MSA FiveStar Technical Manual
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MSA FiveStar Technical Manual

MSA FiveStar Technical Manual

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FiveStar
Technical Manual
THIS MANUAL MUST BE CAREFULLY READ BY ALL INDIVIDUALS WHO
HAVE OR WILL HAVE THE RESPONSIBILITY FOR SERVICING THE PRODUCT.
Like any piece of complex equipment, this instrument will perform as
designed only 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.
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
®
Alarm
"
WARNING
"
CAUTION
710440

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Summary of Contents for MSA FiveStar

  • Page 1 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"...
  • Page 2 MSA Portable Instrument Warranty Warranty- ITEM WARRANTY PERIOD Lifetime (MSA will support product Chassis and electronics for five years after production ends) All sensors, unless otherwise specified Two years Pump and drive unit Two years Rechargeable batteries Two years This warranty does not cover filters, fuses, etc. Certain other accessories not specifically listed here may have different warranty periods.

  • Page 3: Table Of Contents

    Alarm Setpoints ....1-9 Figure 1-11. Sample Toxic Alarm Setpoints ....1-9 Table 1-2. Default Factory Alarm Setpoints..1-10 FiveStar Alarm TOC-1...
  • Page 4 Bypass ........2-8 TOC-2 FiveStar Alarm...
  • Page 5 Replacement Parts List ..... . . 4-3 Table 4-3. Replacement Sensors....4-3 FiveStar Alarm TOC-3...
  • Page 6 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 TOC-4 FiveStar Alarm...

  • Page 7: Set-Up And Configuration

    Chapter 1, Setup and Configuration 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.

  • Page 8: Sensor Autoconfiguration And Replacement

    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. FiveStar Alarm...

  • Page 9: Caution

    "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.

  • Page 10: Caution

    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). FiveStar Alarm...

  • Page 11: Table 1-1. Allowable Sensor Installation Locations

    Tox 3 ONLY Chlorine YES - SEE NOTE Tox 3 ONLY Chlorine Dioxide YES - SEE NOTE Tox 3 ONLY NOTE: Biased sensors must be factory installed in units with Serial No. Prefixes of "F" or lower. For units with FiveStar Alarm...

  • Page 12: Warning

    Without proper contact, data may be improperly written to the sensor memory and data may become corrupted, rendering the sensor unusable. • The sensor cover holds the sensors down firmly against the Zebra Strips to ensure proper electrical contact. FiveStar Alarm...

  • Page 13: Removing A Sensor

    • The cover should be in place before turning the instrument back ON to verify configuration. • The sensor cover holds the sensors down firmly against the Zebra Strips to ensure proper electrical contact. 8. Install battery pack. FiveStar Alarm...

  • Page 14: Sensor Autoconfiguration

    • Instrument must be turned OFF to silence the alarm. • Pressing the RESET (YES) button causes instrument to re-read sensor memories. • FIGURE 1-6 screen appears. • Instrument now allows user to select Figure 1-7. format for the combustible display. Units Measured FiveStar Alarm...

  • Page 15: Figure 1-8. Gases Measured

    • After resetting the alarm setpoints, the instrument again scrolls through the alarms pages. • Once the alarm setpoints are reset, the "Accept Alarms" Figure 1-11. screen no longer reappears. Sample Toxic Alarm Setpoints FiveStar Alarm...

  • Page 16: Table 1-2. Default Factory Alarm Setpoints

    Zebra Strip condition. Also ensure that the sensor cover is screwed down tight to obtain a solid contact between the sensor memory board and the sensor board. 1-10 FiveStar Alarm...

  • Page 17: Caution

    It is recommended that all sensor calibrations be checked after autoconfiguration is run and prior to instrument use. FiveStar Alarm 1-11...

  • Page 18: Manual Sensor Configuration

    4. Re-install the battery pack while holding the RESET button. • The instrument screen turns black. 5. Immediately press and hold the PAGE button until the setup query page appears. • The instrument enters the Sensor Setup mode. 1-12 FiveStar Alarm...

