Sierra Monitor Corporation 5100-06-IT, 5100-05-IT, 5100-04-IT, T12020, 5100-03-IT User Manual

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MODEL 5100-XX-IT
IT Series
TOXIC GAS SENSOR MODULE
Version 2.0
APPLICABILITY & EFFECTIVITY
Effective for all Model 5100-XX-IT and 5100-XX-IT-SS Modules manufactured after March 1, 2008
5100-03-IT 5100-04-IT 5100-05-IT 5100-06-IT
Instruction Manual Part Number T12020
Rev A
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Contents
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TABLE OF CONTENTS
PRODUCT DESCRIPTION .............................................................................................................................1
1.
1.1 GENERAL........................................................................................................................................................1
1.2 PRODUCT CONFIGURATION........................................................................................................................1
1.3 THEORY OF OPERATION..............................................................................................................................1
1.4 MODES OF OPERATION................................................................................................................................1
1.4.1 SENTRY INTERFACE..............................................................................................................................1
1.4.2 MODBUS OPERATION............................................................................................................................2
1.4.3 ANALOG OPERATION ............................................................................................................................2
1.4.4 REMOTE SENSOR AND DISPLAY (APPENDIX D)................................................................................2
1.4.5 REMOTE ALARM RESET (DIGITAL INPUT) (Figure 3-7) ......................................................................2
1.4.6 OPTIONAL INTEGRAL RELAYS .............................................................................................................2
MECHANICAL ............................................................................................................................................................2
1.4.7 ENCLOSURE ...........................................................................................................................................2
1.4.8 TRANSMITTER ELECTRONICS .............................................................................................................4
1.4.9 SENSOR ASSEMBLY ..............................................................................................................................4
1.5 INTERCONNECT WIRING..............................................................................................................................4
1.6 POWER REQUIREMENTS .............................................................................................................................4
2. CAUTIONS & WARNINGS .............................................................................................................................5
2.1 INTRODUCTION .............................................................................................................................................5
2.2 IT MODULES - GENERAL ...............................................................................................................................5
2.3 WIRING............................................................................................................................................................5
3. INSTALLATION ..............................................................................................................................................7
3.1 SENSOR MODULE LOCATIONS....................................................................................................................7
3.2 WIRING............................................................................................................................................................7
3.2.1 ANALOG 4-20 mA OPERATION..............................................................................................................7
3.2.2 MODBUS OPERATION USING RS-485 CONNECTION ........................................................................7
3.2.3 SENTRY OPERATION USING SMC SENTRY CONNECTION ..............................................................7
3.2.4 GENERAL ................................................................................................................................................7
3.3 ENCLOSURE INSTALLATION........................................................................................................................8
3.4 TRANSMITTER AND SENSOR INSTALLATION ............................................................................................8
3.5 MODULE ADDRESS SWITCH ......................................................................................................................10
4. OPERATION .................................................................................................................................................17
4.1 INTRODUCTION HUMAN-MACHINE INTERFACE SYSTEM ...................................................................17
4.2 HUMAN-MACHINE INTERFACE ..................................................................................................................17
4.3 MAIN MENU...................................................................................................................................................18
4.4 CONFIGURE SET-POINTS...........................................................................................................................19
4.5 MAINTENANCE FUNCTIONS.......................................................................................................................22
5. CALIBRATION..............................................................................................................................................24
5.1 CALIBRATION FREQUENCY .......................................................................................................................24
5.2 CALIBRATION PREPARATION ....................................................................................................................24
5.2.1 CALIBRATION GAS DELIVERY METHODS.........................................................................................24
5.3 CALIBRATION PROCEDURE.......................................................................................................................24
5.3.1 SENSOR EXPOSURE TO GAS.............................................................................................................25
6. SERVICE........................................................................................................................ ...............................26
6.1 SENSOR MODULE CONFIGURATION ........................................................................................................26
6.2 ENCLOSURE REPLACEMENT ....................................................................................................................26
6.3 TRANSMITTER REPLACEMENT .................................................................................................................27
6.4 SENSOR REPLACEMENT............................................................................................................................27
Contents
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6.5 INSTALLATION INSPECTION ......................................................................................................................27
6.5.2 INSPECTION AND TROUBLESHOOTING GUIDE ...............................................................................28
6.5.3 IF MODULE DOES NOT RESPOND TO GAS ......................................................................................28
6.5.4 IF THE MODULE DISPLAYS “STARTING” FOR MORE THAN 1 HOUR .............................................28
7. APPENDICES ...............................................................................................................................................29
APPENDIX A - SPECIFICATIONS ...........................................................................................................................29
APPENDIX B: - MODEL NUMBERS & PARTS LIST ................................................................................................31
APPENDIX C: LIMITED WARRANTY ......................................................................................................................32
APPENDIX D: REMOTE SENSOR/DISPLAY DRAWING 5394-52..........................................................................33
APPENDIX E: MODBUS MEMORY MAP.................................................................................................................34
Contents
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1. PRODUCT DESCRIPTION
1.1 GENERAL
The Model 5100-XX-IT Toxics Gas Sensor Module is a member of the Information Technology ”IT” family of
gas sensor transmitter modules. Members of the IT Toxics family include:
5100-03-IT Oxygen Deficiency Gas Sensor Module
5100-04-IT Carbon Monoxide Gas Sensor Module
5100-05-IT Hydrogen Sulfide Gas Sensor Module
5100-06-IT Chlorine Gas Sensor Module
IT modules offer a broad array of features, including:
Integral alphanumeric LED display
180 day calibration frequency
4-20 mA output
Modbus
SMC Sentry interface
316 Stainless steel enclosure option
®
RTU interface
Auxiliary integral relay option
Remote display option
Low maintenance and operation costs
IT modules are designed, and approved for installation and operation in hazardous locations.
1.2 PRODUCT CONFIGURATION
Various module configuration options are available. Where applicable, these options are factory configured prior to shipment. Options which can be re-configured by the installer or field technician are fully described in this manual.
1.3 THEORY OF OPERATION
Electrochemical sensors are fuel cell-like devices consisting of an anode, cathode and electrolyte. The components of the cell are selected so a subject gas, allowed to diffuse into the cell, will cause a chemical reaction and generate a current. The cells are diffusion limited so the rate the gas enters the cell is solely dependent on the gas concentration. The current generated is proportional to the rate of consumption of the subject gas in the cell.
