MSA S5000 Operating Manual

Operating Manual

General Monitors S5000

Gas Monitor

Order No.: MANS5000/06

Print Spec: 10000005389 (EO)

CR:800000042524

MSAsafety.com

WARNING!

Read this manual carefully before using or maintaining the device. The device will perform as designed only if it is used and maintained in accordance with the manufacturer's instructions. Otherwise, it could fail to perform as designed, and persons who rely on this device could sustain serious injury or death.

The warranties made by MSA with respect to the product are voided if the product is not installed and used in accordance with the instructions in this manual. Please protect yourself and your employees by following the instructions.

Please read and observe the WARNINGS and CAUTIONS inside. For additional information relative to use or repair, call 1800-MSA-2222 during regular working hours.

For countries of Russian Federation, Republic of Kazakhstan and Republic of Belarus, the gas detector will be delivered with a passport document that includes valid approval information. On the CD with manual instruction attached to the gas detector the user will find the documents "Type Description" and "Test Method" - appendixes to Pattern Approval Certificate of Measuring instrument, valid in the countries of use.

MSA is a registered trademark of MSA Technology, LLC in the US, Europe and other Countries. For all other trademarks visit https://us.msasafety.com/Trademarks.

This product incorporates Bluetooth® wireless technology. The Bluetooth word mark and logos are registered trademarks owned by Bluetooth SIG, Inc., and any use of such marks by MSA is under license. Other trademarks and trade names are those of their respective owners.

This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

You are cautioned that changes or modifications not expressly approved by the party responsible for compliance could void the user's authority to operate the equipment.

English:

This device complies with RSS-210 of the Industry Canada Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

French:

Ce dispositif est conforme à la norme CNR-210 d'Industrie Canada applicable aux appareils radio exempts de licence. Son fonctionnement est sujet aux deux conditions suivantes: (1) le dispositif ne doit pas produire de brouillage préjudiciable, et (2) ce dispositif doit accepter tout brouillage reçu, y compris un brouillage susceptible de provoquer un fonctionnement indésirable.

