MSAsafety.com
Instruction Manual
SM5000 Sampling Module, DC Pump Model
Order No.: 10103804/02
Print s
pec.: 10000005389(A)
WARNING!
This manual must be carefully read by all individuals who have or will have the responsibility for using or
servicing the product. Like any piece of complex equipment, this device 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 MSA 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 regard ing this equipment prior to use or for
any additional information relative to use or service.
In the U.S., to contact your nearest stocking location, dial toll-free 1-800-MSA-INST.
To contact MSA International, dial 1-412-967-3228.
This manual is available on the Internet at www.MSAsafety.com.
1000 Cranberry Woods Drive
Cranberry Township, PA 16066
USA
Phone 1-800-MSA-2222
Fax 1-800-967-0398
For your local MSA contacts please go to our website www.MSAsafety.com
©
MSA 2017. All rights reserved
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SM5000 Sampling Module - DC Pump Model
MSA Permanent Instrument Warranty
1. Warranty - Seller warrants that this product will be free from mechanical defect or faulty workmanship
for a period of eighteen (18) months from date of shipment or one (1) year from installation, whichever
occurs first, provided it is maintained and used in accordance with Seller's instructions and/or recommendations. This warranty does not apply to expendable or consumable p art s whose normal life expectancy is less than one (1) year such as, but not limited to, non-rechargeable batteries, sensor element s,
filter, lamps, fuses etc. 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 af firm ation, represent ation or war ranty
concerning the goods sold under this contract. Seller makes no war ranty concerning components or
accessories not manufactured by the Seller, but will pass onto the Purchaser all warranties of manufacturers of such components.
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.
2. 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
repair and/or replacement at Seller's option, of any equipment or p art s thereof, wh ich af ter examinat ion
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 repair any noncon fo rm in g pr od u ct
shall not cause the remedy established hereby to fail of its essential purpose.
3. 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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SM5000 Sampling Module - DC Pump Model
General Warnings and Cautions
WARNING!
1. The SM5000 Sampling Module - DC Pump Model described in this manual must be installed, operated,
and maintained in strict accordance with the labels, cautions, warnings, instructions, and within the limitations stated.
2. An SM5000 Sampling Module - DC Pump Model is designed to sample gases or vapors in air. It cannot
sample the concentration of gases or vapors in steam or condensing streams or inert or oxygen deficient atmospheres.
3. The unit must not be painted. If painting in an area where this unit is located, ensure that paint is not
deposited on the module inlet fitting. Such paint deposits interfere with the sampling process and can
result in improper readings.
4. Sensors are sealed units containing a corrosive electrolyte. Should a sensor develop leakage, immediately remove it from service; then, remove it from its housin g assembly and discard it properly. Ensure
that the electrolyte does not contact skin, eyes, clothing or circuitry; otherwise, personal injury (burns)
and/or equipment damage may result.
5. Use only genuine MSA replacement parts when performing any maintenance procedures provided in
this manual. Failure to do so may seriously impair instrument performance. Repair or alteration of the
SM5000 Sampling Module - DC Pump Model, beyond the scope of these maintenance instructions or
by anyone other than an authorized MSA service person, could cause the product to fail to perform as
designed, and persons who rely on this product for their safety could sustain severe personal injury or
death.
6. Properly vent the exhaust of this unit to a safe area. Improper venting of the exhaust can cause personal injury or death.
7. Extremely high concentrations of combustible gas or vapor between t he lower explosive limit (LEL) and
the upper explosive limit (UEL) will cause the indication on the SM5000 Gas Monitor to indicate full
scale or above full scale. If the concentration level is further increased and exceeds the UEL, the display will continue to show an above scale indication. Gas or vapor concentrations above the UEL are
extremely dangerous since the instrument cannot measure them accurately, and when reduced by the
addition of air to a level below the UEL, they again constitute a violently explosive mixture. Therefore,
every alarm causing condition or situation must be investigated to determine that the area being monitored does not contain a gas or vapor in air mixture that exceeds the LEL or UEL.
