OTIS GEN II OI-6000 Operation Manual
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OTIS GEN II OI-6000 Operation Manual

Explosion-proof wire powered ambient air hazardous gas detector
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Do you have a question about the GEN II OI-6000 and is the answer not in the manual?

Questions and answers

Gavin Moncks
February 19, 2025

Do you need or should you do daily gas bump tests on the monitor heads?

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1 comments:
Mr. Anderson
May 14, 2025

No, OTIS GEN II OI-6000 monitor heads do not require daily gas bump tests. The recommended maintenance includes monthly calibrations, assuming no damage or power outage has occurred.

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Summary of Contents for OTIS GEN II OI-6000

  • Page 3 WALL TO COMPLY WITH THE HAZARDOUS LOCATION RATING OF THIS PRODUCT DANGER DANGER: OTIS INSTRUMENTS INC. OI-6000-X-X-X-X-O IS AN AMBIENT AIR HAZARDOUS GAS SENSOR ASSEMBLY AND ONLY MONITORS IN THE IMMEDIATE VICINITY OF THE SENSOR HOUSING. A SITE SURVEY IS REQUIRED IN ORDER TO DETERMINE THE BEST PLACEMENT AND QUANTITY OF SENSOR ASSEMBLIES.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS PRODUCT OVERVIEW ............................1 INTRODUCTION ..............................1 PRODUCT SPECIFICATIONS ..........................2 SYSTEM DIAGRAMS ............................. 3 1.3.1 EXTERNAL SYSTEM DIAGRAM ........................... 3 1.3.2 INTERNAL SYSTEM DIAGRAM..........................4 1.3.3 ASSEMBLY DIAGRAM ............................5 INSTALLATION AND START-UP .......................... 6 PRODUCT PLACEMENT ............................
  • Page 6 TABLE OF CONTENTS OPERATION SETTINGS ............................. 39 POWERING THE DEVICE ........................... 39 4.1.1 POWERING OFF ..............................39 4.1.2 POWERING ON ..............................39 SENSOR CALIBRATION ............................40 4.2.1 NULLING THE SENSOR (AUTO NULL) ......................40 4.2.2 CALIBRATING THE SENSOR (MANUAL CAL) ....................42 4.2.3 CALIBRATING THE SENSOR (AUTO CAL) ......................

  • Page 7: Product Overview

    Non-intrusive interface with the OI-6000 is made possible by use of the Otis Magnetic Tool included in the purchase of the device. The OI-6000 display screen will always show the present concentration of gas being detected by the sensor assembly.

  • Page 8: Product Specifications

    PRODUCT OVERVIEW 1.2 PRODUCT SPECIFICATIONS System Specifications Operating Voltage +12 to +35 VDC Current Draw 250 mA Maximum Operating Temperature Range -40⁰C to +54⁰C Humidity Range 0% to 98% Relative Humidity, Noncondensing Measurement Range Varies based on gas type Response Time Varies based on gas type Protection Power Electromagnetic Interference (EMI) Filter...

  • Page 9: System Diagrams

    5 SUB Button 6 Mounting Hole 7 HIGH Alarm LED 8 Sensor Housing Assembly 9 Sensor Rain Guard 10 Otis Magnetic Tool 11 LOW Alarm LED 12 ADD Button 13 Enclosure Lid Locking Screw 14 Display Screen 15 Optional Antenna Fitting...

  • Page 10: Internal System Diagram

    PRODUCT OVERVIEW 1.3.2 INTERNAL SYSTEM DIAGRAM RS-485 Modbus Terminal Block Fault Terminal Block Power Input/4-20mA Output Terminal Block Radio Module (If equipped) Sensor Housing Socket Antenna Fitting Connector (If equipped with a radio module) Relay 1 Terminal Block (If equipped with relays) Relay 2 Terminal Block (If equipped with relays) OI-6000-X-X-X-X-O OPS_GUIDE_REV 3.1...

  • Page 11: Assembly Diagram

    PRODUCT OVERVIEW 1.3.3 ASSEMBLY DIAGRAM Enclosure Lid Internal System Antenna Fitting Plug (If equipped with a radio module) Enclosure Body Antenna Fitting (If equipped with a radio module) or #7 (If not equipped with a radio module) 900 MHz or 2.4 GHz Antenna (If equipped with a radio module) Explosion Proof Plug (If not equipped with a radio module) Sensor Housing Base Sensor Element...

