STATUS SCIENTIFIC CONTROLS LC Series Instruction sheet

STATUS SCIENTIFIC CONTROLS LTD.
Hermitage Lane Industrial Estate,
Kings Mill Way,
Mansfield,
Nottinghamshire.
NG18 5ER
England
Tel
Fax
: 01623 651381
: 01623 421063
Internet
:www.status-scientific.com
LC Series Control Units
Type 8 Installation and Hardware
Configuration Manual
Date:
18.08.2011.
Issue:
4


STATUS SCIENTIFIC CONTROLS
LC Controller System Installation and Hardware Configuration Manual
The LC Controller Manuals
The LC Series Environmental Monitoring Systems have a range of manuals covering various aspects
of their operation:
•LC Controller Installation and Hardware Configuration Manual
This manual covers all of the hardware aspects of the LC Controller. Each of the component parts of
the system is discussed and hardware configuration is explained. Dimensional drawings are included.
•LC Software Configuration and System Calibration Manual
The operation of the LC Controller is discussed as well as the software configuration and calibration
procedures.
End of Life Disposal
The LC Controller does not represent a waste hazard but must be disposed of in accordance
with the European Waste Electrical and Electronic Equipment Directive (WEEE) 2002/96/EC.
This means that it should be disposed of responsibly in accordance with an approved
collection and disposal scheme or alternatively returned to Status Scientific Controls Ltd for
recycling or safe disposal.
Important
Status Scientific Controls strive to continually improve their products in line with customer’s
requirements and technological advancement. Status Scientific reserve the right to modify the design
of the system at any time.
Due to continual improvement not all of the features described within this manual may be available on
earlier models, contact Status for further details.

STATUS SCIENTIFIC CONTROLS
LC Controller System Installation and Hardware Configuration Manual
1Introduction................................................................................................................................ 1-1
1.1 MICROCONTROLLER MODULE.................................................................................................1-3
1.1.1 LCD contrast adjustment................................................................................................1-4
1.2 I/O CIRCUITRY ......................................................................................................................1-5
1.3 FIELD CONNECTIONS.............................................................................................................1-6
1.4 POWER SUPPLY MODULE ......................................................................................................1-7
2MCU Installation......................................................................................................................... 2-8
2.1 SITING THE MCU...................................................................................................................2-8
2.2 SYSTEM WIRING....................................................................................................................2-9
2.3 POWER SUPPLY INPUT...........................................................................................................2-9
2.3.1 A.C. Mains Connection...................................................................................................2-9
2.3.2 DC Voltage Connection..................................................................................................2-9
CABLE ROUTING...............................................................................................................................2-10
2.4 CABLE SCREENING..............................................................................................................2-10
3Gas Detector Head Installation............................................................................................... 3-11
3.1 SITING THE DETECTORS ......................................................................................................3-11
3.2 INSTALLATION IN A NON-HAZARDOUS AREA ..........................................................................3-11
3.3 INSTALLATION IN A HAZARDOUS AREAS.................................................................................3-12
3.3.1 Hazardous area installations using Safety Barriers......................................................3-13
4Input Module Configuration...................................................................................................... 4-1
4.1 INPUT CONFIGURATION..........................................................................................................4-2
4.2 STATUS SCIENTIFIC CONTROLS GAS DETECTORS...................................................................4-2
4.2.1 FGD2, FGD3, FGD4 and FGD10b O2and Toxic Detector Heads .................................4-2
4.2.2 FGD3 Infrared Gas Detector Head.................................................................................4-4
4.2.3 FGD3 Pellistor Gas Detector Head.................................................................................4-5
4.2.4 FGD4, FGD9, FGD10a, FGD10b Gas Detector Heads..................................................4-6
4.2.5 Pellistor Only Gas detectors...........................................................................................4-8
4.2.6 FGD56-IR........................................................................................................................4-9
4.2.7 External powered 4-20 mA Source...............................................................................4-10
4.3 ANALOGUE OUTPUT CONFIGURATION...................................................................................4-11
4.3.1 4-20mA Current Source................................................................................................4-11
4.3.2 4-20mA Current Sink ....................................................................................................4-12
4.3.3 1-5V Voltage Output .....................................................................................................4-13
4.4 ROUTINE SERVICING............................................................................................................4-15
4.4.1 Routine Inspection........................................................................................................4-15
5Dimension Details...................................................................................................................... 5-1
5.1 LC8 CONTROL UNIT ..............................................................................................................5-1
6Specifications............................................................................................................................. 6-2
6.1 LC8 CONTROL UNIT ..............................................................................................................6-2

