Sierra Monitor Corporation 5100-03-IT, 5100-05-IT, 5100-04-IT, 5100-06-IT, 5100-10-IT User Manual

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Manual # T12020

Document Revision: D4

Model 5100-XX-IT

IT Series

Toxic Gas Sensor Module

5100-03-IT 5100-04-IT 5100-05-IT (FM Approved) 5100-06-IT 5100-08-IT 5100-10-IT 5100-12-IT 5100-21-IT 5100-25-IT 5100-26-IT 5100-88-IT

APPLICABILITY & EFFECTIVITY

Effective for all systems manufactured after May 2017.

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protected by the copyright laws of the United States, international copyright treaties, and all other applicable national laws. This manual contains information regarding technology that is protected under one or more issued or pending United States and foreign patents.

Sierra Monitor and Sentry IT are trademarks of Sierra Monitor Corporation. All other trademarks are the property of their respective owners.

This manual is licensed to users of Sierra Monitor products and may be copied, in whole or in part. The offices of Sierra Monitor are located at:

Sierra Monitor Corporation 1991 Tarob Court Milpitas, CA 95035 USA

Customer Service: Telephone: (408) 262-6611

Fax: (408) 262-9042 Toll-Free: (800) 727-4377

Email: support@sierramonitor.com Website: www.sierramonitor.com

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FM PERFORMANCE APPROVAL

ONLY THE FOLLOWING ITEMS, FUNCTIONS AND OPTIONS ARE FM* APPROVED

Model 5100-05-IT Hydrogen Sulfide Gas Sensor Module

Sensor Module

Model 5100-05-IT

Sensor Module - Hydrogen Sulfide

Calibration Equipment

Model 1250-01

Gas Sensor Calibration Kit, Type A

Model 1260-05

Hydrogen Sulfide in N2, 25 ppm Gas Cylinder

Model 1260-45

Hydrogen Sulfide in N2, 10 ppm Gas Cylinder

Model 5358-01

Calibration Adapter

Notes:

1) Apparatus must be installed in accordance with National Electrical Code.

2) FM Comments *FM Approvals, a subsidiary of FM Global

 Project# 3034435

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TABLE OF CONTENTS

Product Description ...................................................................................................................... 7

1.1 General ......................................................................................................................................................... 7

1.2 Product Configuration .................................................................................................................................. 8

1.3 Theory of Operation ..................................................................................................................................... 8

1.4 Modes of Operation ...................................................................................................................................... 8

1.4.1 Sentry Interface ..................................................................................................................................... 8

1.4.2 Modbus Operation ................................................................................................................................ 8

1.4.3 Analog Operation .................................................................................................................................. 8

1.4.4 Remote Sensor ..................................................................................................................................... 8

1.4.5 HART Connection ................................................................................................................................. 9

1.4.6 Remote Alarm Reset ............................................................................................................................. 9

1.4.7 Optional Integral Relays ........................................................................................................................ 9

1.5 Mechanical ................................................................................................................................................... 9

1.5.1 Enclosure .............................................................................................................................................. 9

1.5.2 Transmitter Electronics ....................................................................................................................... 11

1.5.3 Sensor Assembly ................................................................................................................................ 11

1.6 Interconnect Wiring .................................................................................................................................... 11

1.7 Power Requirements .................................................................................................................................. 11

Cautions & Warnings .................................................................................................................. 12

2.1 Introduction ................................................................................................................................................. 12

2.2 Gas Sensor Modules – General ................................................................................................................. 12

2.3 Wiring Warnings ......................................................................................................................................... 12

2.4 Calibration Frequency ................................................................................................................................ 12

Quick Start ................................................................................................................................... 13

3.1 Overview .................................................................................................................................................... 13

3.2 Wiring ......................................................................................................................................................... 13

3.3 Module Installation ..................................................................................................................................... 13

3.4 Transmitter Installation ............................................................................................................................... 13

3.5 Startup and Operation ................................................................................................................................ 14

3.6 Zero Stabilization ....................................................................................................................................... 14

Installation ................................................................................................................................... 15

4.1 Sensor Module Locations ........................................................................................................................... 15

4.2 Wiring ......................................................................................................................................................... 16

4.2.1 Analog 4-20 mA Operation ................................................................................................................. 16

4.2.2 Modbus Operation Using RS-485 Connection.................................................................................... 16

4.2.2.1 Termination Resistor Jumpers .................................................................................................... 16

4.2.2.2 Bias Jumpers (BIAS A, BIAS B) ................................................................................................. 16

4.2.3 Sentry Operation Using Sentry Connection ........................................................................................ 16

4.2.4 General ............................................................................................................................................... 17

4.3 Enclosure Installation ................................................................................................................................. 17

4.4 Transmitter and Sensor Installation ........................................................................................................... 18

