Net Safety Monitoring, Inc.

2721 Hopewell Place NE

Calgary, Alberta T1Y 7J7
Canada

July 19, 2012

ATTENTION:

PLANT / PRODUCT SAFETY OFFICER

IMPORTANT PRODUCT SAFETY NOTIFICATION

THIS LETTER IS TO NOTIFY AFFECTED CUSTOMERS OF A POTENTIAL SAFETY
CONCERN INVOLVING CERTAIN:
Net Safety Monitoring
Model ST321 Solid State H2S Sensor
Our records indicate you received the hardware assemblies affected by this notification
as identified in Appendix A.

>>PLEASE READ CAREFULLY <<

FORWARD TO ALL APPROPRIATE INDIVIDUALS IMMEDIATELY.
FAILURE TO TAKE ACTION COULD RESULT IN A LOSS OF PROCESS CONTROL,
PROPERTY DAMAGE, SERIOUS PERSONAL INJURY OR DEATH.
If you resold or transferred any of the affected products in question, please immediately
forward this important Product Safety Notification to the eventual user so they can take
appropriate action.
Overview
Net Safety Monitoring has identified a potential safety concern involving their ST321
Solid State H2S sensors shipped between June 1, 2010 and November 30, 2011.
During internal reliability and audit testing, unexpected responses to gas were observed
with sensors exposed to extreme environmental conditions such as high temperatures
(greater than 40C) and large fluctuations in temperature and humidity in short periods
of time.
Test results have shown that these sensors may have lower than expected response
levels to gas, potentially not putting the sensor into the alarm state as required, or not

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responding to gas at all. The root cause behind this failure is currently being
investigated and a full resolution is expected in August/September 2012.
Additionally, inaccuracies to gas were observed when operating in high temperature
(>40C) environments where the sensor will output a gas level when gas is not present.
Root cause investigation has been traced to an unexpected failure mechanism in a
supplier component.
Potential Effect
Due to the nature of the failure mechanisms, Net Safety recommends that the affected
sensors be investigated to ensure that they are responding to gas as required. Net
Safety recommends that a bump test, using air balanced calibration gas at 50% of the
span that the sensor is programmed for, must be completed to ensure that an
appropriate response to gas is achieved. Refer to Appendix C for the bump test
procedure. The expected accuracy of this sensor is 2ppm. If the accuracy of the
sensor is off, a calibration of this sensor is recommended, followed by another bump
test to verify the calibration.
If the response to gas is acceptable after calibration, Net Safety recommends that a
bump test and calibration, as required, be completed on a monthly basis until a
replacement solid state sensor can be supplied.
If the response to gas is not acceptable, Net Safety recommends that the sensor be
replaced with an electrochemical sensor on an interim basis. Please contact Net Safety
as outlined below to arrange for electrochemical sensors to be sent for replacement.
The electrochemical sensor will work with the existing Millennium II transmitter, so the
transmitter is not required to be replaced.
If unexpected levels of gas are being recorded, Net Safety recommends that a
calibration, as per the procedure listed in Appendix C, be completed on a monthly basis
until the sensor can be replaced. If this situation continues, please contact Net Safety
and replacement electrochemical sensors will be supplied on an interim basis until an
updated solid state sensor can be released.
Since our products are used in many unique applications, each user must determine the
effect of this issue upon their respective application and act accordingly.
Final Action
To remedy the situation, we ask you that you do the following:

Identify the serial number on all potentially affected products in your possession.
Refer to Appendix B on how to locate the serial number on the sensor and cross
reference it with the serial number(s) of the affected products listed in Appendix
A.

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If the affected sensor has not been installed in your process, please mark it as
unusable per your plant procedures. A replacement electrochemical sensor will
be provided to you at no charge as required on a temporary basis. Please
provide your commissioning schedule so that the timing of the shipment can be
arranged accordingly. Please contact Net Safety Monitoring at +1 403 2190688 to make arrangements for return of the affected unit(s) and to order a
replacement(s)

If the affected sensor is installed in your process, please make arrangements to

bump test and calibrate the sensor, as per the procedures listed in Appendix C,
as quickly as possible. If after completing the calibration and bump test, it is
determined that a replacement sensor is required, an electrochemical sensor will
be provided to you at no charge on an interim basis. Please contact Net Safety
Monitoring at +1 403 219-0688 to make arrangements for return of the affected
unit(s) and to order a replacement(s)

Once the updated solid state sensors have been released, replacement solid state
sensors will be sent out in accordance with the serial numbers listed in Appendix A.
Please contact your local Emerson Process Management sales representative or Net
Safety directly with any questions regarding this notification or for technical support. For
additional assistance, please contact Net Safety or Emerson Process Management by
any of the methods below.
Contact Information
1. Customer Care
+1 403 219-0688
2. Email to nsm.service@emerson.com
We apologize for any inconvenience this situation may cause you and your
organization. Net Safety is committed to delivering instrumentation solutions of the
highest quality and reliability. We have strict processes in place to ensure all products
shipped from our global facilities meet our published specifications. Notifying you of a
potential product nonconformance is a required part of our quality process to help you
ensure the safe and reliable operation of your facility. Thank you for your attention to
this important matter and for allowing us to serve you now and in the future.
Sincerely,
Kevin Algar
Vice President and General Manager
Net Safety Monitoring, Inc.

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Appendix A
Model Number
ST321A-100-ASSY

Serial Number
SN1017710

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Appendix B
Serial Number Location

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Appendix C

CALIBRATION PROCEDURE
Always allow the ST321 sensor to warm up for at least 48 hours prior to calibration.
There are specific steps to be followed when calibrating with the ST321 Solid State H2S sensor
with the Millennium II Basic and the Millennium II Transmitters. These steps should be followed
if accurate results are to be obtained. The calibration of Solid State sensors requires the
presence of oxygen, as a result, an air balanced calibration gas should be used for
calibration, otherwise these sensors will not calibrate properly.