1.4 MODES OF OPERATION
1.4.1 SENTRY INTERFACE
IT gas sensor modules can be installed on Sierra Monitor Sentry Model 5000 controllers. The gas sensor module communicates as a toxic gas sensor module (Type 4 – communication) and are automatically detected by the Sentry controller. When it is installed in a Sentry system the IT module must have a unique address which can be established by setting an address between 1 and 8 on the Module Address Switch
®
Registered trademark of Schneider Electric
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accessible from the cover plate as illustrated in Figure 3-1. Figure 3-6 in this manual provides the wiring terminations for connections to the Sentry controller.
When the module is operated in conjunction with a Sentry controller, the alarms outputs in the module can both be set to “Sentry”, allowing the Sentry controller to manage alarm acknowledge and reset rather than the sensor module. The alarm relay outputs are triggered by the alarm values established in the module, and can be independent of the settings in the Sentry controller.
The Sentry configuration allows daisy chain installation using the Sentry multiplex capability, thus reducing costs by avoiding the requirement for wiring junction boxes. The connector card has two sets of
connections, allowing for a continuous run to the next module.
1.4.2 MODBUS OPERATION
An RS-485 Modbus RTU serial interface allows direct connection to standard PLCs and DCSs. The Module Address Switch (section 3.5) allows the user to select up to 16 different Modbus addresses. Also, an additional 238 Modbus addresses (for a total of 254 different Modbus Addresses) are available via menu selection. Figure 3-6 in this manual provides the wiring terminations for Modbus connections. The 5100-XX-IT provides the additional terminal connectors to enable the user to connect In/Out terminations of a RS-485 connection.
1.4.3 ANALOG OPERATION
The 4-20 mA interface allows direct connection to standard analog controllers or PLCs. The 5100-XX-IT 4­20 mA connection can be wired as a Type 3 (3-wire) or Type 4 (4-wire) circuit as described by ANSI/ISA-
50.00.01-1975 Standard (see figure 3-5).
1.4.4 REMOTE SENSOR AND DISPLAY (APPENDIX D)
The Remote Sensor and Display option (5394-52) can be used to remotely mount the sensor up to 100’ from the transmitter.
1.4.5 REMOTE ALARM RESET (DIGITAL INPUT) (Figure 3-7)
An input is available for connection of remote alarm reset/acknowledge. Figure 3-4 provides the wiring termination for connecting the remote alarm reset. This only resets local alarms, not Sentry alarms. This input can be wired as supervised or non-supervised.
Note that when the Remote Alarm Reset is operated in a supervised mode that both the switch and resistor must be present as outlined in Figure 3-7.
1.4.6 OPTIONAL INTEGRAL RELAYS
The optional relays are integral to the gas sensor module and are rated as SPDT, 250VAC, 8 Amps for the High Alarm and Low Alarm relays and SPDT, 250 VAC, 2 Amp for the Trouble relay.
If the gas sensor module is provided with the optional relays, it will include Terminal P4 on the interface board (Figure 3-2). Relay output connections are on P4.
MECHANICAL
The sensor module of comprised of the following three primary components:
1.4.7 ENCLOSURE
Standard on the 5100-XX-IT is an explosion-proof, rain-tight cast aluminum electrical housing (Figure 1-1) with three ¾” FNPT conduit hubs. The 5100-XX-IT-SS (Figure 1-2) has a 316 Stainless Steel enclosure. Both enclosure covers have a viewing window. The design of the enclosure allows 3-way mounting choices as shown in figure 1-3.
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Model 5100-05-IT Toxic Gas Sensor Module – Aluminum Enclosures, Dimensions
Figure 1-1
Figure 1-2
Model 5100-05-IT Toxic Gas Sensor Module – 316 Stainless Steel Enclosures, Dimensions
.
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Figure 1-3
Model 5100-XX-IT Toxic Gas Sensor Module – Mounting Options
1.4.8 TRANSMITTER ELECTRONICS
Electronic Assembly consist of one top transmitter board (connected to the cover plate) and on lower interface board. Connectors for wiring for power, signal interface and alarm relays are located on the interface board assembly
1.4.9 SENSOR ASSEMBLY
The sensor assembly includes an explosion proof housing containing the gas sensor and a wiring harness for connection to the transmitter. The sensor assembly threads into one hub of the enclosure. The exposed end of the sensor assembly is threaded to allow connection of a rain-shield or calibration gas delivery fitting.
1.5 INTERCONNECT WIRING
Not supplied with the sensor module, but necessary to the installation and operation is the multi conductor wiring which connects the module to its power source and controller. Before this wiring is installed it is important to read and understand the control system installation instructions to determine wiring requirements and alternatives.
1.6 POWER REQUIREMENTS
IT modules operate on DC power between 10 VDC and 30 VDC. Regulated DC power must be supplied from
a separate source, or from an approved Sentry or IT controller.
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2. CAUTIONS & WARNINGS
2.1 INTRODUCTION
Although IT Transmitter Modules are designed and constructed for installation and operation in industrial
applications including "hostile" environments, caution should be taken to insure that the installation is made in compliance with this instruction manual and that certain procedures and conditions are avoided. This chapter
discusses the necessary cautions. Read the entire chapter prior to installation of the equipment.
2.2 IT MODULES - GENERAL
Avoid installing sensor modules where they will be unnecessarily exposed to wind, dust, water (esp. direct hose down), shock, or vibration. Observe temperature range limitations.
Sensors may be adversely affected by prolonged exposure to certain materials. Loss of sensitivity, or corrosion, may be gradual if such materials are present in low concentrations. These materials include: Halides (compounds containing chlorine, fluorine, bromine, iodine), acid vapors, caustic liquids or mists.
Care has been taken by the manufacturer to ship your modules in protective packaging to avoid contamination prior to installation. It is recommended that the modules remain protected during installation and that the covering be removed immediately prior to system start-up.
During normal use the sensor is protected from dirt and oil contamination by a sintered metal cover. If this cover becomes clogged, the response of the sensor will be reduced. Protect the sensor from contamination by careful placement, or by use of rain and dust shields.