4.5 Module Address Switch .............................................................................................................................. 19

Operation ..................................................................................................................................... 25

5.1 Introduction ................................................................................................................................................. 25

5.2 Data Entry Keypad ..................................................................................................................................... 25

5.3 Main Menu .................................................................................................................................................. 26

5.4 Set-Up ........................................................................................................................................................ 27

5.5 Maintenance Sub-Menu ............................................................................................................................. 29

Calibration ................................................................................................................................... 30

6.1 Calibration Frequency ................................................................................................................................ 30

6.2 Calibration Preparation .............................................................................................................................. 30

6.3 Calibration Gas Delivery Methods.............................................................................................................. 30

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6.4 Sensor Exposure to Gas ............................................................................................................................ 31

6.5 Calibration Sub-Menu ................................................................................................................................ 32

6.5.1 5100-03-IT Oxygen Deficiency ........................................................................................................... 33

6.5.2 5100-88-IT Carbon Dioxide................................................................................................................. 33

Appendix A. Service .......................................................................................................................... 34

Appendix A.1. Sensor Module Configuration ........................................................................................................ 34

Appendix A.2. Enclosure Replacement ................................................................................................................ 34

Appendix A.3. Transmitter Replacement .............................................................................................................. 35

Appendix A.4. Sensor Replacement ..................................................................................................................... 35

Appendix A.5. Installation Inspection .................................................................................................................... 36

Appendix A.5.1. Controller Installation .............................................................................................................. 36

Appendix A.5.2. Cabling Installation ................................................................................................................. 36

Appendix A.5.3. Sensor Module Installation ..................................................................................................... 36

Appendix A.5.4. Moisture Traps and Rainshields ............................................................................................. 36

Appendix A.5.5. Standard Voltages .................................................................................................................. 36

Appendix A.6. Inspection and Troubleshooting Guide.......................................................................................... 36

Appendix A.6.1. Ir Module Does Not Respond to Gas ...................................................................................... 36

Appendix A.6.2. Module Displays “Starting” for more than 1 Hour ................................................................... 36

Appendix A.6.3. Module Does Not Display the Correct %PPM ........................................................................ 37

Appendix A.6.4. Display Shows ‘F’ – Sensor Missing or Bad Sensor .............................................................. 37

Appendix A.6.5. Module Shows “***Calibration Required***” ........................................................................... 37

Appendix A.6.6. Display Shows “H” or “L” ......................................................................................................... 37

Appendix A.6.7. Display Shows “M” – Not Calibrated ....................................................................................... 37

Appendix A.6.8. Display Shows “C” – Calibration Mode ................................................................................... 37

Appendix A.6.9. Display Shows “S” – Sentry Connection ................................................................................. 37

Appendix A.6.10. Diagnostic LEDs ................................................................................................................... 37

Appendix B. Specifications ............................................................................................................... 38

Appendix C. Model Numbers and Parts List .................................................................................... 41

Appendix D. Limited 2 Year Warranty .............................................................................................. 42

Appendix E. Remote Sensor Drawing .............................................................................................. 43

Appendix F. Modbus Memory Map ................................................................................................... 44

Appendix G. HART ............................................................................................................................. 45

Appendix H. Gas Sensor Module Calibration .................................................................................. 52

Appendix H.1. Calibration for 5100-25-IT ............................................................................................................. 52

Appendix H.2. Calibration for 5100-26-IT ............................................................................................................. 56

Appendix I. 5100-88-IT Dimensions .................................................................................................. 57

Appendix J. 5100-05-IT FM Performance Approval ......................................................................... 58

Appendix K. 5100-XX-IT SIL-2 Certificates ....................................................................................... 60

Appendix L. 5100-05-IT ATEX Certificate ......................................................................................... 60

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LIST OF FIGURES

Figure 1: Model 5100-XX-IT Toxic Gas Sensor Module – Mounting Options ............................................................9

Figure 2: Model 5100-05-IT-S1/S2 Toxic Gas Sensor – Stainless Steel Enclosure, Dimensions .......................... 10

Figure 3: Model 5100-05-IT-A1/A2 Toxic Gas Sensor – Cast Aluminum Enclosure, Dimensions ......................... 10

Figure 4: Specific Gravities ...................................................................................................................................... 15

Figure 5: Typical Mounting Options ......................................................................................................................... 15

Figure 6: Minimum Wire Gauges ............................................................................................................................. 17

Figure 7: Sensor Module Address Switch Positions ................................................................................................ 19

Figure 8: Transmitter Face Plate ............................................................................................................................. 19

Figure 9: Interface Board Connectors ..................................................................................................................... 20

Figure 10: RS-485 – Termination, BIAS Jumper ..................................................................................................... 20

Figure 11: mA Circuit Types .................................................................................................................................... 21

