold time in progress.

3.3 Channel Reset - TWA Calculations

To reset a channel short term (STEL) and long term (LTEL) exposure
timer and calculations:

(1) First select the required channel using the procedure outlined in
Section 3.4.1.

(2) With the channel selected, press the RESET/SELECT push-button

continuously for five seconds. During this period the select icon will
flash on and off.

(3) When the flashing stops the exposure timer will be restarted from
zero.

3.4 Card and Channel Select

3.4.1 Card Select

To select a channel card for operations controlled from the Engineering

Card, push and hold the required channel card RESET/SELECT push-
button for approximately 1.5 seconds until the icon display changes
from the normal display to the selected display as shown below:

Normal Operation Selected

Digital
Display

Icon

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3.4.2 Channel Select
Once a card has been selected, a particular channel can then be
selected by using the ( ) and ( ) push-buttons on the Engineering
Card. The selected channel number will be shown on the message
display.
3.5 Deselect
3.5.1 Card Deselect
To deselect a selected channel card, briefly push its front panel RESET/
SELECT push-button.
The channel card will be deselected and any user operations in progress
which have not been confirmed will be cancelled. It should be noted
that the channel card will not be reset unless the RESET/SELECT
push-button is again momentarily pushed.
3.5.2 Card Deselect with Channel Display Lock
If the control card has been configured for a sequential channel display
mode, it is possible to lock the display to a particular channel by
deselecting the card using the push-button.
To lock the display to a particular channel:
(1) Select the required channel as indicated in Section 3.4.2.
(2) Briefly press the push-button and the select icon will clear.
The channel display will remain locked to the desired channel until the
card is next reset or selected.
4. ENGINEERING CARD
4.1 General
The Engineering Card push-button functions will only operate if a
channel card is selected. See Section 3.3.
Without the Engineering Key fitted to the Engineering Card, the following
Engineering Card push-buttons will not be available:
Inhibit
Zero
Span
1st Span
If any of these push-buttons are pushed, a locked symbol ( ) will be
briefly displayed on the selected channel card message display.

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4.2 Timeout

When operating the Engineering Card without an Engineering Key fitted

there is a timeout period of 30 seconds. If no push-buttons are pressed
within the timeout period, the selected channel card will automatically
be deselected.

4.3 Bargraph Display

When operating the Engineering Card without an Engineering Key fitted,

the selected channel's bargraph display will continue to indicate the
actual gas reading during the operation of the available Engineering
Card functions.

4.4 Catalytic Sensor Bridge Current

The operation associated with the BEAD mA push-button only applies

to catalytic channel cards. Operating this push-button with other types
of channel cards selected has no effect and the warning message
(XXXX) is displayed for a short time.

To enter the catalytic sensor bridge current operation, proceed as

follows:

(1) Push and hold the required channel card RESET/

SELECT push-button for approximately 1.5 seconds
until the selected icon appears on the channel
display.

(2) Use the Engineering Card ( ) and ( ) push-buttons

to select the required channel.

(3) Push the BEAD mA push-button and the selected

channel card display will indicate the configured
bridge current. eg. 200mA alternating with the selected
channel number.

(4) Push the reject ( ) push-button or wait 30 seconds to

exit the Bead mA mode.

4.5 View Alarm Level Settings

The operation of the ALARMS push-button allows the viewing of the

alarm threshold point and alarm type (rising or falling) for each alarm
set point A1, A2 and A3.

To enter the alarm view operation, proceed as follows:

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(1) Push and hold the required channel card RESET/SELECT push-
button for approximately 1.5 seconds until the selected icon appears
on the channel display.

(2) Use the Engineering Card ( ) and ( ) push-buttons to select the

required channel.

(3) Push the ALARMS push-button and the selected

channel card display will indicate the A1 level alarm
alternating with the selected channel number as
indicated opposite.

Note: The up arrow indicates a rising alarm while the

down arrow indicates a falling alarm.

(4) Push the ALARMS push-button a second time and the

selected channel card display will indicate the A2 level
alarm.

Note: Step (5), (6) and (7) will only be available if the control
card is configured for the stated alarm.

(5) Push the ALARMS push-button a third time and the selected channel
card display will indicate the A3. level alarm.

(6) Push the ALARMS push-button a fourth time and the selected
channel card display will indicate the STEL level alarm.

(7) Push the ALARMS push-button a fifth time and the selected channel
card display will indicate the LTEL level alarm.

(8) Further pushes of the ALARMS push-button will scroll through the
alarm level set points again.

(9) Push the ( ) or ( ) push-buttons or wait 30 seconds to exit the

ALARMS mode.

4.6 Sensor Signal Monitoring

The operation of the SIGNAL push-button allows the monitoring of the

selected channels sensor signal value. The displayed parameter is
dependent upon the type of selected channel card.

To enter the sensor signal monitoring operation, proceed as follows:

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(1) Push and hold the required channel card RESET/SELECT push-
button for approximately 1.5 seconds until the selected icon appears
on the channel display.

(2) Use the Engineering Card ( ) and ( ) push-buttons to select the

required channel.

(3) Push the SIGNAL push-button and the selected channel card display
will indicate the sensor signal alternating with the selected channel
number. The displayed value will depend on the type of control card
fitted as follows:

a. Four Channel Control Card - Catalytic

The display will show the live bridge

voltage measured between 01 and
02 in mV. 02 is the centre point of the
second half of the Wheatstone bridge
which is on the channel card.

b. Four Channel Control Card - 4-20mA

The display will show the live sensor

loop current in mA.

(4) Push the ( ) or ( ) push buttons or wait 30

seconds to exit the SIGNAL mode.