Failure to follow the above warning can result in serious personal injury or death.
CAUTION!
1. Perform periodic leak check on all of this unit's flow system components and fittings. Ensure the flow is
within specifications.
2. As with all sensors, high levels of, or long exposure to, certain compounds in the tested atmosphere
contaminate the sensors. In atmospheres where an SM5000 Sampling Module - DC Pump Model may
be exposed to such materials, calibration should be perfor med freq uently to e nsure that chann el operation is dependable and display indications are accurate. Ensure the flow is checked to be with in spec ifications.
3. The only absolute method to ensure the proper overall operation of this unit is to check the associated
sensor(s) with a known concentration of the gas for which it has been calibrated. Consequently, calibration checks must be included as part of the routine inspection of the system along with ensuring flow to
be within specifications.
Failure to follow the above caution can result in injury, product damage, and/or an unsafe condition.
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Table of Contents
1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.1.1 The SM5000 Sampling Module - DC Pump Model: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.1.2 Unpacking Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.1.3 Unit Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.1.4 Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Mounting the Pump Sampling Module Unit (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.3 Sample Line Placement between Pump Sampling Module and Ultima X, Ultima X5000, or
S5000 Gas Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Sample Line Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.5 Exhaust Line Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.6 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.6.1 Electrical Connection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.7 Initial Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3 Calibration and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.2 Calibration Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.2.1 Zeroing with the Pump Sampling Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.2.2 Spanning with the Pump Sampling Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4 Maintenance and Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.1 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.2 Filter Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.3 Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.4 Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
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SM5000 Sampling Module - DC Pump Model
1 General Information
1.1 Introduction
1.1.1 The SM5000 Sampling Module - DC Pump Model:
• must be used with an Ultima X, Ultima X5000, or an S5000 Gas Monitor with a digital sen sor ( available
separately).
NOTE: Does not work with S5000 IR400, passive catalytic bead or metal oxide semicondu ctor (MOS)
sensors.
• draws a gas sample from the monitored area, through a sample line (sold separately, see Tab. 3 for
details) to the sensor.
• samples areas that are remote, inaccessible, too hot or too cold for direct sensor monitoring, such as:
• ducts carrying combustible or toxic gas
• wet wells, water vapor in the sampling must not condense (RH must be less than 95%)
• printing drying ovens
• blanking or inerting operations
• must be used with a special flow cap to ensure proper sensor sampling (sold separately, see Tab. 3).
A properly-installed unit for a single Ultima X5000 Gas Monitor is shown in Fig. 1. It is also possible for one
Pump Sampling Module to supply sample gas for up to three Ultima X, Ultima X5000, or S5000 Gas Monitors. This procedure:
• is useful when monitoring up to three different gases.
• requires additional Ultima X, Ultima X5000, or S5000 Gas Monitors with individual flow caps.
• is further detailed in chapter 2 "Installation".
When using Ultima XIR or XIR PLUS sensor(s), locate the sensor on the exhaust side of the Pump
Sampling Module (see Fig. 2) to ensure the most accurate readings (the thre e-way valve from the XIR flow
cap must be installed on the inlet side of th e pump). The Pump Sampling Module is not compatible with the
S5000 IR400 sensor.
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SM5000 Sampling Module - DC Pump Model
Fig. 1 Sampling module installation with Ultima X5000 oxygen, toxic, and catalytic combustible sensors
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SM5000 Sampling Module - DC Pump Model
Fig. 2 Sampling module installation with Ultima XIR PLUS sensor
1.1.2 Unpacking Unit
Carefully unpack your Pump Sampling Module from shipping carton(s). Compare enclosed items with the
packing list to ensure all parts ordered were received; contact shipper or carrier if discrepancies exist.