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1 INTRODUCTION
The LC Series Control Units that provide facilities to monitor a wide variety of industry standard
environmental and other sensors.
The LC8 provides up to 8 monitoring channels.
The LC range has been designed primarily for environmental monitoring. However, the versatility of
the range extends its application to other aspects of industry where monitoring of remotely connected
sensors is required. The specification allows the use of any sensor that can produce a voltage or
current output within a specified range.
Care has been taken with the design of the MCU housings and internal chassis to facilitate ease of
connection and wire termination. All on-site wiring to the system is via screw terminal connectors. The
terminal cover has an internal label giving details of the external connections.
The LC Control Unit houses all of the components required to implement a sophisticated and reliable
monitoring system (alarm relays etc).
•LC8 Control Unit –128x128 graphics display.
POWER
AL 2
AL 3
AL 1
FAULT
MENU
8 Channel Control Unit
LC Series
Type LC8
Status Scientific Controls Ltd
Hermitage Lane Industrial Estate,
Mansfield, Nottinghamshire NG18 5ER United kingdom
Tel:+44(0)1623 651381 Fax:+44(0)1623 421063
60 %LEL CH 4
0.0 %v/v CO 2
%v/v O2
0.0 PPM CL 2
20.9
C1
C2
C3
C4
0%LEL CH 4
0PPM CO
ppm O3
0PPM NH 3
0.0
C5
C6
C7
C8
STATUS
SCIENTIFIC
SSC
..
•LC8 Control Unit –240x128 graphics display.
POWER
AL 2
AL 3
AL 1
FAULT
MENU
8 Channel Control Unit
LC Series
Type LC8
Status Scientific Controls Ltd
Hermitage Lane Industrial Estate,
Mansfield, Nottinghamshire NG18 5ER United kingdom
Tel:+44(0)1623 651381 Fax:+44(0)1623 421063
STATUS
SCIENTIFIC
SSC
..
60 %LEL CH 4
0.0 %v/v CO 2
%v/v O2
0.0 PPM CL 2
20.9
C1
C2
C3
C4
0%LEL CH 4
0PPM CO
ppm O3
0PPM NH 3
0.0
C5
C6
C7
C8

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LC8 main PCB
CH1 CH2
CH5 CH6
CH3 CH4
CH7 CH8
CHANNEL 1 CHANNEL 2
CHANNEL 5 CHANNEL 6 CHANNEL 7 CHANNEL 8
CHANNEL 4CHANNEL 3
130254 ISS.2
Display
connector
FS1SW1 RL18 RL17RL16 RL15
RL8 RL7
RL6 RL5
RL14 RL13
RL4 RL3
RL11RL12
RL2 RL1
RL10 RL9
EXIT PREV
CHANNEL 1
ALARM LEVELS
ALARM DELAY
ALARM HYSTERESIS
CALIBRATION
SET VOLTAGE
SENSOR TYPE
FSD
UNITS
DECIMAL PLACES
NEXT GOEXIT PREV
CHANNEL 1
ALARM LEVELS
ALARM DELAY
ALARM HYSTERESIS
CALIBRATION
SET VOLTAGE
SENSOR TYPE
FSD
UNITS
DECIMAL PLACES
NEXT GO
The diagram above show a pictorial representation of the various module positions within the LC8
Control Units
There is no power supply within the LC8 PCB, the system is supplied with a nominal 24Vdc supply.
The microcontroller module and LCD display are mounted directly on the PCB via stand-off pillars and
connects to the main PCB via a single flat ribbon cable.

