RC System SENSMART 2000, SENSMART 3000 User Manual

SenSmart 3000 User's Manual

Warning: Read & understand contents of this manual prior

to operation. Failure to do so could result in serious injury or death.
Users are responsible for correct translations of this manual into

their native language.

Document: UM-1003 Revision Level B

INSTRUCTION

MANUAL

R.C. SYSTEMS CO. INC.

MODEL SENSMART 3000/2000 SENSOR TRANSMITTER

(Built with our Proven St-48 Transmitter)

PH. 409-986-9800 FAX [phone]

8621 Hwy. 6 Hitchcock, TX 77563

Website: http://www.rcsystemsco.com

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SECTION 1 – SAFETY INFORMATION ......................................................................................... 1

1.1 Safety Information – Read Before Installation & Applying Power ......................... 1

1.2 Contacting R. C. Systems Co. Inc. ............................................................................. 1

SECTION 2 – INSTALLATION INSTRUCTIONS ........................................................................... 1

2.1 Introduction .................................................................................................................. 1

2.2 Ratings and Certifications .......................................................................................... 3

2.2.1 SenSmart 3000 ATEX Certified Model ................................................................ 3

2.3 Sensor Location .......................................................................................................... 3

2.4 Mounting the Enclosure.............................................................................................. 4

2.5 System Design Specifications ................................................................................... 5

2.6 Field Wiring Installation .............................................................................................. 6

2.7 SenSmart 2000 2-Wire Intrinsically Safe & Explosion Proof Installations ............ 6

2.7a Installation Drawing # 11-0100 ............................................................................ 8

2.8 3-Wire 4-20mA Mode Installation ............................................................................... 9

2.9 Alarms / RS-485 Modbus 10-0234 Option Installation ........................................... 10

2.10 Isolated 4-20mA Output 10-0250 Option ................................................................. 11

2.11 Sensor Installation (with Smart / Simple Sensor Definition) ................................. 11

2.12 “Sensor Type” and SenSmart 3000 Signal Conditioning ...................................... 12

SECTION 3 – INITIAL START-UP ................................................................................................ 13

3.1 “Transmitter Configuration” Menu .......................................................................... 13

3.1.1 Single / Dual Gas Monitor Configuration ......................................................... 14

3.1.2 Output Zero / Output Span Trims (Factory Preset, Technicians only!): ....... 14

3.1.3 Model Name ............................................................................................................ 14

3.1.4 Real Time Clock ........................................................................................................... 14

3.1.5 Backlight ....................................................................................................................... 14

3.2 Initial Bridge Sensor Monitor Start-Up .................................................................... 15

3.2.1 Initial Bridge Sensor Monitor “Sensor Volts” Check ..................................... 15

3.2.2 Initial Bridge Sensor Monitor “Balance” Check .............................................. 15

3.2.3 Initial Bridge Sensor Monitor “Span” Check ................................................... 15

3.3 Initial Toxic / Oxygen Sensor Monitor Start-Up ...................................................... 15

3.3.1 Initial Toxic / Oxygen Sensor Monitor “Span” Check .................................... 15

SECTION 4 – OPERATING INSTRUCTIONS .............................................................................. 16

4.1 Routine Sensor Calibrations .................................................................................... 16

4.2 ALARM OPERATION ................................................................................................. 18

4.2.1 ALARM 3 – UNDERSTANDING FAULT / LEVEL OPERATION........................ 18

SECTION 5 – SETUP MENU CONFIGURATION ........................................................................ 18

5.1 Menus Database Configuration ............................................................................... 18

5.2 Configuration Using the Magnetic Wand: ............................................................... 19

5.3 System Configuration Menus: ................................................................................. 20

Measurement Name ........................................................................................................ 20

Eunits ............................................................................................................................... 20

Zero .................................................................................................................................. 20

Span ................................................................................................................................. 20

Decimal Points ................................................................................................................ 20

Cal Span Value ................................................................................................................ 20

Readout Deadband ......................................................................................................... 20

Track Negative ................................................................................................................ 20

Temp Compensation ...................................................................................................... 21

Backup Config. ............................................................................................................... 21

Restore Config. ............................................................................................................... 21

Upload Sensor Data ....................................................................................................... 21

Cal Marker ....................................................................................................................... 21

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TX Sensor Life ................................................................................................................ 22

5.4 Alarm Settings: .......................................................................................................... 22

5.4.1 Relay Configuration (if equipped): ................................................................... 23

5.5 Sensor Information: .................................................................................................. 23

5.6 CLOCK/DELAY SETUP: ............................................................................................ 24

5.7 LCD Contrast Adj: ..................................................................................................... 25

5.8 HELP Screen: ............................................................................................................. 25

5.9 Diagnostics: ............................................................................................................... 25

5.10 RS-485 / MODBUS SETUP: ....................................................................................... 25

5.10.1 MODBUS REGISTER AND FUNCTION CODE SUMMARY ............................ 26

5.11 SYSTEM SECURITY: ................................................................................................. 29

SECTION 6 – TECHNICIANS ONLY MENUS .............................................................................. 29

6.1 Introduction: .............................................................................................................. 29

6.2 Set Balance / Set Sensor Voltage (Technicians only!): ......................................... 30

6.3 Set Gain to Unity (Technicians only!): .................................................................... 31

6.4 PreAmp Gain Adjust (Technicians only!): .............................................................. 31

6.5 Simple Sensor Input Type (Technicians only!): ..................................................... 32

6.6 Zero Cal Value (Technicians only!): ........................................................................ 32

6.7 Raw Min / Max Counts (Technicians only!): ........................................................... 33

6.8 4-20mA Input Marker / Message (Technicians only!): ........................................... 33

SECTION 7 – SPECIAL ORDER CONFIGURATIONS ................................................................ 33

7.1 ARCTIC Option .......................................................................................................... 33

7.1.1 ARCTIC Smart Sensor Temperature Setpoint Option .................................... 33

7.2 Special Order; 18VAC Primary Power Supply Option ........................................... 34

7.3 Special Order; 4-20mA Input to Bridge Channel .................................................... 35

7.3.1 4-20mA Input Marker / Message (Technicians only!): .................................... 36

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SECTION 1 – SAFETY INFORMATION

1.1 Safety Information – Read Before Installation & Applying Power

IMPORTANT

Users should have a detailed understanding of SenSmart 3000 operating and maintenance
instructions. Use the SenSmart 3000 only as specified in this manual or detection of gases and
the resulting protection provided may be impaired. Read the following WARNINGS prior to use.

WARNINGS

 Calibrate with known target gas at start-up and check on a regular schedule, at least

every 90 days. More frequent inspections are encouraged to spot problems such as dirt,
oil, paint, grease or other foreign materials on the sensor head.

 Do not paint the sensor assembly or the Transmitter.
 Do not use the SenSmart 3000 if its enclosure is damaged or cracked or has missing

components.

 Make sure the cover, internal PCB’s and field wiring are securely in place before

operation.

 Use only a sensor assembly compatible with the SenSmart 3000 and approved by R. C.

Systems Co. Inc. (See the section ____ for Replacement Parts.) *Not Available this
printing*

 Periodically test for correct operation of the system’s alarm events by exposing the

monitor to a targeted gas concentration above the High Alarm setpoint.

 Do not expose the SenSmart 3000 to electrical shock or continuous severe mechanical

shock.

 Protect the SenSmart 3000 from dripping liquids and high power sprays.
 Use only for applications described within this manual.

CAUTION: FOR SAFETY REASONS THIS EQUIPMENT MUST BE OPERATED AND
SERVICED BY QUALIFIED PERSONNEL ONLY. READ AND UNDERSTAND INSTRUCTION
MANUAL COMPLETELY BEFORE OPERATING OR SERVICING.

ATTENTION: POUR DES RAISONS DE SÉCURITÉ, CET ÉQUIPEMENT DOIT ÊTRE UTILISÉ,
ENTRETENU ET RÉPARÉ UNIQUEMENT PAR UN PERSONNEL QUALIFIÉ. ÉTUDIER LE

MANUE D’INSTRUCTIONS EN ENTIER AVANT D’UTILISER, D’ENTRETENIR OU DE
RÉPARER L’ÉQUIPEMENT.

1.2 Contacting R. C. Systems Co. Inc.

To contact R. C. Systems Co. Inc., call, fax, email or write:
409–986-9800 FAX [phone] Email: [e-mail] 8621 Hwy. 6 Hitchcock, TX 77563
Or visit us on the World Wide Web: www.rcsystemsco.com

SECTION 2 – INSTALLATION INSTRUCTIONS

2.1 Introduction

Important: This manual describes both the 2-Wire (SenSmart 2000) and the 3-Wire (SenSmart

3000) 4-20mA versions of the ST-48 transmitter. SenSmart 2000 2-Wire versions are only
possible if the 10-0232 Display PCB IS THE ONLY PCB IN THE ENCLOSURE. If the 10-0233
I/O Power Supply is installed it is a 3-Wire version.

The SenSmart 3000 is a single or dual channel fixed-point monitor designed to provide
continuous monitoring of hazardous gases in the workplace. Monitored values are displayed in

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their engineering units as well as graphically as a bar graphs or 30-minute trends (Figure 2.1).

Input types include Electrochemical toxic / oxygen sensors, catalytic bead combustible sensors,
MOS solid-state sensors, as well as various millivolts, volt and 4-20mA inputs. Sensors supplied
by the factory include an 8-wire Smart Sensor interface capable of configuration data uploads to
the SenSmart 3000. Traditional 3-wire Simple sensors, without the smart interface, are also
supported by the SenSmart 3000. Its advanced microcontroller electronics and superior graphic
LCD operator interface offers enhanced diagnostics and fault analysis not possible in competing
products. The SenSmart 3000 provides a standard 4-20 mA output signal for connection to
control systems or other alarm instrumentation. Available options include an Alarm Relay / RS­485-Modbus board or an Isolated 4-20mA output. Non-volatile memory retains all configuration
data during power interruptions. The magnetic, non-intrusive calibration can be easily performed
by one person without opening the enclosure. A standard “real time clock & calendar” feature
allows data logging of calibrations and alarm events for recall to the LCD readout or over the
serial port.

A separate PC compatible USB Interface allows a Smart sensor to be loaded with configuration
variables via a PC and upload this data to the SenSmart 3000. This includes alarm set points,
range, target gas, calibration constants and other variables required to match the SenSmart 3000
to a specific application. For traditional Simple sensors, without the smart interface, the USB
interface allows direct SenSmart 3000 configuration from a PC or a six channel SenSmart 3000
Educator device.

Toxic and oxygen monitors are capable of 2-wire 4-20mA operation (section 2.7) when the alarms
/ Modbus option and LCD backlight are not required. Catalytic LEL sensors, or addition of the 10­0234 Alarms / Modbus option, require the 10-0233 I/O Power Supply board providing 3-wire 4­20mA operation (section 2.8).

Only periodic calibration checks are needed to assure dependable performance. Operator
interface is very intuitive with the LCD displaying data both graphically as bar-graphs / trends and
in engineering units (Figure 2-1). Additional features include:

 No potentiometer or jumper settings required. All setup is with menus accessed via the LCD

/ magnetic keypad operator interface without opening the enclosure.