Sensor modules must not be painted. Paint may contain compounds which will contaminate the sensor. Paint will cause clogging of the sintered metal cover and will cause difficulties during attachment of the calibration head or other maintenance activity. It is recommended that the module be tagged
2.3 WIRING
"DO NOT PAINT".
The manufacturer recommends that extra caution be taken where the installation is near any sources of electromagnetic or radio frequency interference. Precautions include:
Avoid running sensor module cable close to high power cables, radio transmission lines, or cables subject to pulses of high current.
Avoid running cables near large electric motors or generators.
When the sensor module is to be operated in analog (4-20mA output) mode shielded cable is required.
When the risk of interference is present use shielded cables. In conduit installations the shield should
be connected to the conduit. In cable applications the shield should be connected to the cable connector.
All splices must be via either a termination hardware system or soldered. Improperly spliced cable can result in corrosion, resistance changes and system errors.
Installation and wiring must be in accordance with the National Electrical Code.
AC Voltage conductors are not to be run in the same conduit as DC voltage
NOTE
conductors.
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3. INSTALLATION
All modules are tagged to indicate the configuration including the sensor module number.
All IT modules are factory are pre-configured and calibrated.
Identify all components during unpacking and install using the factory configuration.
3.1 SENSOR MODULE LOCATIONS
NOTE
Select locations for each sensor modules based on the following:
Modules should be placed close to the potential source of gas.
Modules should be placed in areas accessible for calibration.
Sensors should be pointed down and the conduit should include an inverse trap to reduce moisture
(condensation) from accumulating in the electronics enclosure.
Remote calibration fitting (5360-00) should be used to facilitate calibration gas delivery. Run polyurethane tubing (1/4” O.D. x 1/8” I.D.) from fitting to an accessible location.
3.2 WIRING
3.2.1 ANALOG 4-20 mA OPERATION
The 4-20 mA output for the 5100-XX-IT can be either 3-wire or 4-wire operation. If using 3-wire operation, use a minimum of 18 AWG, shielded, 3-conductor cable up to 2000’. For 4-wire operation, use a minimum of 2 each, 18 AWG, twisted, shielded, pair up to 2000’.
3.2.2 MODBUS OPERATION USING RS-485 CONNECTION
Use a minimum of 18 AWG, 2 conductor for DC power connection. No shield required. In addition use a minimum of 24 AWG, low capacitance, shielded data cable for RS-485 half duplex communication. The installation may be planned in a manner which provides up to 32 sensor modules on a single home run.
Refer to Figure 3-3 units ship with BIAS jumpers connected. For all installations, except very long cable runs, these jumpers connected. The TERM jumpers should be installed in the last (furthest) module of every loop.
3.2.3 SENTRY OPERATION USING SMC SENTRY CONNECTION
Wire shall be rated as 600 volt tray cable, such as Belden (or equivalent) 27331 or 27331 AS (shielded). If high RFI or EMI levels exist wiring should be protected by conduit or shield. The installation may be planned in a manner which provides up to 4 sensor modules on a single home run to a Sentry controller.
NOTE:
Be sure to follow all local electric code and safety requirements when installing the 5100-XX-IT Gas Sensor Module
3.2.4 GENERAL
Install conduit as required by local code or construction specifications. When sensor modules are to be multiplexed for Sentry or RS-485 communication two alternatives may be planned:
Install splice boxes above each sensor module. Use multi-position positive contact terminals to connect daisy chain wiring and provide a pigtail to connect to the sensor module transmitter board.
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NOTES
The drain wire of shielded cable must NOT be used as one of the conductors.
Installation and wiring must be in accordance with the National Electrical Code. Temperature
rating of cable wire must be at least 75oC. If cable runs through higher temperature
environments, it must be specified for that environment.
3.3 ENCLOSURE INSTALLATION
To protect the transmitter and sensor assembly they should be removed from the enclosure and preserved until final installation and wiring termination.
Prior to installation and wiring.
1. Remove the transmitter from the module housing by:
Unscrew the two captive panel screws in the face plate.
Lift the transmitter out of the housing.
Unplug the sensor cable from transmitter connector P2.
Remove the sensor assembly from the enclosure hub.
2. Install the module housing onto the end of the supply conduit and/or bolt into position as required.
NOTES
When housing earth grounding is required for the installation a grounding lug is located in the
base of the enclosure. Install the earth ground wire under the green lug.
When installing the enclosure be sure to mount the FM Approved plate near the sensor
enclosure. This plate states “Caution: this area must be known to be free of flammable
concentrations prior to opening the enclosure.”
3.4 TRANSMITTER AND SENSOR INSTALLATION
When all pre-wire is complete:
1. Install sensor assembly in the open hub on the module enclosure. The sensor assembly thread must be fully seated into the hub and tightened to maintain explosion proof assembly.
2. Connect the wires which return to the controller to interface board connectors P1, P2, P3 and P4 according to Figure 3-2.
3. Connect the sensor assembly cable to top transmitter board connector P2.
4. Align the headers between the top transmitter board and the lower interface board and push together.
5. Turn rotary switch to correct sensor address.
The interface board should be wired to remote controllers first before installing the front
NOTE
transmitter board.
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6. Carefully return the transmitter to the enclosure installing it over the two stand-off’s. Tighten the retaining screws into the stand-offs.
P1 PCB Label Function
1 IN + Digital Input SW + 2 3 IN + 4-20 mA Input + 4 5 GND Ground 6 OUT + 4-20 mA Output + 7
P2 PCB Label Function
1 + RS 485 (+) (A) 2 - RS 485 (-) (B) 3 4 + RS 485 (+) (A) 5 - RS 485 (-) (B) 6
P3B PCB Label Function
1 P Power 2 S Signal 3 G Ground
P3A
4 P Power 5 S Signal 6 G Ground
P4 Connections are only available when the optional Relays are included
P4 PCB Label Function
1 N/C Low Alarm Relay NC 2 COM Low Alarm Relay COM 3 4 N/C High Alarm Relay NC 5 COM High Alarm Relay COM 6 7 N/C Trouble Alarm Relay NC * 8 COM Trouble Alarm Relay COM* 9 * Trouble relay is fail safe so it is energized for normal operation, functions are labeled for normal operation.