Each Pump Sampling Module package contains:
• Pump Sampling Module
• Tubing and in-line filter
• End-of-line filter
• Instruction manual
1.1.3 Unit Identification
There is one possible Pump Sampling Module configuration:
• Explosion-proof (P/N 10043264) unit
Reference the identification label located on the side of the unit (see Fig. 3). See Tab. 1 for unit specifications.
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SM5000 Sampling Module - DC Pump Model
Fig. 3 Identification label
Tab. 1 Performance specifications for SM5000 Sampling Mod ule - DC Pump Mo de l
Maximum power consumption 8.5 watts at 9 to 30 VDC
Cable requirements Four-conductor, shielded, 18 AWG (typical)
Sample transport time
30 seconds at 0.5 LPM with 50 feet (15.25 meters) of
.180 (4.57 mm) ID sample tubing
Nominal sample flow rate 2 CFH (1 LPM)
Minimum sample flow rate 1 CFH (.500 LPM)
Maximum sample tubing length 100 feet (30 meters)
Maximum exhaust tubing length 20 feet (6 meters)
Inlet fitting 1/4" (6.35 mm) OD tube fitting
Exhaust fitting 1/4" (6.35 mm) OD tube fitting
Calibration fitting 1/4" (6.35 mm) OD barbed fitting
Overall dimensions 9" x 6" x 5" (228.5 cm x 152.4 cm x 127 cm)
Weight 4.5 lbs. (2 kg)
Rating
Explosion-proof enclosure, Class I, Groups A, B, C
and D, Division 1, Hazardous Locations
Electrical entry 3/4-14 NPT
Flow failure relay
SPDT at 0.6 Amps, 125 Volts AC or 110 Volts DC
at 2.0 Amps, 30 Vo lts DC
Temperature range -20°C to 55°C (-4 to 122°F)
Humidity 15 to 95% RH, non-condensing
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1.1.4 Terminology
Tab. 2 Terminology
Electrochemical sensor
Sensor employing the reactions of chemicals generating electric
currents to detect ce rtain gases.
Exhaust gas Gas after it has passed through the sensor.
Flow rate The volume-per-minute of gas in the sample line.
Span gas value
The gas concentration in % LEL that is used to set the calibration value
during spanning. This value is usually printed on the gas cylinder
containing the gas.
Spanning
Process of placing a full scale or up scale meter reading on the display
by using calibration span gas cylinders.
Zero
A zero (0) indication on the meter display usually indicates ambient air
present or no hazardous gases present.
Zeroing Processes for placing a zero indication on meter display.
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SM5000 Sampling Module - DC Pump Model
2 Installation
2.1 General
Install the Pump Sampling Module in the correct area classified in your facility .
NOTE: The explosion-proof model hazardous area classification is Class I, Division 1, Groups A, B, C
and D. It is important that all local and national codes be followed when installing this model in a classified
area.
Double check the area classification of the Pump Sampling Module.
Refer to Fig. 3 to find the area classification label on your unit. Ensur e that the gas monitor being use d with
the sample pump is rated properly by referring to the gas monitor instruction manual for more details.
WARNING!
Do not mix units with diff erent area classifications. All units used in a classi fied area must have the proper
area classification. Otherwise, an explosion hazard will exist, resulting in a possible explosion, injury or
death.
The Pump Sampling Module for a general-purpose (GP) monitor can be a source of ignition. Install, locate
and operate only in a non-hazardous area and in accordance with applicable codes.
If sampling from or exhausting into a separate location, the installation requires flashback arrestors at the
inlet from a hazardous location and at the outlet to a hazardous lo cation, to prevent the prop agation of ignition of hazardous gases. Routinely check for pump system leaks that could create an explosive environment
inside the enclosure.
Read and follow all instructions, warnings and cautions pertaining to this gas monitor.
Failure to follow this warning can cause ignition of explosive environments resulting in serious personal
injury or death.
2.2 Mounting the Pump Sampling Module Unit (All Models)
(1) Locate the Pump Sampling Module and the gas monitor(s) in a clean, accessible location.