  • Page 19: Calibration

    Chapter 2 Calibration Optional Fresh Air Setup The FiveStar Alarm can be set to allow the user to automatically zero the measurement systems and calibrate the oxygen system when the unit is turned ON. Activating the Fresh Air Setup Option Configuration of the Fresh Air Setup is done by way of the MSA LINK program.

  • Page 20: To Perform Fresh Air Setup

    Technical Manual To Perform Fresh Air Setup Press the RESET (YES) button within five seconds. • The FiveStar Alarm begins to perform a Fresh Air Setup. • Oxygen is set at 20.8 percent. • All other gases are set at zero.

  • Page 21: Calibration Procedures

    • The instrument turns ON (FIGURE 2-2): To Cancel Calibration: Press the PAGE (NO) button or wait five seconds. • The FiveStar Alarm begins warming up and enters the Exposure display page. To Continue Calibration: 2. Press the RESET (YES) button.

  • Page 22: Figure 2-4. Adjusting Zeroes

    • During this time, the FIGURE 2-4 display appears. Figure 2-4. Adjusting Zeroes After the fresh air adjustments are made, the FiveStar Alarm is ready to complete span calibration. Figure 2-5. Combustible Gas Calibration Display •...

  • Page 23: Figure 2-6. Calibration Cap Installation

    Press the PAGE (SKIP) button to skip calibration for any gases you do not want to change. 6. There are three means to supply gas to the FiveStar instrument for calibration: • Metal Calibration Cap (P/N 710572): To attach the Metal Calibration Cap: Figure 2-6.

  • Page 24: Oxygen Sensor Calibration Check

    Adjustment change continuously. 10. Push the ON/OFF (OK) button to accept the reading. • The new reading is stored in memory, and the FiveStar Alarm automatically moves to next reading. Oxygen Sensor Calibration Check After the combustible gas calibration is completed, the instrument automatically moves to the oxygen sensor calibration check.

  • Page 25: Toxic Gas Sensor Calibration

    1.2 or higher, the instrument automatically turns Figure 2-11. ON and goes into the normal Power OFF operation mode. • For instruments with software versions lower than 1.2, A long beep sounds and the FiveStar Alarm turns OFF automatically (FIGURE 2-11): FiveStar Alarm...

  • Page 26: Special Instructions For Instruments

    When calibrating with a chlorine dioxide generator you must either ensure the flow supplied by the generator exceeds the FiveStar pump draw (typically between 0.25 and 0.40 lpm) or you can supply the gas directly through a calibration cap. Hooking the pump directly to the generator may result in altering the concentration supplied;...

  • Page 27: Troubleshooting And Maintenance

    Toxic sensor does not calibrate √ Clock not holding time. Recharge or replace the cells before replacing battery pack. In all of the above cases and for any other problems, you may return the FiveStar Alarm to MSA for repairs. FiveStar Alarm...
  • Page 28 Improper sensor installed in Check sensor placement against TABLE 1-1 combustible site improper sensor installed in Check sensor placement against TABLE 1-1 oxygen site Improper sensor installed in Check sensor placement against TABLE 1-1 Toxic 1 FiveStar Alarm...
  • Page 29 If autoconfiguration is disabled or your instrument software is earlier than version 1.2, the user must run through the key sequence on battery attachment given in Chapter 1, "Manual Sensor Configuration." FiveStar Alarm...

  • Page 30: Repair Procedures

    4. Pull out the battery pack by gripping it at the edge of the battery pack case and pulling it away from the unit. 5. Remove the six case mounting screws from back of the case. 6. Carefully remove the back of the case. FiveStar Alarm...

  • Page 31: Caution

    15. Replace back of the case and tighten the six case-mounting screws securing the back of the case in the Figure 3-2. Display Connector FiveStar Alarm...