Switch
IN - Digital Input SW -
4-20
4-20
RS 485
RS 485
LO ALM
HI ALM
TRBL ALM
Sensor Module External Interfaces (See Figure 3-2)
IN - 4-20 mA Input -
OUT - 4-20 mA Output -
S RS 485 shield (Isolated GND)
S RS 485 shield (Isolated GND)
N/O Low Alarm Relay NO
N/O High Alarm Relay NO
N/O Trouble Alarm Relay NO*
Table 3-1
7. Establish the module address according to section 3.5.
NOTE
The starting delay period normally takes approximately 3 minutes but under some
circumstances can take longer.
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3.5 MODULE ADDRESS SWITCH
For digital interface applications the module address switch (or Modbus node) must be set per Table 3-2:
POSITION ADDRESS POSITION ADDRESS
1 Sensor 1 9 Sensor 09
2 Sensor 2 A Sensor 10
3 Sensor 3 B Sensor 11
4 Sensor 4 C Sensor 12
5 Sensor 5 D Sensor 13
6 Sensor 6 E Sensor 14
7 Sensor 7 F Sensor 15
8 Sensor 8 0 Software
Menu
Table 3-2
Sensor Module Address Switch Positions
NOTE
For Sentry applications only sensor addresses 1-8 are allowed. If using Modbus output sensor
addresses 1-15 are available. Position 0 allows the Modbus Address to be set by software
menu, in the range 16-254.
Figure 3-1
Transmitter Face Plate
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Interface Board Connectors
Figure 3-2
Figure 3-3
RS-485: 120 ohm termination not selected, BIAS shunted for 100K ohm bias
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Figure 3-4
4-20mA Circuit Types
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yp
4-20mA Circuit T
Figure 3-5 e Connections for 5100-XX-IT
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For end of line, refer to Figure 3-3
Figure 3-6
Wiring Connections for Modbus and Sentry Interface
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P1
4-20
4-20
SWITCH
OUT
+
GND
- -
IN
+
-
IN
+
SWITCH IN
SWITCH IN
5100-05-IT REMOTE ALARM RESET (SUPERVISED)
+
-
4.7K OHM (CUSTOMER SUPPLIED)
Figure 3-7
Wiring Connections for Remote Alarm Reset
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4. OPERATION
/
\
\
/
4.1 INTRODUCTION – HUMAN-MACHINE INTERFACE SYSTEM
The Gas Sensor Module utilizes a visual menu system operated by means of a magnet. A magnetic tool (5358-50) is supplied for this purpose. The menu system is used to configure alarm set-points, calibrate the sensor module, and for maintenance procedures and alarms acknowledge.
4.2 HUMAN-MACHINE INTERFACE
The module menu system is operated by means of directing the magnet stick toward each of four independent hall-effect magnetic switches. Each switch functions as if it is a manually activated panel key. The keys are located above and below the faceplate display and are labeled key functions are as follows:
M , E , and as shown in Figure 4-1. The
Key
M : MODE
Key E : ENTER
Key ▲: UP (+)
Key ▼: DOWN (-)
Key M
Key
IT Module
Figure 4-1:
Menu Switch Locations
Key E
Key
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4.3 MAIN MENU
Table 4-1 describes the primary man-machine interface operation.
Function Display Description Reference
Key
M E
ST
M E
ST
ME
S T
ME
S T
Mode Switch [M]
Enter Switch [E]
Up Switch [] Previous Menu
Down Switch [] Next Menu
5100-XX First screen at power up: Model No.
VXX-XX-- Second screen at power up: Version No.
STARTING Third screen at start up: Starting Delay
XXXPPM Normal condition - default display
M E
ST
M E
ST
Mode ALMRSET: Mode Function - Alarm Reset
Banner: "Press [E] to reset alarm"
RESET Alarm Reset
XXXPPM Default Display
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
Mode ALMRSET: Mode Function - Alarm Reset
Mode CALIB:-- Mode Function - Calibrate Table 5-1
Mode SETUP:-- Mode Function - Set Point Adjustments Table 4-3
Mode MAINT:-- Mode Function - Maintenance Table 4-4
Mode EXIT-?-- Exit Menu
Enter XXXPPM Apply Selected Mode (Exit)
XXXPPM Default Display
(Once a minute the sensor displays module address)
Table 4-1 Master Menu
Table 4-2 describes the operational display values of the human-machine interface system.
DISPLAY DESCRIPTION
STARTING
XXX PPM
LXXXPPM
HXXXPPM
Delay from loss of power at start-up
Concentration
Low Alarm
High Alarm Measures gas, concentration exceeds
CXXXPPM
100% to Full Scale Calibration Mode
Acknowledged Function
Table 4-2 Operation Display Values
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Model 5100-XX-IT Toxic Gas Sensor Module
4.4 CONFIGURE SET-POINTS
The sensor module set-points menu is used to initially set-up the alarm set points, relay actions, gas type and range, 4-20 mA action and RS-485/Sentry address and baud rates.
Alarm Set-points: Once the Set-up menu is selected, press [E] to activate the Alarm Set-point
screen. Use the [] or [▼] keys to select Low Alarm or High Alarm menu. Key [▲] will adjust the setpoint upwards and Key [] will adjust the value downwards. Once it reaches the desired setpoint, Key [E] will accept it and ACK will appear.
Set-points can be configured using this menu up to the following values:
5100-03-IT O 5100-04-IT C0 5100-05-IT H 5100-06-IT Cl
19.5%
2
500 PPM
S 20 PPM
2
5 PPM
2
Alarm Relay Set-up: Once the Set-up menu is selected, press key [] once and press [E] to
activate the Relay Set-up menu. Use the [] or [] keys to select High Alarm or Low Alarm relay menu and press [E]. Use the [] or [] keys to select the correct alarm relay action for the application, Latch, Sentry or Non-Latch. Selecting “Sentry” enables the Sentry controller to make all alarm action decisions. * indicates the current selection.
Range: Once the Set-up menu is selected, press key [] twice and press [E] to activate the Range
Set-up menu. Use the [] or [] keys to select Range menu and press [E]. When “Range” is selected menu provides any choices of ranges available for the gas type selected. Use the [] or [] keys to select the desired range. If the “User” range is selected, use the [] or [] keys to adjust the high end of the range desired.