 Field adjustable alarm levels may be high, low, fault, fail-safe, latching and acknowledgeable.
 New alarms cause front LED’s to flash and become steady after acknowledge.
 CAL MODE advises when to apply gas during calibrations
 One half hour trend screen shows rate of change of gas exposures
 Sensor life bar-graph updates after each SPAN calibration.
 Modular design affords efficient installation and plug in sensors allow changing target gases

after installation

 New smart sensors are recognized by the SenSmart 3000 and prompts users to either

upload new configuration data or continue with data from the previous smart sensor.

 Sensors are industry proven for fast response and long life.

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SenSmart 3000 User's Manual

NEXTUP/

EDITDOWN/CAL

TXD

RXD

RS485

ALM1 ALM2 FAIL

ALM RST

% O

2

De f .

Dual Channel Split Screen

(Dual Sensor Mode Only)

% L E L

17 . 8

0

A 1
A 2

NEXTUP/

EDITDOWN/CAL

TXD

RXD

RS485

ALM1 ALM2 FAIL

ALM RST

10 % L E L

Engrg. Units / 30-Minute Trend

NEXTUP/

EDITDOWN/CAL

TXD

RXD

RS485

ALM1 ALM2 FAIL

ALM RST

Me a su r e men t Na me

% L E L

10

Engrg. Units / Bar Graph

NEXT key

toggles
readout

NEXT key

toggles
readout

Document: UM-1003 Revision Level B

Figure 2-1: Data Displays

2.2 Ratings and Certifications

CSA certified for Division 1 & 2 hazardous area installations for explosion proof Class 1 Groups
B,C,D, and intrinsically safe (SenSmart 2000 2-wire loops only) Class 1 Groups A,B,C,D. Also
see sections 2.7, 2.7a & 2.8. Designed to meet CSA C22.2 No.152 for Combustibles Monitors
and ISA 92.0.01 Part 1 for Toxic Monitors.

2.2.1 SenSmart 3000 ATEX Certified Model

An ATEX certified SenSmart 3000 model (certificate # DNV-2007-OSL-ATEX-1845) is also
available by changing the SenSmart 3000 designation to ST-ATEX48. ATEX certified models
including sensors are supplied only with sensor head part # 10-2072 and are not available with
the 10-0247 sensor head or the 0010-1200 “Y” fitting. ATEX installations must be in compliance
with EN60079-14 or suitable National or international standard and all cable glands and closing
devices must carry a suitable ATEX marking.

The ATEX label is shown below:

2.3 Sensor Location

Factors such as air movement, gas density in relation to air, emission sources and environmental
variables affect correct sensor location. Air movement by fans, prevailing winds and convection
should be carefully evaluated to determine if a leak is more likely to raise gas levels in certain
areas within the facility. Vapor density of a gas determines if it will rise or fall in air when there
are no significant currents. Lighter than air gases should have the monitors mounted 12 – 18
inches (30 – 45 centimeters) above the potential gas leak and heavier than air gases should be
this distance below. Even though the SenSmart 3000 is designed for rugged service, sensors
should be protected from environmental damage from water, snow, shock, vibration and dirt.

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SenSmart 3000 User's Manual

0010-1200 “Y” Fitting not available
on ATEX compliant model

Document: UM-1003 Revision Level B

2.4 Mounting the Enclosure

The SenSmart 3000 standard enclosure is a cast aluminum explosion-proof (NEMA 7) enclosure
as shown in Figure 2-2. Figure 2-2a shows dimensions with the dual local sensor ‘Y’ included.

Figure 2-2: SenSmart 3000 Explosion-Proof Housing

Figure 2-2a: SenSmart 3000 Explosion-Proof Housing with Dual Sensor Head Adaptor

Modular design simplifies the installation of the SenSmart 3000 (Figure 2-3). A top Display
Assembly is mounted with captive thumbscrews and is easily removed to access field-wiring
terminals. An optional 10-0234 Alarms/Modbus board mounts piggyback to the back of the
Display Assembly. Wiring from toxic or oxygen sensors terminates at the 10-0232 Display
Assembly along with 2-wire 4-20mA signal wires. This Display Assembly is the only PC board

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SenSmart 3000 User's Manual

ATEX compliant model requires
10-2072 ATEX marked sensor head

Document: UM-1003 Revision Level B
supplied with toxic / oxygen SenSmart 3000s not requiring relays, RS-485 Modbus or LCD

backlight. The optional bottom 10-0233 I/O Power Supply board generates voltages needed for
LCD backlight, relays, RS-485 Modbus and Bridge sensor and is required with any of these I/O
functions. The enclosure is equipped with two threaded 3/4 inch NPT conduit fitting outlet and
pre-drilled mounting flanges.

WARNING: Qualified personnel should perform the installation according to applicable electrical
codes, regulations and safety standards. Insure correct cabling and sealing fitting practices are
implemented. Do not aim the sensor pointing upward. Install the SenSmart 3000 to a wall or
bracket using the predrilled mounting flanges with I.D. 0.25 on 5.5 inch centers (Figure 2-2). If
conduit is rigid and able to support the weight of the SenSmart 3000, the mounting bolts may be
omitted.

CAUTION: The sensor should never be installed pointing upwards.

2.5 System Design Specifications

Supply Voltage:

10 to 30 volts

Power Consumption:

 With a typical .5 watt Bridge Sensors (requires 10-0233 I/O Power Supply and 3-wire

operation): 100 mA @ nominal 24 VDC

 Toxic/Oxygen Sensors without Relays / Modbus Option (2-wire 4-20mA operation): 25 mA

max @ nominal 24 VDC.

Figure 2-3: Outline Drawing

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 Relays / RS-485 Modbus Option Board (requires 10-0233 I/O Power Supply and 3-wire

operation): 40 mA per relay (120 mA total with all 3 energized); RS-485 use adds 20mA

Memory:

Non-volatile E2 memory retains configuration values in the event of power outages.

Loop Resistance at nominal 24 VDC power:

650 ohms maximum in 2-wire mode
750 ohms maximum in 3-wire mode.

Relays (Optional):

Three configurable form C (SPDT) relays rated for 5 amp at 30 VDC or 240 ~VAC RESISTIVE.
Relay 1 and Relay 2 level alarms are configurable for HIGH or LOW trip, for normally energized

(Failsafe) or normally de-energized and for latching or non-latching.
Relay 3 is always normally energized for failsafe operation so loss of power to the SenSmart

3000 will be indicated as a “FAULT” condition.
CAUTION: Relays are rated for RESISTIVE loads. Inductive loads, such contactor coils or

motors may cause contact arcing, which emits RFI into the sensor signals. Use appropriate
snubbers and MOV’s across inductive loads and keep wiring away from signal wires.

2.6 Field Wiring Installation

4-20mA Transmission Range Info:

The distance 4-20 mA signals can travel is dependent upon several factors including the cable
gauge, DC power supply voltage level and impedance of the input of the receiving device.
Assuming a nominal 24 VDC power supply, maximum total loop resistance is 650 ohms in the 2­wire mode.

Note: ST-71 Controllers have 4-20mA input resistance of 100 ohms.

2.7 SenSmart 2000 2-Wire Intrinsically Safe & Explosion Proof
Installations

SenSmart 2000s equipped with 10-0247 sensor heads are NRTL (Nationally Recognized Testing
Lab) certified as suitable for both intrinsically safe and explosion proof installations. SenSmart
2000s equipped with 10-0247IS sensor heads (XP flame arrestor is not installed to allow
monitoring of highly reactive gases such as chlorine) are NRTL certified as suitable for
intrinsically safe installations. All SenSmart 2000s are NRTL certified for explosion proof
installations as long as the sensor head is CSA certified as explosion proof. Follow instructions
on Installation Drawing # 11-0100 in section 2.7a for correct intrinsically safe installations.

Description:

The 2-wire current sinking transmitter is the easiest and most economical to install since there are
only two wires. All of the power needed comes from the current loop and wire sizes may be
smaller. However, only very low power applications are eligible for such transmitters. The
SenSmart 2000 Display assembly shown in Figure 2-4 consumes <2.5 mA of quiescent current.
Toxic and oxygen electrochemical sensors generate their own signals and therefore require no
additional current. If a 4-20mA output is all that is required for toxic / oxygen measurements (no
LCD backlight, alarms or RS-485) the SenSmart 2000 may be used in the 2-wire mode.
CAUTION: It is important to understand the receiver, or controller device must supply the loop
power in 2-wire 4-20mA modes. Be sure the receiver to be used supports this type of operation.

Instructions:

Unscrew the cover on the SenSmart 2000 explosion-proof enclosure. Loosen the 2 thumbscrews
holding the display assembly in place and remove it. A small sensor cable is attached with

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sufficient length to allow access to the back of the display assembly where 2 position TB1 is

located. Route the receiver wires through the conduit entry and connect to TB1. Steering diodes
in the SenSmart 2000 2-wire 4-20mA output automatically correct for polarity so positive and
negative are interchangeable. Reassemble the SenSmart 2000. Follow the procedures and
recommendations in the receiver manual to complete the installation. Be sure the SenSmart
2000 enclosure and conduit are properly grounded. Apply loop power by appropriately powering
the receiver device (DCS, PLC, Controller, etc) and the SenSmart 2000 should function. Proceed
to section-3.

Figure 2-4: 10-0232 Display / SenSmart 2000 2-Wire 4-20mA Assembly

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2.7a Installation Drawing # 11-0100

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2.8 3-Wire 4-20mA Mode Installation

CAUTION: SenSmart 3000’s equipped with the 10-0233 I/O Power Supply board only operate as
3 or 4-wire 4-20mA transmitters and are not compatible with 2-wire intrinsically safe installations
(see sections 2.7 and 2.7a). Such units should not be combined with 10-0247IS Sensor Heads
without flame arrestors unless the area is classified as non-hazardous.

SenSmart 3000’s equipped with the 10-0233 I/O Power Supply and 10-0234 Alarms / Modbus
option are NRTL certified as suitable for Div 1 & 2 Groups B,C,D explosion proof installations with
the 10-0247 or with any sensor head with an equivalent CSA certification.

Description:

3-wire sourcing transmitters require an additional dedicated 24 VDC wire. The 4-20mA loop
current is then delivered, or sourced, from the transmitter output and the receiver device must not
provide 24 VDC from its input terminal. When the SenSmart 3000 is equipped with the bottom
10-0233 I/O Power Supply board shown in Figure 2-5, the 2-wire 4-20mA output is disabled and
one of the 10-0233’s 3-wire outputs must be used. TB2 terminal 2 is for ECHEM toxic / oxygen 3­wire 4-20mA output signals and TB2 terminal 3 is for LEL 3-wire 4-20mA output signals.

Instructions:

Unscrew the cover on the SenSmart 3000 explosion-proof enclosure. Loosen the 2 thumbscrews
holding the display assembly in place and remove it. A small ribbon cable is attached with
sufficient length to allow access to the I/O PCB mounted in the bottom of the enclosure (Figure 2-

5). Power and signal connections are to TB2 where 24 VDC, Signal and Common wires must be
connected. A blocking diode protects the SenSmart 3000 if polarity of the power supply is
reversed but it will not operate. Reassemble the SenSmart 3000. Follow the procedures and
recommendations in the receiver and power supply manuals to complete the installation. Be sure
the SenSmart 3000 enclosure and conduit are properly grounded. Apply power and the
SenSmart 3000 should function. Proceed to section-3.