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1.1 Microcontroller Module
Situated within the LC Control Unit front panel is the Microcontroller Module. This module
communicates with all Input channels connected to the system PCB.
The Microcontroller Module provides a user interface in the form of a back lit graphics display and a
four button multifunction keypad.
Five LED indications are provided directly by the Microcontroller Module and these are visible via MCU
front panel:
➢Green LED for power.
➢Red LED indication of Alarm level 3.
➢Red LED indication of Alarm level 2
➢Red LED indication of alarm level 1.
➢Yellow LED indication of fault condition.
An Audible signal is also provided by a sounder mounted within Microcontroller module. This provides
a local audible tone during alarm conditions.
The Microcontroller Module also provides the user with many configuration and interrogation facilities
via the LCD and keypad. These facilities include:
➢Sensor Configuration.
•Allows adjustment of Sensor type and range (e.g. Flammable 100%LEL).
➢Calibration of the system.
•This allows each channel to be calibrated independently. The sensor zero point and span
can be set via this function.
•Calibration of the retransmitted output for each channel.
•Calibration of the channel power supply.
➢Input Module Relay Configuration.
•Each Input Module contains two relays for alarm levels 1 and 2. The alarm levels can be
individually set to be either rising or falling.
•Fault relay.
•All relays can be configured normally energised or de-energised as required. Latching
and non-latching functions can also be selected.
The microcontroller module contains all of the software required to communicate with up to 8 detecting
channels. The software is common to all LC Series Control Units.

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1.1.1 LCD contrast adjustment
128x128 Graphics Module
Display
connector
EXIT PREV
CHANNEL1
ALARM LEVELS
ALARM DELAY
ALARM HYSTERESIS
CALIBRATION
SET VOLTAGE
SENSOR TYPE
FSD
UNITS
DECIMAL PLACES
NEXT GOEXIT PREV
CHANNEL1
ALARM LEVELS
ALARM DELAY
ALARM HYSTERESIS
CALIBRATION
SET VOLTAGE
SENSOR TYPE
FSD
UNITS
DECIMAL PLACES
NEXT GO
LCD Contrast
Adjust
240x128 Graphics Module
Display
connector
LCD Contrast
Adjust
60 %LEL CH4
0.0 %v/v CO 2
%v/v O2
0.0 PPM CL 2
20.9
C1
C2
C3
C4
0%LEL CH4
0PPM CO
ppm O3
0PPM NH3
0.0
C5
C6
C7
C8
ALARM L123

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1.2 I/O Circuitry
The input circuit is identical for all channels. Each channel monitors the status of an externally
attached sensor and interfaces the signals that it receives to the microcontroller module.
The input module is designed to accommodate modules that supplies it status signal in any of the
following formats:
(a) 2- wire Current source 4 –20mA.
(b) 3-wire power plus Current source 4 –20mA.
(c) 3-Wire Pellistor Bridge type.
The channel outputs are as follows.
The transmitted signal can be configured using jumpers to provide one of three output options:
•4 –20mA Current Source proportional to the detected signal.
•4 –20mA Current Sink proportional to the detected signal.
•0-5V Voltage Output proportional to the detected signal.
Situated on each Input Module are 2 single-pole change-over relays, each relay having contacts rated
at 5A (240V AC). These relays operate at the alarm levels when enabled. Status Scientific Controls
are able to implement modifications to the software to meet a customer’s specific requirement. Contact
Status for further information.
Note:
1) The relays are selected to be either normally open or normally closed by solder links on
the underside of the PCB. The factory default settings are closed contacts when the
power is off. This setting has been chosen such that the channel is in an alarm condition
when the power fails.
2) The solder links are on the underside of the PCB to meet the low voltage directive and
make sure that the user is not exposed to bare terminals that may be at high voltages
when switching mains voltages.
There are two solder links under each relay. The link must be made for the desired operation. Only 1
of the links must be made. The factory default setting is shown below, the relay is energised for
healthy condition, the contacts will close for an alarm condition and loss of power.
Relay Off
Normally closed
contact
Normally open
contact