Figure 12: 4-20 mA Circuit Type Connections for 5100-XX-IT ................................................................................ 22

Figure 13: Wiring Connections for Modbus and Sentry Interface ........................................................................... 23

Figure 14: Wiring Connections for Remote Alarm Reset ........................................................................................ 24

Figure 15: Face Plate with Operator Keypad .......................................................................................................... 25

Figure 16: Master Menu .......................................................................................................................................... 26

Figure 17: Operation Display Values ....................................................................................................................... 26

Figure 18: Set-Up Configuration Part 1 ................................................................................................................... 28

Figure 19: Set-Up Configuration Part 2 ................................................................................................................... 29

Figure 20: Maintenance Menu ................................................................................................................................. 29

Figure 21: Model 5358-01 Calibration Adapter ....................................................................................................... 30

Figure 22: Calibration Sub-Menu ............................................................................................................................. 32

Figure 23: Module Components .............................................................................................................................. 34

Figure 24: Remote Sensor Drawing ........................................................................................................................ 43

Figure 25: Wiring Connections Table ...................................................................................................................... 45

Figure 26: 4-20 mA Circuits Types 5100-XX-IT – Connections - HART ................................................................. 46

Figure 27: Electrolyte Replacement ........................................................................................................................ 52

Figure 28: Sensor Assembly – Exploded View ....................................................................................................... 54

Figure 29: Model 5100-25-IT-A1/A2 and Model 5100-26-IT-A1/A2 ........................................................................ 55

Figure 30: Model 5100-25-IT-S1 and Model 5100-26-IT-S1 ................................................................................... 55

Figure 31: Model 5100-88-IT-A1 Dimensions ......................................................................................................... 57

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PRODUCT DESCRIPTION

1.1 General

The Model 5100-XX-IT Toxic Gas Sensor Module is a smart transmitter and member of the IT Series family and it offers a broad array of features including:

• Integral alphanumeric LED display

• Up to 180 day calibration frequency

• FM Approval for performance and safety

• SIL-2 Certified

• Optional integral alarm relays (3)

• 4-20 mA output

• Modbus® RTU interface 1

• SMC Sentry interface

• Optional HART interface

• 316 Stainless steel enclosure option

• Remote sensor option

• Low maintenance and operation costs

• ATEX Approval (5100-05-IT)

The 5100-XX-IT is designed and approved for installation and operation in hazardous locations. Members of the 5100-XX-IT Series Toxic Gas family include:

• 5100-03-IT Oxygen 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

• 5100-08-IT Chlorine Dioxide Gas Sensor Module

• 5100-10-IT Sulfur Dioxide Gas Sensor Module

• 5100-12-IT Nitrogen Dioxide Gas Sensor Module

• 5100-21-IT Hydrogen Chloride Gas Sensor Module

• 5100-25-IT Ammonia Gas Sensor Module

• 5100-26-IT Hydrogen Fluoride Gas Sensor Module

• 5100-88-IT Carbon Dioxide Gas Sensor Module

1 ®

Registered trademark of Schneider Electric

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1.2 Product Configuration

Various module mounting configurations can be implemented without special fixtures. Where applicable, these options are factory configured prior to shipment. Mounting configuration can be selected by the installer or field technician and are fully described in this manual. Sensor must always be oriented downward.

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.

Sierra Monitor electrochemical sensors provide improved reliability by allowing the gas to diffuse into the sensor through a capillary port, rather than diffusing through membranes. The result is an extremely stable sensor with very low temperature and pressure coefficients and the capability to monitor gas as ppm.

1.4 Modes of Operation

1.4.1 Sentry Interface IT gas sensor modules can be installed on Sierra Monitor Sentry Model 5000 controllers Ver. 6.XX MFD after

9/1/95. 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 accessible from the cover plate as illustrated in Figure 8. Figure 13 in this manual provides the wiring terminations for connections to the Sentry controller.

NOTE: The Model # 5100-88-IT CO2 gas sensor module range is 0-5000 ppm. Therefore, the Sentry

Controller must be configured for a 0-100 % full scale input. The Sentry cannot display engineering units up to 5000. The alarm set points need to be set as a percentage of full scale. For example, a 2500 ppm alarm set point is equal to 50% scale.

When the module is operated in conjunction with a Sentry controller, the alarm relay set-up (Section 5.3) should

be set to “Sentry”, allowing the Sentry controller to manage alarm relay action rather than the 5100-XX-IT Gas Sensor 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 4.5) allows the user to select up to 15 different Modbus addresses. Also, an additional 254 Modbus addresses are available via menu selection. Figure 13 in this manual provides the wiring terminations for Modbus connections. The 5100-XX-IT provides the wiring terminations for Modbus connections.