  • Page 12: Installation And Start-Up

    (1) the site/facility where the equipment is being installed and (2) the potentially present gas types and their dispersion. Otis strongly recommends that the end-user consults with the appropriate third party Health, Safety and Environmental (HSE) and Industrial Hygiene (IH) professionals to determine the final quantity and placement of your gas detection devices.

  • Page 13: Product Mounting

    INSTALLATION AND STARTUP 2.2 PRODUCT MOUNTING It is recommended to mount the unit to a solid structure (such as a concrete wall, steel column, or angle iron) where a minimum of vibration will be transmitted to the unit. Alternately, a pole may be used along with a strap or a U-bolt, as long as it is rigid and of sufficient strength.

  • Page 14: Opening The Enclosure

    To provide power to the OI-6000, you will need to connect the power cable from the sensor terminal block on an Otis monitor, or alternate user supplied power source, to the OI-6000 power terminal block located on the back of the control board. Refer to the following instructions for how to wire your device: On the GEN II Model OI-6000 Detector: 1.
  • Page 15 To utilize the added functionality of the device, additional wiring is necessary. If an Otis Monitor is not used, the OI-6000 can be powered from any +12 to +35 VDC power supply that is capable of supplying at least 250 mA.

  • Page 16: Connecting 4-20 Ma Output

    To utilize the 4-20 mA wired data output feature of the OI-6000, you will need to connect the signal cable from your Otis Monitor sensor terminal block to the OI-6000 power terminal block located on the control board. Refer to the following instructions for how to wire your device: On the GEN II Model OI-6000 Detector: 1.
  • Page 17 INSTALLATION AND STARTUP OTIS MONITOR OI-6000 SENSOR TERMINAL POWER TERMINAL +12 to +35 VDC WHITE +12 to +35 VDC WHITE BLACK BLACK 4-20 mA GREEN 4-20 mA GREEN OI-6000-X-X-X-X-O OPS_GUIDE_REV 3.1...

  • Page 18: Connecting Rs-485

    The OI-6000 supports Modbus RTU over a RS-485 link. To integrate your device with RS-485 Modbus data communications, you will need to connect the Modbus cable from your Otis Monitor RS-485 input terminal block to the OI-6000 RS-485 output terminal block located on the control board of the unit. Refer...
  • Page 19 BROWN NOTICE If an Otis Monitor is not used, the OI-6000 can be connected to a Programmable Logic Controller (PLC) for RS-485 Modbus data communications. For integration and setup, refer to the Modbus Register Map found in Appendix C of this manual.

  • Page 20: Connecting Relays/Alarms

    INSTALLATION AND STARTUP 2.3.5 CONNECTING RELAYS/ALARMS The OI-6000 relays are commonly used to power and control external alarming devices, such as alarm lights (visual) and horns (audio). Refer to the following instructions for how to wire your device. If you do not have relays in your OI-6000 skip to section 2.3.6 CONNECTING THE FAULT TERMINAL.
  • Page 21 INSTALLATION AND STARTUP OI-6000 OI-6000 POWER TERMINAL RELAY 1 TERMINAL +12 to +35 VDC BLUE 4-20 mA BLUE NOTICE It is recommended that the relay connections are wired as normally-open (NO). However, normally- closed (NC) wiring configurations provide an inherent fail-safe and may be preferred. OI-6000-X-X-X-X-O OPS_GUIDE_REV 3.1...
  • Page 22 INSTALLATION AND STARTUP 2.3.5.1.1 CONNECTING NORMALLY-OPEN (NO) RELAYS On the external alarming device (light/horn): 1. Locate the power (RED) and ground (BLACK) wires on the alarming device. On the GEN II Model OI-6000 Detector: 1. Feed the alarming device wires through the power hub and into the enclosure. 2.
  • Page 23 INSTALLATION AND STARTUP 2.3.5.1.2 CONNECTING NORMALLY-CLOSED (NC) RELAYS On the external alarming device (light/horn): 1. Locate the power (RED) and ground (BLACK) wires on the alarming device. On the GEN II Model OI-6000 Detector: 1. Feed the alarming device wires through the power hub and into the enclosure 2.
  • Page 24 INSTALLATION AND STARTUP 2.3.5.2 CONNECTING RELAY 2 On the GEN II Model OI-6000-IR-152 Detector: 1. Locate the Relay 1 terminal block on the radio/relay board and complete the following: a. Connect a second power (BLUE) wire to the “COM” terminal. 2.
  • Page 25 INSTALLATION AND STARTUP 2.3.5.2.1 CONNECTING NORMALLY-OPEN (NO) RELAYS On the external alarming device (light/horn): 1. Locate the power (RED) and ground (BLACK) wires on the alarming device. On the GEN II Model OI-6000 Detector: 1. Feed the alarming device wires through the power hub and into the enclosure. 2.
  • Page 26 INSTALLATION AND STARTUP 2.3.5.2.2 CONNECTING NORMALLY-CLOSED (NC) RELAYS On the external alarming device (light/horn): 1. Locate the power (RED) and ground (BLACK) wires on the alarming device. On the GEN II Model OI-6000-IR-152 Detector: 1. Feed the alarming device wires through the power hub and into the enclosure. 2.