4.7 View Clock/Calendar

The operation of the CLOCK push-button will cause the present time
and date to be displayed on a selected channel card.

Note: This operation requires a control card to be selected but the

operation has no effect on the selected control card, which is used
as a display device only.

To enter the clock/calendar operation, proceed as follows:

(1) Push and hold the required channel card RESET/SELECT push-
button for approximately 1.5 seconds until the selected icon appears
on the channel display.

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(2) Push the CLOCK push-button and the
selected channel card display will indicate
the present time alternating with the
selected channel number.

Note: The clock uses the 24 hour format.

(3) Push the CLOCK push-button a second

time and the selected channel card display
will indicate the present day, month and
year alternating with the selected channel
number.

Note: 1. The display format for day and month can read either DD.MM
or MM.DD depending on the configuration of the system.

2. Further pushes of the CLOCK push-button will toggle the

display between time and date.

(4) Push the ( ) or ( ) push-buttons or wait 30 seconds to exit the

CLOCK mode.

4.8 Maintenance Record Print Out

A detailed printout of the status for each channel or a summary of the

whole rack can be initiated using the Engineering Card. The data is fed
in ASCII text format to the engineering serial port on the Engineering
Card front panel.

To output the maintenance record for each channel card, proceed as

follows:

(1) Plug a RS232 printer into the Engineering card serial port.

(2) Push and hold the required channel card RESET/SELECT push-
button for approximately 1.5 seconds until the selected icon appears
on the channel display.

(3) Use the Engineering Card ( ) and ( ) push-buttons to select the

required channel.

(4) Push the up ( ) and down ( ) buttons simultaneously. The selected

channel card will display PRN while outputting the following data:

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17/10/96 1:42
Slot : 04.3
Card Type : 5704
Sensor Type : 4 - 20mA
S/W : v01.00
Serial Number : 01234A02
Range : 0 - 100
Units : LEL
Sensor : 780
Gas : Methane
Tag : Vent 04
First Span : 10/04/96
Last Span : 16/09/96
Cal. rem. : 06 months
A1 : 0025 %fsd
A2 : 0050 %fsd
A3 : 0076.8 %fsd
Relay 01 active low
Local events assoc'd to this relay
Events : FT
Relay 02 active high
Local events assoc'd to this relay
Events : A1
Relay 03 active high
Local events assoc'd to this relay
Events : A2
Relay 04 active high
Local events assoc'd to this relay
Events : A3
Relay 12 active high
Local events assoc'd to this relay
Events : A3
Relay 13 active high
Local events assoc'd to this relay
Events : A2
Relay 14 active high
Local events assoc'd to this relay
Events : A1
Relay 15 active high
Local events assoc'd to this relay
Events : IN
Relay 16 active high
Local events assoc'd to this relay
Events : FT
Complex update activates relays:
13
Update assoc'd with the following
Events : A3 A2 A1

Note: 1. The information printed will vary slightly depending on the

type of control card fitted.

2. If an RS232 device is not connected or is not able to accept

characters, the selected control card display will show
XXXX.

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Chapter 6 - Operating Instructions

To output a summary of the whole rack, proceed as follows:

(1) Plug an RS232 printer into the Engineering Card serial port.

(2) Push the up ( ) and down ( ) buttons simultaneously without any

channel card being selected and the following data will be printed:

15/08/96 12:05
Type : Engineering Card
S/W : v00.70
Eng key override : inactive
Customer name :
DMT
Customer site :
Essen
Serial No : 01234A17
--
Slot : 01
Type : 5704
S/W : v01.00
Serial No : 01234A01
Tag : Unknown
Gas : Unknown
Range : 0 - 100
Active alarms : FT
--
Slot : 02
Type : 5704
S/W : v01.00
Serial No : 01234A02
Tag : 23C-03
Gas : Methane
Range : 0 - 100
Active alarms : A1
--
Slot : 12
Type : 5701
S/W : v00.75
Serial No : 01234A12
Tag : Unknown
Gas : Unknown
Range : 0 - 100
Active alarms : None

Note: The information printed will vary slightly depending on the type of
control card fitted.

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Chapter 7 - Engineer's Operating

Instructions

5704 Series

Control System

Chapter 7

Engineer's

Operating Instructions

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Chapter 7 - Engineer's Operating

Instructions
Contents
Section Page

1. General 7-3

2. Engineering Operating Routines 7-3

3. Unlocking the Engineering Card 7-4

4. Selected Card Operations 7-4

5. Channel Inhibit 7-5

6. Alarm Configuration and Relay Test 7-6

7. Catalytic Sensor Bridge Current Adjustment 7-9

8. Zero Signal Calibration 7-10

9. Span Signal Calibration 7-11

10. First Time Span Signal Calibration 7-13

11. Sensor Signal Monitoring 7-13

12. Setting the Clock/Calendar 7-14

13. Maintenance Operating Routines 7-15

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Chapter 7 - Engineer's Operating

Instructions
1. General
The engineer's operating instructions refer to the additional facilities
available to setup and maintain the system. Because the operation of
the system can be altered or impeded by these functions, they can
only be performed when the Engineering Card is unlocked by the
Engineering Key.

2. Engineering Operating Routines

Depending upon the which keypad function push-button is operated,
the following engineering operating routines may be carried out:

Channel Reset.

Channel Select.

Channel Inhibit.

Alarm Configuration and Relay Test.

Catalytic Bridge Current Adjustment.

Zero Signal Calibration.

Span Signal Calibration.

1st Span Signal Calibration.

Sensor Signal Monitoring.

Clock/Calendar Adjustment.