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1.3 Field Connections
Located on the lower half of the main PCB is a number of screw connectors. This is used to provide
connections for inputs and outputs for each channel:-
REMOVABLE CONNECTOR
CHANNEL 11
RLB RLA
J1
J2
J3
J4
J5
J6
J7
J8
J9
SENSOR
OPTIONS ANALOGUE
OUTPUT
ALARM
LEVEL1
CONTACTS
ALARM
LEVEL2
CONTACTS
12 3 4 5 6 7 8 9 10
The Power input, common relays and sounder output are located at the lower RHS of the PCB.
SW1 is used to isolate the main circuitry from both the incoming power supplies.
FS1SW1 RL18 RL17
12 3 4 5 6 7 8 9 10
1 Fused power input +Ve 24Vdc.
2 Fused power input -Ve.
3 Battery power input +Ve 24Vdc, fused on PCB, FS1.
4 Battery power input -Ve.
5 & 6 Fault relay contacts, RL18.
7 & 8 Common alarm level 3 relay contacts, RL17.
9 Sounder +Ve 24Vdc.
10 Sounder -Ve supply.

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1.4 Power Supply Module
The Power Supply is situated on the RHS of the main PCB within the enclosure and provides the
power for the whole system. The power supply is a standard item and does not require any
modifications regardless of the type and quantity of detector heads being used.
123456
Power Led
Voltage adjust
PSU mounting
PSU mounting
Warning cover
mounting post
Warning cover
mounting post
WARNING!
ISOLATE MAINS INPUT
BEFORE REMOVING
THIS COVER
Warning
cover
The warning cover must be removed to gain access to the terminal connections. The power supply
connections are as follows:
1. Live 100-240V AC Mains supply input.
2. Neutral 100-240V AC Mains supply input.
3. Earth 100-240V AC Mains supply input.
4. No connection
5. –Ve DC supply output.
6. +Ve DC supply output.

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2 MCU INSTALLATION
The MCU Control Units and FGD Gas Detectors are fully tested prior to delivery. However, after
installation we strongly recommend that full system testing and commissioning be carried out. Status
Scientific Controls Service personnel are best equipped to perform the relevant tests and
commissioning and will be able to offer advice regarding installation faults.
WARNING Installation should be made in accordance with either British Standard BS
EN60079-14 (which supersedes BS5345) “Electrical Apparatus for Explosive Gas
Atmospheres”, or in accordance with the relevant National or Local regulations.
CAUTION
The MCU Control Units and associated modules contain no user serviceable parts. Refer all servicing
to qualified service personnel.
2.1 Siting the MCU
THE LC SERIES CONTROL UNITS MUST BE SITED IN A NON-HAZARDOUS LOCATION WHERE
THERE IS NO RISK OF THE PRESENCE OF POTENTIALLY EXPLOSIVE GAS.
Either a 100-240VAC 50 Hz supply or a 24V DC supply can be used to power the control unit.
The site of installation should be chosen with regard to the following:
•This equipment should not be located near to known sources of heat.
•Operating personnel should be within convenient reach of the equipment and within audible
distance of alarms.
•Maximum loop lengths of cable runs and cable inductance to resistance ratios must not
exceed limits shown in the relevant loop diagrams (refer to section 3.2).
•Avoid mounting this equipment near potential sources of electrical interference e.g. motors,
switch gear, radio transmitters etc.
Mounting details for the LC Controller enclosures are located within the Appendix (section 5).

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2.2 System Wiring
All connections should be made according to the appropriate sensor or loop diagram for the
configuration required. It is advised that ‘Bootlace Ferrules’ or ‘flat blade crimps’ be used for tidy and
reliable connections of wires into the Control Unit and Detector Head connectors.
2.3 Power Supply Input
An isolating switch should be provided between the power source and the MCU control units to allow
the supply to be easily disconnected. This should incorporate over current protection or a circuit
breaker. Alternatively a fused supply would suffice.
2.3.1 A.C. Mains Connection
The LC8 is powered from a mains supply that is housed within the enclosure.
The power supply has a 6-way screw terminal connector assigned for the connection of an AC supply.
Pin 1 = Live input
Pin 2 = Neutral input
Pin 3 = Earth
Recommendation for mains input cable:
3-Core - Conductors having cross sectional area of 0.75mm2minimum (24/0.2).
The output from the mains power supply is
Pin 4 = N/C
Pin 5 = 0V DC
Pin 6 = +24V DC
2.3.2 DC Voltage Connection
The main PCB has two DC inputs.
Internal supply:
Pin 1 = +24V DC input
Pin 2 = 0V DC input
External supply, which may be a battery back-up supply.
Pin 3 = +24V DC input
Pin 4 = 0V DC input
Note: the two supplies are connected together after two reverse blocking diodes. This means that
the supply that has the highest voltage will power the system.
Warning: some switch mode battery chargers may damage the processor and display, consult Status
Scientific Controls for advice.