Figure 2-5: 10-0233 I/O Power Supply / 3-Wire 4-20mA Assembly

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SenSmart 3000 User's Manual

7

TB2

TB1

TB3

K2

K3

K1

Remote Alarm Reset

ST-48 Alarm / ModBus Option

Assy: 10-0234

1
C
NC
NO
C
NC
NO
C
NC

Relay 1
(K1)

Relay 2
(K2)

Relay 3
(K3)

2

3

4

5

6

8

9

NO

1
2
3
4
5

P1

J1

U1

A (Installs RS-485 Terminating Resistor)
B (Omits RS-485 Terminating Resistor)

A
B
S
A
B

1

RS-485 ‘A’ & ‘B’ terminals are
connected internally for easier
IN / OUT cabling.
‘S’ is “no connect” for shield
to continue.

Document: UM-1003 Revision Level B

2.9 Alarms / RS-485 Modbus 10-0234 Option Installation

Description:

The optional 10-0234 Alarms/RS-485 Modbus board supplies two level alarm relays, a FAULT
relay and an RS-485 Modbus RTU slave port (Figure 2-6). This board is “piggybacked” behind
the 10-0232 Display Assembly (Figure 2-3). Addition of this option requires 3-wire mode 4-20mA
operation and thereby requires the 10-0233 I/O Power Supply board (Figure 2-5). This is since
relays and RS-485 circuits require much more power than 2-wire 4-20mA loops can deliver.

CAUTION: Alarm relays have dry contacts and power must be supplied from an external source.
Contacts are rated for RESISTIVE loads! Inductive loads, such as contactor coils or motors, may
cause contact arcing, which shortens life and emits RFI into the sensor signals. Use appropriate

arcing snubbers and MOV’s across inductive loads and keep wiring away from signal wires.

External wiring to TB3 (Remote Alarm Reset) should be shielded and protected from noise spikes
to prevent false Alarm Reset.

Figure 2-6: 10-0234 Alarm Relays / Modbus Option

Instructions:

Unscrew the cover on the SenSmart 3000 explosion-proof enclosure. Loosen the two
thumbscrews holding the display assembly in place and remove it. A small ribbon cable is
attached with sufficient length to access the back of the Display assembly where the Alarms/RS­485 Modbus board option is located. It is possible to use only the relays, only RS-485, or use
both. Relay terminals are labeled NO (normally open), NC (normally closed) and C (common or
the pole). These designators correspond to the shelf, or de-energized, state of the relays. The
FAULT relay is always failsafe, meaning it is energized when there is not a fault condition and
therefore its action is reverse of the designators.

RS-485 Modbus networks should be wired as shown in Figure 2-7. Each SenSmart 3000
connected represents an RTU and must have a unique RTU address. RTU addresses are
assigned in the Modbus setup menu described in section 4.10. Cabling must be a “daisy chain”

as opposed to a “star” pattern for reliable operation. The “end of line” unit should have J1
installed in the ‘A’ position for terminating resistor installation. All others should have J1 in the ‘B’

position. Front panel Rx / Tx LEDs are helpful troubleshooting tools.

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SenSmart 3000 User's Manual

U8

TB1

P1

FUSE

Assy: 10-0250

1
2
3
4

­+

­+

Isolated 4-20mA Output Option

1/2A

Document: UM-1003 Revision Level B

Figure 2-7: RS-485 Modbus Wiring

2.10 Isolated 4-20mA Output 10-0250 Option

Description:

The optional 10-0250 Isolated 4-20mA option (Figure 2-8) provides dual 4-20mA outputs that are
electrically isolated from sensor inputs and the 24 VDC power source. Each 4-20mA output
share the same common terminal and are not isolated from each other. This board is
“piggybacked” behind the 10-0232 Display Assembly (Figure 2-3). Addition of this option requires
4-wire mode 4-20mA operation and thereby requires the I/O Power Supply board (Figure 2-5).

Figure 2-8: 10-0250 Isolated 4-20mA Output Option

2.11 Sensor Installation (with Smart / Simple Sensor Definition)

Many manufacturers offer industry standard electrochemical and catalytic bead sensors for toxic /
oxygen and LEL combustible gas detection. These are referred to as Simple sensors in this
manual. The SenSmart 3000 design accommodates users wishing to continue use of their
existing simple sensors by accepting electrochemical types into TB2 of the 10-0232 Display
Assembly or catalytic bead types into TB1 of the 10-0233 I/O Power Supply (mounted to the
bottom of the enclosure). The SenSmart 3000 Smart Sensor interface also uses proven
electrochemical technology for toxic / oxygen and catalytic bead for LEL combustibles BUT has

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SenSmart 3000 User's Manual

SMA R T SE N S OR

T y p e : Ca t - B e a d
Sp a n : 10 0
Z e r o : 0
SN: x x x x x x
Bo r n On : 0 1/ 2 8 / 0 4
L a s t Ca l : 0 4 / 05 / 04
A NY k e y t o Ex i t

ERROR COD E 0 1

I n c o r r e c t Se n s o r
i n s t al l e d . I n s t a l l
c o r r e c t s e n s o r o r
u p d a t e t r a n s mi t t e r .
SE E MANUAL
EDI T k e y t o u p d a t e .
An y o t h e r t o a b o r t .

If installed sensor
type does not match
transmitter database

Document: UM-1003 Revision Level B
taken this technology a step further. A tiny memory IC is incorporated into SenSmart 3000

factory supplied Smart sensors allowing them to contain the entire database of SenSmart 3000
parameters onboard the replaceable Smart Sensor assembly (Figure 2-9). This unique Smart
Sensor Interface may be used to configure smart sensors and / or SenSmart 3000’s from a PC
rather than entering all variables via the magnetic keypad.

Electrochemical and catalytic bead smart sensors both plug into the 10-0247 Smart Sensor
Head that connects to SenSmart 3000 electronics with its 8-conductor Smart Sensor Interface
cable (Figure 2-9).
CAUTION: 10-0247 Smart sensor heads with electrochemical toxic / oxygen sensors must
connect to S1 located on the back of the 10-0232 Display Assembly (Figure 2-4). 10-0247 Smart
sensor heads with catalytic bead combustible sensors must connect to S1 located on the optional
I/O PCB assembly (Figure 2-5).

Figure 2-9: 10-0247 Smart Sensor Head Assembly

Smart Sensors are automatically recognized by the SenSmart 3000. The Smart Sensor
identification screen in Figure 2-10 is shown after power-up, upon installation of a new smart
sensor or by viewing INPUT type in the SENSOR SETTINGS / INFO menu (section 5-5).

Figure 2-10: Smart Sensor Info / ERROR Screens

2.12 “Sensor Type” and SenSmart 3000 Signal Conditioning

Catalytic bead and electrochemical sensors obviously have different signal conditioning
requirements. In addition, same sensor types have different response coefficients, signal
strength and gain and offset requirements. The block / wiring diagram in Figure 2-11 illustrates
how SenSmart 3000’s are able to accept many sensor types without the need of manual
potentiometers or jumpers. Smart Sensors carry this setup information with each sensor.

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Figure 2-11: SenSmart 3000 Block / Wiring Diagram

SECTION 3 – INITIAL START-UP

3.1 “Transmitter Configuration” Menu

Figure 3-1shows the SenSmart 3000 XMITTER CONFIG menu used to activate channels,
precisely calibrate 4-20mA outputs and set time / date. Its menus are set at the factory and
typically not needed by the user. To access from any data display, press and hold the NEXT key
for 5-seconds until the screen appears requesting a special key sequence (4-UP keystrokes).

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SenSmart 3000 User's Manual

XMI T T E R CONF I G

O2 / T OXI C ON
L E L / CURRE NT ON
Ou t p u t Z e r o
Ou t p u t Sp a n
Re a l T i me Cl o c k
Mo d e l S T - 4 8
Ba c k L i g h t ON

>
>
>

En t e r Ke y S e q u e n c e
t o a c c e s s me n u .
* * * *
NE X T k e y t o Ex i t .

Se e Ma n u a l / HE L P

PRESS
UP KEY
4-TIMES

HOLD
NEXT KEY
5-SECONDS

Document: UM-1003 Revision Level B

Figure 3-1: Transmitter Configuration Menu

3.1.1 Single / Dual Gas Monitor Configuration

SenSmart 2000’s are 2-wire 4-20mA devices and support only one electrochemical sensor.
Addition of the 10-0233 Power Supply board (SenSmart 3000LEL) automatically adds the
catalytic bead sensor input and dual 4-20mA outputs. If both the O2/TOXIC and LEL/Current
menu items are ON, the SenSmart 3000 will function as a dual gas monitor with both sensor
inputs and 4-20mA outputs active. Either input may be turned off for single gas EC or LEL
monitors.

3.1.2 Output Zero / Output Span Trims (Factory Preset, Technicians only!):

The Output Zero Trim / Output Span Trim entries are digital to analog (D2A) values that
determine the SenSmart 3000’s final 4-20mA output. Their purpose is to provide precise
SenSmart 3000 4mA and 20mA outputs. To trim these values, attach a precision milliamp meter
to the SenSmart 3000 4-20mA output being used. Enter the correct OUTPUT ZERO TRIM menu
shown in Figure 3-2. Use the UP/DOWN keys to trim the milliamp value to 4.00mA. Next, enter
the correct OUTPUT SPAN TRIM menu and use the UP/DOWN keys to trim the milliamp value to

20.00mA. Press the NEXT key to exit this menu. The SenSmart 3000 stores these new D2A
values and uses them as the 0 & 100% of full-scale endpoints.

WARNING: Target gas monitoring and alarm processing are halted during these adjustments.

Figure 3-2: Output ZERO / SPAN Trim Menus

3.1.3 Model Name

When power is applied to the SenSmart 3000 it will briefly show a 10 digit ASCII model name or
company name as it starts up. The name can be edited in the Transmitter Configuration menu by
editing the Model field.

3.1.4 Real Time Clock

Adjust the date and time here for use in EVENT LOGGING. This is a factory setting but may
need to be adjusted for the end users location.

3.1.5 Backlight

During high power mode this menu allows the user to turn the backlight off. There are three
settings ON, OFF and TIMED. During TIMED mode the backlight will turn on when a key is hit,

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during calibration process and when an alarm is present. It will stay on for 15 seconds after any

of these events clear.

3.2 Initial Bridge Sensor Monitor Start-Up

SenSmart 3000 LEL Monitors that are factory equipped with a local Simple or Smart Bridge
sensor rarely require adjustments, other than routine calibrations, to provide accurate LEL
readings. However, after installation the following checks should be performed to insure proper
operation. In addition, alarm levels, Measurement Name ASCII fields and other variables may
require configuration by users in order to best serve their application.

3.2.1 Initial Bridge Sensor Monitor “Sensor Volts” Check

CAUTION: Sensor Volts in excess of the rated values may destroy catalytic bead sensors.
SenSmart 3000 sensors are rated for 2 volts.