26776 Simpatica Circle Lake Forest, CA 92630 USA

For your local MSA contacts please go to our website www.MSAsafety.com

General Monitors S5000 3

Contents

1 Safety Regulations 7

1.1 Correct Use 7

1.2 Product Warranty 9

2 Description 10

2.1 Display 10

2.2 No Tool Interface 10

2.3 Bluetooth® Wireless Technology 11

2.4 Dual Sensing 11

2.5 Retrofit Installations 12

2.6 XCell Sensors Optimized for Fixed Gas Applications 12

2.7 TruCal Sensing Technology for CO and H2S Electrochemical Sensors 12

2.8 SafeSwap 13

2.9 Housing 13

2.10 Component Overview 14

2.11 Label Overview 15

3 Installation 17

3.1 Installation Warnings - Read Before Installation 17

3.2 Reviewing Shipment and Identifying Product Model 17

3.3 Product Installation Check List 18

3.4 Mounting 18

3.4.1 Sensor Mounting Location 19

3.4.2 Transmitter Mounting Location 19

3.4.3 Sensor Orientation 19

3.4.4 Connecting Sensor to Transmitter Housing or Remote Junction Box 20

3.4.5 Integrated Mounting Points 22

3.4.6 Adjustable Pipe Mount 23

3.4.7 Duct Mount 24

3.4.8 Mounting with a Sunshield 24

3.4.9 Mounting with an SM5000 Sampling Module 25

3.5 Installing a Remote Sensor Junction Box 26

3.6 Electrical Power Connections 27

3.6.1 Electrical Warnings - Read before Connecting Power 27

3.6.2 Retrofit Applications with S4000CH, S4000TH, or TS4000H 28

3.6.3 Electrical Hardware Requirements 28

3.6.4 Power Load Requirements and Maximum Mounting Distances 29

3.6.5 Instructions for Power and Analog Output 35

3.6.6 Relay Electrical and Power Connections 37

4 Operation 39

4.1 Startup 39

4.1.1 Initial Startup 39

4.1.2 Sensor Warm Up Times 39

4.1.3 Startup after Power Failure 40

4.2 Settings 40

4.2.1 Instrument Settings 41

4.2.2 Sensor Setup 53

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4.2.3 Relay Settings 56

4.2.4 HART Settings 58

4.2.5 HART AO 58

4.2.6 Calibration Alert 59

4.2.7 Bluetooth 59

4.2.8 Modbus Settings 60

4.2.9 EZ Touch Button 61

4.2.10 Swap Delay 61

4.2.11 UI Password 62

4.2.12 Transmitter Setting Reset 63

4.3 Info Menu - Viewing Device Status 63

4.3.1 AO Type 63

4.3.2 View or Change System Time 64

4.3.3 Last Calibration 64

4.3.4 Non-Critical Fault Log 64

4.3.5 Device Tag 64

4.3.6 Bluetooth FCC/IC ID 65

4.3.7 Sensor Life and Health Status (only displayed if XCell Sensor is connected) 65

4.4 Setting only configurable via Bluetooth®, Modbus, or HART 65

4.4.1 AO Custom Levels 66

4.4.2 Relay Zone - Horn Mode 66

4.4.3 Unit Device ID/Tag 66

4.4.4 Alarm Direction 67

4.4.5 Alarm Enable/Disable 67

5 Calibration 68

5.1 Calibration Equipment 68

5.2 Calibration Frequency 70

5.3 Calibration Frequency for XCell Sensors with TruCal (H2S & CO only) 71

5.3.1 XCell Sensor with TruCal and Diffusion Supervision (CO&H2S Only) 71

5.3.2 XCell Sensor with TruCal without Diffusion Supervision (CO&H2S Only) 71

5.4 Calibration Types: Zero vs. Span 71

5.5 How to Zero Calibrate XCell and IR Sensors 72

5.6 How to Calibrate XCell Sensors 73

5.7 How to Calibrate an Oxygen XCell Sensor 75

5.8 How to Calibrate an IR Sensor 75

5.9 How to Calibrate a Passive Sensor (Catalytic Bead or MOS) 75

5.10 XCell Catalytic Bead Failsafe 76

5.11 Calibration Confirmation 76

6 Maintenance 77

6.1 IR Sensor Cleaning Procedure 77

6.2 Replacing an XCell Sensor 78

6.3 Clearing a Blockage 80

6.4 Replacing a Passive Sensor (Cat Bead or MOS) 81

6.5 Troubleshooting 81

7 Ordering Information 87

7.1 Replacement Parts 87

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8 Appendix: Specifications 90

9 Appendix: General Certification Information 94

10 Appendix: HART Specific Information 101

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1 Safety Regulations

1.1 Correct Use

The S5000 Gas Monitor, hereafter also called device, is a gas monitor for measuring toxic and combustible gases as well as oxygen. Using sensors, the device tests the ambient air and triggers the alarm as soon as the gas exceeds a specific concentration level.

WARNING!

Do not use silicone-type lubricants in assembling the device and do not allow silicone vapors to be drawn into the flow system while in operation. Silicone can desensitize the combustible gas sensor, thereby giving erroneously low readings.

Use only genuine MSA replacement parts when performing any maintenance procedures provided in this manual. Failure to do so may seriously impair sensor and gas monitoring performance, alter flameproof/explosionproof characteristics or void agency approvals.

Failure to follow these warnings can result in serious personal injury or death.

WARNING!

As with all gas monitors of this type, high levels of, or long exposure to, certain compounds in the tested atmosphere could contaminate the sensors. In atmospheres where an S5000 Gas Monitor may be exposed to such materials, calibration must be performed frequently for dependable operation and to confirm that display indications are accurate.

These effects include, but are not limited to:

• Passive MOS sensors may be adversely affected by prolonged exposure to certain substances. Loss of sensitivity or corrosion may be gradual if such agents are present in low concentrations or it may be rapid at high concentrations. Examples of these substances are as follows:

– Halides: compounds containing fluorine, chlorine, bromine and iodine

– Heavy metals, e.g. tetraethyl lead

– Caustic and Acidic liquids and vapors

– Glycol

• The H2S Digital Sensor may be adversely affected by the following substances:

– Alcohols (methanol, ethanol, isopropanol)

– Nitrogen dioxide (NO2)

– Chlorine (Cl2)

– Paint solvents (acetone, turpentine, toluene, mineral spirits, etc.)

• The CO Digital Sensor may be adversely affected by the following substances:

– Alcohols (methanol, ethanol, isopropanol)

– Paint solvents (acetone, turpentine, toluene, mineral spirits, etc.)

•

The O2 Digital Sensor may be adversely affected by the following substances:

– Long term exposure to low levels of Acetylene

– Paint solvents (acetone, turpentine, toluene, mineral spirits, etc.) in high concentrations larger than 1000 ppm or

prolonged exposure to lower concentrations

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1 Safety Regulations

• Prolonged exposure of the H2S Digital Sensor to humidity levels of 5% RH or lower will result in gas measurement readings of H2S that are greater than the actual gas concentration present.

• It is not recommended to expose the O2, H2S and CO Digital Sensors to environments containing oxygen levels above 30% (v/v) or below 5% (v/v). The O2sensor will operate at concentrations below 5% (v/v) but not for prolonged periods of time.