4-20mA: Once the Set-up menu is selected, press key [] three times and press [E] to activate the
4-20mA Set-up menu. Use the [] or [] keys to select Calib or CalibOut menu and press [E]. The “Calib” section of the menu allows the user to calibrate the 4 mA and 20 mA outputs. To calibrate the 4 mA and 20 mA outputs it is necessary to have an amp meter connected to the 5100­XX-IT and upon selecting the 4 mA output calibration then the [] or [] keys can be used to adjust the 4 mA reading on the amp meter until it reads 4 mA. Similar steps can then be performed for the 20 mA output. The CalibOut section allows the user to select the 4-20 mA output action desired during calibration. * indicates the current selected value. Available selections include:
Track – the 4-20mA value tracks the calibration gas exposed to the gas sensor module  Zero – the 4-20mA value is held at 0mA during calibration  C1.50mA – the 4-20mA value is held at 1.50mA during calibration  C4.00mA – the 4-20mA value is held at 4.0mA during calibration.
RS-485 - Once the Set-up menu is selected, press key [] four times and press [E] to activate the
RS-485/Sentry Set-up menu. Use the [] or [] keys to select Address or Baud rate menu and press [E]. Note that the 5100-XX-IT has a rotary switch on the faceplate and it is used to select addresses 1-15. When connected to Sentry the user can select 1-8 and using Modbus RS-485 the user can select addresses 1-15. For Modbus addresses above 15, set the rotary switch to 0 and then use the “Address” menu to select any address between 16 and 254. The Baud rate menu allows the user to select a baud rate of 38400, 19200, 9600, 4800 or 2400. * indicates current selection.
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Model 5100-XX-IT Toxic Gas Sensor Module
Function Display Description Reference
Key
--0%LEL- Default Display
M E
ST
M E
ST
M E
ST
M E
ST
ME
S T
ME
S T
ME
S T
ME
S T
M E
ST
M E
ST
ME
S T
M E
ST
Mode ALMRSET: Mode Function - Alarm Reset
Mode CALIB:-- Mode Function - Calibrate
Mode SETUP:--- Mode Function - Set Point Adjustments
Enter Alarms S.P. Function - Alarm Adjust * A Below
Down Relays S.P. Function - Relays Adjust * B Below
Down Gas S.P. Function - Range Adjust * Page 21
Down 4-20mA S.P. Function - 4-20 mA Adjust * Page 21
Down RS-485 S.P. Function - RS-485/Sentry Output Adjust * Page 21
High Alarm Set Point Adjustment Example
Enter H.Alarm S.P. Function - High Alarm Adjust *A
Enter HASP:60- High Alarm Set Point: current = 60
Use S or T keys to adjust to new set point
Down (x5) HASP:55- High Alarm Set Point: new = 55
Enter ACK Momentary Acknowledge of new Set Point
H.Alarm S.P. Function - High Alarm Adjust
M E
ST
ME
S T
M E
ST
ME
S T
ME
S T
Relays Set Point Adjustment Example
Enter H. Relay S.P. Function - High Alarm Relay Adjust *B
Down L.Relay S.P. Function - Low Alarm Relay Adjust
Enter Latch
Down Sentry
Use S or T keys to adjust to new relay action (Latch, Sentry, NonLatc) * indicates current NOTE: Sentry indicates that Sentry controls relay action and not the IT Sensor Module
Down *Sentry High Alarm Relay set to Sentry
Table 4-3A Set-Up Configuration
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M E
ST
M E
ST
ME
S T
ME
S T
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
ME
S T
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
ME
S T
M E
ST
Model 5100-XX-IT Toxic Gas Sensor Module
Gas Range Adjustment Example
Enter Range S.P. Function - Range Adjust *C
Enter *100 PPM
Down 10 PPM Press [E] if selecting 0-10 PPM range
Down USER Press [E] if selecting User adjustable range
Enter 100 PPM
Enter Calib S.P. Function - Calib Adjust *D
Enter Out: 4mA Use S or T keys to select 4 mA or 20mA
Enter 4mA Selects 4 mA
Enter ACK Momentary Acknowledge of new Set Point
Mode Calib S.P. Function - Calib Adjust
Down CalibOut S.P. Function - Output during Calibration Adjust
Enter Track Use S or T keys to select Track, Zero, C1.50mA, C4.00mA
Enter *Track * = Current selection
Enter Address S.P. Function - RS-485 Address Adjust *E
Enter Addr:016 Use S or T keys to enter new address
Enter ACK New address selected
Enter Address S.P. Function - RS-485 Address Adjust
Down Baud S.P. Function - RS-485 Baud Rate Adjust
Enter *38400 Press [E] to select or [S] or [T] to select another
Select [E] to select or S or T to select another and press [E]
Select [E] to select or S or T to select another and press [E]
4-20 mA Adjustment Example
Track = Output during calibration tracks the calibration gas, Zero = Output is Zero during calibration, C1.50mA = Output during calibration is 1.50 mA, C4.00mA = Output during calibration is 4.0 mA
RS-485 Adjustment Example
Table 4-3B Set-Up Configuration
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Model 5100-XX-IT Toxic Gas Sensor Module
4.5 MAINTENANCE FUNCTIONS
The maintenance menu enables the operator to view sensor and software versions. Sierra Monitor technical support has access to other values as needed.. The maintenance menu operation is described in Table 4-4.
Key
Function Display Description Reference
XXXPPM Default Display
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
Mode ALMRSET: Mode Function - Alarm Reset
Mode CALIB:-- Mode Function - Calibrate
Mode SETUP:- Mode Function - Set Point Adjustments
Mode MAINT:-- Mode Function - Maintenance
Enter Ver1.00aA Module Software Version Number
Enter CCC001 Module Custom Configuration Control number
Table 4-4
Maintenance Menu
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Model 5100-XX-IT Toxic Gas Sensor Module
THIS PAGE INTENTIONALLY LEFT BLANK
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Model 5100-XX-IT Toxic Gas Sensor Module
5. CALIBRATION
5.1 CALIBRATION FREQUENCY
The 5100-XX-IT has been calibrated in the factory prior to shipment. It is recommended that the user check calibration before placing in service. The toxic sensor module must be calibrated every six months. Periodic functional tests are advisable for critical applications and hostile environments.