Section 6.2 describes reading and setting “sensor volts” using the SenSmart 3000 LCD. The
voltage displayed on the LCD is monitored across TB1-REF and TB1-ACT on the SenSmart 3000
Power Supply board (Figure 2.4) and may be confirmed with a voltmeter. This TB-1 value is
correct for locally mounted sensors only. Sensors mounted more than a few feet away from the
SenSmart 3000 may receive a lower voltage due to the inherent voltage drop across sensor
wiring. Remote mounted sensors must have their sensor voltage (across ACTIVE and
REFERENCE beads) measured AT THE SENSOR end of the cable. The SenSmart 3000 setting
will require a higher value in order to achieve the correct voltage at the sensor. Correct sensor
voltage should be confirmed after start-up for locally and remotely mounted catalytic bead
sensors.

3.2.2 Initial Bridge Sensor Monitor “Balance” Check

Catalytic bead sensors connect to a bridge circuit that may require a balance adjustment after
installation especially when the sensor is remote mounted from the SenSmart 3000. Section 6.2
describes using the LCD to read and adjust BALANCE settings. Correct BALANCE setting should
be confirmed after start-up for locally and remotely mounted catalytic bead sensors.

3.2.3 Initial Bridge Sensor Monitor “Span” Check

Prior to the initial Routine Sensor Calibration described in section 4.1, a coarse SPAN gas
reading verification should be performed after installation. After correct Sensor Volts and
BALANCE have been verified, apply an upscale gas value such as 50% LEL to the sensor. The
indicated value should read between 35 and 65% LEL with 50% LEL gas applied. Larger errors
may indicate incorrect sensor wiring or defective sensor. Remember that this is only a coarse
check and precision calibrations are performed in Routine Sensor Calibrations described in the
following section 4.1. Section 6.4 describes PREAMP GAIN adjustments that may be required if
full-scale ranges are changed.

3.3 Initial Toxic / Oxygen Sensor Monitor Start-Up

SenSmart 3000 Toxic / Oxygen Monitors, factory equipped with a local Simple or Smart
electrochemical sensor, rarely require adjustments (other than routine calibrations) to provide
accurate readings. However, after installation the following checks should be performed to insure
proper operation. In addition, alarm levels, Measurement Name ASCII fields and other variables
may require attention by users in order to best serve their application.

3.3.1 Initial Toxic / Oxygen Sensor Monitor “Span” Check

Prior to the initial Routine Sensor Calibration described in section 4.1, a coarse SPAN gas
reading verification should be performed after installation. Apply an upscale gas value of at least
25% of full scale to the sensor. For example, if 0-100ppm H2S is the measurement range, apply

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at least 25ppm but not more than 100ppm. The indicated value should read within 15% of full

scale. Remember that this is only a coarse check and precision calibrations are performed in
Routine Sensor Calibrations described in the following section 4.1. Section 6.4 describes
PREAMP GAIN adjustments that may be required if full-scale ranges are changed.

SECTION 4 – OPERATING INSTRUCTIONS

4.1 Routine Sensor Calibrations

Caution: For calibration of R.C. Systems Inc. Millenium sensors refer to Section 8 for calibration
procedures. A Zero calibration of the sensor is the only calibration that is required. The
transmitter is factory calibrated and does not require routine calibration when using the Millenium
sensor.

Calibration is the most important function for insuring correct operation of the SenSmart 3000.
The CAL MODE (flow chart shown in Figure 4-2) is designed to make calibration quick, easy and
error free. A successful ZERO and SPAN calibration requires only four keystrokes. The 4-20mA
output indicates CAL MODE by transmitting 3mA for 2-wire installations and 1.5mA for 3-wire
installations. It then transmits 4mA during the subsequent CAL PURGE delay to prevent external
alarms during calibration. Local SenSmart 3000 alarm relays (if equipped) are inhibited during
CAL MODE. CAL MODE automatically exits if no keystrokes are detected after 5 minutes.

Follow these SenSmart 3000 calibration guidelines:

 Calibration accuracy is only as good as the calibration gas accuracy. R. C. Systems

recommends calibration gases with NIST (National Institute of Standards and
Technology) traceable accuracy to increase the validity of the calibration.

 Do not use a gas cylinder beyond its expiration date.
 Calibrate a new sensor before use.
 Allow the sensor to stabilize before starting calibration (approximately 5 minutes).
 Calibrate on a regular schedule. (R. C. Systems recommends once every 3 months,

depending on use and sensor exposure to poisons and contaminants.)

 Calibrate only in a clean atmosphere, which is free of background gas.

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Figure 4-1: Calibration Gas Input

Use the following step-by-step procedure to perform ZERO and SPAN calibrations.

1. To enter the CAL MODE from either data display, press the DOWN / CAL key and within
5 seconds press the EDIT key.

2. Using the Cal-Cup, apply a clean ZERO gas or be sure there is no background target gas
in the monitored area. After the reading is stable, (approximately 1 minute) press the
EDIT key to perform a ZERO calibration.

3. If the ZERO calibration is successful, press the NEXT key to proceed to the SPAN check.

4. Apply the correct SPAN gas at .5 liters/min. After the reading is stable, (approximately 1
minute) press the EDIT key to perform a SPAN calibration.
WARNING: The SPAN gas used must match the value specified since this is what the
SenSmart 3000 will indicate after a successful SPAN calibration. The Cal Span Value
may be edited if it becomes necessary to apply a different gas concentration (see Cal
Span Value in section 5.3).

5. If the SPAN calibration is successful, the display flashes “REMOVE CAL GAS” and starts
the CAL PURGE delay.

6. CAL MODE will be complete after the end of the CAL PURGE delay.

The flow chart in Figure 4-2 illustrates the above procedure. UP, CAL, NEXT & EDIT labels
indicate keystrokes using the magnetic wand. The CAL MODE information screen (top of the
chart) is available for advanced users to see Offset / Gain calibration constants and live analog to
digital converter (A/D) counts. Span Gas calibration values may also be edited from this screen.
Holding the UP key, for 5 seconds during CAL MODE, displays this screen.

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Calibration history records are logged and may be viewed in the Sensor Information menu (see

section 5-5).

Figure 4-2: Cal-Mode Flow Chart and Menus

4.2 ALARM OPERATION

SenSmart 3000’s have front panel LED indicators for Alarm 1, Alarm 2 and Alarm 3. An optional
10-0234 Relay/Modbus board adds K1, K2 & K3 relays for these alarms.
CAUTION: SenSmart 3000 Alarm LED indicators function even without the presence of the 10­0234 Relay option. With 2-Wire 4-20mA operation, to conserve power, alarm LED’s only flash
during alarm events. With 3-Wire 4-20mA operation, alarm LED’s flash when new, and become
steady after an operator ACKNOWLEDGE - pressing the UP/RESET key.

4.2.1 ALARM 3 – UNDERSTANDING FAULT / LEVEL OPERATION

The “A3” alarm is typically dedicated to FAULT conditions indicating sensor failures or “out of

measurement range” conditions. However, some applications require a third level alarm. The A3

menu is identical to A1 & A2 and may be set to trip at an upscale level value. A3 WILL ALSO
TRIP WITH MISSING OR FAILED SENSORS REGARDLESS OF THE LEVEL VALUE!
CAUTION: Missing or failed sensors always trip Alarm 3 and relay K3 (if equipped). This is true
even with A3 configured as a level alarm and it must be accepted that A3 level alarm events
might be caused by the monitored level, or, by a missing or failed sensor.

SECTION 5 – SETUP MENU CONFIGURATION

5.1 Menus Database Configuration

All SenSmart 3000 configuration variables are stored in its menu database. Many menu items will

contain default values from the factory and require changes to better match a user’s particular

application. SenSmart 3000 menus may be configured from the magnetic keypad in 5-10
minutes per transmitter. For installations consisting of numerous points, an interface device is
offered to allow Smart sensors and SenSmart 3000’s be configured from a PC’s USB port. This
is useful when SenSmart 3000’s are not yet installed or if a portable computer may be carried to
each unit.

The SenSmart 3000’s configuration menus are shown in Figure 5-1.

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5.2 Configuration Using the Magnetic Wand:

Passing the magnetic wand past the EDIT key, from either data display, displays SETUP PAGE 1
as shown in Figure 5-2. The UP / DOWN keys maneuver the pointer while EDIT enters sub­levels of menu items. All SETUP menu items have at least one page of sub-menus. Items with
sub-menus are indicated by the > symbol (right hand pointing arrow) at the end of each line. Edit
menu items by pointing to them, press the EDIT key to display the cursor, press UP / DOWN to
change that character, press NEXT to move the cursor, then press EDIT again to load the new
item and remove the cursor. Press NEXT to reverse out of the sub-menu. To view SETUP
PAGE 2, press the DOWN key with the pointer aimed at the bottom item on PAGE 1.

Figure 5-1: Configuration Menu Tree

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SenSmart 3000 User's Manual

L E L I NP UT 2

L CD Co n t r a s t Ad j .
Mo d b u s RS4 8 5 Po r t
Se c u r i t y
T e c h n i c i a n s ONL Y

Se n s o r T e mp

F i r mwa r e Re v .

>
>
>
>

>

“Sensor Temp” menu only present
with “Arctic” smart sensor installed.
See section 7.1.

EDIT

L E L I NP UT 1
Sy s t e m Co n f i g .
Al a r m S e t t i n g s
Se n s o r I n f o r ma t i o n
Cl o c k / De l a y s
Di a g n o s t i c s
HE L P

>
>
>

>

>

>

(Instructions)

SY S T E M CONF I G. P G 1

Me a s u r e me n t Na me -

16

Eu n i t s X X XXX X XXX X-

10

Z e r o (0 %)

(Eunits)

Sp a n ( 10 0 %)

(Eunits)

De c i ma l P o i n t s 0
Ca l S p a n V a l 5 0

UP/
DOWN

SY S T E M CONF I G. P G 2

*Simple Sensor Installed **Smart Sensor Installed

>
>
>

*“Restore” available only
without smart sensor installed.

**“Upload” available only
with smart sensor installed.

Re a d o u t De a d b a n d 0 %
T r a c k Ne g a t i v e NO
T e mp Co mp e n s a t i on
Ba c k u p Co n f i g .
*

Re s t o r e

or **

Up l o a d
Ca l Ma r k e r 3 . 0 0 mA
T X S e n s o r L i f e NO

Document: UM-1003 Revision Level B

Figure 5-2: Setup Menu Entry

5.3 System Configuration Menus:

The System Config. group consists of two pages of menus as shown in Figure 5-3. Each item’s
description follows in this section.

Measurement Name may be edited to contain virtually any 16-character ASCII field. It is

typically used to describe the monitored point by user tag # or other familiar terminology.

Eunits (engineering units) may have up to a 10 character ASCII field. Many common gases

have pre-configured Eunits based upon the sensor type and each may be edited in this menu as
described in Configuration Using the Magnetic Wand section 5-2.

Zero (0%) defines the reading to be displayed when 4mA (0%) is the SenSmart 3000 output.
Span (100%) defines the reading to be displayed when 20mA (100%) is the SenSmart 3000

output. The highest reading allowed is 9999 includes negative polarity sign and one decimal
point. Polarity is only indicated for negative readings.