  • Page 27: Connecting The Fault Terminal

    INSTALLATION AND STARTUP 2.3.6 CONNECTING THE FAULT TERMINAL The fault terminal is used to provide indication of a device failure. The fault terminal is a normally-closed (NC), or fail-safe, configuration, terminating power to the external fault device when prompted. Unlike the optional relay terminals, the fault terminal is a wet-contact, requiring only the power and ground wires of the external fault device to be wired during installation.
  • Page 28 INSTALLATION AND STARTUP OI-6000-X-X-X-X-O OPS_GUIDE_REV 3.1...

  • Page 29: Closing The Enclosure

    During warmup, the display will show a countdown of the time remaining until the system start-up is complete. The Otis logo and the unit information will also show on the display screen during start-up. At the end of the countdown, the device will be in normal operating mode.

  • Page 30: Normal Operating Mode

    INSTALLATION AND STARTUP 2.5 NORMAL OPERATING MODE During normal operating mode, the OI-6000 continuously samples the air and updates the measured concentration of the target gas on the display screen. The display, when in normal operation, appears as shown below. ④...

  • Page 31: Product Settings And Configuration

    PRODUCT SETTINGS AND CONFIGURATION 3 PRODUCT SETTINGS AND CONFIGURATION The product settings and configuration menu allows the end-user to tailor the device settings to meet their required specifications and/or site conditions. The product settings and configuration menu consist of the following screens: ...

  • Page 32: Performing The Relay Test

    3. Press the MENU button to advance to the System Information screen. 3.2 NETWORK ID The Network ID is used to synchronize the communication between the Otis Monitor and Sensor Assembly: There are 52 networks available with the GEN II 900 MHz radio.

  • Page 33: System Information

    PRODUCT SETTINGS AND CONFIGURATION 3.3 SYSTEM INFORMATION The system information screen allows the end-user to view the following information: The status of the radio link (Only present if radio module is installed)   The scale of the sensor element. The supply voltage of the sensor unit.

  • Page 34: Unit Information

    PRODUCT SETTINGS AND CONFIGURATION 3.5 UNIT INFORMATION The unit information screen allows the end-user to view the following information:  The number of missed radio transmissions to the monitor (Only present if radio module installed)  The date of manufacture of the sensor assembly. The serial number of the sensor assembly.

  • Page 35: Latching And Non-Latching Relay Settings

    PRODUCT SETTINGS AND CONFIGURATION 3.7 LATCHING AND NON-LATCHING RELAY SETTINGS Relay 1 and Relay 2 can be set to latching or non-latching. Relays set to non-latching will automatically deactivate when the detected gas level falls below the corresponding alarm setting. Conversely, latching relays, once activated, MUST be manually reset at the device, regardless of the change in gas detection level readings.

  • Page 36: Relay 2: Latching/Non-Latching Setting

    PRODUCT SETTINGS AND CONFIGURATION 3.7.2 RELAY 2: LATCHING/NON-LATCHING SETTING 1. Use the ADD and SUB buttons to toggle between the “UnLatch” and “Latch” options. 2. Press the MENU button to select the desired setting and to advance to the Relay 1 fail-safe setting screen.

