MSA FiveStar User manual

FiveStar®Alarm
Technical Manual
"WARNING
THIS MANUAL MUST BE CAREFULLY READ BY ALL INDIVIDUALS WHO
HAVEORWILLHAVETHERESPONSIBILITYFORSERVICINGTHEPRODUCT.
Like any piece of complex equipment, this instrument will perform as
designedonly if it is used and serviced in accordance with the manufacturer’s
instructions. OTHERWISE IT COULD FAIL TO PERFORM AS DESIGNED AND
PERSONS WHO RELY ON THIS PRODUCT FOR THEIR SAFETY COULD
SUSTAIN SEVERE PERSONAL INJURY OR DEATH.
The warranties made by Mine Safety Appliances Company with respect to the product are voided if
the product is not used and serviced in accordance with the instructions in this manual. Please
protect yourself and others by following them. We encourage our customers to write or call
regarding this equipment prior to use or for any additional information relative to use or repairs.
"CAUTION
For safety reasons, this equipment must be operated by qualified personnel
only. Read and understand the instruction manual completely before
operating.
In the U.S., to contact your nearest stocking location, dial toll-free 1-800-MSA-2222. To contact MSA
International, dial 1-412-967-3000 or 1-800-MSA-7777.
This manual pertains to:
North American approved instruments with Serial Number prefix "F" and "G"
Australian approved instruments with Serial Number prefix "A"
EN approved instruments with Serial Number prefix "A".
© MINE SAFETY APPLIANCES COMPANY 2005 - All Rights Reserved
Manufactured by
MSA INSTRUMENT DIVISION
P.O. Box 427, Pittsburgh, Pennsylvania 15230
(L) Rev 9 710440

MSA Portable Instrument Warranty
1. Warranty-
ITEM WARRANTY PERIOD
Chassis and electronics Lifetime (MSA will support product
for five years after production ends)
All sensors, unless otherwise specified Two years
Pump and drive unit Two years
Rechargeable batteries Two years
Thiswarrantydoesnotcoverfilters,fuses,etc.Certainotheraccessories
not specifically listed here may have different warranty periods. This
warrantyisvalidonlyiftheproductismaintainedandusedinaccordance
with Seller’s instructions and/or recommendations. The Seller shall be
released from all obligations under this warranty in the event repairs or
modifications are made by persons other than its own or authorized
service personnel or ifthe warranty claim resultsfrom physical abuseor
misuse of the product. No agent, employee or representative of the
Seller has any authority to bind the Seller to any affirmation,
representation or warranty concerning this product. Seller makes no
warranty concerning components or accessories not manufactured by
the Seller, but will pass on to the Purchaser all warranties of
manufacturers of such components. THIS WARRANTY IS IN LIEU OF
ALL OTHER WARRANTIES, EXPRESSED, IMPLIED OR
STATUTORY, AND IS STRICTLY LIMITED TO THE TERMS
HEREOF. SELLER SPECIFICALLY DISCLAIMS ANY WARRANTY
OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR
PURPOSE.
2. ExclusiveRemedy-It is expressly agreed that Purchaser’s sole and
exclusive remedy for breach of the above warranty, for any tortious
conduct of Seller, or for any other causeof action, shall bethe repair
and/or replacement at Seller’s option, of any equipment or parts
thereof, which after examination by Seller is proven to be defective.
Replacement equipment and/or parts will be provided at no cost to
Purchaser, F.O.B. Seller’s Plant. Failure of Seller to successfully
repair any nonconforming product shall not cause the remedy
established hereby to fail of its essential purpose.
3. Exclusion of Consequential Damages- Purchaser specifically
understands and agrees that under no circumstances will seller be
liable to purchaser foreconomic, special,incidental or consequential
damages or losses of any kind whatsoever, including but not limited
to, loss of anticipated profits and any other loss causedby reason of
nonoperation of the goods.This exclusion is applicable to claims for
breach of warranty, tortious conduct or any other cause of action
against seller.

Table of Contents
Chapter 1
Set-up and Configuration. . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Sensor Autoconfiguration and Replacement . . . . . . . . . . . . . 1-2
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Replacing a Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Figure 1-1. Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
"WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Installing a New Type of Sensor. . . . . . . . . . . . . . . . . . . 1-4
Table 1-1. Allowable Sensor Installation Locations. . 1-5
Figure 1-2. Sensor and Zebra Strip Locations in Sensor Cavity 1-5
"WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Figure 1-3. Removing the Jumper . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Removing a Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Sensor Autoconfiguration. . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Figure 1-4. New Sensor Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Figure 1-5. Sensor Update? Yes/No . . . . . . . . . . . . . . . . . . . . . 1-8
Figure 1-6. Please Wait . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Figure 1-7. Units Measured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Figure 1-8. Gases Measured . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Figure 1-9. Sample Combustible Alarm Setpoints. . . . . . . . . . . . 1-9
Figure 1-10. Sample O2Alarm Setpoints . . . . . . . . . . . . . . . . . . 1-9
Figure 1-11. Sample Toxic Alarm Setpoints . . . . . . . . . . . . . . . . 1-9
Table 1-2. Default Factory Alarm Setpoints. . . . . . 1-10
Technical Manual Table of Contents
FiveStar Alarm TOC-1