Failure to follow these warnings can result in serious personal injury or death.

This device complies with Part 15 of the FCC Rules. Operation is subject to the -following two conditions:

• this device may not cause harmful interference, and

• this device must accept any interference received, including interference that may cause undesired operation.

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.

WARNING!

The Digital Sensor Xcell sensor module utilizes thread locker suitable to an ambient temperature of -55°C to +74°C. If the Digital Sensor is exposed to temperatures outside of its listed ratings, reapplication of thread locker when changing out the Xcell sensor module may be required.

Failure to follow this warning can result in serious personal injury or death.

NOTICE

This is a Class A product in accordance with CISPR 22. In a domestic environment, this product may cause radio interference, in which case the user may be required to take adequate -measures.

NOTICE

The XCell sensor refers to the sensor portion of the Digital Sensor throughout this manual.

FCC Warning Statements

Changes or modifications not expressly approved by the manufacturer could void the user's -authority to operate the equipment.

Industry Canada (IC) Warning Statements

The installer of this radio equipment must ensure that the antenna is located or pointed such that it does not emit RF field in excess of Health Canada limits for the general population; consult -Safety Code 6, obtainable from Health Canada's website www.hc-sc.gc.ca.

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1.2 Product Warranty

The warranties made by GM with respect to the product are voided if the product is not installed, used and serviced in accordance with the instructions in this manual. Please protect yourself and your employees by following the instructions.

ITEM WARRANTY PERIOD

S5000 Gas Monitor MSA warrants that this product will be free from mechanical defects and faulty workmanship for

the period specified in this table for each component, provided it is maintained and used in accordance with MSA’s instructions and/or recommendations. Warranty shall not exceed.

1 Safety Regulations

Main Transmitter Housing and PCBA

XCell Sensors 3 years from date of shipment.

IR Sensor 2 years from date of shipment.

Passive Catalytic Bead

Passive MOS 2 years from date of shipment.

This warranty does not cover filters, fuses, etc. Certain other accessories not specifically listed here may have different warranty periods. This warranty is valid only if the product is maintained and used in accordance 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 if the warranty claim results from physical abuse or 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.

2 years from date of shipment.

Shall not exceed 2 years and 6 months from date of manufacture.

Shall not exceed 3 years and 6 months from date of manufacture.

Shall not exceed 2 years and 6 months from date of manufacture.

2 years from date of shipment.

Shall not exceed 2 years and 6 months from date of manufacture.

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.

Exclusive Remedy

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 cause of action, shall be the 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 replace any nonconforming equipment or parts shall not cause the remedy established hereby to fail of its essential purpose.

Exclusion of Consequential Damage

Purchaser specifically understands and agrees that under no circumstances will seller be liable to purchaser for economic, special, incidental or consequential damages or losses of any kind whatsoever, including but not limited to, loss of anticipated profits and any other loss caused by reason of non-operation of the goods. This exclusion is applicable to claims for breach of warranty, tortious conduct or any other cause of action against seller.

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2 Description

2.1 Display

The S5000 utilizes a dot matrix LED display, capable of displaying four alphanumeric characters at a time. The display will scroll words that exceed four letters. Most of the messages scroll twice across the screen before moving onto next selection.

Figure 1 S5000 Main Display

In addition to the red LED display, the S5000 uses six icons to indicate status. Green LED indicates power supply status. A yellow triangle and red bell indicate fault and warning or alarm conditions respectively. The Bluetooth®icon indicates that the Bluetooth®wireless technology is enabled on the device. Yellow "1" and "2" icon indicate which sensor gas reading is being displayed, or during configuration which sensor's options are being accessed.

2.2 No Tool Interface

The S5000 does not require any tools or third party devices to change settings, reset alarms or perform any maintenance operation. The EZtouchbutton works through the glass and does not require opening the explosion proof enclosure. The EZtouchbutton works with bare fingers or with gloved hands, so long as the gloves are not black. See 4 Operation for more information on navigating the menu with the EZtouchbutton.

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2 Description

Figure 2 Interface

The user menu can also be accessed using the round GM magnet on the General Monitors logo.

2.3 Bluetooth®Wireless Technology

The S5000 comes by default with Bluetooth communication. Using the X/SConnectApp on an appropriate smart phone or tablet, users are able to interface with the S5000 menu options in a larger and more user friendly setting. The Bluetooth communication can interact with the device within a maximum transmission distance of 70feet (21m).

WARNING!

Bluetooth operation is dependent upon signal availability of the wireless service(s) necessary to maintain the communication link. Loss of wireless signal will prevent communication of alarms and other information to linked devices. Take appropriate precautions in the event a loss of wireless signal occurs.