  • Page 32: Warning

    Technical Manual sequence shown in FIGURE 3-3. NOTE: Do not over-tighten screws. 16. Reconnect battery pack. 17. Completely recalibrate the FiveStar Alarm. " 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.

  • Page 33: Warning

    NOTE: When replacing the sensor board, this board must slide in under the keyboard ribbon cable. 16. Calibrate the FiveStar Alarm. " 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.

  • Page 34: Caution

    17. Pull keypad cable away from the unit. 18. Grasping the display module, gently rock and pull it up and away from case. 19. To re-assemble, gently place new display module into unit and rock module firmly into place. FiveStar Alarm...

  • Page 35: Caution

    25. Replace the main pc board, ensuring gasket is appropriately placed around the entire perimeter of the instrument. 26. Replace the six screws securing the back of the case. 27. Ensure zebra strips are included in their appropriate locations. 28. Place sensors into their appropriate positions. FiveStar Alarm...

  • Page 36: Warning

    Technical Manual 29. Replace gasket and sensor cover and attach with four screws. 30. Reconnect battery pack. 31. Completely recalibrate the FiveStar Alarm. " 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.

  • Page 37: Parts List

    ; 300 ppm CO and 10 ppm H Calibration Gas - 58% LEL pentane simulant / 804769 804769 804769 15% O ; 10 ppm H *These accessories may vary according to the country of use; please contact your nearest MSA Distributor Office for details. FiveStar Alarm...
  • Page 38 Chapter 4, Parts List Technical Manual Figure 4-1. North American (through Serial Number Prefix "E") Replacement Parts NOTE: This version does not have the sealing gasket around the sensor cover (Item 18) FiveStar Alarm...

  • Page 39: (Through Serial Number Prefix "E")

    S Sensor 710657 710657 710657 710657 NO Sensor 710662 710662 710662 710662 Sensor 710663 710663 710663 710663 Sensor 710664 710664 710664 710664 (Phosphine) Sensor 10011530 10011530 10011530 10011530 (Ammonia) Sensor 10012286 10012286 10012286 10012286 10012282 10012282 (Chlorine) Sensor FiveStar Alarm...
  • Page 40 Chapter 4, Parts List Technical Manual Figure 4-2. Australian and European Approved Replacement Parts and North American (Serial Number Prefix "F" or Higher) Replacement Parts NOTE: New version has the updated sensor cover and new sealing gasket (Item 14). FiveStar Alarm...
  • Page 41 710427 Rechargeable Battery Pack Assembly, Replaceable 710955 10008607 710955 Standard Belt Clip 710953 710953 710953 10013125 10013125 Toxic Channel 3 Bias Jumper For chlorine compatible instruments, refer to FiveStar Instruction Manual (P/N 710436), Chapter 4 - "Special Instructions." FiveStar Alarm...
  • Page 42 Insulator, PCB/Case Top 10011218 10011218 710487 710487 Sensor Cover Labels (for missing sensors) Pump Module 10007440 10008724 10009305 10008608 Aspirator Module Battery Pack, Standard Ni-Cd Rechargeable 711024 10013094 Battery Pack Assembly, Replaceable 10007351 710794 710794 Standard Belt Clip FiveStar Alarm...
  • Page 43 Aspirator and fittings 10007340 10007340 Manifold Gasket Pump and drive (North 711195 711195 711195 American version) Pump and drive 10011686 (Australian version) Pump and drive (EN 10011686 version) 634261 634261 634261 Internal backup filter Figure 4-3. Replacement Parts FiveStar Alarm...
  • Page 44 AMERICAN PLATED PART APPROVED APPROVED APPROVED INSTRUMENT INSTRUMENT INSTRUMENT PART NO. PART NO. PART NO. 710955 10008607 10007351 Replaceable Battery Pack Spare Fuses 655836 655836 10006582 Replacement Internal Gasket 710958 710958 710958 Figure 4-4. Battery and Fuse Location FiveStar Alarm...

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