Channel select and reset are carried out by the channel card RESET/
SELECT push-button. See Chapter 6, Section 3.

The remaining engineering functions are carried out after a control card
has been selected using the Engineering Card push-button controls.

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Chapter 7 - Engineer's Operating

Instructions
3. Unlocking the Engineering Card
To unlock the Engineering Card, plug the Engineering Key into the
Engineering Card front panel socket. The Engineering Card Unlocked
LED ( ) will illuminate to indicate that it is unlocked.

External Engineering Port Engineering Key

Note: Inserting and then removing the Engineering Key resets the
Engineering Card communications failure warning indication.

4. Selected Card Operations
The operation to be carried out on the selected control card channel
is chosen by pushing one of the following Engineering Card control
push-buttons:

Bead mA ALARMS

ZERO SIGNAL

SPAN 1st SPAN

INHIBIT CLOCK

Once an operation has been selected, there are four control push-
buttons which may be used to manipulate the operation as required.
These are:

a. The up push-button, which may be used to raise the selected

control card indicted value. If held in the operated position, the
display will be increased by one unit every 0.5 seconds.

b. The down push-button, which may be used to lower the selected

control card indicated value. If held in the operated position,
the display will be decreased by one unit every 0.5 seconds.

c. The accept push-button, which may be used to accept the

selected control card displayed value and store this permanently
as part of the configuration. Returns the control card to the
selected mode.

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Chapter 7 - Engineer's Operating

Instructions
d. The reject push-button, which may be used to reject the selected
control card displayed value and return to the previous set
value. Returns the control card to the selected mode.

5. Channel Inhibit
INHIBIT

Pushing the Engineering Card INHIBIT push-button toggles the selected

control card channel inhibit mode between on and off.

When the inhibit mode is set to on, either locally from the Engineering
Card or remotely by the Remote Inhibit input, the selected control
card:

a. channel inhibit relay, if configured, is actuated.

b. channel LED shows continuous amber to indicate INHIBIT.

c. remaining channel relays are locked in their non-active state.

To select the inhibit function, proceed as follows:

(1) Plug the Engineering Key into the Engineering Card front panel
socket and check that the Unlocked LED ( ) is illuminated.

(2) Push and hold the required control card RESET/SELECT push-
button for approximately 1.5 seconds and check that the selected
control card indicates it has been selected by displaying the select
icon.

(3) Use the Engineering Card ( ) and ( ) push-buttons to select the

required channel.

(4) Push the INHIBIT push-button to toggle the channels inhibit mode
on/off.

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Chapter 7 - Engineer's Operating

Instructions
6. Alarm Configuration and Relay Test
ALARMS
The alarm configuration and relay test operation cycles through different
stages as follows:

a. Set thresholds for A1, A2, A3, STEL, LTEL.

These stages are used to set the A1, A2, A3, STEL and LTEL alarm
threshold points and do not affect the alarm LEDs and relays.

b. Test lamps and optional relays for A1, A2, A3, Fault, STEL, LTEL.

These stages provide a lamp test and relay test function.

Note: When not configured for STEL/LTEL threshold, a row of dashes will
be displayed instead of a level and the STEL and LTEL faclilities
will be set permanently to off.

To select the alarm configuration operation, proceed as follows:

(1) Plug the Engineering Key into the Engineering Card front panel
socket and check that the Unlocked LED ( ) is illuminated.

(2) Push and hold the required control card RESET/SELECT push-
button for approximately 1.5 seconds and check that the selected
control card indicates it has been selected by displaying the select
icon.

(3) Use the Engineering Card ( ) and ( ) push-buttons to select the

required channel.

(4) Push the Engineering Card ALARMS push-button for the first
time.

(5) Check that the selected control card message display shows A1
for a rising alarm threshold or A1 for a falling alarm threshold
alternating with the selected channel number.

(6) Check that the selected control card digital display indicates the A1
alarm threshold point.

Note: The analogue display continues to show the sensor live

measurement.

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Instructions
(7) If required, use the ( ) and ( ) push-buttons to set a new A1 alarm
threshold point.

Note: The threshold level can only be set to a level that is between the
high and low points set in the Control Card configuration.

(8) When the correct level has been set, and if no more adjustments
are required, push the push-button to set the new level and store
this permanently. Otherwise proceed to the next step.

Note: If it is required to cancel the procedure at any time without altering

the original setting to the displayed value, press the push
button.

(9) Push the Engineering Card ALARMS push-button a second time

and repeat Steps (5) to (8) for the A2 threshold points setting.

(10) Push the Engineering Card ALARMS push-button a third time and
repeat Steps (5) to (8) for the A3 threshold points setting.

(11) Push the Engineering Card ALARMS push-button a fourth time and
repeat Steps (5) to (8) for the STEL threshold points setting.

(12) Push the Engineering Card ALARMS push-button a fifth time and
repeat Steps (5) to (8) for the LTEL threshold points setting.

(13) Push the Engineering Card ALARMS push-button for a sixth time
and TEST will be displayed on the message display alternating with
the selected channel number. Initially the A1 level of the selected
channel is displayed on the digital and analogue displays and the
associated CHL LED is illuminated at the A1 Alarm rate. The ATTN
LED will also be lit.

(14) Use the ( ) and ( ) push-buttons to raise or lower the simulated

gas level over a range of levels that includes the A1, A2, A3 and
underrange Fault values. Check that the selected control card
indicates the simulated gas level on the analogue and digital display,
and that the appropriate alarm states are indicated on the selected
channel LED.