NOTE: Since the unit enclosure is non-corrosive, it can be mounted to the outside of a building or in
other wet environments. Note the temperature and RH requirements.
NOTE: Use of Teflon tape or non-hardening thread sealant for environmental reasons is acceptable.
NOTE: When installing multiple gas monitors, ensure all monitors have co nduit seals placed within the
requisite distances as outlined in their respective user manuals.
CAUTION!
Ensure that Pump Sampling Module or the gas monitor(s) display(s) are not blocke d or obscured. A blocked
display will obscure the gas reading indication and sampling module indications. The unit must be mounted
with the electrical input facing down and the label clearly readable.
(2) Mount the Pump Sampling Module and gas monitor(s):
• From the electrical condulet or
• By using optional mounting bracket (P/N 10047561) and the four holes in the rear of the
Pump Sampling Module.
• By using the optional mounting bracket (P/N 10179361) for the Ultima X5000 Gas Monitor.
• Assemblies are also available that will allow monitoring in vent pipe lines 4-6" in diameter.
Use PN 10147544 for digital sensors and PN 10126895 for XIR/XIR PLUS sensors.
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SM5000 Sampling Module - DC Pump Model
(3) Mount gas monitor such that the digital sensor inlet is facing downward. If installing with an Ultima XIR
or XIR PLUS, mount such that the sensor inlet is horizontal.
(4) Mount Pump Sampling Module exhaust tubing so that the end of the tubing is facing downwar d and is
the lowest point of the tubing (see Fig. 1).
CAUTION!
The gas monitor must be mounted with its sensor at the bottom of the case and the digit al sensor inlet fitting
pointed downward or XIR/XIR PLUS sensor pointed horizontal; otherwise, the unit may become inoperative.
2.3 Sample Line Placement between Pump Sampling Module and Ultima X, Ultima X5000, or
S5000 Gas Monitor
(1) Remove all protective p ackaging plugs and/or caps from Pump Samp ling Module gas inlet and exhaust
ports.
(2) On new installations, skip to Step 4.
On existing installations of the Ultima X, Ultima X5000, or S5000 gas monitors: Remove the red or
black sensor guard and any gaskets remaining on the sensor. Do not remove the sensor element.
(3) Install the flow block(s) on the gas monitor(s) where the red or black sensor guard was removed in the
previous step (see Fig. 1 and Fig. 4).
NOTE: Flow caps are purchased separately. See Tab. 3 for part numbers.
(4) Attach the supplied tubing to the Pump Sampling Module port labeled "TO ULTIMA".
(5) Attach the other end of the supplied tubing to the side of the flow block (see Fig. 1).
NOTE: Tubing can be trimmed to ensure that there are no kinks.
NOTE: In-line filter (P/N 10 051406) must be used somewhere along the tubing length. Ensure that the
arrow on the in-line filter is pointing towards the Pump Sampling Module.
Tab. 3 Parts purchased separately
CAUTION!
The in-line filter must be used before the Pump Sampling Module to preve nt water entry from damaging unit.
If installing additional gas monitors, install tubing between units as shown in Fig. 4. Use tubi ng compatible
with the gas being sampled.
MSA tubing is available (P/N 600771).
Item Part no.
End-of-line filter for wet area sampling 10015787
End-of-line filter for humid area sampling 637921
4-6" vent pipe mount for mounting with digital sensor 10147544
4-6" vent pipe mount for mounting with
XIR/XIR PLUS sensor
10126895
Sample line water deflector (for hosed-down areas) 10087383
Ultima X, Ultima X5000 and S5000 Digital Sensor Flow
Block
10041866
Ultima XIR/XIR PLUS Flow Block 10042600
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SM5000 Sampling Module - DC Pump Model
Fig. 4 Three Ultima X5000 Gas Monitors and a Sampling Module
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SM5000 Sampling Module - DC Pump Model
2.4 Sample Line Placement
The Pump Sampling Module draws a gas sample to the internally mounted Ultima X, Ultima X5000, or
S5000 Gas Monitor sensor.