  • Page 37: Relay 1: Fail-Safe Setting

    PRODUCT SETTINGS AND CONFIGURATION If the fault terminal cannot be used, Otis Instruments recommends one of the following configurations: Recommended Configurations for Relay Fail-Safe Setting Power Source Relay Wiring Fail-Safe Outcome OI-6000 Normally-Closed (NC) No (Off) Normal Operation: Closed Alarm Activation: Open...

  • Page 38: Calibration Method

    PRODUCT SETTINGS AND CONFIGURATION 3.9 CALIBRATION METHOD The calibration method selection allows you to choose how you calibrate the sensor element. Manual calibration is the default method for all gas types.  Manual calibration lets you use the ADD and SUB buttons during calibration to match the reading shown on the screen to the value of the gas being applied.

  • Page 39: Modbus Address Setting

    1 to 255. Eight of the addresses are used for internal system settings, leaving addresses 1 to 247 available for your device. The RS-485 Modbus communication parameters used in Otis devices is 8 data bits, no parity, and 1 stop bit; these parameters are fixed and cannot be changed. The floating point data values are presented with the least significant bytes first.

  • Page 40: Modbus Baud Setting

    OI-6000 MUST match the baud rate setting on the attached Otis Monitor, or other Modbus device. All Otis devices have factory default Modbus baud settings of 9600 bps. The RS-485 Modbus communication...

  • Page 41: Ma Offset Settings

    Setting the 4-20 mA offset allows the end-user to calibrate the sensor’s analog output. Upon installation of the device, if the detected gas reading on OI-6000 does not correspond to the reading on the Otis Monitor, or other monitoring device, the zero offset (4 mA) and the full-scale offset (20 mA) can be adjusted on the unit.

  • Page 42: Full-Scale Offset Setting

    1. Use the ADD and SUB buttons to increase and decrease the full-scale offset, respectively, until the Otis Monitor reads the full scale value for that channel. 2. Press the MENU button to save the desired setting and to advance to the display screen contrast setting screen.

  • Page 43: Return To Factory Default Settings

    PRODUCT SETTINGS AND CONFIGURATION 3.14 RETURN TO FACTORY DEFAULT SETTINGS Returning the OI-6000 to its factory default settings will reset all customization of the device, including the null and calibration settings of the sensor element. OI-6000 Product and Configuration Factory Default Settings Configuration Setting Relay Test...
  • Page 44 PRODUCT SETTINGS AND CONFIGURATION 1. Press the ADD button to select “Yes” to return the device to its factory default settings and to advance to the return to factory default settings confirmation screen. If you do not wish to return the device to its factory default settings, press the SUB button to select “No”...

  • Page 45: Operation Settings

    During the 1-minute warmup, the display will show a countdown of the time remaining until the system start-up is complete. The Otis logo and the unit information will also flash on the display screen and, at the end of the countdown, the device will be in normal operating mode.

  • Page 46: Sensor Calibration

    4.2 SENSOR CALIBRATION Calibration is the process of evaluating and adjusting the precision and accuracy of measurement equipment. Although Otis calibrates every device at the factory, for best accuracy, the detector SHOULD be calibrated in the environment where it is installed.
  • Page 47 OPERATION SETTINGS 3. Press the ADD button to select “Yes” to confirm that the sensor is in clean air and to begin nulling the sensor. If the sensor is not in clean air, press the SUB button to select “No” to discontinue the null process and to return to the previous screen.

  • Page 48: Calibrating The Sensor (Manual Cal)

    OPERATION SETTINGS 4.2.2 CALIBRATING THE SENSOR (MANUAL CAL) You should ONLY perform the calibration of the sensor after the null process has been completed. For best results, use 50% of the sensor scale of your target gas in an air balance with a flow rate of 0.25 to 0.5 LPM.

  • Page 49: Calibrating The Sensor (Auto Cal)

    OPERATION SETTINGS 4.2.3 CALIBRATING THE SENSOR (AUTO CAL) You should ONLY perform the calibration of the sensor after the null process has been completed. For best results, use 50% of the sensor scale of your target gas in an air balance with a flow rate of 0.25 to 0.5 LPM.
  • Page 50 OPERATION SETTINGS 6. Attach the tubing on the Calibration Adapter Kit to the regulator on the calibration gas bottle. 7. Ensure that the gas is flowing and press the MENU button to begin calibrating the sensor, the unit will automatically begin the calibration process, the amount of time on the timer will vary based on the gas type.