(15) Push the Engineering Card ALARMS push-button for a seventh time
and STEL will be displayed on the message display alternating with
the selected channel number. The digital display will indicate OFF
indicating the channel is in the STEL test mode but the STEL alarm
is switched off.
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Chapter 7 - Engineer's Operating

Instructions
(16) If required, use the Engineering Card ( ) and ( ) push-buttons to
switch the STEL on.

Note: The STEL Alarm can only be switched on if the Control Card has
been configured for this alarm.

(17) Push the Engineering Card ALARMS push-button for a eighth time
and LTEL will be displayed on the message display alternating with
the selected channel number. The digital display will indicate OFF
indicating the channel is in the LTEL test mode but the LTEL alarm
is switched off.

(18) If required, use the Engineering Card ( ) and ( ) push-buttons to

switch the LTEL on.

Notes: 1. The LTEL Alarm can only be switched on if the Control Card
has been configured for this alarm.

2. The TEST function automatically inhibits the control card

channel to allow a display test and a lamp test of the channel
LED alarm indications and prevent accidental alarms being
generated. In order to test the relays and FAULT indications,
the INHIBIT push-button must be used to set the control card
channel into the uninhibited state.

3. A selected control card may be deselected while in the TEST

mode by pushing the selected control card front panel RESET/
SELECT push-button. The simulated gas level and relay states
will remain set allowing several control cards to be tested
simultaneously. When the control card is reselected the card
will return to the TEST mode. The ATTN LED indicates which
cards have channels in the alarm test mode.

4. If the inhibit is removed, the external relays will operate.

Important

When the TEST mode is used, always ensure that the channel control
card is returned to the uninhibited state after the test.

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Chapter 7 - Engineer's Operating

Instructions
7. Catalytic Sensor Bridge Current
Adjustment BEAD mA

The operation associated with the BEAD mA push-button only applies

when a catalytic control card has been selected. The pressing of the
push-button with other types of control cards selected has no purpose
and a warning (XXXX) is displayed to this effect.

To enter the catalytic sensor bridge current operation, proceed as

follows:

(1) Plug the Engineering Key into the Engineering Card front panel
socket and check that the Unlocked LED ( ) is illuminated.

(2) Push and hold the required control card RESET/SELECT push-
button for approximately 1.5 seconds and check that the selected
control card indicates it has been selected by displaying the select
icon.

(3) Use the Engineering Card ( ) and ( ) push-buttons to select the

required channel.

(4) Push the Engineering Card BEAD mA

push-button and check that the selected
control card message display shows mA
alternating with the selected channel
number. and the digital display shows the
actual bridge current.

(5) If the displayed bridge current is not set to the required value, use
the ( ) and ( ) push-buttons to raise or lower the indicated bridge
current reading until the required value is displayed.

Note: Pressing the push-button will cancel the displayed current without
alteration to the stored value.

(6) Push the push-button to permanently set the new bridge current.
The selected control card channel will then automatically return to
the normal selected state.

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Chapter 7 - Engineer's Operating

Instructions
8. Zero Signal Calibration
ZERO
To select the zero operation, proceed as follows:

(1) Plug the Engineering Key into the Engineering Card front panel
socket and check that the Unlocked LED ( ) is illuminated.

(2) Push and hold the required control card RESET/SELECT push-
button for approximately 1.5 seconds and check that the selected
control card indicates it has been selected by displaying the select
icon.

(3) Use the Engineering Card ( ) and ( ) push-buttons to select the

required channel.

(4) Push the Engineering Card ZERO push-button and the Engineering
Card will automatically inhibit the selected control card channel to
prevent false alarms being generated. One of the following displays
will be shown on the selected control message display:

a. Indicates a stable gas reading.

b. Indicates a rising gas reading.

c. Indicates a falling gas reading.

(5) Check that the selected control card digital display and
bargraph continue to display the current sensor signal
level.

Note: Pushing the push-button at this stage will return the control card
to the selected mode without any changes to the original zero
reading.

(6) Ensure the selected channel sensor is in a gas free atmosphere. If

required apply zero gas, normally air not containing the gas to be
measured, at the flow rate and for a time according to the selected
channels sensor instruction manual.

(7) When the message display shows , to indicate a stable

reading, push the push-button.

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Chapter 7 - Engineer's Operating

Instructions
(8) The selected control card will display oooo on the message display
while the Control Card carries out the following:

a. Zeroes itself at the current sensor signal, providing this is within

the configured upper and lower zero signal limit values. The
control card will then automatically return to the normal selected
state.

b. If the signal is outside the stored signal limits an error message

will be displayed on the selected control card display.

c. Automatically return to the normal selected state, however, the

inhibit on the control card channel will remain active.

(8) If the Span Signal Calibration (Section 9) is not to follow this

procedure, remove the inhibit.

9. Span Signal Calibration

SPAN

Note: If a new sensor is being calibrated for the first time, use the 1st
Span procedure in Section 10.

To select the span operation, proceed as follows:

(1) Plug the Engineering Key into the Engineering Card front panel
socket and check that the Unlocked LED ( ) is illuminated.

(2) Push and hold the required control card RESET/SELECT push-
button for approximately 1.5 seconds and check that the selected
control card indicates it has been selected by displaying the select
icon.

(3) Use the Engineering Card ( ) and ( ) push-buttons to select the

required channel.

(4) Push the Engineering Card SPAN push-button and

the selected control card channel will automatically
be inhibited and one of the following displays will be
shown on the control card message display:
a. Indicates a stable gas reading.

b. Indicates a rising gas reading.

c. Indicates a falling gas reading.

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Chapter 7 - Engineer's Operating

Instructions
(5) Check that the selected control card digital display indicates the
required span gas concentration to be used, if not, use the ( ) and
( ) push-buttons to raise or lower the indication until the correct
concentration is displayed.