• The Pump Sampling Module can be mounted up to 100 feet (3 0 meters) away from the monitored area.
• It uses 1/4-inch (6.35 mm) OD tubing to connect the Pump Sampling Module sample inlet to the end of
the sample line in the monitored area.
• Tubing must be compatible with the sampled gas.
• It takes a maximum of 30 seconds for the sample gas to reach the Pump Samp ling Module when 50 feet
(15.25 meters) of tubing is used:
• To decrease this time, shorten the sample line length.
• It is generally good practice to make the sample line as short as possible.
• Depending on the gas characteristics, the end of the sampling tubing and the sample inlet should be
mounted to best optimize sampling of that particular gas. Consult your architect, facility manager or
safety engineer for guidance in proper placement of the sampling tube inlet.
• T esting for ventilation p atterns is useful in establishing sample inlet location. Smoke tubes (P/N458481)
are useful in measuring the direction and rate of air flow to determine which areas to monitor.
• The particulate filter provided should be used at the sample end of the sample line to help prevent dirt
and dust from clogging the sample line. This filter must be compatible with the gas being sampled.
• Alternative end of line filters are available if sampling from wet areas. If sampling from a hot and moist
area, use in line filter PN 637921. If sampling from an out door a rea where the sample lin e end is at risk
for submerging under water, use in line filter PN 10015787. Both filters are purchased separately.
• If installing in an area that is hosed-down or sanitized, use the water deflector accessory PN 10087383
for end of line sample, available for purchase separately.
• It is recommended that a stainless steel of Teflon (Trademark of the DuPont Company) sample line be
used for monitoring gases that are highly reactive such as:
• Nitrogen dioxide
• Sulfur dioxide
•Chlorine
• Chlorine dioxide
• Hydrogen chloride
•Ammonia
• Fluorine
•Bromine.
• With the above gases, use filter (P/N 637921). The filter and sample line should be inspected periodically
and replaced if dirty.
CAUTION!
Do not attempt to clean the sample line by applying compressed air.
All gas monitors must be mounted in ambient, interference-free air; otherwise, erroneous readings may
result.
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SM5000 Sampling Module - DC Pump Model
(1) Remove all protective packaging plugs and/or caps from the Pump Sampling Module:
• gas inlet
• exhaust ports.
(2) Attach a 1/4-inch (6.35 mm) OD sample tubing to the flow block sample inlet fitting on the gas monitor
(see Fig. 1). Ensure tubing is compatible with the sampled gas.
(3) Route the sample tubing to the area to be monitored.
NOTE: Do not run the sample tubing in water or across areas of vibration, doorways, man ways or
access ways; otherwise, a sample tubing leak or tripping hazard may result.
(4) Using suitable hardware (not supplied):
a) fasten the sample tubing to supports.
b) fasten the end of the sample tubing and sample inlet in the monitoring area.
NOTE: The sample inlet should be pointed downward to prevent dirt and water from ente ring the
sample tubing line.
(5) Install the provided end -of-line filter at the end of the sample tubing, if applicable.
(6) Check for leaks along the entire length of the sample tubing line. Any leak will dilute the gas sample
from the area of interest and give a lower than actual gas reading.
(7) The in-line filter will trap water and block the flow.
2.5 Exhaust Line Placement
(1) Attach a 1/4-inch (6.35 mm) OD sample tubing to the exhaust outlet fitting on the Pump Sampling
Module unit.
(2) Route the exhaust tubing into a safe area where the gas sample can be vented. Avoid any sharp bends
or elbows. Route the tubing to allow any collected water to drain.
NOTE: The maximum exhaust tubing length is 20 feet (6 meters).
NOTE: Do not run the exhaust tubing in water or across areas of vibration or across doorways, man
ways or access ways; otherwise, a leak in the exhaust tubing or a tripping hazard may result.