Decimal Points sets the resolution of the LCD readings and may be for 0, 1 or 2. Example:

ZERO readings for 0, 1 & 2 DP’s respectively are 0, 0.0 & 0.00.

Cal Span Value sets what upscale value must be applied when performing Span calibrations.
Readout Deadband allows forcing low values to continue to read zero. This is useful when

there are small amounts of background gases that cause fluctuating readouts above zero. The

highest amount of deadband allowed is 5%. The 4-20mA output is not affected by this menu
item.

Track Negative, set to NO, causes negative values to read the Zero (0%) value in data

displays. The CAL MODE readout displays negative values regardless of this setting and

Figure 5-3: System Config. Menus

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SenSmart 3000 User's Manual

COMPE NSA T I ON

T E MP - 4 0 . 0 C
GA I N 1. 0 0 0
% o f f s e t 0 . 0 0 0

En t e r Ke y S e q u e n c e
t o a c c e s s me n u .
* * * *
NE X T k e y t o Ex i t .

Se e Ma n u a l / HE L P

PRESS
UP KEY
4-TIMES

Document: UM-1003 Revision Level B
negative values below the Fault set point will still cause the Fault alarm to trip. The 4-20mA

output always locks at 4mA when the reading is negative.

Temp Compensation allows user to adjust the gain and offset that is applied to sensors to

compensate for temperature drift. Factory supplied sensors are preprogrammed with these
values are automatically uploaded to the SenSmart 3000 from the smart sensor. The default
values are 1.000 for gain and 0.000 for offset. With these default values entered there is no extra
gain or offset applied to the sensor. This menu is not accessible unless a smart sensor that is
equipped with the temperature sensor is installed. From the menu pictured in Figure 5-4 enter
the gain and offset that will be applied into the SenSmart 3000. The gain is applied to the span
value. This number is multiplied to the preamp gain value that is set prior to the initial calibration
for each of the specified temperatures (-40°C - 60°C in 10° increments). Offset is the needed
adjustment to make the sensor read zero at the different temperatures. To prevent accidental
data entry a special keystroke sequence, of 4 consecutive UP keys, is required to enter this
menu.

Figure 5-4: Temperature Compensation Menu

Backup Config. allows users to store the entire current SenSmart 3000 menu database into

non-volatile memory for restoration later if incorrect values are accidentally entered or uploaded.

Restore Config. restores the SenSmart 3000 menu database to the values from the most

recent Backup Config. This menu item is only available if a smart sensor is not installed. The
special keystroke sequence of 4 consecutive UP keys is also required to perform backup and
restore operations.

Upload Sensor Data allows manually uploading the entire smart sensor database to the

SenSmart 3000 from the smart sensor.

Cal Marker allows setting the 4-20mA output value during ZERO and SPAN calibrations at a

level to prevent alarm trips by calibration values. 3-Wire models may be set from 0 to 20mA.
Quiescent current of 2-wire models limits this setting to 3 to 20mA.

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AL ARM S E T T I NGS

Al a r m 1
Al a r m 2
Al a r m 3/ F a i l
Re l a y s Co n f i g .
Al a r m Ev e n t L o g

AL A RM x S E T UP

Se t P o i n t 2 0
De a d - Ba n d 1%
ON D e l a y 0s
OF F D e l a y 0 m
L o w T r i p NO
L a t c h i n g N O

Alarm 1, 2, 3 menus
are identical

>
>
>
>
>

RE L A Y C ONF I G

K1 F a i l s a f e NO
K2 F a i l s a f e N O
K2 A c k n o w l e d g e N O
K2 Re f r e s h Of f

* K3 a l wa y s F a i l s a f e *

EV E N T L OG

Di s p l a y E v e n t L o g
Cl e a r Ev e n t Lo g

0 8 / 12 / 0 4 0 3 : 17 A 1 I N
0 8 / 12 / 0 4 0 3 : 5 1 A 2 IN
0 8 / 12 / 0 4 0 3 : 5 5 A CK
0 8 / 12 / 0 4 0 4 : 16 A 2 O UT
0 8 / 12 / 0 4 0 4 : 2 3 A 1O UT
0 8 / 12 / 0 4 15 : 0 0 A 1 I N
0 8 / 12 / 0 4 16 : 4 3 A 1OU T
0 8 / 13 / 0 4 0 2 : 0 8 A 3 I N

Edit

0 8 / 13 / 0 4 02 : 18 A3 OU T

- - - E N D OF L OG - - -

Down

Document: UM-1003 Revision Level B

TX Sensor Life set for YES, causes the SenSmart 3000 4-20mA output to transmit a sensor

life value after successful calibrations during the CAL PURGE delay (see section 4.1). Normal
operation is the SenSmart 3000 transmits 4mA during the CAL PURGE delay. But with TX
Sensor Life = YES it transmits 4mA for the first 10-seconds, then for 5-seconds transmits a value
between 4mA and 5mA, with 4mA equal to 0% sensor life and 5mA equal to 100% sensor life
(see Figure 5-5). The output then returns to 4mA for the remainder of the CAL PURGE delay.
For example, if after a calibration sensor life is 75%, the SenSmart 3000 transmits 4.75mA during
the 5-second interval.
Note: TX Sensor Life should always be set for NO unless the 4-20mA receiver is capable of
interpreting the sensor life signal. The R. C. Systems ST-71 Controller is capable of this function.

Figure 5-5: Transmit Sensor Life Timing Diagram

5.4 Alarm Settings:

The Alarm Settings page has the Alarm 1, 2, 3 Setups, Relays and Event Log submenus
shown in Figure 5-6. Alarm 1, Alarm 2 and Alarm 3/Fail menus are identical and therefore
described only once in this section.
IMPORTANT: Alarm functions and their associated LED’s are active without the 10-0234 Relay /
Modbus option installed.

Figure 5-6: Alarm Settings Menus

Set Point enters the engineering unit value where the alarm trips. It may be negative and trip

when monitored values fall out of range in this direction. A3 has a default setting of negative 10
with Low Trip set for YES. This makes it function as a FAULT alarm and trip when the monitored
value falls to less than negative 10. It is important to adjust this value when the transmitter’s span
value is set for another value other than 100. For example, a typical span setting for monitoring
oxygen level is 25 therefore the fault level value should be adjusted to -2.5 which is equal to
negative 10% of full scale.

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RE L A Y CON F I G

K1 F a i l s a f e NO
K2 F a i l s a f e NO
K2 A c k n o wl e d g e NO
K2 R e f r e s h Of f

* K3 a l wa y s F a i l s a f e *

Document: UM-1003 Revision Level B
Dead-Band has a minimum value of 1% and a maximum value of 10%. It is useful for preventing

alarm cycling when the monitored value is hovering around the set point. EXAMPLE: With a
range of 0-100 ppm, if Dead-Band equals 5% and the set point is 20 ppm, after tripping at 20 ppm
the value must drop below 15 ppm to reset.

ON Delay allows entering a maximum 10 second delay before this alarm becomes active. This is
useful for preventing nuisance alarms caused by brief spikes beyond the set point.

OFF Delay allows entering a maximum 120 minute delay before clearing an alarm after the alarm
condition is gone. This is useful for continuing an alarm function, such as operation of an exhaust
fan, for a period of time after the alarm condition clears.

Low Trip set to YES causes the alarm to trip as the value falls below the set point.
Latching set to YES causes the alarm to remain active even after the condition is gone and only

reset when the UP / RESET key is pressed from a data display.

5.4.1 Relay Configuration (if equipped):

Relay Config has the submenu shown in Figure 5-7. The optional relay PCB must be installed to

access this menu or a “HARDWARE NOT PRESENT” message appears.

Figure 5-7: Relay Config. Menu

K1 / K2 Failsafe set for YES means the relay de-energizes during alarm and energizes with no

alarm. This is useful for also signaling alarm when SenSmart 3000 power is lost. K3 is a FAULT
alarm and is always failsafe.

K2 Acknowledge set for YES means the UP / RESET key (RESET key during either data
display) will set K2 to the normal state EVEN when an Alarm 2 condition exists. This is useful for
silencing an audible device, driven from K2, during the alarm condition.

K2 Refresh set for ON causes an acknowledged Alarm 2 condition to reactivate K2 if it continues
beyond the designated Refresh interval (0-99 minutes). This feature insures against “forgotten”
alarms after an Acknowledge.

5.5 Sensor Information:

Sensor Information has the SENSOR SETUP/INFO menus shown in Figure 5-8

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SenSmart 3000 User's Manual

SE N S OR S E T T I NGS / I NF O

I n s t a l l S e n s o r
Re c a l l Ca l Hi s t o r y
I n p u t T y p e SMA R T
Ne w Se n s o r 0 1/ 2 8 / 0 4
Re c e n t C a l 0 4 / 0 5 / 0 4

>
>

I NST A L L N E W S E N S OR
EDI T t o i n s t a l l

Ne w Se n s o r .
An y o t h e r k e y

t o E x i t .

CA L I B RA T I ON D A T E S

Re c o r d 2 2 o f 2 2
CA L Da t e : 0 4 / 0 5 / 0 4

UP / D OWN t o s c r o l l
NE X T t o EX I T .

I NS T A L L N E W S E N S OR

Hi s t o r i c a l C A L d a t a
Wi l l b e D e l e t e d .

EDI T t o Ac c e p t
NE X T t o Ab o r t

EDIT

EDIT

S e n s o r L i f e

>

SMA RT S E N S OR

T y p e : Ca t - B e a d
Sp a n : 10 0
Z e r o : 0
SN : x x x x x x
Bo r n On : 0 1/ 2 8 / 0 4
L a s t C a l : 0 4 / 0 5 / 0 4
ANY k e y t o Ex i t

CL OCK / DE L A Y SE T U P

T i me 12 : 3 5 : 4 2
Da t e 0 4 / 2 2 / 0 4
Wa r m Up Se c 12 0
Ca l Pu r g e Se c 10 0

Document: UM-1003 Revision Level B

Figure 5-8: Sensor Information Menus

Install New Sensor should always be performed when a new simple sensor is installed. This

deletes historical CAL data and sets sensor life to 100% after initial calibration of the new simple
sensor. The SenSmart 3000 Smart sensor interface will automatically detect new smart sensors
and this menu is therefore not available with a smart sensor connected.

Recall Cal History recalls each successful calibration. These dates may be reviewed by
scrolling with the UP / DOWN keys.

Input Type indicates what kind of input or sensor the SenSmart 3000 is configured to accept and
is typically pre-configured at the factory. There are five Input Type possibilities consisting of
bridge, EC negative, EC positive, 4-20mA and Smart. Smart sensors upload sensor type and
other data to the SenSmart 3000 and may be viewed on the SMART SENSOR information
screen.

New Sensor displays the date when a new sensor was last installed.
Recent Cal displays the most recent calibration date.

5.6 CLOCK/DELAY SETUP:

Since the SenSmart 3000 is equipped with a Real Time Clock & Calendar Time and Date must
be set to correctly match its location. They are set at the factory in a 24 hour format but may

require adjustment to match the location’s time & date after shipment. Follow the procedure in

Configuration Using the Magnetic Wand in section 3.3.

5-9 shows the menu for these items.