Note: 1. The analogue display will continue to show the current sensor
live signal level.

2. Pushing the button at this stage will return the control card
to the selected mode without any changes to the original span
setting.

(6) Apply the span gas at a flow rate and for a time according to the
selected channels sensor instruction manual.

Note: 1. Apart from oxygen, every sensor should be zeroed before

being spanned. See Section 8.

2. Although a Span Gas as low as 15% of the fsd value of the

sensor may be used, it is recommended that a value of 40%
or above is used.

(7) When the message display shows to indicate a stable reading,

push the push -button. The selected control card will then display
on the digital display while it carries out the following:

a. Adjusts its span calibration parameter to the new displayed

value, providing this is within the configured upper and lower
span signal limit values.

b. Set the last calibration date to the current date and reset the
calibration reminder if this is enabled.

c. Automatically return to the normal selected state, however, the

inhibit on the control card channel will remain active.

d. If the displayed value is outside the stored signal limits, display

an error message.

e. On control cards for catalytic sensor inputs, the present sensor

signal will be compared with that recorded when the sensor
was new. A warning will be displayed if the sensitivity of the
sensor has fallen to below 50% of its original value.

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Chapter 7 - Engineer's Operating

Instructions
Important

When the span gas has been removed and the sensor signal has
returned to normal, do not forget to return the control card channel to
its uninhibited state.

10. First Time SPAN Signal Calibration

1st SPAN

When the 1st SPAN push-button is pressed, the operation of the

selected control card channel is similar to when the SPAN push-button
is pressed.

To carry out the first time span calibration, proceed as indicated in

Section 9 Steps (1) to (6) but push the 1st SPAN push-button.

Note: 1. In Step (6) when the span calibration is updated, the new sensor
calibration date and the last sensor calibration date will both
be set to the current date.

2. On control cards for catalytic sensor inputs, the sensor span

signal value is recorded as the new sensor value. This value will
be used to provide sensor life monitoring data by comparison
with subsequent values obtained during later calibrations using
the SPAN button.

11. Sensor Signal Monitoring

SIGNAL

The operation of the SIGNAL push-button allows the monitoring of the

selected channels sensor signal value. The displayed parameter is
dependent upon the type of control card.

To enter the sensor signal monitoring operation, proceed as follows:

(1) Push and hold the required channel card RESET/SELECT push-
button for approximately 1.5 seconds until the selected icon appears
on the channel display.

(2) Use the Engineering Card ( ) and ( ) push-buttons to select the

required channel.

(3) Push the SIGNAL push-button and the selected channel card display
will indicate the sensor signal. The displayed value will depend on the
type of sensor drive module fitted to the channel card as follows:

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Chapter 7 - Engineer's Operating

Instructions
a. Four Channel Control Card - Catalytic

The display will show the live bridge voltage

measured between 01 and 02 in mV. 02 is the
centre point of the second half of the Wheatstone
bridge which is on the channel card.

b. Four Channel Control Card - 4 - 20mA

The display will show the live sensor loop current

in mA.

(4) No alterations can be made to the above readings and

pressing either the or push-buttons will return the
selected control card to the selected mode.

12. Setting the Clock/Calendar

CLOCK
Note: This operation requires a control card to be selected but the
operation has no effect on the selected control card, which is used
as a display device only.

To set the clock time and calendar date, proceed as follows:

(1) Plug the Engineering Key into the Engineering Card front panel
socket and check that the Unlocked LED ( ) is illuminated.

(2) Push and hold the required control card RESET/SELECT push-
button for approximately 1.5 seconds and check that the selected
control card indicates it has been selected by displaying the select
icon.

(3) Push the Engineering Card CLOCK push-button and the

selected control card digital display will show the time
of day (eg. 23:59) with the HOURS value flashing.

(4) Push the Engineering Card CLOCK push-button a

second time and the selected control card digital display
will display the time of day (eg. 23:59) with the MINUTES
value flashing.

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Chapter 7 - Engineer's Operating

Instructions
(5) Push the Engineering Card CLOCK push-button a third time and
the selected control card will display:

a. The year (eg. 1995) on the message display

(flashing).

b. The month and day (eg. 08-26) or day and month

(eg. 26-08) on the digital display depending upon
the international date format configuration.

(6) Subsequent pushes of the CLOCK push-button will cause the month
and then the day to flash.

(7) Further pushes of the CLOCK push-button will repeat Steps (3) to
(6).

(8) At each stage, use the ( ) and ( ) push-buttons to raise or lower

the displayed numerical value as required to set any new date and
time.

Note: Pressing the push-button at any time during the above sequence
will return the Engineering Card to the selected mode without
changing the clock time and calendar date.

(9) Press the push-button to set the Engineering Card real time clock
to the new date and time, and return the control card to the selected
mode.

13. Maintenance Record Printouts

For details of the maintenance record printouts, refer to Chapter 6
Section 4.8.

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Chapter 7 - Engineer's Operating

User Notes
Instructions

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Chapter 8 - Specification

5704 Series

CONTROL SYSTEM

Chapter 8

SPECIFICATION

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Chapter 8 - Specification
Contents
Section
Page

1. APPROVALS AND STANDARDS 8-3

2. ENVIRONMENTAL 8-3

3. RFI/EMC CONFORMITY 8-3

4. POWER SUPPLIES 8-4

5. INDIVIDUAL MODULE PARAMETERS 8-4

5.1 Quad Relay Interface Card 8-4

5.2 Relay Interface Assembly 8-4
5.3 Four Channel Control Card - General 8-5
5.4 Four Channel Control Card - Catalytic 8-6
5.5 Four Channel Control Card - 4 - 20mA 8-7
5.6 Analogue Output Module 8-7
5.7 Engineering Card 8-8
5.8 DC Input Card 8-8

6. CABINET ASSEMBLIES 8-9

7. RACK ASSEMBLIES 8-10

8. POWER SUPPLY UNITS 8.12

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Chapter 8 - Specification
1. Approvals and standards
Designed to comply with:

EN 60079-29-1 General Requirements and performance.