(3) Fasten the exhaust tubing to supports using suitable hardware (not supplied).
(4) Fasten the end of the exhaust tubi ng in the ar ea o f inter est by using suitable hardware (not supplied).
NOTE: Exhaust inlet should be pointed downward to prevent dirt and water from entering the exhaust
tubing line.
(5) Check for leaks along entire length of the exhaust tubing line.
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SM5000 Sampling Module - DC Pump Model
2.6 Electrical Connection
A flow detector within the Pump Sampling Module activate s a relay when sufficient flow exists for proper
gas detection. Generally, the Ultima X5000 transmitter analog output signal can be routed through the
sampling module relay. When the flow is insufficient, the relay opens and the (AO) analog output signal is
interrupted. Equipment monitoring the AO can be configured to sound an alarm when the signal is interrupted. See Fig. 5, Fig. 6 and Fig. 7 for a typical wiring schematic of the Sampling Module and Ultima X5000
Gas Monitor.
Other devices that alert when the flow loss relay activates can be connected to relay contact with the
Pump Sampling Module.
NOTE: The Pump Sampling Module utilizes a shielded four-conductor wiring harness. It is recommended
to use the shielded wire harness if installing the system where portable two-way radio, welding or large
machinery are located.
Fig. 5 Typical wiring - Ultima X
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SM5000 Sampling Module - DC Pump Model
Fig. 6 Typical wiring - SM5000 and X5000
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SM5000 Sampling Module - DC Pump Model
Fig. 7 Typical wiring - SM5000 and S5000
2.6.1 Electrical Connection Procedure
(1) Turn power OFF from the receiving instrument or power supply for the system.
WARNING!
Failure to remove power from instrument may damage the Pump Sampling Module and/or Ultima X5000
Gas Monitor during wiring.
(2) If connecting the field wires to the wiring harness, observe the identity of the conductors within the
wiring harness. Connect field wires to the appropriate harness conductors.
(3) If not using the attached wiring harness:
a) Remove the top cover of the Pump Sampling Module by rotating the cover counter-clockwise.
b) Unscrew and remove the two top-cover screws.
c) Lift top cover to expose the wiring terminal strip on the bottom side of the cover.
d) Loosen terminal strip screws and remove the wiring harness.
If not using the attached wire harness:
• Remove and discard the wiring harness.
• Install a conduit seal into the enclosure.
• Use of Teflon tape or non-hardening thread sealant for environmental reasons is acceptable.
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SM5000 Sampling Module - DC Pump Model
e) Route a cable (not supplied) through the electrical entry of the Pump Sampling Module.
f) Connect the conductors to the wiring terminal strip noting the identity of the wires (see Fig. 4 and
Tab. 4).
g) Replace the top cover and tighten with the two screws.
h) Replace lid and tighten in place.
WARNING!
Do not allow lid to remain off of the explosion-proo f Pump Sampling Module. Flammable or combustible ga s
in the atmosphere may ignite a spark; that, in turn, may cause an explosion and result in injury or death.
(4) Wire the other end of the wiring cable to your read-out instrumen t and power supply , ensuring the cable
from the Pump Sampling Module is wired to the proper connections on the instrument. Consult the
instrument instruction manual for more wiring details.
Tab. 4 Wiring identification
2.7 Initial Start-Up
Before starting up the Pump Sampling Module:
(1) Check wiring connections (see Fig. 5 and Tab. 4).
(2) Ensure that power supplied to the controlling instrument is the proper voltage with sufficient current
capacity to operate the instrument. Refer to the gas mo nit or instr uc tio n ma nu a l for pr op e r pow e r
set-up.
(3) Apply power to the instrument through a remote circuit breaker.
CAUTION!
If relays in the controlling instrument are wired to external devices (e.g. horns, exhaust fans, and fire
suppression systems), these devices may activate while adjustments are performed during the following
procedures. Consult equipment instruction manual for further details. All instruments must be returned to
normal operation when Pump Sampling Module and gas monitor adjustments are completed.