The sensor module microprocessor software includes high level self checking algorithms which provide continuous sensor diagnostic and self adjustment. Users may elect to increase calibration periods based on low drift experience during the first two calibration periods.
5.2 CALIBRATION PREPARATION
Calibration of the Toxic Gas Sensor Module is accomplished by simple menu based steps and application of span gas.
If an error is made during any stage of the calibration process, hold the magnet stick at the
Switch [M] for 10 seconds. A scrolling display will indicate “Calibration aborted” and the
sensor module will exit the calibration activity and return to normal operating mode. The
calibration procedure can then be restarted
NOTE
Calibration must be performed only when the area is known to be clear of the applicable toxic gas. If necessary, use a portable instrument to confirm that there is no background toxic gas.
For compliance with Factory Mutual (FM) Apparatus, the Sierra Monitor Model 1250-01, 1256-01, 1260-XX are the only FM Approved calibration gas delivery device. Use Model 5358-00 or 5358-01 Calibration Adapter or Model 5360-00 Gas Delivery Fitting.
5.2.1 CALIBRATION GAS DELIVERY METHODS
Calibration gas is can be delivered to the sensors via the following delivery devices:
Model 5358-00: Calibration Adapter - used with portable calibrators. See 5-1.
Model 5360-00: Calibration Gas Delivery fitting - permanently installed fitting which allows tubing to be run to a convenient delivery location
5.3 CALIBRATION PROCEDURE
Table 5-1 shows the step by step process of the calibration procedure.
The procedures requires that the menu “keys” be activated using the magnet stick. Each key press steps through the process of setting the zero value for clean air and then setting the span value.
At each of these steps, apply calibration gas of the value corresponding to the setting accepted on the sensor module display.
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Sample Gas In
Figure 5-1
Model 5358-01 Calibration
Adapter
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Model 5100-XX-IT Toxic Gas Sensor Module
-
5.3.1 SENSOR EXPOSURE TO GAS
Calibration gas must be delivered to the sensor using the flow rate and duration listed in below:
Model Gas Flow Period
5100-03-IT Oxygen 300 cc/min Until Stable 5100-04-IT Carbon Monoxide 300 cc/min Until Stable 5100-05-IT Hydrogen Sulfide 300 cc/min Until Stable 5100-06-IT Chlorine 300 cc/min Until Stable
Key
Function Display Description Reference
XXXPPM Default Display
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
Mode ALMRSET: Mode Function - Alarm Reset
Mode CALIB:--
Enter
AL-0PPM-
Mode Function - Calibrate
Banner: Apply zero gas, enter <E> when done
Operation: Confirm area clear of gas, or apply zero air to sensor.
Enter ACK Zero gas setting acknowledged
Banner: Select span, enter <E> to calibrate sensor
Banner: Apply span gas, then enter <E> to calibrate gas sensor
Operation: Apply calbrat i on gas. Operation: As gas is applied the reading will increase - wait 3
minutes
Enter
10PPM-SP
C 4 PPM
C 4 PPM
CXXXPPM
Enter CAL-OK Calibration Passed - now remove gas
WAIT-300
Operation: Five minute time out bef o re sensor is returned to service.
Sub-Routines
Sub A
Sub B
ME
S T
ME
S T
M E
ST
M E
ST
M E
ST
M E
ST
10PPM-SP
Up 25PPM-SP
Up Adj-SPAN
Enter 25PPM-SP
Enter C 25PPM
C 25PPM
Enter CAL-FAIL
WAIT-300
Mode
(Any)
XXXPPM Default Display
Banner: Select span, enter <E> when done
Operation: Change Span Gas Value t o 25PPM Operation: User adjustable value Operation: Ready for user adjus tment
Banner: Apply 25PPM gas, then enter <E> to calibrate gas sensor
Operation: Apply calbrat i on gas. Operation: No calibration gas appl i e d, or sensor did not respond
correctly. Operation: Five minute time out bef o re sensor is returned to
service. Operation: Hold magnet over Mode Switch for ten senconds t o abort calibration
Banner: Calibration Aborted
Table 5-1
Calibration
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Sub A
Sub B
Sub C
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Model 5100-XX-IT Toxic Gas Sensor Module
6. SERVICE
6.1 SENSOR MODULE CONFIGURATION
The gas sensor module is comprised of the following sub-assemblies (Figure 6-1):
5100-XX-IT Gas Sensor Module
SPL21810 Aluminum Enclosure (SPL32178 316SS Enclosure) SPL21825 Transmitter Assembly XXXXXXX Sensor Assembly (See Appendix B) 5200-XX-IT Sensor (See Appendix B)
6.2 ENCLOSURE REPLACEMENT
Figure 6-1
Module Components
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Model 5100-XX-IT Toxic Gas Sensor Module
The enclosure should be replaced if the cover threads or conduit threads have been damaged, or if the enclosure has been damaged sufficiently that it no longer meets the required NEMA classification.
To replace the enclosure follow the transmitter and sensor assembly removal instructions, remove the damaged enclosure from its conduit, install a new enclosure and replace the transmitter and sensor assembly.
6.3 TRANSMITTER REPLACEMENT
The transmitter assembly should be replaced when it is determined that it is unreliable, noisy or cannot be adjusted for calibration. This may occur due to age, corrosion or failed components.
To replace the transmitter assembly:
a. Remove the cover of the main enclosure b. Unscrew the two thumb screws in the top of the cover plate, lift the assembly and rotate 90
wiring service loop c. Unplug the sensor connector from the transmitter d. Plug connector into new transmitter (be sure to match numbers between connector and socket). e. Restore power and allow a minimum of 3 hours for stabilization before re-calibration
6.4 SENSOR REPLACEMENT
The gas sensor which is located inside the sensor assembly housing can be replaced without replacement of the housing. The gas sensor needs replacement when:
The “CAL-FAIL” message appears after calibration The sensor output signal is noisy, causing erroneous gas level readings
To replace the sensor:
a. Confirm that system power has been removed b. Remove the gas sensor module enclosure cover, c. Unscrew the two thumb screws in the top of the faceplate, lift the transmitter assembly and rotate 90
relieve the wiring service loop. d. Unplug the sensor connector from the transmitter e. Unscrew the old sensor assembly from the enclosure conduit hub. Remove the sensor assembly with its
harness f. Unscrew sensor housing cover from the sensor (be sure to loosen the set screw first) g. Carefully pull the old sensor straight up from the socket h. Press the new sensor into the socket. i. Reverse the preceding steps to install the sensor assembly. j. Allow the new sensor to stabilize for a minimum of 3 hours and then calibrate using the procedure in
Section 6.