EN 50271 Software and Digital Technologies.

Meets Exe isolation requirements for 50V operation.

DEKRA EXAM GmbH, EC-type examination certificate BVS 04 ATEX

G 001 X

Note: If compliance with the EC-type examination certificate BVS 04

ATEX G 001 X is required, refer to chapter 10 ‘Special Conditions
for Safe Use’. Ensure that all conditions therein are met.

HONEYWELL

2. Environmental
Operating Temperature: -5OC to +55OC.
(*0OC for EXAM approved systems)
Storage Temperature: -25OC to +55OC.
Humidity: 0 to 90% RH. Non-condensing.

3. RFI/EMC Conformity
EMC Directive 2004/108/EC

Conforms to:

EN50270: 2006 EMC/RFI

LV Directive 73/23/EEC

Constructed in accordance with good engineering practice. Guided by

the principles of EN 61010/1 1990/1992.

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Chapter 8 - Specification
4. Power Supplies
Power Consumption : Dependent upon configuration.
(System) See Chapter 4, Section 5.

External DC Power Supply: 18V to 32V to DC Input Card.

External AC Power Supply: 85V to 264V at 47Hz to 440Hz.

(Using optional AC to DC PSU).

5. Individual Module Parameters

5.1 Quad Relay Interface Card (05704-A-0121)

Dimensions: Height 132mm.

Width 25mm.
Depth 119mm.

Weight: 230g.

Power: 1.7W (maximum) 1W (typical).

Relays: 4 x SPCO.

Relay Operation: Selectable.

Latching/Non-Latching.
Energised/De-Energised.

Relay Contact Rating: 5A at 110V/250V ac (non inductive).

5A at 32V dc (non- inductive).

Field Terminals: 2.5mm2 (14 AWG).

5.2 Relay Interface Assembly (05704-A-0131)

Consists of a Expansion Relay Card fitted to a Quad Relay Interface

Card.

Dimensions: Height 132mm.

Width 52mm.
Depth 122mm.

Weight: 500g.

Power: 6.5W (maximum) 3.5W (typical).

Relays: 12 x SPCO.
4 x SPST.

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Chapter 8 - Specification
Relay Operation: Selectable.
Latching/Non-Latching.
Energised/De-Energised.

Relay Contact Rating: 5A at 110V/250V ac (non inductive).

5A at 32V dc (non- inductive).

Field Terminals: 2.5mm2 (14 AWG).

5.3 Four Channel Control Card - General

Four-Part Liquid Display:

Analogue Display: 25 segment.

Digital Display: Four character.
Message Display: Four character.
Icon Section: Power On/Card Select.

LED Indicators: CHL 1, CHL 2, CHL 3, CHL 4 and ATTN.

CHL Indicators: Two colour amber / red providing warnings

of:

A1 Alarm: 1 quick red flash per second.

A2 Alarm: 2 quick red flashes per second.
A3 Alarm: 3 quick red flashes per second.
STEL, LTEL Slow red flash, 1 second on 1 second off.

Fault: Flashing amber.

Inhibit: Steady amber.

ATTN Indicator:

Hardware
or Software Fault: Slow flashing amber.

Update Alarm
Condition: Fast flashing amber.

Alarm Test: Steady amber.

Push-Button: Alarm Reset/Card Select.

Initial accuracy: ±1%.

Alarm Setting Point

Resolution: In 1% fsd steps.

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Display/Alarm Point:

Linearity: ±2% fsd.

Repeatability: ±2% fsd.
Remote Facilities: Inhibit/Alarm Reset.
Remote Inhibit / Reset Inputs
Active For Inputs: More than 2V.
Maximum Input Voltage: 32V.
Maximum Input Current: 5mA.
DC Supply: 18V to 32V dc.
Electronic Drift: Less than ±3% / 6 months.
Dimensions: Height: 132mm.
Width: 25mm.
Depth: 172mm.
Weight: 170g.
5.4 Four Channel Control Card - Catalytic
Power Consumption: 12.8W (maximum at 200mA sensor
current).
8.5W (typical).
Drive: Constant Current.
Initial Accuracy: ±1%.
Current Adjustment: Electronic in 1mA stepsfrom 90 to
315mA.
Maximum Drive Voltage: 10V.
Protection: Protected against short circuit and
open circuit.
Maximum Line Resistance: 40 ohms (including sensor) at
200mA.
Full Scale Signal Range: 15mV to 300mV.
Bridge Imbalance Default Limits: ±100mV from centre at 2V bridge
voltage.
Adjustment: Electronic adjustment of bridge
balance and signal gain.

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Chapter 8 - Specification
Fault Detection: Open circuit.
Short circuit single bead failure.
Over-Range Default: +10% above fsd.
Under-Range Default: -10% below zero.

5.5 Four Channel Control Card - 4 - 20mA

Power Consumption: 8.3W (maximum). 7.5W (typical).

Loop Powered Output Voltage: Isolated 24V ± 5% regulated, 25mA

maximum for loop powered devices.

Transmitter Supply Output

Voltage: None.

Loop Protection: Short circuit, open circuit voltage of

±50V.

Configuration: Sensor current source.

Measurement Signal Range: 0 to 25mA (linear).