(4) Ensure the exhaust is not restricted.
(5) The front panel low flow indication, red LED, should NOT be ON.
NOTE: If front panel low flow indication is ON, see chapter 4.3 "Troubleshooting Guidelines".
Position Description
1 Normally closed contact of the flow loss relay
2 Normally open contact of the flow loss relay
3 Common position of the flow loss relay
4 Ground or negative of the power supply
5 Positive or supply position of the power supply
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Calibration and Operation
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SM5000 Sampling Module - DC Pump Model
3 Calibration and Operation
3.1 Introduction
Calibration of the sensor when used with the Pump Sampling Module should follow the operating instructions for the gas monitor used.
If this calibration procedure cannot be performed at any step, consult chapter 4.3 "Troubleshooting Guidelines", localize the problem and replace the inoperative component.
MSA offers periodic service that is available on a contract basis; for more information, please call MSA at
1-800-MSA-INST.
3.2 Calibration Procedures
Place the instrument receiving the signal from the gas monitor into calibration mode, if applicable.
WARNING!
It is necessary to put the receiving instrument in calibration mode. If the instrument is not in calibration
mode, any alarm relays may energize and activate any safety devices which are connected to the alarm
relays of the instrument.
Equipment needed:
• Ultima X (calibration kit #42)
X5000/S5000 (CALKIT2)
• Appropriate zero and span gas cylinders (see gas monitor instruction manual).
• If using an Ultima X, Controller (P/N 809086) or an Ultima X Calibrator (P/N 809997).
NOTE: If unsure of which span gas to use or of the span gas value, co nsult your safety engineer or officer
or facility manager.
(1) Locate the zero gas cylinder and the appropriate regulator and tubing. Screw the regulator into the
cylinder and connect the tubing to the regulator outlet. Ensure that tubing is compatible with the gas
within the cylinder.
(2) Before initiating the calibration procedure s on the gas monitor, connect the tubing from the zero gas
cylinder to the calibration inlet (see Fig. 1).
3.2.1 Zeroing with the
Pump Sampling Module
(3) Initiate the calibration procedure on the gas monitor (see gas monitor instruction manual).
(4) When the gas monitor indicates "APPLY ZERO GAS", press and hold the button by the calibration
inlet. Turn the knob on the regulator to permit the zero gas to flow . Simu ltaneously, the gas monitor will
make all corrections to the zero signal; there are no adjustments necessary.
(5) When the gas monitor is done zeroing, close the cylinder valve, release the button by the calibration
inlet, and quickly rotate the zero gas cylinder to remove the zero gas cylin der. Do not remove th e tubing
from the flow controller .
(6) Locate and screw regulator into the cylinder.
NOTE: If unsure of which span gas to use or of the span gas value, consult your safety engineer or
officer or facility manager.
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Calibration and Operation
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SM5000 Sampling Module - DC Pump Model
3.2.2 Spanning with the Pump Sampling Module
(7) When calibrating, the span immediately follows the zero (see gas monitor instruction manual).
(8) When the gas monitor displays "APPL Y SP AN GAS", press and hold the button by the calibration inlet.
Turn the regulator knob to permit the span gas to flow. The gas monitor will make all corrections to its
calibration; there are no adjustments necessary.
(9) When the gas monitor calibration is complete, release the button by the calibration inlet, close the
cylinder valve and remove the span gas cylinder.
(10) Unscrew the regulator from the gas cylinder and replace all calibration components in the kit.
(11) Return instrument receiving the signal from the gas monitor to normal run mode operation.
3.3 Operation
There are only two indicators on the front cover of the Pump Sampling Module which af fect the operation of
the unit.
• The NORMAL indicator, the green LED, shows that there is power to the unit and the flow is greater than
.5 LPM.