6.5 INSTALLATION INSPECTION
o
to relieve the
o
to
Prior to system start-up or trouble shooting the entire system should be visually inspected. The following are guidelines for that inspection:
6.5.1.1 CONTROLLER INSTALLATION
Controller installed in conformance to instruction manual recommendations.
AC power is correctly grounded.
Hot AC and relay connections have safety covers installed.
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Model 5100-XX-IT Toxic Gas Sensor Module
6.5.1.2 SENSOR MODULE INSTALLATION
Module installation in conformance with this manual.
Modules accessible for calibration.
Wiring terminations clean and correct.
6.5.1.3 MOISTURE TRAPS AND RAINSHIELDS
Conduit seals and drains installed to avoid moisture build up in electronics enclosure. Water accumulation in sensor module enclosures is a major cause of damage and system failures - take precautions to seal electrical conduits and provide moisture traps and drains to avoid water damage
Rain-shields installed where applicable.
6.5.1.4 STANDARD VOLTAGES
DC Voltage to be applied to the sensor module must be between 10 VDC and 30 VDC.
6.5.2 INSPECTION AND TROUBLESHOOTING GUIDE
The inspection and troubleshooting guide can be used to step through the system start-up and to determine the corrective action if a fault occurs.
6.5.3 IF MODULE DOES NOT RESPOND TO GAS
1. Repeat calibration procedure.
2. Remove the gas and wait for the timer to completely count down.
3. Apply 50 PPM and verify that the sensor sees 50 PPM gas after calibration.
4. If the sensor still does not see gas, power cycle the unit and repeat calibration.
6.5.4 IF THE MODULE DISPLAYS “STARTING” FOR MORE THAN 1 HOUR
1. Make sure the sensor is placed in an ambient room temperature environment.
2. Power cycle the sensor.
3. Ensure that the sensor is not exposed to the gas of interest during warm-up.
6.5.4.1 IF THE MODULE DOES NOT DISPLAY THE CORRECT PPM
1. Power cycle the unit
2. Recalibrate the sensor.
6.5.4.2 IF THE DISPLAY SHOWS ‘F’
1. Power down the unit
2. Open the enclosure and unplug the sensor assembly from the transmitter board.
3. Plug the sensor back into the transmitter board carefully and ensure a secure fit.
4. Power up the unit.
6.5.4.3 IF THE DISPLAY SHOWS ‘C’
1. Complete calibration and exit to operating mode.
6.5.4.4 IF THE DISPLAY SHOWS ‘S’
1. Check connections with Sentry Connections.
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Model 5100-XX-IT Toxic Gas Sensor Module
7. APPENDICES
APPENDIX A - SPECIFICATIONS
Sensor type: Electrochemical
Max. Range 0-25 %Vol 0-1000 PPM 0-100 PPM 0-10 PPM User Settings Range 0-100, 0-500, variable 0-10, variable 0-5, variable Zero Drift +/- 0.1% +/- 1 PPM +/- 0.5 PPM +/- 0.5 PPM Repeatability +/- 0.2% +/- 1 PPM +/- 1 PPM +/- 0.5 PPM Linearity +/- 0.2% +/- 1 PPM +/- 1 PPM +/- 0.5 PPM Resolution +/- 0.1% 0.5 PPM 0.1 PPM 0.1 PPM Response Time (1) <10 sec <25 sec. <30 sec. <60 sec Accuracy +/- 0.2% +/- 1 PPM +/- 0.5 PPM +/- 0.5 PPM Sensor Life 2 years 2 years 2 years 2 years
(1) Response time to 90% full signal value for applied concentration (2) Sensor life typical for use at standard temperature and pressure with occasional exposure to gas of interest
Output:
Display: Fixed and Scrolling LED Relays (Optional): 8 Amp, High Alarm, Low Alarm, 2 Amp Trouble all SPDT Analog Output (Optional) Analog 4-20 mA (Trouble 0 mA, Calibration 1.5 mA) Signal Output: Sentry bus Serial RS-485 Modbus RTU
Input:
Remote Alarm Reset: Normally open digital input (supervised or non-supervised)
Electrical Data:
Power consumption: 2 watts Connection type: 3 wire Input voltage: 24 VDC nominal: 10-30VDC
5100-03-IT O2 5100-04-IT CO 5100-05-IT H2S 5100-06-IT Cl2
Operating Range:
Ambient Temp (oF) 5 to 122 oF -4 to 122 oF -40 to 122 oF -4 to 122 oF Ambient Temp (oC) -15 to 50 oC -20 to 50 oC -40 to 50 oC -20 to 50 oC Relative Humidity 5 – 99% 5 – 99% 5 – 99% 5 – 99%
Enclosure:
Material - Standard: Polyester powder-coated, sand-cast, copper-free aluminum Material - Stainless Steel Option 316 Stainless Steel (FM approval pending) Dimensions: 7.5 x 5.0 x 4.8 inches Al, 7.5 x 5.0 x 4.4 inches SS (H x W x D) (21.6 x 12.7 x 12.2 cm) Weight: 2.7 lb. (1.3 Kg) (standard Aluminum enclosure)
5.4 lb. (2.6 Kg) 316 Stainless Steel Housing: NEMA 4X
Electrical Classification
Performance: Explosion proof, Class 1, Div. I, Groups B, C, D Class I, Zone 1, groups IIB+H2 IP66
Approvals: FM Approved Performance and Safety Approval Pending
5100-03-IT O2 5100-04-IT CO 5100-05-IT H2S 5100-06-IT Cl2
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Model 5100-XX-IT Toxic Gas Sensor Module
Modbus:
Baud: 38400 (Adjustable 2400 to 38400 Baud)
Parity: None
Stop bit: 1 Data bits: 8
Flow Control: None Memory map: Appendix E
Warranty: Limited Warranty 2 years
Specifications subject to change without notice
Ordering Information:
5100 - XX - IT - YY - ZZ
|- 5100 Series | | | | |- 03 = O |- 04 = CO |- IT Series | | |- 05 = H |- 06 = Cl
| | |
2
S |- Al (Aluminum Enclosure) |- 01= Sentry, RS-485, 4-20mA, & Digital Input
2
|- SS (Stainless Steel) |- 02= Sentry, RS-485, 4-20mA, Digital Input & Relays
2
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APPENDIX B: - MODEL NUMBERS & PARTS LIST