Maximum Line Resistance: 500 ohms loop resistance including

sensor.

Isolation Breakdown Voltage: More than ±50V dc to system 0V.

5.6 Analogue Output

Output Compliance Range: 40V.

Protection: Short circuit protected.

Reverse voltage up to 36V dc.
Transient voltage of less than 60V dc.

Configuration: Isolated current sink/source with 18

-40V external supply.

Signal Range: 0 - 25mA.

Measurement Signal Range: 0 - 20mA or 4 - 20mA selected by the

software.

Linearity From Input: Better than ±2% fsd.

Repeatability From Input: Better than ±1% fsd.

Isolation Breakdown
Voltage: More than ±50V dc to system 0V.

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Chapter 8 - Specification
5.7 Engineering Card

LEDs: Power On ( - Green LED).

Unlocked ( - Red LED).

Push-Button:

Operating: Up ( ) and Down ( ).

Reject ( ) and Accept ( ).
Print (Up and Down together).

Functions: Bead mA Alarms

Zero Signal
Span 1st Span
Inhibit Clock

Power Consumption: 1.5W (typical). See rack details.

DC Supply: 18V to 32V dc.

Dimensions: Height: 132mm.

Width: 25mm.
Depth: 170mm.

Weight: 152g.

5.8 DC Input Card

DC Supply: 18V to 32V dc.

Dimensions: Height: 112mm.

Width: 25mm.
Depth: 102mm.

Weight: 129g.

Fuse Rating: 10A Anti-surge. 11/4 x 1/4 inches.

Field Terminals: 2.5mm˝ (14 AWG).

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Chapter 8 - Specification
6. Cabinet Assemblies
Material: Mild steel.

Weight: 8-way: 10.0kg

16-way: 13.5kg.

Gland Entries: Knock-out.

8-way 2 x M25 6 x PG11

8 x M20 2 x PG16

16-way 3 x M25 10 x PG11

16 x M20 4 x PG16
Cabinet Dimensions:

All dimension
shown in mm.
630

8 way 337 268

16 way 540

Wall Mounting Bracket Hole Locations

8 way 367mm
16 way 570mm

100

All dimension
430 shown in mm.

100

15 15

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Chapter 8 - Specification
Cabinet Mounting Brackets 27
15

36

10.2

All dimension shown in mm. 10

Hinged: Left hand side.

Lock: Right hand side.
Colour: RAL 7015 slate grey.
Mounting Bracket Holes: 10mm (0.4'') diameter.
Rack Mounting: Universal 19 inch profile.
19 inch width and half 19 inch width.
Earthing Points: Main cabinet M6.
Door M5.
Mounting Plate: Galvanised steel.
7. RACK ASSEMBLIES
Rack Assemblies Contains: Engineering Card.
DC Input Card.
Interconnect Cable (front access rack
only).

Material: Galvanised steel.

Earthing Point: M5 stud.

Mounting: Universal 19 inch and half width (19

inch mounting).
Power Consumption: 1.5W.
Supply Voltage: 18 to 32V dc.

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Chapter 8 - Specification
Weight: (including Engineering Card and DC Input Card)

16 Way Front Access: 5.8kg.

16 Way Rear Access: 4.1kg.
8 Way Front Access: 3.9kg.
8 Way Rear Access: 2.8kg.

Table of Sizes (mm)

Rack Assembly A B C D E Depth

8 Way Rear Access 279.4 261.9 57.0 37.8 132.5 287.6

8 Way Front Access 279.4 261.9 190.5 37.8 266.0 217.6

16 Way Rear Access 482.6 465.1 57.0 37.8 132.5 287.6

16 Way Front Access 482.6 465.1 190.5 37.8 266.0 217.6

Panel Cutout Clearance

8 Way Width: 247 Height as column E

16 Way 450 as column E

A
A
B B

C E

D
C E

(holes 6mm
diameter)

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Chapter 8 - Specification
8. Power Supply Units
Mounting: Universal 19'' and half 19'' mounting.

Supply Voltage: 85V to 264V ac 47Hz to 440Hz.

110V to 340V dc.

(For information on dc input contact
Honeywell Analytics).

Inrush Current: Typically 30A at 230V input on full load

per 50W Module.

Leakage Current: 0.75mA maximum per 50W Module.

Overload Protection: Operates at more than 105% of rated

full load and recovers automatically.

Safety Approvals: 50W Module approved to UL1950,

IEC950, CSA 22.2 No 234.

Output Voltage: 24V ± 10% dc.

Output Configurations:

Half 19'' Rack: 50W or 100W.

Full 19'' Rack: 50W, 100W, 150W or 200W.

Earthing Point: M5 stud.

Weight:

Half 19'' Rack 50W: 900g.

Full 19'' Rack 50W: 960g.

50W Module: 230g.

Sub Unit: 815g.