Figure 1-12. Accept Alarms Reset/Show/OK. . . . . . . . . . . . . . . 1-10
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Figure 1-13. Check Sensor Cover/ Label Empty Slots / Quit - OK 1-11
Manual Sensor Configuration. . . . . . . . . . . . . . . . . . . . . 1-12
To Enter the Sensor Setup Mode Manually . . . . . . . . . 1-12
Chapter 2
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Optional Fresh Air Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Activating the Fresh Air Setup Option. . . . . . . . . . . . . . . 2-1
To Cancel Fresh Air Setup . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-1. Fresh Air Setup? . . . . . . . . . . . . . . . . . . . 2-1
To Perform Fresh Air Setup . . . . . . . . . . . . . . . . . . . . . . 2-2
Calibration Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Preparing to Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-2. Calibration - No/Yes?. . . . . . . . . . . . . . . 2-3
Figure 2-3. Apply Fresh Air. . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-4. Adjusting Zeroes. . . . . . . . . . . . . . . . . . . 2-4
Figure 2-5. Combustible Gas Calibration Display . . . 2-4
Figure 2-6. Calibration Cap Installation . . . . . . . . . . . 2-5
Figure 2-7. Snap Calibration Cap Installation . . . . . . 2-5
Oxygen Sensor Calibration Check. . . . . . . . . . . . . . . . . . 2-6
Figure 2-8. Combustible Gas Span Adjustment. . . . 2-6
Toxic Gas Sensor Calibration . . . . . . . . . . . . . . . . . . . . . 2-7
To repeat calibration procedure: . . . . . . . . . . . . . . . . . . 2-7
To end calibration procedure: . . . . . . . . . . . . . . . . . . . . . 2-7
Figure 2-9. Remove Cal Cap . . . . . . . . . . . . . . . . . . 2-7
Figure 2-10. Saving Calibration
Please Wait . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Figure 2-11. Power OFF. . . . . . . . . . . . . . . . . . . . . . . 2-7
Special Instructions for Instruments
with Chlorine Dioxide Sensors. . . . . . . . . . . . . . . . . . . . . 2-8
Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Figure 2-12. Setup for Chlorine Dioxide Generator
Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Table of Contents Technical Manual
TOC-2 FiveStar Alarm

Chapter 3
Troubleshooting and Maintenance . . . . . . . . . . . . . . . . . 3-1
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Table 3-1. Troubleshooting Guidelines . . . . . . . . . . . 3-1
Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Battery Pack Replacement . . . . . . . . . . . . . . . . . . . . . . . 3-4
Remove the Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Replace the Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Main Electronics Board Replacement. . . . . . . . . . . . . . . 3-4
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Figure 3-1. Battery Pack Removal. . . . . . . . . . . . . . . 3-4
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Figure 3-2. Display Connector . . . . . . . . . . . . . . . . . . 3-5
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Sensor Board Replacement. . . . . . . . . . . . . . . . . . . . . . . 3-6
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Figure 3-3. Sequence for Tightening Screws . . . . . . 3-6
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Display Module Replacement. . . . . . . . . . . . . . . . . . . . . 3-7
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Figure 3-4. Keypad Ribbon Cable Replacement. . . . 3-9
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Chapter 4
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Table 4-1. North American/Australian Common
Accessory Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Figure 4-1. North American
(through Serial Number Prefix "E")
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Table 4-2. North American
(through Serial Number Prefix "E")
Replacement Parts List . . . . . . . . . . . . . . . . . . . . . . . 4-3
Table 4-3. Replacement Sensors. . . . . . . . . . . . . . . . 4-3
Technical Manual Table of Contents
FiveStar Alarm TOC-3

Figure 4-2. Australian and European Approved
Replacement Parts and North American
(Serial Number Prefix "F" or Higher)
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Table 4-4. North American
(Serial Number Prefix "F" or "G")
Replacement Parts List. . . . . . . . . . . . . . . . . . . . . . . . 4-5
Table 4-5. Australian/European Replacement Parts List. 4-6
Table 4-6. Pump and Aspirator Assembly
Replacement Parts List. . . . . . . . . . . . . . . . . . . . . . . . 4-7
Figure 4-3. Replacement Parts. . . . . . . . . . . . . . . . . . 4-7
Figure 4-4. Battery and Fuse Location . . . . . . . . . . . 4-8
Table 4-7. Replaceable Battery Pack Parts List . . . . 4-8
Table of Contents Technical Manual
TOC-4 FiveStar Alarm