Failure to follow this warning can result in serious personal injury or death.

If ordered with Bluetooth, the device will be shipped with Bluetooth enabled. See 4 Operation for instructions on disabling Bluetooth.

If the device was not ordered with Bluetooth it cannot be upgraded.

The S5000 and user provided communication device will need to be paired. This requires both devices to be in range and for a pairing sequence inputting a 6digitpairing code. The instructions will be displayed on both the S5000 and communication device.

There are communication devices capable of being used in classified areas. Please contact your MSA representative for additional information.

2.4 Dual Sensing

The S5000 supports two Digital Sensors, or one IRSensor point IR detector and one Digital Sensor simultaneously with four wire connections. However, the device will only support one passive sensor, either combustible catalytic bead or metal oxide semiconductor (MOS) sensors, based on the ATO configuration. Passive catalytic bead uses three wires, passive MOS uses four wires.

The S5000 Gas Monitor generates two independent analog outputs; one for each sensor connected to the transmitter. The analog output associated with Sensor1 also has the digital HART (Highway Addressable Remote Transducer)

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2 Description

communication superimposed on the analog signal. If two sensors are connected, the digital HART communication carries information for both sensors.

2.5 Retrofit Installations

The S5000 has the conduit entries located in the exact same orientation and distance from the wall and the mounting holes for attaching to a wall are identical to the S4000Series detectors. Users will be able to re-use the existing wiring for the remotely mounted sensors.

2.6 XCell Sensors Optimized for Fixed Gas Applications

XCell toxic and combustible catalytic bead sensors are developed and manufactured by MSA. Now optimized for fixed gas applications, the XCell sensor platform is available in the S5000 and provides multiple benefits, including a standard 3-year warranty on all XCellsensors.

One important optimization for fixed gas was incorporating the GM catalytic bead into the XCell sensor.

The XCell Oxygen sensor does not use lead, but rather a non-consuming reaction chemistry. The XCell Oxygen sensor is expected to last well over 3years and can be safely stored on the shelf for at least 1 year without sensor performance degradation. Changes in barometric pressure across the range of 86 kPA - 108 kPA have a negligible effect on the operation of the sensor.

2.7 TruCal Sensing Technology for CO and H2S Electrochemical Sensors

Using patented pulse check technology and proprietary Adaptive Environmental Compensation (AEC) algorithms, all XCell sensors with TruCal verify operation by actively adjusting the sensor output for changes in sensitivity. Some XCell sensors with TruCal also include Diffusion Supervision, which monitors the sensor inlet for obstructions that could prevent gas from reaching the sensor.

Every six hours, an electrical pulse stimulates the XCell sensor similar to having actual calibration gas applied, providing a snapshot of the sensor's sensitivity at the time of the pulse. Using this sensitivity snapshot, the sensor can diagnose sensor failures like electrode poisoning, electrolyte leaking, or electrical connectivity issues.

AEC uses the sensitivity snapshots provided by the pulse check to adjust sensor output, compensating for environmental impacts on sensor accuracy. If the AEC adjustment is greater than expected based on typical environmental impact variations, the transmitter LED’s will slowly flash GREEN, alerting users that the sensor should be calibrated to reset the AEC cycle. Users can also enable a Calibration Alert function that will send a milli-amp signal on the analog output to the control room. The result is a sensor that actively self-monitors for operation and accuracy, with far fewer manual calibrations.

Diffusion supervision actively monitors the sensor inlet for obstructions. If an obstruction is detected, the sensor will go into a fault mode to alert users and the control room that it is not seeing gas due to an obstruction. Objects residing directly on or in the sensor inlet that result in a significant impact to the gas path are very likely to be detected by Diffusion Supervision. Examples include paint, tape, water, and dirt. Small amounts of these materials can be visible on the inlet while not impacting the gas path enough to trigger a Diffusion Supervision Fault. A fault signal will only be sent out when the system determines that the amount of material that has accumulated on or inside the sensor inlet is negatively affecting the gas path.

Actual TruCal sensor performance will depend on the application, background gas exposure, and environment. To validate XCell sensors with TruCal, it is recommended that users follow their regular calibration cycle and record the "as found" and "as left" values. This data can be used to extend the time between calibrations depending on the required specification of the application.

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2 Description

2.8 SafeSwap

The S5000 comes with patented SafeSwap technology, which allows users to change or replace XCellsensors without needing to power down the instrument. Swap delay is enabled on the S5000 by default; a feature that gives users a 2minute window to change sensors without triggering a fault condition. SafeSwap and Swap Delay are only applicable for XCellsensors. For more information on SafeSwap and Swap Delay, see 6 Maintenance.