• The LOW FLOW indicator, the red LED, indicates that the flow detector has insufficient gas flow for
proper monitoring. See chapter 4.3 "Troubleshooting Guidelines" for corrective action.
WARNING!
The pressure switch can fail and the orifice can clog if water enters the system. Always use the proper inline filter (P/N 10051406).
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Maintenance and Troubleshooting Guidelines
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SM5000 Sampling Module - DC Pump Model
4 Maintenance and Troubleshooting Guidelines
4.1 Maintenance
The Pump Sampling Module requires minimal maintenance. However, the filters need routine inspection
and possible replacement. It is good practice to have on hand replacement filters to minimize any down time
of your unit (see Tab. 6).
4.2 Filter Maintenance
Filter maintenance consists of visual inspection of the two filters, end-of-line filter and in-line filter. When
new, filters are white or slightly yellowed; when loaded with dust or dirt, they normally turn dark in color . V isually inspect the two filters periodically. The frequency of this inspection depends on the environment; if your
environment is extremely dirty or dusty , this inspection should be done often.The in-line filter is hydrophobic
and will not pass liquids.
End-of-line filters must be located so that they are not exposed to liquids or steam. If liquids become
entrapped within a filter, replace the filter as it will interfere with proper operation of the unit.
4.3 Troubleshooting Guidelines
Tab. 5 Troubleshooting guidelines
Symptom Possible cause Probable solution
Low flow indicator is ON Sample line clogged Check and replace or clean sample line
A leak internal to the Pump Sampling
Module
Check tubing inside the Pump Sampling
Module, especially the fittings
Inoperative flow switch Replace flow switch
The sample line is under a vacuum Remove vacuum from sample line inlet
Dirty end-of-line or in-line filter Replace dirty end-of-line or in-line filter
Exhaust clogged Clean or replace exhaust tubing
No sensor output or low
output
Sensor is approaching its end-of-life Replace sensor
The ambient is too cold or too hot for
the sensor
Place Pump Sampling Module in a
warmer or cooler ambient environment
A leak in the sample line
Check/repair any leaks in the sample
line
Inoperative sensor pre-amp electronics Replace sensor printed circuit board
Exhaust clogged or restricted
Unclog or remove the restriction on the
exhaust
Dirty or wet sample filter Replace sample filter
Inoperative flow switch Replace flow switch
Sensor wiring plug loose Reconnect sensor wiring plug
Bad wiring connection between instru-
ment and Pump Sampling Module
Check wiring and replace or repair any
inoperative wiring or connections
No power to the unit Turn control instrument ON
Improper voltage selection at the
control instrument
Select proper voltage at the control
instrument
Inoperative relay Replace printed circuit board assembly
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Maintenance and Troubleshooting Guidelines
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SM5000 Sampling Module - DC Pump Model
4.4 Replacement Parts
Tab. 6 Parts list
NOTE: It is the user’s responsibility to follow all applicable regulations and to ensure continued compliance with
the certification, as marked on the label.
Description Part no.
PC board assembly (requires new label - listed below) 10052349
Pressure switch 10050076
Pump and drive 8153 9 5
Pump bracket 10047561
End-of-line filter (wet) 10015787
Filter, in-line 10051406
Filter, end-of-line, includes cartridge (standard) 637920
Filter, end-of-line (humid or reactive samples) 637921
Filter cartridge for end-of-line filter (general purpose) 95302
Flashback arrestor for explosion-pr oo f mo d els only 813159
Flow cap - digital sensor 10041866
Flow cap - XIR/XIR PLUS sensor 10042600
Valve, push-button 635729
Gasket, flow block, explosion-proof 10051112
Sample line tubing 1/4" 600771
O-ring, Ultima XIR flow block 10042428
4-6" vent pipe mount - digital sensor 10147544
4-6" vent pipe mount - XIR/XIR PLUS sensor 10126895
Water deflector 10087383
For local MSA contacts, please visit us at MSAsafety.com
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