Chapter 1
Set-up and Configuration
The user must be familiar with the procedures in the FiveStar
Alarm Instruction Manual, including all cautions and warnings.
The FiveStar Alarm can be configured in many ways to meet
your changing gas detection needs. There are four means for
making instrument configuration changes (the first two are
described in the instruction manual, the third is described in this
chapter, and the fourth is accessible only with FiveStar LINK):
1. At instrument turn-ON,
the following setup option is available:
•Fresh Air Setup (if enabled).
2. When attaching the battery to the instrument,
the following setup options are available:
•Language for displays (if enabled)
•Operating Beep
•Peak / STEL / TWA displays (all/none)
•Set time and date
•Sensor configuration.
3. During Sensor setup or sensor autoconfiguration,
the following setup options are available:
•LEL versus CH4combustible display
•Gas sensors installed
•Reset alarm settings to factory defaults.
4. FiveStar Link is a separately-supplied software package for
communicating to the FiveStar instrument with a personal
computer. To operate, FiveStar Link requires a set of
software and an Infrared adapter. These components may
be purchased together (as P/N 710988) or separately.
With FiveStar Link software, the following options can be reset:
Technical Manual Chapter 1, Setup and Configuration
FiveStar Alarm 1-1

•Eight-character instrument "name" shown on
instrument startup (default is "PASSPORT")
•Change alarm setpoints
•Set backlight time-out (1 minute to 20 minutes)
•Operating beep
•Individually turn ON/OFF Peak, STEL
and/or TWA pages
•Disable Fresh Air Setup (available only in
instruments with software V1.2 or higher)
•Set Time and Date (available only in instruments
with software V1.2 or higher)
•Disable Autoconfigure (available only in instruments
with software V1.2 or higher)
•Enable or disable Data Tagging
(software V2.0 or higher)
•Enable or disable the "display alarms" on start-up
option (software V2.01 or higher)
•Enable or disable the multilingual function
(English/Spanish/Canadian French
software V2.01 or higher)
•Disable Autocalibration capability
(software V3.0 or higher)
•Change Periodic Datalog intervals
(software V3.0 or higher).
Sensor Autoconfiguration
and Replacement
When a sensor is replaced, when a new type of sensor is
installed or when a sensor is removed, the FiveStar Alarm steps
the user through an "autoconfiguration" program. All instruments
leave the factory with the autoconfigure feature enabled. The
FiveStar Link program may be used to disable this feature if the
user desires.
Chapter 1, Setup and Configuration Technical Manual
1-2 FiveStar Alarm

The autoconfiguration feature allows the user to change the
instrument sensor configuration as the user’s gas sensing needs
change. The unit steps through the autoconfiguration sequence
(listed later in this chapter) when the instrument recognizes that:
•a new serial number sensor is installed (a replacement)
•a sensor is removed
•a new type of gas sensor is added.
"CAUTION
When removing or installing the combustible gas sensor,
remove the battery pack. Otherwise, the sensor pins may
short to the case and cause an "ERROR 5" message (damage
to the combustible sensor circuit).
Replacing a Sensor
To replace a sensor in your FiveStar Alarm:
1. Verify that instrument is OFF; remove the battery pack.
2. Remove sensor cover screws and cover.
3. Gently lift out and properly dispose of sensor to be replaced.
4. Inspect the condition of electrical contact "Zebra Strip" located
below the sensor.
•The "Zebra Strip" is a small, black conductive elastomer
which makes contact to the sensor memory chip on the
bottom of the sensors (see Chapter 4, FIGURE 4-1).
•If this is not in place or is not making good contact,
the instrument will not properly recognize the
installed sensors.
5. If the Zebra Strip is damaged or missing,
replace it with a new Zebra Strip (P/N
655188) before installing new sensor.
6. If replacement sensor is equipped with a
shorting plate, clip or wire attached to
its pins, remove plate, clip or wire
before inserting the replacement
sensor.
7. Carefully align the new sensor contact
pins with the sockets on the Sensor
Board. Figure 1-1.
Sensor Replacement
Technical Manual Chapter 1, Setup and Configuration
FiveStar Alarm 1-3

8. Press the new sensor into place.
9. Replace the sensor gasket and sensor cover.
10. Re-install screws to hold down the sensor cover.
"CAUTION
Do not operate the instrument without the sensor cover
fully installed. The zebra strips require pressure to enable
proper contact. Without proper contact, data may be written
improperly to the sensor memory and the data may become
corrupted, rendering the sensor unusable.
NOTE: NO, Cl2, ClO2, and NH3 sensors are "biased"
sensors. As such, they require approximately 12
hours once installed (with battery pack attached, but
turned OFF) for the output to stabilize. Allow the unit
to stabilize before calibrating and using in the field.
11. Replace cover before turning instrument back ON to
verify configuration.
•The sensor cover holds the sensors down firmly against
the Zebra Strips to ensure proper electrical contact.
12. Turn the instrument ON and proceed through sensor setup.
•The instrument proceeds to a sensor update mode similar
to that for adding or deleting a sensor. See "Sensor
Autoconfiguration" later in this chapter for instructions.
•If instrument autoconfiguration is disabled, the instrument
shows an error message. See "Manual Sensor
Configuration" later in this chapter for instructions on
manual configuration.
"WARNING
Verification of calibration response is required; otherwise the
instrument will not perform as required and persons who rely
on this product for their safety could sustain serious personal
injury or death.
Installing a New Type of Sensor
1. Verify that unit is OFF.
2. Remove battery.
3. Remove sensor cover screws and sensor cover (FIGURE 1-2).
Chapter 1, Setup and Configuration Technical Manual
1-4 FiveStar Alarm