WARNING!

• As part of the product certification, it was verified that optional communication functions of this gas detection instrument while operating at the maximum transaction rate do not adversely affect the gas detection operation and functions of the instrument. The product certification, however, does not include or imply approval of the SafeSwap feature, communications protocol or functions provided by the software of this instrument or of the communications apparatus and software connected to this instrument.

• Follow the warnings below when removing or replacing sensors. Reference Figure 3 for component overview.

– Never remove or replace a Sensor Body Assembly or an IRSensor while under power or when explosive hazards

are present.

– Confirm that the area is free of explosive hazards before removing or replacing an XCell Sensor under power.

– To remove an XCell Sensor, unscrew XCell Sensor three full turns, wait 10 seconds, and then remove the XCell

Sensor completely.

Failure to follow these warnings can result in serious personal injury or death.

2.9 Housing

The S5000 comes in 316StainlessSteel for the highest corrosion resistance. All housings have ¾”NPT conduit entries. Custom tags are available and easily attach to an integral ring. The JB5000 junction box comes in 316 Stainless Steel for the highest corrosion resistance. The housing is offered in ¾" NPTof M25 conduit entries.

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2.10 Component Overview

Figure 3 Exploded View

2 Description

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2.11 Label Overview

Figure 4 Transmitter - Position of Labels

2 Description

Figure 5 Board stack - Position of Labels

Figure 6 Digital Sensor - Position of Labels

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Figure 7 IRSensor - Position of Labels

Figure 8 Passive Sensor - Position of Labels

2 Description

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3 Installation

3.1 Installation Warnings - Read Before Installation

WARNING!

• Refer to 9 Appendix: General Certification Information before installation and operation.

• Some Digital Sensors are provided in a fritless sensor housing. The fritless sensor housing is labeled as Div 2 or Zone 2 and is approved for Div 2 or Zone 2 installations only. The protection method is Nonincendive or Type n respectively. Ensure all components are approved for the wiring method being used and in accordance with the National Electric Code of the country of use, any applicable local regulations, and this manual.

• Follow the warnings below when removing or replacing sensors. Reference Figure 3 for component overview.

– Never remove or replace a sensor body assembly or an IRSensor while under power or when explosive hazards

are present.

– Confirm that the area is free of explosive hazards before removing or replacing an XCell Sensor under power.

– To remove an XCell Sensor, unscrew XCell Sensor three full turns, wait 10 seconds, and then remove the XCell

Sensor completely.

• Plug all unused conduit entries with a suitably certified blanking/stopping plug.

• Do not paint the device. Avoid painting in areas where the S5000 and remote sensor junction box are located. If painting is required in an area where an S5000 or remote sensor has been installed, exercise caution to ensure paint is not deposited on the sensor inlet fitting. Paint solvents can also cause an alarm condition to occur or potentially poison electrochemical sensors.

• Protect the device from extreme vibration.

• Do not mount the sensing head in direct sunlight without a sunshield (P/N 10180254).

• IR Sensors contain no user- or field-serviceable parts and must be returned to the factory for repair. Any attempt to open the monitor will damage the unit and void the warranty.

Failure to follow these warnings can result in serious personal injury or death.

NOTICE

When installing the IRSensor, under no circumstances should a pry-bar be applied to the two legs that support the unit's reflectors during installation or removal of the sensor. Applying force to the legs can permanently damage the IRSensor.

3.2 Reviewing Shipment and Identifying Product Model

To determine the sensor type and options, check the shipping carton.

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3 Installation

Figure 9 Shipping Label

Passive, Digital, and IR sensors are shipped attached to the S5000. Passive and IR Sensors are one-piece sensors. Digital sensors comprise two parts: the Sensor Body Assembly and the XCell Sensor. Sensor Body Assemblies must be installed and tightened using a strap wrench.

Check the sensor details before attaching to the S5000 housing. The sensor details are listed on the inside of the XCell Sensor. Unscrew the XCell Sensor from the sensor body assembly and check the label on the inside for gas type, range, configuration ordered, serial number, and firmware revision number.

3.3 Product Installation Check List

Before Installation

• Review national electrical codes

• Review local procedural and building codes

• Determine optimum transmitter placement

• Determine wire requirements

• Determine mounting hardware requirements

• Review approvals and ensure suitability for installation

Mounting

• Attach appropriate sensor to housing or junction box (see 3.4.3 Sensor Orientation for proper sensor orientation)

• Mount transmitter or junction box using appropriate mounting hardware

• Confirm free air flow around the sensor

3.4 Mounting

WARNING!

Refer to 9 Appendix: General Certification Information before installation.