Warm Up and Cal Purge time delays are also available to prevent unwanted alarm trips. Figure

Figure 5-9: Clock & Calendar / Delay Timer Menu

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SenSmart 3000 User's Manual

CON T R A S T

UP / DOWN t o c h a n g e

NEX T t o EX I T

* * * WARNI N G * * *

Al a r m p r o c e s s i n g wi l l

b e h a l t e d d u r i n g

d i a g n o s t i c mo d e !

EDI T t o c o n t i n u e .

An y o t h e r k e y t o e x i t .

DI A GN OS T I CS

Ou t p u t St i mu l a t i o n
Re l a y T e s t

OU T P UT ST I MU L AT OR

Ou t p u t 4 . 0 mA
EDI T t o c h a n g e .

Ne x t t o e x i t .

EDIT

AC T I V A T E RE L A Y S

Re l a y 1 OF F
Re l a y 2 OF F
Re l a y 3 OF F

Document: UM-1003 Revision Level B

5.7 LCD Contrast Adj:

LCD Contrast Adj. may be set for optimum viewing using the menu shown in Figure 5-10.

Figure 5-10: LCD Contrast Adjust Menu

5.8 HELP Screen:

The HELP screen contains several pages of information describing how to operate the SenSmart

3000. This is the bottom menu on page 1 of the SETUP screen.

5.9 Diagnostics:

IMPORTANT: Gas monitoring and alarm processing are not performed while using the
Diagnostics menus. Access requires a special key sequence of four consecutive UP
keystrokes.

There are two Diagnostics menus useful for driving outputs without exposing the sensor to the
target gas. The OUTPUT SIMULATION menu allows setting the 4-20mA output to virtually any
desired value. This is useful for checking responses of devices receiving the SenSmart 3000’s 4­20mA output. The ACTIVATE RELAYS menu allows tripping of alarm relays (if equipped)
without tripping alarm set-points with the target gas. This is useful for testing alarms events such
as lights and audible devices.

5.10 RS-485 / MODBUS SETUP:

The RS-485 MODBUS SETUP menu allows setting the RTU address (if RS-485 equipped) for
each SenSmart 3000 on the RS-485 network. Each SenSmart 3000 must have a different RTU
address when communicating on the same 2-wire RS-485 cable. The factory default Baud rate is
9600 but can be adjusted to 1200, 2400, 4800 and 19200. Parity and Stop Bit are fixed at
industry standard values of none and 1.

Note: If “Marker TX LED” (see section 6.8) is selected RS-485 MODBUS SETUP menu is not
available, because the serial port is no longer active.

Figure 5-11: Diagnostics Menus

25

SenSmart 3000 User's Manual

RS4 8 5 MODB US SE T U P

RT U Ad d r e s s 1
Ba u d Ra t e 9 6 0 0
Pa r i t y No n e
St o p Bi t 1

Document: UM-1003 Revision Level B

Figure 5-12: Modbus RS-485 Setup Menu

5.10.1 MODBUS REGISTER AND FUNCTION CODE SUMMARY

The following table identifies SenSmart 3000 Modbus register locations and function codes.
“Chan 1” designations represent the EC channel while “Chan 2” represent the LEL / 4-20mA Input
channel.

VARIABLE ALIAS READ FUNCTION CODE WRITE FUNCTION CODE

Read Only Discretes:

Chan 1 Alarm 1 2001 2 NA
Chan 1 Alarm 2 2002 2 NA
Chan 1 Fault 2003 2 NA
Chan 2 Alarm 1 2004 2 NA
Chan 2 Alarm 2 2005 2 NA
Chan 2 Fault 2006 2 NA
K1 2007 2 NA
K2 2008 2 NA
K3 2009 2 NA
Chan 1 Cal Mode 2010 2
NA
Chan 2 Cal Mode 2011 2
NA

Read/Write Coils:

Alarm Ack/Reset 12001 1
5

Note: After writing a TRUE to this register, it resets back to FALSE automatically.
Read Only Registers:

D2A Raw Chan 1 31001 4
NA
D2A Raw Chan 2 31002 4
NA
Calibrated 10 bit value representing the D2A value of 0 to 1023 for -25 to 105 %FS (200=0% &
1000=100%).

IMPORTANT: READ REGISTERS 31001 / 31002 TO CREATE READINGS THAT MATCH
SenSmart 3000 DISPLAY VALUES! THESE SHOULD ALSO BE READ BY ST-71 MODBUS
MASTERS.

A2D Raw Chan 1 31003 4
NA
A2D Raw Chan 2 31004 4
NA
10 bit value representing the A2D value of 0 to 1023 before calibration constants are applied.

Chan 1 Status 31005 4 NA
Chan 2 Status 31006 4 NA

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SenSmart 3000 User's Manual

Document: UM-1003 Revision Level B
(16 bit status words; bit assignment for each channel)

ALARM1_BELOW BIT0
ALARM2_BELOW BIT1
ALARM3_BELOW BIT2
ALARM1_LATCH BIT3
ALARM2_LATCH BIT4
ALARM3_LATCH BIT5
ALARM3_ACTIVE BIT6
CHANNEL_DISABLED BIT7
CHANNEL_CAL BIT8
CHANNEL_LINEARIZE BIT9
FAULT_RELAY_LATCH BIT10
DISPLAY_NEGATIVE BIT11
TRANSMIT SENSOR LIFE ENABLED BIT12

Alarm Status Word 31007 4 NA
(16 bit status word; bit assignment for system status)

CH1_ALM1 BIT0
CH1_ALM2 BIT1
CH1_FAULT BIT2
CH2_ALAM1 BIT4
CH2_ALM2 BIT5
CH2_FAULT BIT6
K1_STATUS BIT8
K2_STATUS BIT9
K3_STATUS BIT10

Transmitter Status Word 31008 4
NA
(16 bit status word; bit assignment for system status)

CHAN_1_ACTIVE BIT0
CHAN_2_ACTIVE BIT1
SECURE_LEVEL BIT2
MARKER Tx LED BIT3
K1_FAILSAFE BIT12
K2_FAILSAFE BIT13
K2_ACK BIT14
LOCK BIT15

Chan 1 Sensor Life 31009 4 NA
Chan 2 Sensor Life 31010 4 NA
(16 bit signed integer ranging from –1 to 100 where -1 indicates Cal Required)

Chan 1 Sensor Temperature 31011 4 NA
Chan 2 Sensor Temperature 31012 4 NA
(16 bit integer ranging from 1 to 4095 scaled for –55 to +125 degrees C)

Memory Floating Point:
Note: Returned as 15bit plus sign 2s complement with +/- 5% over/under range applied.

Consider over/under range when scaling values to be displayed at the workstation. The following
equation may be used to determine a value for display.

Display Value =
.05]}

MODBUS Value [ (Span Value -Zero Value) 1.1]

FP Value Chan 1 33001 4
NA
FP Value Chan 2 33002 4
NA

+ {Zero Value - [(Span Value - Zero Value)

32767

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SenSmart 3000 User's Manual

Document: UM-1003 Revision Level B

Memory ASCII Strings:

User Info Chan 1 40401-40408 3
NA
User Info Chan 2 40409-40416 3
NA
16 ASCII characters (2 per register) assigned to the unit identifier read as bytes.

Chan 1 ASCII Reading 40417-40419 3 NA
Chan 2 ASCII Reading 40420-40422 3 NA
6 ASCII characters (2 per register) reflecting the display readout.

EUNITS Chan 1 40423-40427 3 NA
EUNITS Chan 2 40428-40432 3 NA
10 ASCII characters (2 per register) assigned to the engineering units read as bytes.

Byte Variables:

PreAmp/Gain Ch1 40433 3 NA
PreAmp/Gain Ch2 40434 3 NA
2 bytes representing Pre Amp (HiByte) and PGA (LoByte) settings.

Firmware Version:

Version 40435-40436 3 NA
4 ASCII characters (2 per register) reflecting the firmware version.

Memory Reals:
Note: Real value represents float value without the decimal point such as 123.4 is returned as

1234. Decimal Divisor is returned as 1, 10, 100, or 1000 for decimal position of 1, 2, 3, or 4,
where 123.4 would return the value 10.

Chan 1 Cal Zero Real 41001 3 NA
Chan 1 Cal Zero Divisor 41002 3 NA
Chan 1 Cal Span Real 41003 3 NA
Chan 1 Cal Span Divisor 41004 3 NA
Chan 1 Zero Real 41005 3 NA
Chan 1 Zero Divisor 41006 3 NA
Chan 1 Span Real 41007 3 NA
Chan 1 Span Divisor 41008 3 NA
Chan 1 Fault Real 41009 3 NA
Chan 1 Fault Divisor 41010 3 NA
Chan 1 Alarm 1 Real 41011 3 NA
Chan 1 Alarm 1 Divisor 41012 3 NA
Chan 1 Alarm 2 Real 41013 3 NA
Chan 1 Alarm 2 Divisor 41014 3 NA
Chan 1 Alarm 3 Real 41015 3 NA
Chan 1 Alarm 3 Divisor 41016 3 NA
Chan 1 Manual Gain Real 41017 3 NA
Chan 1 Manual Gain Divisor 41018 3 NA
Chan 1 Manual Offset Real 41019 3 NA
Chan 1 Manual Offset Divisor 41020 3 NA

Chan 2 Cal Zero Real 41021 3 NA
Chan 2 Cal Zero Divisor 41022 3 NA
Chan 2 Cal Span Real 41023 3 NA
Chan 2 Cal Span Divisor 41024 3 NA

28

SenSmart 3000 User's Manual

SY ST E M SE C U R I T Y

Co n t a c t N a me
Se c u r e L e v e l L OW
Pa s s Co d e

Un l o c k e d

Document: UM-1003 Revision Level B

Chan 2 Zero Real 41025 3 NA
Chan 2 Zero Divisor 41026 3 NA
Chan 2 Span Real 41027 3 NA
Chan 2 Span Divisor 41028 3 NA
Chan 2 Fault Real 41029 3 NA
Chan 2 Fault Divisor 41030 3 NA
Chan 2 Alarm 1 Real 41031 3 NA
Chan 2 Alarm 1 Divisor 41032 3 NA
Chan 2 Alarm 2 Real 41033 3 NA
Chan 2 Alarm 2 Divisor 41034 3 NA
Chan 2 Alarm 3 Real 41035 3 NA
Chan 2 Alarm 3 Divisor 41036 3 NA
Chan 2 Manual Gain Real 41037 3 NA
Chan 2 Manual Gain Divisor 41038 3 NA
Chan 2 Manual Offset Real 41039 3 NA
Chan 2 Manual Offset Divisor 41040 3 NA

Binary Cal Data:

Chan 1 A2D MIN 41041 3 NA
Chan 1 A2D MAX 41042 3 NA
Chan 1 D2A MIN 41043 3 NA
Chan 1 D2A MAX 41044 3 NA
Chan 2 A2D MIN 41045 3 NA
Chan 2 A2D MAX 41046 3 NA
Chan 2 D2A MIN 41047 3 NA
Chan 2 D2A MAX 41048 3 NA
Min and Max calibration points for the A/D and D/A converters.