  • Page 51: Sensor Alarm Settings

    OPERATION SETTINGS 4.3 SENSOR ALARM SETTINGS The OI-6000 has two alarm settings: LOW alarm and HIGH alarm. Regardless of whether the device includes the optional two dry-contact relays, the system alarm settings are available on the device. All alarm set-points are field adjustable up to 60% of the full scale gas concentration.

  • Page 52: Sensor Low Alarm Rise/Fall Setting

    OPERATION SETTINGS 4.3.2 SENSOR LOW ALARM RISE/FALL SETTING 1. Use the ADD and SUB buttons to select between activation on a Rising or a Falling gas level, respectively. 2. Press the MENU button to save the desired setting and to advance to the sensor HIGH alarm setting screen.

  • Page 53: Sensor High Alarm Rise/Fall Setting

    OPERATION SETTINGS 4.3.4 SENSOR HIGH ALARM RISE/FALL SETTING 1. Use the ADD and SUB buttons to select between activation on a Rising or a Falling gas level, respectively. 2. Press the MENU button to save the desired setting and to advance to setting the radio address (if you have a radio module installed), otherwise you will return to Normal Operating Mode.

  • Page 54: Manual Reset For Activated Latching Alarms

    OPERATION SETTINGS 4.5 MANUAL RESET FOR ACTIVATED LATCHING ALARMS Relay alarms set to latching will not deactivate until the alarms are manually reset at the device. This includes LOW and HIGH alarm indicator LEDs and optional wired relays. When latching alarms have been activated, refer to the following instructions for how to manually deactivate the alarms on your device: 1.

  • Page 55: Product Maintenance

    5 PRODUCT MAINTENANCE 5.1 SCHEDULED MAINTENANCE Otis recommends that our equipment be calibrated a MINIMUM of every 90 days, and STRONGLY advise that calibration be performed every 30 days. Without knowing the specific application, sensor assembly location, gas exposure and other factors, the company recommends monthly calibrations – assuming no damage or potential damage has occurred to the sensor and that there has not been a power outage to the sensor assembly.

  • Page 56: Sensor Replacement

    The sensor elements used in the OI-6000 detects gas in either % or PPM concentrations, this element must be fully functional in order for the system to operate correctly. Otis recommends replacing the sensing element whenever a slow response to gas is observed during the normal calibration process. After replacing the sensing element the device MUST then be nulled and calibrated for proper operation of the device.

  • Page 57: Product Troubleshooting

    APPENDICES 5.3 PRODUCT TROUBLESHOOTING OI-6000 Fault Codes Problem Cause(s) Solution(s) 1. The control board has lost communication with 1. Check connection between the sensor the digital sensor interface adapter board. housing connector header and the digital Check sensor interface adapter board plug-in. Sensor 2.

  • Page 58: Product Replacement Parts And Accessories

    While not all of the components on the OI-6000 can be field-replaced, there are several parts that are replaceable by an Otis Approved Service Technician. To purchase accessories/replacement parts for your device, contact the sales representative of this product for assistance.
  • Page 59 INTRODUCTION TO 4-20 mA CURRENT LOOP SIGNALS APPENDIX B: MODBUS COMMUNICATIONS APPENDIX C: MODBUS REGISTER MAP APPENDIX D: OTIS INSTRUMENTS PRODUCT WARRANTY STATEMENT APPENDIX E: INFORMATION ABOUT RMA SERVICE REPAIRS APPENDIX F: INFORMATION ABOUT RMA RETURNS FOR CREDIT OI-6000-X-X-X-X-O OPS_GUIDE_REV 3.1...

  • Page 60: Appendix A: Introduction To 4-20 Ma Current Loop Signals

    20 mA the highest. The relationship between the current loop and the gas value is linear. In addition, Otis devices use values below 4 mA to indicate special status conditions, as shown below:...
  • Page 61 APPENDICES Sensor Element Scale Ranges Sensor Type Gas Type Formula Range Electrochemical (EC) Hydrogen Sulfide 0-100 PPM Electrochemical (EC) Hydrogen Sulfide (High Range) H2S2K 0-2000 PPM Electrochemical (EC) Sulfur Dioxide 0-20 PPM Electrochemical (EC) Oxygen 0-25 % Electrochemical (EC) Carbon Monoxide 0-1000 PPM Electrochemical (EC) Chlorine...