Some toxic gases are provided in a fritless sensor housing. The fritless sensor housing is labeled as Div 2 or Zone 2 and is approved for Div 2 or Zone 2 installations only. The protection method is Nonincendive or Type n respectively. Ensure all

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3 Installation

components are approved for the wiring method being used and in accordance with the National Electrical Code of the country of use, any applicable local regulations, and this manual.

Failure to follow this warning can result in serious personal injury or death.

3.4.1 Sensor Mounting Location

The best location for the transmitter and the sensor may not be the same location. Sensors should be placed in a location where a gas leak is most likely to be detected. When the best sensor placement would not allow the transmitter display to be easily viewed or accessed, a remote junction box can be used to mount the sensor remotely from the transmitter, allowing both to be installed in the optimum location.

Two main factors should be considered when choosing a sensor location. The first is the density of the target gas relative to the air. Gases, such as propane, that are heavier than air should be placed near ground level while gases that are lighter than air should be placed above potential leak sources.

Optimum sensor placement will depend on the surrounding processing equipment, such as pipes, valves, or turbines. MSA offers a gas and flame mapping service that systematically evaluates potential sources of leaks and recommends detector quantity and placement to create the most effective detection system.

3.4.2 Transmitter Mounting Location

The transmitter display should be mounted so that the screen is visible and easily accessed after installation. The electronics assembly inside the enclosure have one orientation inside the cylindrical housing. Take care to position the conduit entries and display so that the display is read in the correct orientation.

3.4.3 Sensor Orientation

WARNING!

Mount the IR Sensor with the sensor inlet fitting extended horizontally from the main enclosure (see Figure 10 ) to prevent the build-up of particulate or liquid matter on the monitor's optical surfaces.

Mount the digital sensor with the sensor inlet fitting (see Figure 11 ) pointed downward; otherwise, the inlet may become clogged with particulate matter or liquids.

Failure to follow this warning can result in serious personal injury or death.

Sensor orientation will depend on the sensor type. If mounting an IRSensor, whether locally on the transmitter or via remote junction box, the sensor should be mounted horizontally. If the IRSensor is not mounted horizontally, the sensor will be prone to more frequent beam blocking issues due to accumulated dust and condensation on the surface of the IRSensor. Figure 10 shows the correct and incorrect mounting orientations for the IRSensor.

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3 Installation

Figure 10 Correct and Incorrect Mounting Orientations for IR Sensor

All other sensors, including electrochemical, catalytic bead, oxygen, passive catalytic bead, and passive MOS should be mounted vertically with the gas inlet pointed downward. If the sensor is not mounted with the gas inlet facing down, it is more likely to become clogged with particulate matter or liquids. Figure 11 shows the correct and incorrect mounting orientation for digital sensors. Passive catalytic bead and MOS sensors come already installed on the transmitter housing.

Figure 11 Correct and Incorrect Mounting Orientation for Digital Sensors

3.4.4 Connecting Sensor to Transmitter Housing or Remote Junction Box

Digital and IRSensors are shipped attached to the main enclosure. The main sensor input is provided via a four-terminal connection that provides a digital interface for all sensor modules. Up to two sensors (excluding passive sensors) can be connected to a single transmitter with two analog outputs capable of representing the readings of the individual sensors.

Passive sensors are shipped already attached and electrically wired to the device. Only one passive sensor can be used on a single S5000, and they are not interchangeable with other passive sensors or digital sensors.

Consider the sensor dimensions when choosing a mounting location for the transmitter or junction box.

To connect the sensor:

(1) Loosen the set screw located on the lid using a 1.5mm Allen wrench.

(2) Turn the lid counter-clockwise to remove.

(3) Pull out display module to expose terminal connections.

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Figure 12 Terminal Connections

3 Installation

(4) Route the cable from the sensor through a conduit entry hole in the enclosure so that the sensor is oriented in the

correct position (see 3.6 Electrical Power Connections for details).

(Repeat to attach a second sensor to the S5000 transmitter).

(5) Connect the sensor to the "Sensor 1" position on the electronics assembly.

a) If using a second sensor, connect it to the second sensor position.

NOTICE

If only using one sensor and it is connected to “Sensor2”position, the S5000 will enter Sensor Missing fault. See Disable Sensor in 4.2.2 Sensor Setup for details on how to clear this fault.

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3 Installation

Figure 13 Connecting Sensor to the Stack and Grounding Terminal

Figure 14 SOURCE/SINK Switch Location

(6) Verify the sensor connector is firmly seated on the terminal board.

(7) Attach the sensor's ground to either of the grounding screws inside the S5000 housing.