Sensor Module
5100-03-IT Gas Sensor Module, Oxygen 5100-03-IT-SS Gas Sensor Module, Oxygen, Stainless Steel Enclosure 5100-04-IT Gas Sensor Module, Carbon Monoxide 5100-04-IT-SS Gas Sensor Module, Carbon Monoxide, Stainless Steel Enclosure 5100-05-IT Gas Sensor Module, Hydrogen Sulfide 5100-05-IT-SS Gas Sensor Module, Hydrogen Sulfide, Stainless Steel Enclosure 5100-06-IT Gas Sensor Module, Chlorine 5100-06-IT-SS Gas Sensor Module, Chlorine, Stainless Steel Enclosure
Model 5100-XX-IT Toxic Gas Sensor Module
Options
5394-52 Remote Sensor/Display Option 5311-00 Rainshield
Calibration Items
1250-01 Gas Sensor Calibration Kit, Type A (O 1250-03 Gas Sensor Calibration Kit, Type C (Cl
2, CO, H2
)
2
1260-00 Gas Cylinder, Air, (Type A) , 105 litres 1260-04 Gas Cylinder, CO 100 PPM, (Type A) 57 litres 1260-05 Gas Cylinder, H 1260-06 Gas Cylinder, Cl
S in N2, 25 PPM, (Type A) 57 litres
2
, 5 PPM, (Type C) 104 litres
2
1260-13 Gas Cylinder, CO, 1000 PPM, (Type A), 105 liters 5360-00 Calibrator Head Standard 1256-01 Regulator Type A Calibrator
1265-03 Regulator Type C Calibrator 5358-01 Calibration Adapter - Direct, Standard 5358-50 Calibration/Configuration Magnetic Tool
Spare Parts
5200-03-IT Sensor, for 5100-03-IT
5200-04-IT Sensor, for 5100-04-IT
5200-05-IT Sensor, for 5100-05-IT
5200-06-IT Sensor, for 5100-06-IT
SPL21834 Sensor Assembly, Aluminum, for 5100-03-IT
SPL21832 Sensor Assembly, Aluminum, for 5100-04-IT
SPL21830 Sensor Assembly, Aluminum, for 5100-05-IT
SPL21833 Sensor Assembly, Aluminum, for 5100-06-IT
SPM27082 Sensor Assembly, 316SS, for 5100-03-IT SPM27083 Sensor Assembly, 316SS, for 5100-04-IT
SPM27079 Sensor Assembly, 316SS, for 5100-05-IT
SPM27084 Sensor Assembly, 316SS, for 5100-06-IT
SPL21824 Transmitter
SPL21810 Enclosure, Transmitter, Aluminum
SPL21825 Enclosure Transmitter, 316SS
SPL21825 Interface Board with Relay
SPL27826 Interface Board without Relay
S)
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Model 5100-XX-IT Toxic Gas Sensor Module
APPENDIX C: LIMITED WARRANTY
SIERRA MONITOR CORPORATION warrants its products to be free from defects in workmanship or material under normal use and service for two years after date of shipment. SMC will repair or replace without charge any equipment found to be defective during the warranty period. Final determination of the nature and responsibility for defective or damaged equipment will be made by SMC personnel.
All warranties hereunder are contingent upon proper use in the application for which the product was intended and do not cover products which have been modified or repaired without SMC approval or which have been subjected to accident, improper maintenance, installation or application, or on which original identification marks have been removed or altered. This Limited Warranty also will not apply to interconnecting cables or wires, consumables (ie. calibration gases, batteries, sensors), nor to any damage resulting from battery leakage.
In all cases SMC’s responsibility and liability under this warranty shall be limited to the cost of the equipment. The purchaser must obtain shipping instructions for the prepaid return of any item under this warranty provision and compliance with such instruction shall be a condition of this warranty.
Except for the express warranty stated above, SMC disclaims all warranties with regard to the products sold hereunder including all implied warranties of merchantability and fitness and the express warranties stated herein are in lieu of all obligations or liabilities on the part of SMC for damages including, but not limited to, consequential damages arising out of/or in connection with the use or performance of the product.
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Model 5100-XX-IT Toxic Gas Sensor Module
APPENDIX D: REMOTE SENSOR/DISPLAY DRAWING 5394-52
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Model 5100-XX-IT Toxic Gas Sensor Module
APPENDIX E: MODBUS MEMORY MAP
Read Register Table
Register Description Comments
40001 Concentration Gas Concentration multiplied by 100 40002 Temperature Temperature in degrees Celsius scalled by a factor of 100 40003 High Alarm Relay Boolean indicating the High Alarm Status, 0 No Alarm, 1 High Alarm 40004 Low Alarm Relay Boolean indicating the Low Alarm Status, 0 No Alarm, 1 Low Alarm 40005 Low Alarm Value Low alarm set point, used for activating Alarms 40006 High Alarm Value High alarm set point, used for activating High Alarms 40007 Reserved 40008 Reserved 40009 Reserved 40010 Reserved 40011 Trouble Bits 0 for no trouble 40012 Trouble 1 for any trouble, 0 for no trouble 40013 High Alarm Immediate Like 40003. but never latched 40014 Low Alarm Immediate Like 40004, but never latched 40015 Random ID Randomly generated permanent ID of sensor 40016 Restart Count 40017 Run time – high In minutes 40018 Run time – low In minutes 40019 Max. gas value *scale ((see 40024) 40020 Model 51005, 51003, 51004, 51006, etc 40021 Range *scale (see 40024) 40022 Units 3 is PPM 40023 Temperature Units 0 is C, 1 is F 40024 Gas Scale Value like 1 or 100 40025 Temperature Scale Value like 1 or 100
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