  • Page 62: Appendix B: Modbus Communications

    Based on the type of circuit used, there is a limit on how many devices that can be connected to a Modbus sensor network. Otis Monitors currently allow a maximum of 32 devices on a single network. The data is transferred along the Modbus network at a specified Modbus baud, or rate of speed.
  • Page 63 APPENDICES The signal wire of each unit is run to the signal terminal of the neighboring sensor. With each device connected to the previous device via the signal wire, a “chain” is created, with the first device in the chain directly connected to the monitor. RS-485 Modbus Connection Distances for Electrical Wiring Distance Length...

  • Page 64: Appendix C: Modbus Register Map

    APPENDICES APPENDIX C: MODBUS REGISTER MAP OI-6000 MODBUS REGISTER MAP Register Register Address Address Data Description Length Unit Valid Response(s) (Hex) (Dec) Gas Reading FLOAT Numerical Gas Reading Modbus Address UINT 0 – 247 Gas Type ENUM 0 – 26, see below Unit Type ENUM 0 –...
  • Page 65 APPENDICES OI-6000 MODBUS REGISTER MAP ENUMERATION KEYS Register Address 4: Gas Type Response Gas Type H2S – Hydrogen Sulfide SO2 – Sulfur Dioxide O2 – Oxygen CO – Carbon Monoxide CL2 – Chlorine CO2 – Carbon Dioxide LEL – Combustible Gas VOC –...
  • Page 66 APPENDICES Register Address C/12: Sensor Type Response Sensor Type EC – Electrochemical IR – Infrared PID – Photo Ionization Detector Register Address 17/23: Relay Setting Relay Setting Function 0 – Fall Relay 2: Rise/Fall Setting 1 - Rise 0 – Fall Relay 1: Rise/Fall Setting 1 - Rise 0 –...

  • Page 67: Appendix D: Product Warranty Statement

    Otis’ published guidelines; (f) damage, caused by service performed by anyone who is not a representative of Otis or who is not an Otis authorized service provider; (g) damage, caused by product modifications, alterations of functionality or capability; (h) defects, caused by normal wear and tear or otherwise due to the normal aging of the Otis product, or (i) any product in which a product-labeled serial number has been removed, defaced, or altered in any way.
  • Page 68 Otis Warranty service, at their discretion, will (a) repair the device using new or previously used parts that are equivalent to new in performance and reliability, (b) replace the Otis Product with a device that is at least functionally equivalent to the Otis product and is formed from new and/or previously used parts that are equivalent to new in performance and reliability, or (c) exchange the Otis Product for a refund of your purchase price, when an Otis Product is submitted.

  • Page 69: Appendix E: Information About Rma Service Repairs

    (i.e. magnetic switches, resistors, capacitors, relays, etc.). There is no charge for RMA Service repairs that are within the specified warranty period. For a copy of the Otis Instruments, Inc. Product Warranty Statement, please visit our website at www.otisinstruments.com/official_statements. Products/parts that are not within the specified warranty period will result in a charge to the customer for service.
  • Page 70 APPENDICES INTERNATIONAL RMA SERVICE REPAIRS The customer is responsible for complying with all import/export requirements for shipment of RMA/Service repairs to Otis Instruments, Inc. OTIS INSTRUMENTS RMA SERVICE DEPARTMENT Otis Instruments / Repairs 301 South Texas Ave. Bryan, Texas 77803 Office: 979.776.7700...

  • Page 71: Appendix F: Information About Rma Returns For Credit

    IMPORTANT INFORMATION All RMA Returns for Credit must be shipped to OTIS Instruments / RMA Returns, 301 S. Texas Avenue, Bryan, Texas 77803. Product/part returns must be in their original condition and packaging, as shipped from the manufacturer. Returns that do not meet these specifications will be rejected for return for credit.
  • Page 72 Otis Instruments 301 S. Texas Avenue, Bryan, Texas 77803 Tel: 979.776.7700 Fax: 979.776.7719 sales@otisinstruments.com service@otisinstruments.com www.otisinstruments.com...

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