Millennium II Basic (M2B) Calibration Procedure

Calibrations may be performed either by using the magnet (non-intrusive) or by using
the push buttons (intrusive).
1. Confirm successful power up of transmitter, (green blip/blink of status LED every
second: no fault indicated).
2. Bypass any output alarms (recommended).
3. For analog model connect a standard current meter to the transmitters Test
Jacks (not required but gives visual confirmation).
4. Press and hold the push button (or activate the Reed switch using the
magnet) for at least 15 seconds, the status LED flashes green fast, and then
goes solid green (first solid green). Keep holding push button or magnet, after
which, status LED goes solid red. When this occurs, release push button or
remove magnet.
5. When the current output is 3 mA (indicated by analog models) and the Status
LED is once again solid green (second solid green), apply zero gas (clean air).
6. When the current output is 3.3 mA (indicated by analog models) and the Status
LED is flashing red, apply specific calibration gas (50% of full span).
Recommendation: Flow span gas at a rate of 0.5 liter per minute to the sensor
for direct sensor calibrations. If sensor is remotely mounted and long tubing run
is used, increase gas flow rate (e.g. 1.0 liter per minute) to ensure tubing length
does not affect calibration results.
7. When the current output is 3.6 mA (indicated by analog models) and the Status
LED is solid green, remove the gas.
8. Apply zero gas (clean air) again to purge the system.
9. After the sensor is purged of gas, the detector will return to normal operation.
Note: When calibrating with the Millennium II Basic Transmitter always use 50% span
gas (half the scale). Calibration gas MUST be air balanced for ST321 sensors.
Millennium II Transmitter (M21/M22) Calibration Procedure
1. Enter the main menu, first by pressing any key to get the enter main menu
prompt, then press/select menu button 1 or Reed switch 1 to select yes.

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2. When Calibrate Sensor? is displayed, select the enter key (menu button 3 or
Reed switch 3).
3. When Calibrate Sensor #1? is highlighted, press the enter key (menu button 3
or Reed switch 3) if this is the sensor to be calibrated or,
4. If Sensor #2 is to be calibrated, select the down arrow key (menu button 2 or
Reed switch 2) to scroll to Calibrate Sensor #2?
5. When the desired sensor to be calibrated is highlighted, activate the enter key
(menu button 3 or Reed switch 3).
6. Select YES (menu button 1 or Reed Switch 1) to confirm the selection.
7. Apply clean air when Apply Clean Air is displayed, then select Z & Span using
(menu button 1 or Reed Switch 1) for normal calibration. Setting zero will be
displayed as the sensor is being zeroed. (Ensure no contaminant gases are
present if ambient air is being used).
8. Apply 50% calibration gas when prompted. Recommendation: Flow span gas at
a rate of 0.5 liter per minute to the sensor for direct calibrations. If sensor is
remotely mounted and long tubing run is used, increase gas flow rate (e.g. 1.0
liter per minute) to ensure tubing length does not affect calibration results.
9. The display will show Spanning with the gas value (PPM ) as the gas is
detected.
10. Remove the calibration gas when Remove Cal Gas is displayed.
11. Cal Complete will be displayed when calibration is complete.
12. Apply zero gas (clean air) to purge system.

BUMP TEST PROCEDURE

Always allow the ST321 sensor to warm up for at least 48 hours prior to completing a
bump test.
There are specific steps to be followed when bump testing the ST321 Solid State H2S sensor
These steps should be followed if accurate results are to be obtained. In order for solid state
sensors to accurately detect gas the presence of oxygen is required, as a result, an air
balanced calibration gas should be used for the bump test, otherwise erroneous readings
will be achieved.

Millennium II Basic (M2B) Bump Test Procedure

1. Confirm successful power up of transmitter, (green blip/blink of status LED every
second: no fault indicated).
2. Bypass any output alarms (recommended).
3. Monitor the output of the transmitter at the gas detection system or for analog
models connect a standard current meter to the transmitters Test Jacks.
4. Connect the calibration gas and calibration cup to the bottom of the sensor.
Recommendation: Flow span gas at a rate of 0.5 liter per minute to the sensor
when performing a bump test. If sensor is remotely mounted and long tubing run
is used, increase gas flow rate (e.g. 1.0 liter per minute) to ensure tubing length
does not affect bump test results.

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5. The analog output should read around 12mA (0.64mA for 50ppm range), or
50% of the range that the sensor is setup for. If the output is outside of this
range then a calibration as per Appendix B should be completed.
Millennium II Transmitter (M21/M22) Bump Test Procedure
1. Confirm successful power up of transmitter.
2. Bypass any output alarms (recommended).
3. Monitor the ppm level sown on the display of the transmitter. Additionally, you
can monitor the output of the transmitter at the gas detection system or for
analog models connect a standard current meter to the transmitters Test Jacks.
4. Connect the calibration gas and calibration cup to the bottom of the sensor.
Recommendation: Flow span gas at a rate of 0.5 liter per minute to the sensor
when performing a bump test. If sensor is remotely mounted and long tubing run
is used, increase gas flow rate (e.g. 1.0 liter per minute) to ensure tubing length
does not affect bump test results.
5. The display should be within 2ppm of the calibration gas applied. If you are
measuring the analog output, the analog output should read around 12mA
(0.64mA for 50ppm range), or 50% of the range that the sensor is setup for. If
the output is outside of this range then a calibration as per Appendix B should be
completed.

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