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Cable Routing
Due to the low signal levels generated by gas detectors it is recommended that all wiring to the
sensors by segregated away from AC mains or other high voltage/power lines to avoid interference.
2.4 Cable Screening
The use of a screened cable is recommended for the installation of all detector heads. The screening
is used to minimise the effects of electrical interference generated by external equipment e.g. motors,
switchgear etc. The correct strategy for connecting the screens depends upon the area in which the
detector head is to be used (i.e. hazardous/ non-hazardous). In all cases the screen should not be
connected at the detector head.

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3 GAS DETECTOR HEAD INSTALLATION
3.1 Siting the Detectors
Mounting positions for the gas detectors need to be considered individually, Status Scientific Controls
will offer advice and assistance with regard to the siting of detectors in varying environments. Some
initial points for consideration are:
•Ensure all gas detectors are mounted to allow routine calibration and maintenance to be
carried out as required.
Note: Sensors can operate reliably for several years however the environment may
reduce the sensor expected life.
•Ensure the proposed site will not interfere with movement of existing equipment, e.g.
cranes, doors etc
•Install all cables neatly and securely.
•Detectors for gases that are lighter than air should be positioned at a high level.
•Detectors for gases that are heavier than air should be located at below head height.
•Avoid siting the gas detectors adjacent to potential sources of radio frequency interference,
e.g. radio transmitters, control switchgear, motors etc.
•Ensure the detectors are mounted with sufficient space to allow air movement around the
sensor section, and the opening of the front hinged lid.
3.2 Installation in a Non-Hazardous Area
Where gas detector heads are to be installed in an area where there is no potential of an explosive
gas hazard present, the cable lengths are limited solely by the resistance of the cable. The FGD2,
FGD3 or FGD10b gas detectors fitted with either oxygen or toxic sensors require a minimum of 6V at
its terminals to operate correctly. The maximum cable loop resistance is therefore
(20-6)/25mA i.e. 560.
Cable resistance values depend upon the size of the cable. Typical resistance values are:
1.0mm2solid core 40/Km loop.
1.5mm2solid core 25/Km loop.
The correct wiring method for all Status Scientific FGD2 / FGD3 Detector Heads (in a non-hazardous
location) is shown below. It is important to note that this drawing shows the wiring connections but
does not discuss the Input Module configuration. Prior to connecting the Detector Head ensure the
Input Module is correctly configured (refer to section 4.1).
For installation diagrams for FGD Flammable Gas Detector Heads refer to section 3.3.

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3.3 Installation in a Hazardous Areas
Where gas detector heads are to be mounted within a potentially explosive atmosphere then electrical
safety barriers must be fitted in order to limit the electrical energy that is supplied into the hazardous
area. This prevents an incendive spark occurring under an electrical fault condition.
When using barriers to create an I.S. supply, certain restrictions are imposed on the parameters of the
interconnecting cables used. These parameters are defined by the manufacturer of the barrier and
limit the maximum capacitance, inductance and inductance to resistance ratio of the cable. The
installation is only intrinsically safe when the combination of the barrier and connecting cables comply
with the manufacturer’s specification.
As with a non-I.S. installation, the cable length is restricted by the cable loop resistance. With the
introduction of a barrier, the cable loop resistance is reduced because of the internal resistance of the
barrier. The end to end resistance of the barrier must therefore be subtracted from the overall cable
loop resistance when calculating cable lengths.
Barriers must be selected to restrict the parameters of the I.S. supply to the gas detectors within the
following limits:
Gas Detector
Terminals
Umax
Imax
Pin
FGD2/3 Oxygen or Toxic
0V and SIG
30V
0.15A
0.81W
FGD2/3 Flammable
0V and SIG
30V
0.15A
0.81W
0V and PWR+
7.5V
0.75A
1.4W
When considering the capacitance and inductance allowable across the barrier output terminals, note:
There is zero capacitance and zero inductance between terminals 0V and SIG on any model of FGD
Detector head.
There is an equivalent of 1.4F capacitance and zero inductance between terminals 0V and PWR on
the FGD2 and FGD3 flammable gas detectors.