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Chapter 8 - Specification
Dimensions:
A

8.4 B

43.6 31.8
5.9

Mounting holes = 7mm

PSU Assembly A B Clearance

Width Height Depth

8 Way 279.4 261.9 222 41 190

16 Way 482.6 465.1 443 41 190

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Chapter 8 - Specification
User Notes

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Chapter 9 - Ordering Information

5704 Series

Control System

Chapter 9

Ordering Information

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Chapter 9 - Ordering Information

SYSTEM 57

5704 Control System

Four Channel Four Channel Interconnecting Input/Output

Control Card Control Card Cable Cards
4 - 20mA Catalytic 05704-C-0160
05704-A-0145 05704-A-0144

Analogue Analogue Analogue Analogue Blanking

Output Output Output Output Panel
Module Module Module Module 05701-A-0365
Source Sink Source Sink
04200-A-0146 04200-A-0145 04200-A-0146 04200-A-0145

Quad Relay Relay Interface

Interface Card Assembly
05704-A-0121 05704-A-0131
4 x SPCO 12 x SPCO
4 x SPNO

Engineering Card
05701-A-0361

MODBUS Event Print Alarm Update

Interface Module Kit Module Kit Module Kit
05701-A-0314 05701-A-0309

Alarm Update
RS485/RS422 RS232
Panel
05701-A-0312 05701-A-0313
05701-A-0339

5701 Control System Parts - Sheet 1

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Chapter 9 - Ordering Information

Engineering Cabinets Racks AC to DC

Interface Power Supplies
Kit
05701-A-0551
8-Way 16-Way 8-Way 16-Way
05701-A-0452 05701-A-0451 05701-A-0406 05701-A-0405
Engineering
Interface 50W Module Sub Unit
Software 05701-A-0440 05701-A-0441
05701-A-0121

Engineering 50W Module

Interface Lead 05701-A-0440
05701-A-0120
Front Access Rear Access

8-Way 16-Way 8-Way 16-Way

05701-A-0502 05701-A-0501 05701-A-0512 05701-A-0511

8-Way Sub-rack 16-Way Sub-rack 8-Way Sub-rack 16-Way Sub-rack

05701-A-0516 05701-A-0515 05701-A-0516 05701-A-0515

Engineering Card Engineering Card Engineering Card Engineering Card

05701-A-0361 05701-A-0361 05701-A-0361 05701-A-0361

DC Input Card DC Input Card DC Input Card DC Input Card

05701-A-0325 05701-A-0325 05701-A-0325 05701-A-0325

Interconnecting Interconnecting Key Kit Key Kit

Cable Cable 05701-A-0550 05701-A-0550
05701-C-0390 05701-C-0390

Key Kit Key Kit

05701-A-0550 05701-A-0550

5701 Control System Parts - Sheet 2

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Chapter 10 -Special conditions for safe use according

to EC-type examination certificate BVS 04 ATEX G 001 X

5704 Series

Control System

Chapter 10

Special conditions for

safe use according to
EC-type examination
certificate BVS 04
ATEX G 001 X

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Chapter 10 -Special conditions for safe use according

to EC-type examination certificate BVS 04 ATEX G 001 X

The following special properties have to be considered at operation of

the control unit:
- When operated with remote sensors with 4-20 mA
interface the specifications of the 4-20 mA interface and
the behaviour below 4 mA and above 20 mA have to be
considered.
- The parameters “A/D-average” and “signal filter” shall
be set to the sensor-specific default values. Other settings
shall only be used in exceptional, justified circumstances
and with the manufacturer’s permission. For both
parameters, the lowest settings shall be used which are
possible for the application.
- When configuring the control cards, the sensor specific
default settings should be used for the error codes “ER80”,
“ER81”, “ER87” and “ER88” (parameters “signal over
range”, “signal under range”, “fault over range” and “fault
under range”).
- The error codes “ER87”, “ER88” and “ER81” (parameters
“fault over range”, “fault under range” and “signal under
range”) shall be set latching.
- When operated with remote sensors (e.g. Sensepoint)
which may deliver signals within the measuring range at
concentrations above the measuring range, the error
code “ER80” (parameter “signal over range”) shall be set
latching. If the parameter is set below the default value
all alarm relays shall be configured in such a way that
alarming also takes place in the presence of faults.
- For remote sensors with 4-20 mA interface the parameters
“signal over range” and “fault over range” shall be set in
such a way that during normal operation (including the
application of 100 % gas to the remote sensor) “ER80”
can be activated but not “ER87”.
- The analogue outputs should be operated with live zero
(4-20 mA setting). The “< 4 mA clipping” feature should
be activated only in exceptional cases.
- Irrespective of the operating mode of the analogue output,
the “fault level” and “inhibit level” shall be configured to
different values outside the measuring range. The
signalling of faults and inhibits at the analogue output
shall be activated.
- If no local inhibit relays are configured, a master inhibit
relay shall be configured.
- If no local fault relays are configured, a master fault relay
shall be configured.

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Chapter 10 -Special conditions for safe use according

to EC-type examination certificate BVS 04 ATEX G 001 X

- When relays are used for signalling update alarms, no

other alarms or messages must be allocated to them.
Configuration of update messages for “inhibit” should be
avoided.
- Time delayed relays shall not be used.
- The status of the control unit obtained via Modbus shall
be used only for the purpose of visualisation or
documentation but not for safety purposes. Write access
via Modbus shall be avoided. This certificate is concerned
solely with information which can be obtained from Modbus
functions 02 and 04.
- When a control card 5701 is configured for master or
voted alarms as well as master or voted fault or inhibit
messages, high integrity relay cards should be used. If
no high integrity relay cards are used, triple relay cards
shall be used. In such cases, both the relays and the
LEDs of this control card will reflect only the status of the
master or voting group. For an “X out of Y” linkage with
vote counts (X) > 1, local alarms or messages of this
control card are not displayed if less than X control cards
have entered the alarm, fault or inhibit status, respectively.
Therefore, voting groups have to be configured in such a
way that vote counts of “1” are used for voted faults and
inhibit messages to allow for signalling of local fault and
inhibit states of the control card.
- Relay 1 of a high integrity relay card is always assigned
to a local fault. It is also used for signalling malfunction of
the high integrity relay card itself. Therefore, this relay
shall be monitored for each high integrity relay card.
- The alarm level with the highest safety relevance shall be
configured as latching.
- The control unit shall be mounted in a vibration-free
environment.

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