5.11 SYSTEM SECURITY:

The SYSTEM SECURITY menu offers two levels of protection. A LOW level allows CAL MODE
sensor calibrations but requires the 4-digit Pass Code prior to altering menus. HIGH level locks
the entire menu database and the CAL Mode until the correct Pass Code is entered. LOW and

HIGH security levels always allow viewing of configuration menus but they may not be changed.
Contact Name is a 12 character ASCII field available for displaying a phone # or name of

personal who know the Pass Code. Lost Pass Codes may be recovered by entering the locked
security menu and holding the UP key for 5 seconds. The 4-digit code appears near the bottom
of the screen.

Figure 5-13: System Security Menu

SECTION 6 – TECHNICIANS ONLY MENUS

6.1 Introduction:

WARNING! Users of these menus must have a detailed understanding of their functions.
Monitoring of target gases, processing of alarms, 4-20mA output values and Modbus RS-485
communications should not be relied upon while editing these menus! Back-up the current

29

SenSmart 3000 User's Manual

S E NS OR B A L A NCE

Re a d i n g - 3
Co u n t s 4 9 6

UP / DN t o Ch a n g e .
NE X T t o Ex i t .

S E NS OR V OL T A GE

Vo l t s 2 . 0 4
UP / DN t o Ch a n g e .

NE X T t o Ex i t .
WARNI N G! Hi g h v o l t a g e
ma y d a ma g e s e n s o r

* * * * * WA R NI NG* * * * *

Pr e v i o u s Ca l i b r a t i o n
wi l l b e e r a s e d .

ED I T t o c o n f i r m.
NE X T t o e x i t .

Ga i n = Un i t y

EDIT

EDIT

P GA S E T UP

Ga i n 2 5 . 0 %
Co u n t s 10 11
Re a d i n g 10 0
Up / D n t o Ch a n g e .
Ne x t t o e x i t .

S E L E CT I NPU T

Ca t - B e a d ( 3 - Wi r e )

UP / DOWN t o c h a n g e
E D I T t o s e l e c t
NE X T t o e x i t

SENSOR BALANCE & SENSOR VOLTAGE
menus are only active when input type =
“Cat-Bead” 3-Wire”

S E L E CT EUNI T S

EDIT

% L E L
[ Cu s t o m ]

S e t B a l a n c e
S e t S e n s o r Vo l t a g e
S e t Ga i n t o UN I T Y
P r e A mp Ga i n S e t
I n p u t T y p e
Z ER O Ca l Va l 0

>
>
>

>
>

T EC H N I CA L PA GE 2

Ra w Mi n Cn t s 5 11
Ra w Ma x Cn t s 10 0 0

Ma r k e r A c t i v e Ye s
Ma r k e r T X L E D NO
Ma r k L e v e l 3 . 0 mA
Ma r k As * * ME S S A GE *

T EC H N I CA L PA GE 1

Se t B a l a n c e
Se t S e n s o r Vo l t a g e
Se t Ga i n t o UN I T Y
Pr e A mp Ga i n Se t
I n p u t T y p e
Z E RO Ca l Va l 0

>
>
>

>
>

T E CHNI CA L PAGE 1

T E CHNI CA L PAGE 2

Ra w Mi n Cn t s 511
Ra w Ma x Cn t s 10 0 0

Ma r k e r Ac t i v e Ye s
Ma r k e r TX L E D NO
Ma r k L e v e l 3. 0 mA
Ma r k A s * * ME S SA GE *

Document: UM-1003 Revision Level B
configuration prior to altering any Technical menus in case Restore is required later (see section

5.3).
The TECHNICIAN ONLY menu group contains items that are factory configured depending

upon the type sensor and input connected to the SenSmart 3000. They should not be tampered
with after installation. If configured incorrectly, some items will prevent monitoring of target
gases. The Set Sensor Voltage menu for setting the catalytic bead sensor excitation voltage
could destroy the sensor. Access requires a special key sequence of four consecutive UP
keystrokes to prevent accidental modification of critical items.

6.2 Set Balance / Set Sensor Voltage (Technicians only!):

Set Balance and Set Sensor Voltage are used when Input Type is for Bridge sensors. They
are factory configured and only require field adjustment if the catalytic bead sensor is mounted

Figure 6-1: Technicians Menu Tree

Figure 6-2: Technicians Menu Entry

30

SenSmart 3000 User's Manual

* * * * * WARNI NG* * * * *

Pr e v i o u s Ca l i b r a t i o n
wi l l b e e r a s e d .

EDI T t o c o n f i r m.
NE XT t o e x i t .

Ga i n = U n i t y

EDIT

PGA S e t u p

Ga i n 2 5 . 0 %
Co u n t s 10 11
Re a d i n g 10 0
Up / D n t o Ch a n g e .
Ne x t t o e x i t .

Document: UM-1003 Revision Level B
remote from the SenSmart 3000 or if a new sensor is installed. Other input type entries draw a

line through these menus and they are inactive. SenSmart 3000 bridge sensors may be from 2 to
6 volts excitation voltage at the sensor. This means if the sensor is mounted a long distance
away the voltage at the SenSmart 3000 may have to be higher to compensate for losses in field
wiring. Be careful not to exceed correct sensor volts at the sensor’s A and R terminals.

Set Balance allows balancing of the catalytic bead sensor and must only be performed with
ZERO gas on the sensor (Figure 6-3). Balance is similar to a very coarse ZERO calibration and
does not need to be precise since subsequent calibrations will correct for small errors. ZERO gas
applied to the sensor should provide a Reading of –3 to +3 on the SENSOR BALANCE menu.

Figure 6-3: Catalytic Bead BALANCE & SENSOR VOLTS Adjust Menus

6.3 Set Gain to Unity (Technicians only!):

Set Gain to UNITY allows resetting previous calibration OFFSET to zero and GAIN to one. This
is the definition of UNITY. A calibration should be performed after setting UNITY.

Figure 6-4: Set UNITY GAIN Menu

6.4 PreAmp Gain Adjust (Technicians only!):

Depending upon Input Type, SenSmart 3000 inputs range from a few micro amps to hundreds of
micro amps. PreAmp Gain Set is the adjustment that matches the input signal range to the
SenSmart 3000 input signal conditioning circuits. Altering the PreAmp Gain setting automatically
resets previous calibration OFFSET & GAIN values to UNITY as described in section 6.3.

If it is determined the PreAmp Gain value is incorrect, apply the desired up-scale input and use
the UP / DOWN keys to obtain the correct Reading value. Counts are the 10-bit binary A/D
value with an active range value of 0 - 1023.

CAUTION: For standard installations, this is a factory adjustment. Do not use the PreAmp Gain
Set menu for calibrating sensors. It should only be adjusted if a new measurement gas or input

range is required.

Figure 6-5: PreAmp Gain Adjust (PGA) Menu

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SenSmart 3000 User's Manual

SE L ECT I NPUT

Ca t - B e a d ( 3 - Wi r e )

UP / DOWN t o c h a n g e
EDI T t o s e l e c t
NE X T t o e x i t

SE L ECT EUNI T S

EDIT

% L E L
[ Cu s t o m ]

Coefficient

Electrochemical Sensor Type

Default EUNITS

Negative
Negative
Negative
Negative, Bias
Negative, Bias
Negative
Negative
Negative
Negative
Negative
Negative
Negative
Negative
Negative
Negative
Positive
Positive
Positive

Hydrogen Sulfide
Oxygen
Carbon Monoxide
Ammonia
Nitric Oxide
Ethylene Oxide
Hydrogen Chloride
Hydrazine
Arsine
Sulfur Dioxide
Hydrogen
Hydrogen Cyanide
Phosgene
Phosphine
Hydrogen Fluoride
Nitrogen Dioxide
Ozone
Chlorine

ppm H2S
% Oxygen
ppm CO
ppm NH3
ppm NO
ppm Eth O2
ppm HCL
ppm N2H4
ppm Arsine
ppm SO2
ppm H2
ppm HCN
ppm COCl2
ppm PH3
ppm HF
ppm NO2
ppm Ozone
ppm Cl2

Document: UM-1003 Revision Level B

6.5 Simple Sensor Input Type (Technicians only!):

Smart sensors automatically configure Input Type. Simple inputs must be configured manually
using the Input Type menu. Input Type configures SenSmart 3000 hardware to accept bridge
sensors, positive coefficient electrochemical sensors, negative coefficient electrochemical
sensors or 4-20 mA inputs. Catalytic-bead and 4-20mA inputs require 3-wire operation and the
10-0233 I/O Power Supply. Note: Additional factory installed solder-bridge modifications are
required for 4-20mA inputs (see section 7.2 and 7.3). Positive / Negative coefficient
electrochemical sensors have several gas types available within each group (see table below).
Biased EC sensors require factory installed solder bridge SB1 on the Display Assy PCB - see
Addendum 3.

After selecting Input Type, a SELECT EUNITS screen indicates the default engineering units for
this sensor. These EUNITS may be accepted by pressing the EDIT key, or changed by moving
the pointer to [Custom] and editing as described in Configuration Using the Magnetic Wand in
section 5-2.

6.6 Zero Cal Value (Technicians only!):

The Zero Cal Value menu entry allows the zero calibration value to be set for something other
than a zero reading. For example, a SenSmart 3000 4-20mA input may represent a BTU

Figure 6-6: Input Type Selection Menu

32

SenSmart 3000 User's Manual

Document: UM-1003 Revision Level B
Analyzer range of 500 – 1000 BTU’s. In this case, 0% of full scale equals 500 BTU’s and may be

the desired zero calibration point. Other upscale values may also be used for the zero calibration
point by setting this menu item to the desired engineering unit value. Do not exceed 25% of full
scale.

6.7 Raw Min / Max Counts (Technicians only!):

The Raw Min / Max Counts menus determine the range of 10-bit analog to digital (A/D)
converter counts that define 0 & 100% of full scale. Raw Min A/D counts create 0% readings and
Raw Max A/D counts create 100% readings. These menus are very useful in application with
non-standard input ranges. For example, if instead of a standard 4-20mA input 8-18mA must be
accepted by the SenSmart 3000. Set RAW MIN COUNTS to match the 8mA input counts value
and RAW MAX COUNTS to match the 18mA input counts value. The corresponding Zero 0%
and Span 100% readings are entered in the Configuration Menu describe in section 5.3. Live
A/D count values may be viewed from the CAL MODE Information screen described section 4.1.

6.8 4-20mA Input Marker / Message (Technicians only!):

See section 7.3.1 for description of the 4-20mA Input Marker / Message menus. This
feature is only available with SenSmart 3000 models.

SECTION 7 – SPECIAL ORDER CONFIGURATIONS

7.1 ARCTIC Option

SenSmart 3000 models may be ordered with a special ARCTIC configuration to include a 175
ohm 4-watt heater / temperature controller circuit mounted to the back of the 10-0233 Power
Supply PCB (Figure 2-5). In addition, when equipped with a locally mounted 10-0247 Smart
Sensor Head (Figure 2-9) ARCTIC Smart sensors are available with a 1-watt heater /
temperature controller for warming the sensor compartment. This is important since many
electrochemical sensors have a low temperature rating of only -20C. If incoming 10-30VDC
power is at least 24VDC, the ARCTIC option extends SenSmart 3000 operation down to -55C.