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3.3.1 Hazardous area installations using Safety Barriers.
The following diagrams show how proprietary I.S. barriers can be used (barriers manufactured by MTL
are shown).
Screen
Hazardous area Safe Area
Sig
CHANNEL 1
LEVEL 1
ALARM LEVEL 2
ALARM
J3
4 2
MTL728+
3 1
I.S. Earth
Screen
Connection diagram for FGD2 & 3 Flammable
Detectors in ahazardous area
4 2
MTL758
3 1
0 +
+
-
4-20 mA Loop
4 2
MTL728+
3 1
I.S. Earth
Screen
Screen
Hazardous area Safe Area
CHANNEL 1
LEVEL 1
ALARM LEVEL 2
ALARM
J1
J2
J3
J4
J5
J6
J7
J8
J9
J1
J2
J4
J5
J6
J7
J8
J9
Note:
The system 0V is NOT connected to the earth.
The I.S Earth connection on the power distribution PCB must be connected to the installations’ I.S.
earth point. The connection must be made via a conductor of minimum 4mm2cross sectional area.
Refer to EN60079-14 (previously BS5345:Part 4, section 16) for further details of earthing
requirements.

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4 INPUT MODULE CONFIGURATION
The MCU Systems have been designed to cater for almost all requirements of available detector
heads. For this reason many of the options available require either software or hardware configuration.
The diagram below shows the Input module and the positions of switches etc required during
configuration.
CHANNEL1
LEVEL 1
ALARM LEVEL 2
ALARM
J1
J2
J3
J4
J5
J6
J7
J8
J9
CH1
J10
J11
J12
J13
J14
12 3 4 5 6 7 8 9 10
The relay connections shown are with the relay coil in its de-energised state.
Input configuration
J1 and 9 are for the sensor gain.
J2, J4, J5, J6, J7 and J8 signal conditioning.
Analogue output
J10, J12 and J13 is for current sink / source.
J11 is for voltage output.
J14 select internal 24V to power the loop.
Note: the position of jumpers J10 to J14 are not located next to the relays as shown in the diagram
above, refer to the LC8 main PCB diagram in section 1-1

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4.1 Input Configuration
Section 4.2 discusses the most common configuration options. These are also the configurations
adopted by Status Scientific for use with FGD detector heads (manufactured by Status Scientific
Controls).
Note: The input configurations shown are for detector heads located in non-hazardous
environments. I.S. Barriers are required when mounting in areas where there is a flammable gas
hazard, refer to section 3.3.
4.2 Status Scientific Controls Gas Detectors
Status Scientific Controls design and manufacture a variety of fixed gas detectors. The detector head
used for monitoring oxygen or toxic gases (using conventional sensors) requires a 2-wire connection
whilst detector heads incorporating infrared sensors or pellistors require a 3-wire connection.
4.2.1 FGD2, FGD3, FGD4 and FGD10b O2and Toxic Detector Heads
CHANNEL 1
LEVEL 1
ALARM LEVEL 2
ALARM
J1
J2
J3
J4
J5
J6
J7
J8
J9
+ve -Ve

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Connection Procedure
•Disconnect power from the system.
•Remove the terminal cover to gain access to the wiring.
•Remove the terminal cover and display module to gain access to the configuration link
settings.
•Configure the PCB solder links as shown below (i.e. J1, J2, J4, J5, J8 and J9 switched ON,
all others OFF)
J1
J2
J3
J4
J5
J6
J7
J8
J9
•Connect the wires from the detector head to connector on the input module observing the
following:
Detector Head Label
4-20mA Loop
Channel
Pin Number
+
2
-
3
•Connect power to the system and ensure the detector head operates (text on LCD display,
LED will flash once every six seconds approximately).
•Perform software configuration (refer to ‘LC Software Configuration and System Calibration
Manual’).
•Perform system calibration (refer to ‘LC Software Configuration and System Calibration
Manual’).
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