(8) Set the analog output to SOURCE or SINK using tweezers, flat head screwdriver or similar tool.

a) With the display board removed, locate “S1” switch on the main board (see Figure 14 ).

b) Set “S1” switch in the required position:

For SINK, set switch to the right side.

For SOURCE, set switch to the left side.

(9) Replace the display module. Push firmly on the board stack.

NOTICE

Ensure that the electronics assembly is fully engaged in the mounting holes. If not fully seated, the touch interface performance can be negatively affected.

(10) Replace the cover by turning clockwise.

(11) Tighten the set screw located on the lid using a 1.5mm Allen wrench.

NOTE: The JB5000 junction box is not compatible with IR400 and passive sensors.

3.4.5 Integrated Mounting Points

The S5000 transmitter can be surface mounted without any additional brackets using the integrated mounting tabs.

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Figure 15 Integral Mounting Tabs

3 Installation

Mounting Points JB5000 Junction Box

The JB5000 junction box can be mounted directly using the 4 integrated 10-32 threaded holes on the back of the enclosure or with the use of a mounting bracket (P/N 10206570).

3.4.6 Adjustable Pipe Mount

A Universal Pipe Mount Kit (P/N 10176946) can be used to mount the S5000 on pipes ranging from 20-150mm in diameter. Two brackets are mounted over the top of the integrated mounting tabs and fitted with an adjustable pipe band (not included).

Figure 16 Adjustable Pipe Mount

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3.4.7 Duct Mount

Duct mount kits are available for monitoring atmosphere inside flat or round ducts. Round duct mount kits are available for small ducts 12-20" in diameter (P/N10179323) and large ducts 20-40" in diameter (P/N 10179324). The flat duct mount (P/N10179322) is universal for flat ducts.

NOTICE

Consider the sensor type before choosing a duct mount location. IRSensors should be mounted horizontally and all other sensors should be mounted vertically.

NOTICE

Air flow in the duct must be zero to ensure proper calibration.

Figure 17 Flat Duct Mount

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Figure 18 Round Duct Mount

3.4.8 Mounting with a Sunshield

A sunshield is required to protect the S5000 from direct sun light (P/N 10180254). The sunshield can be used in any of the mounting configurations.

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Figure 19 Sunshield with Surface Mount

Figure 20 Sunshield with Universal Pipe Mount

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3.4.9 Mounting with an SM5000 Sampling Module

An aspirated (P/N10158101) and a DC pump (P/N10043264) model are available for use with the S5000 with the Digital Sensor. For more information on mounting requirements and use with the SM5000 sampling modules, see the SM5000 operating manual(s).

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Figure 21 Mounting the SM5000 with a Digital Sensor

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SM5000 is not for sale in EU.

Diffusion Supervision must be disabled when using the SM5000.

3.5 Installing a Remote Sensor Junction Box

Sensors mounted remotely must use the S5000 junctionbox. The junction box housing is the same construction as the transmitter. The mounting options and instructions for connecting the sensor are the same for sensors connected directly to the S5000 transmitter housing. The junction box is available in 316StainlessSteel.

Sensors can be remote mounted up to 100m from the transmitter housing, as long as the S5000 transmitter is mounted within maximum distance from the power supply, as indicated in Table 1 .

The junction box does not have an illuminated display and has two connectors for attaching a single sensor input and an output connects to the transmitter. A 16AWG 4element cable with a braided shield should be used for the electrical connection between the junction box and the S5000 transmitter. Specific cable recommendations are available upon request.

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Figure 22 Junction Box

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Figure 23 Junction Box Electrical Connections

3.6 Electrical Power Connections

3.6.1 Electrical Warnings - Read before Connecting Power

WARNING!

• Before wiring the S5000 transmitter, disconnect the power source supplying the transmitter and ensure no hazardous atmosphere present; otherwise, electrical shock or ignition of hazardous gases could occur.

• Install wiring in accordance with the electrical code of the country in use, the local authority having jurisdiction and these installation instructions, as applicable.

General Monitors S5000 27

3 Installation

• Do not make any connections to the S5000 main board or junction box input, output, and relay connections while under power. Making connections under power could lead to electrical shock or ignition of a hazardous atmosphere.

• Ensure that water and dirt are not able to enter the unit via the wire or conduit. If the unit is installed in a location known to be wet or damp, it is good practice to loop or bend the entry into the unit that prevents water incursion.

• The internal grounding terminal (located on the interior metal board stack plate) must be used for equipment grounding. The external grounding terminal is only to be used as a supplemental bonding connection where local authorities permit or require such a connection.

• Follow the warnings below when removing or replacing sensors. Reference Figure 3 for component overview.

– Never remove or replace a sensor body assembly or an IRSensor while under power or when explosive hazards

are present.