Important! ARCTIC SenSmart 3000’s consume more power when it is cold! When
temperature inside the SenSmart 3000 enclosure is below -25C the 175 ohm 10-0233 PCB
heater is connected across the incoming DC power terminals. When an ARCTIC Smart Sensor is
installed, its 1-watt heater is connected across the SenSmart 3000’s internal 5VDC power supply
when Sensor Temp is below the Setpoint (see section 7.1.1). These additional loads must be
considered when sizing the installation’s DC power supply.

7.1.1 ARCTIC Smart Sensor Temperature Setpoint Option

Both the O2/TOXIC and LEL/Current channels (see section 3.1.1) are capable of accepting
ARCTIC Smart Sensors with 1-watt heater / temperature controller circuits. ARCTIC sensor
temperature controllers have a unique address that is automatically detected by the SenSmart

3000. This activates the Sensor Temp menu on page 2 of the channel’s main menu as shown
below in Figure 7-1. Selecting Sensor Temp and pressing EDIT opens a window displaying the
sensor’s current temperature and the 1-watt heater’s Setpoint. When the Sensor Temp value is
below the Setpoint value the heater is on. This feature is helpful in applications where the
sensor temperature must be higher than the ambient temperature to function properly.

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SenSmart 3000 User's Manual

L EL / MOS TE MP

Se n s o r T e mp 2 8 . 7 5°C

Se t p o i n t - 0 . 0 0°C

L EL I N P U T 2

L CD Co n t r a s t Ad j .
Mo d b u s RS 4 8 5 P o r t
Se c u r i t y
T e c h n i c i a n s ONL Y
Se n s o r T e mp

F i r mwa r e R e v .

>
>
>
>
>

EDIT

Document: UM-1003 Revision Level B

Figure 7-1: ARCTIC Sensor Temperature Menu

7.2 Special Order; 18VAC Primary Power Supply Option

A special revision of the SenSmart 3000 I/O Power Supply is available for applications requiring
18VAC as primary power instead of the standard 10-30VDC (Order I/O Power Supply part # 10­0233-18VAC). 18VAC is applied to a bridge rectifier and filter capacitor to generate unregulated
24VDC.

The 10-0233-18VAC revision is also configured to accept 4-20mA inputs from 2 or 3-Wire 4­20mA Transmitters into terminals normally reserved for Bridge Sensors. References to Bridge
sensors within the main body of this manual DO NOT APPLY TO THIS REVISION. The 10-0232
Display Assembly is the standard revision and Smart or Simple electrochemical Toxic / Oxygen
sensors may still be connected as described in this manual.

Figure 7-2 shows physical and electrical wiring diagrams.

34

SenSmart 3000 User's Manual

S1

TB1

TP1

C1

C2

TB2

C7

S2

Ribbon to Display Assy.

C8

Q1

Assy 10-0233_18VAC

++

++

1

1

24VDC OUT is unregulated DC power
generated from 18VAC~ input power.

*Apply 18VAC between
18VAC Terms. on TB2.
4-20 OUT +SIG Term. on
TB2

sources

output.
Use 24VDC COMMMON
term. on TB1 for 4-20
OUT -SIG Term.

*10-0233_18VAC is a special
configuration allowing power
from an 18VAC~ power source
and is available by special
order. DO NOT APPLY 18VAC~
TO STANDARD UNITS!

4-20mA IN+ accepts milliamp signal inputs.
24VDC COMMON is “RETURN” rail for

both 4-20mA Input and Output.
(See Block / Wiring diagram)

I/V
Amplifier

TB1

3

2

1

10ohm R13

Amplifier

V/I

+

TB2

3

2

1

A/D

Transmitter 2-Wire

3-Wire

+4-20mA Input

24VDC Common

Neg

+24VDC Output

4-20mA (Unregulated)

5-Watt

D/A

Microcontroller

+4-20mA OUTPUT

Wiring

Monitor

Field

18VAC~

4-20mA OUTPUT

Pos

18VAC~

Bridge
Rectifier

Filter
Capacitor

Supply board with

I/O Power
18VAC Power Input

(Order 10-0233-18VAC)

1 2 3 1 2 34

4

Electrochemical
+4-20mA OUTPUT

Document: UM-1003 Revision Level B

7.3 Special Order; 4-20mA Input to Bridge Channel

A special model SenSmart 3000 is available for applications requiring a 4-20mA input (includes
I/O Power Supply part # 10-0233-4-20mA). Solder bridges are factory installed to rewire TB1 to
continue 24VDC power on to a 4-20mA transmitter as shown in Figure 7-3 below.

Figure 7-2: 10-0233-18VAC Block / Wiring Diagram

35

S1

TB1

TP1

C1

C2

TB2

C7

S2

Ribbon to Display Assy.

C8

Q1

Assy 10-0233-4-20mA

I/O Power Supply

++

++

1

1

*10-0233-4-20mA is a special
configuration allowing 4-20mA
Input to TB1 and is available by
special order.

4-20mA IN+ accepts milliamp signal inputs.
24VDC COMMON is “RETURN” rail for

both 4-20mA Input and Output.
(See Block / Wiring diagram)

I/V
Amplifier

TB1

3

2

1

10 ohm R13

Amplifier

V/I

TB2

3

2

1

A/D

Transmitter 2-Wire

3-Wire

+4-20mA Input

24VDC Common

+24VDC

4-20mA

D/A

Microcontroller

+4-20mA OUTPUT

Wiring

Monitor

Field

with 4-20mA Input

I/O Power Supply
(without catbead)

Order 10-0233-4-20mA

1 2 3 1 2 34

4

Electrochemical
+4-20mA OUTPUT

24VDC Common

+24VDC

SenSmart 3000 User's Manual

Document: UM-1003 Revision Level B

7.3.1 4-20mA Input Marker / Message (Technicians only!):

Important: SenSmart 3000 Input Marker menus are available only with special 4-20mA
input configurations described in sections 7.2 and 7.3 of this manual and when the Input
Type menu setting is 4-20mA (3-Wire) (see section 6.5). Since FAULT alarms are also
tripped in the <4mA region it is important to understand that the Marker events override
the FAULT alarm (see section 5.4).

Some monitors indicate special modes of operation such as Calibration or Maintenance by
transmitting a special <4mA “Marker” value. The SenSmart 3000 offers 4-20mA input “Marker”
menus, shown in Figure 7-4, for detecting inputs between 0 and 3.75mA that represent such

Figure 7-3: 10-00233-4-20mA Block / Wiring Diagram

36

SenSmart 3000 User's Manual

T EC HNI CA L PA GE 2

Ra w Mi n C n t s 5 11
Ra w Ma x C n t s 10 0 0

Ma r k e r Ac t i v e Ye s
Ma r k e r TX L E D NO
Ma r k L e v e l 1. 5 mA
Ma r k As * * I N CAL *

Me a s u r e me n t Na me

I N CAL

0

Document: UM-1003 Revision Level B
events. Once detected, the SenSmart 3000 transmits a constant mA output equal to the Marker

value.
Entering YES in the Marker Active menu also activates Marker TX LED, Mark Level, and Mark

As menus. Mark Level allows entering the <3.75mA value (+.2mA) to detect. Mark As allows
entry of the up to 10 digit ASCII message the LCD readout will display when the Marker is
detected. Marker TX LED menu = YES, causes the front panel TXD LED (see Figure 2-1) to
also illuminate when the Marker is detected. Important: Optional 10-0234 RS-485 modbus

port will not function if “Marker TX LED” menu must = YES.

Figure 7-4: 4-20mA Input “MARKER” Menus

A Marker application example is as follows: Many gas detection monitors transmit a “Cal Marker”
value of between 1 - 3mA during their calibration mode. Configuring SenSmart 3000 marker
menus as shown in Figure 7-4 will provide the LCD readout in Figure 7-5 when 1.5mA is the 4­20mA input. In this example, the SenSmart 3000 4-20mA output will also transmit a 1.5mA
marker signal.

Figure 7-5: 4-20mA Input Type “MARKER” Message

SECTION 8 – Millenium Sensor Calibration

The R.C. Systems Inc. MILLENIUM is factory calibrated zeroed and spanned. Unlike catalytic
sensors it does not require routine span gas calibration to ensure proper operation.

The R.C. Systems Inc. MILLENIUM can be calibrated for almost any hydrocarbon using a
calibration gas of the hydrocarbon that is to be detected (target gas). The R.C. Systems Inc.
MILLENIUM is required to be spanned with gas only one time with the target gas. Typically this is
done at the factory, but it is possible to field span the device by connecting the R.C. Systems Inc.
MILLENIUM to a computer and using a software package provided by R.C. Systems Inc.. Please
contact the factory for further details.

A typical field calibration only requires the use of zero air (or 99.99% nitrogen). If the sensor is

located in an area that is known to be free of the hydrocarbon gases then ambient air can be
used as a zero reference.

If zero air is used for the calibration, there is a fitting on the bottom of the sensor for a 1/8” ID

tubing connection.

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Before beginning calibration use the R.C. Systems Inc. MILLENIUM Insulation Tube to cover

outer cylinder holes and connect a clean air source to the sensor’s calibration port for a minimum

of 3 minutes. To enter into the calibration mode the calibration wire must be connected to
negative (common of the power supply) for ten (10) seconds, upon release the sensor will
automatically enter the zero calibration routine. The electronics will automatically adjust the
sensor’s signal to the new zero reference level. (Applying span gas is not necessary because of
the R.C. Systems Inc. MILLENIUM’s unique software algorithms). During the zero calibration
routine, the current output of the R.C. Systems Inc. MILLENIUM will go to 2.2 mA. Although this
can be accomplished manually, installation of a switch (contact closure) can accomplish the
zeroing procedure. It is recommended that this switch be a momentary type switch to prevent it
from inadvertently being left in the calibrate position. If after 20 seconds the calibration lead has
not been removed from common, the R.C. Systems Inc. MILLENIUM will ignore the signal and

continue operation as normal.

The R.C. Systems Inc. MILLENIUM can be spanned in the field if the customer wishes to change
the target hydrocarbon gas. Please contact factory for additional equipment information and
pricing for R.C. Systems Inc. PC IR Link Package)

SenSmart 3300M SmartCal

The MILLENIUM may also be supplied with the SenSmart 3000 or 6000 sensor transmitters to
add features such as graphic readout, modbus, alarm relays and even a second electrochemical
sensor for oxygen or toxic gas detection. In this case, the 3300M / 6300M is equipped with an
integral reed switch to offer “SmartCal” without opening the XP enclosure.

IMPORTANT: Make certain the MILLENIUM is exposed to zero gas or ambient gas free of the
hydrocarbon gas to be detected.

With zero gas on the MILLENIUM as described in Section IV above, hold the flat surface of the
magnet supplied with the 3300M adjacent to the horseshoe magnet symbol shown in the picture
below FOR 10 SECONDS. This will perform the SmartCal because the internal reed switch will
short the SmartCal wire to common.

Figure 1 SenSmart 3000M calibration mode

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REVISION HISTORY

Revision 3.4 3/27/2012 Update Sections 3.1.4, 3.1.5, 5.3, 5.10 and added

Revision History page

Revision 3.5 4/18/2013 Update Figures 2-2 and 2-2a

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