– Confirm that the area is free of explosive hazards before removing or replacing an XCell Sensor under power.

– To remove an XCell Sensor, unscrew XCell Sensor three full turns, wait 10 seconds, and then remove the XCell

Sensor completely.

Failure to follow these warnings can result in serious personal injury or death.

3.6.2 Retrofit Applications with S4000CH, S4000TH, or TS4000H

The S5000 was designed to be easily retrofitted with existing S4000CH, S4000TH, and TS4000H wiring. When replacing an existing S4000CH, S4000TH, or TS4000H with the equivalent S5000 sensor technology, the following items need to be checked in order for the S5000 to operate:

(1) Wire gauge needs to be 18-14 AWG

(2) Sufficient power must be supplied to the S5000 in accordance with the maximum wire lengths. (See the tables in

3.6.4 Power Load Requirements and Maximum Mounting Distances)

If these requirements are met, performance of the S5000 should meet the noise immunity standard equivalent of the S4000CH, S4000TH, and TS4000H using the existing wiring; However, the installation may not meet the latest EMC EN50270 noise immunity standard that the S5000 meets with the grounding and wiring scheme as indicated in this manual and corresponding I/O drawing.

3.6.3 Electrical Hardware Requirements

Braided shielded, twisted pair, instrument quality wire or cable should be used to minimize the possibility of noise interference and contact with other voltages. Selection of shielded cable must comply with local requirements.

Conduit, in addition to braided shielded wire, may also be needed in areas where a large amount of electrical noise is expected. All cable shields should be terminated to earth ground at one end only.

The S5000 has a four-wire power terminal, one four-wire communication terminal, and three four-wire sensor terminals. Relays can be added as an option. Terminals for power and relays can take wires up to 12AWG while all other terminals take wires up to 14AWG. Four conductors are also required for the S5000 remote junction boxes.

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Incoming power and signal cables should be a braided shield cable such as AlphaWire3248 or equivalent. The braided shield must be terminated to the board stack as shown in Figure 27 , or alternatively, the earth ground at the user’s power source location.

An external Class2 power supply is required to supply 12-30VDC to the S5000. Incoming power and signal cables should be a braided shield cable such as AlphaWire3248 or equivalent.

3.6.4 Power Load Requirements and Maximum Mounting Distances

Consider future needs when selecting cable size and power supply. The maximum distance between the S5000 transmitter and the power supply depends on the sensor configuration (sensing technology and one or two sensors), wire gauge, and the power supply voltage. The table below outlines the maximum transmitter mounting distances. First determine if the sensor(s) will be locally or remotely mounted. Then choose sensor type(s). The corresponding maximum power and mounting distances by wire gauge are shown.

Figure 24 Local Sensors

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Table 1 Maximum Mounting Distance for Local Sensors, Imperial Units

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Local Sensor 1 Local Sensor 2

Max. Power (W)

Max. Distance (ft)

18 AWG 16 AWG 14 AWG 12 AWG

Passive CB None 6.0 1280 2030 3230 5130

Passive MOS None 10.8 710 1130 1790 2850

Digital CB None 6.0 1280 2030 3220 5130

Digital CB 8.4 910 1450 2300 3660

Digital Toxic 6.7 1140 1810 2880 4580

Digital Toxic None 3.6 2130 3380 5370 8550

Digital Toxic 4.3 1770 2820 4480 7120

Digital CB 6.7 1140 1810 2880 4580

IR Sensor None 8.9 860 1370 2180 3470

Digital CB 11.8 650 1040 1650 2620

Digital Toxic 9.6 800 1270 2020 3210

- When sizing a system's 24V supply, a 1A inrush current with a 1ms duration should be

considered for each device on the power supply

Assumes transmitter was ordered with relays

Table 2 Maximum Mounting Distance for Local Sensors, Metric Units

Local Sensor 1 Local Sensor 2

Max. Power (W)

Max. Distance (m)

1 mm

1.5 mm22.5 mm24 mm

Passive CB None 6.0 470 710 1180 1890

Passive MOS None 10.8 260 390 660 1050

Digital CB None 6.0 470 710 1180 1890

Digital CB 8.4 340 510 840 1350

Digital Toxic 6.7 420 630 1050 1690

Digital Toxic None 3.6 790 1180 1970 3150

Digital Toxic 4.3 650 980 1640 2620

Digital CB 6.7 420 630 1050 1690

IR Sensor None 8.9 320 480 800 1280

Digital CB 11.8 240 360 600 960

Digital Toxic 9.6 290 440 740 1180

- When sizing a system's 24V supply, a 1A inrush current with a 1ms duration should be

considered for each device on the power supply

Assumes transmitter was ordered with relays

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