1.4.3 Analog Operation The analog 4-20 mA interface allows direct connection to standard controller and distributed system. The module

is an active current source. The standard configuration is set up for a 3-wire non-isolated connection. An optional 4-wire isolated connection

is also available and can be enabled by changing JP1 and JP2. (Figure 12)

1.4.4 Remote Sensor The Remote Sensor option can be used to remotely mount some sensors up to 15’ from the transmitter. Refer to

Appendix E for allowable distances.

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1.4.5 HART Connection A HART interface option is available. Refer to Appendix G for information.

1.4.6 Remote Alarm Reset An input is available for connection of remote alarm reset. Figure 14 provides the wiring termination for

connecting the remote alarm reset. This only resets local alarms, not Sentry alarms.

1.4.7 Optional Integral Relays The optional relays are integral to the gas sensor module and are rated as SPDT, 250V AC, 5 Amps* for the High

Alarm and Low Alarm relays and SPDT, 250V AC, 0.25 Amp for the Trouble relay. * HART option alarm relays are all SPDT, 250V AC, 2 Amp If the gas sensor module is provided with the optional relays, it will include Terminal P4 on the interface board

(Figure 9 and Figure 10). Relay output connections are on P4.

1.5 Mechanical

The sensor module is comprised of the following three primary components:

1.5.1 Enclosure Standard on the 5100-XX-IT is an explosion-proof, rain-tight cast aluminum electrical housing (Figure 3) with

three ¾” FNPT conduit hubs. The 5100-XX-IT-S has a 316 Stainless Steel enclosure (Figure 2). Both enclosure covers have a viewing window. The design of the enclosure allows 3-way mounting choices as shown in

Figure 1.

NOTE: Module installation must be such that it is mounted vertically with sensor pointing downward.

Figure 1: Model 5100-XX-IT Toxic Gas Sensor Module – Mounting Options

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NOTE: Figure 2 and Figure 3 are valid for all except 5100-25/26-IT. See Appendix H.

Figure 2: Model 5100-05-IT-S1/S2 Toxic Gas Sensor – Stainless Steel Enclosure, Dimensions

Figure 3: Model 5100-05-IT-A1/A2 Toxic Gas Sensor – Cast Aluminum Enclosure, Dimensions

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1.5.2 Transmitter Electronics Electronic Assembly consisting of one printed circuit board assembly mounted under a cover plate, plugged into

one field termination board. Connectors for wiring for power, signal interface and alarm relays are located on the bottom of the termination board.

1.5.3 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.

1.6 Interconnect Wiring

Not supplied with the sensor module, but necessary to the installation and operation is the shield cable 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.

1.7 Power Requirements

The modules operate on 24V DC power between 10V DC and 30V DC. Filtered, regulated DC power must be supplied from a separate source or from an approved Sentry or IT controller.

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CAUTIONS & WARNINGS

2.1 Introduction

Although the 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 Gas Sensor Modules – General

Avoid installing sensor modules where they will be unnecessarily exposed to wind, dust, water (i.e. 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 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 O2, CO, H2S, and SO2 sensors are 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 shields 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 "DO NOT PAINT".

2.3 Wiring Warnings

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 shielding is used, it is recommended that shields be grounded at the controller and nowhere else.

• All splices must be via either a termination hardware system or soldered. Improperly spliced cable can

result in corrosion, resistance changes and system errors. The use of wire nuts and crimp-on connectors is unacceptable.

NOTE: Installation and wiring must be in accordance with the National Electrical Code. Voltage AC

conductors are not to be run in the same conduit as voltage DC conductors.

2.4 Calibration Frequency

The H2S calibration frequency is six months or 180 days. However, prudent gas detector maintenance practices normally suggest a simple recalibration following incidences of exposure to high levels of gas that would lead to alarm activation within any system utilizing the output of the gas sensor module.

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QUICK START

3.1 Overview

The gas sensor module has been supplied factory calibrated and ready for immediate installation and operation. An installer familiar with installation and operation of gas detection products can use this section to begin immediate use of the module.

3.2 Wiring

See Section 4.2 to determine if 3-wire or 4-wire operation is necessary. Provide two conductor twisted shielded wiring from the power supply/control device to the sensor module location.

Use wire that is 18 AWG or larger.

3.3 Module Installation

The sensor can be mounted in a variety of configurations supported by the conduit. See Figure 3 to determine which configuration is best for your specific application. The default configuration enables the modules to be put in line with other modules with the sensor element below the transmitter. To change the configuration simply remove the transmitter and rotate to the appropriate configuration and remount the standoffs and transmitter.

The module is designed to be installed on a ¾” NPT or M20 conduit. During installation heed the following:

• The installation must meet any hazardous environment codes for electrical equipment.

• The sensor module enclosure mounting must be spaced far enough from any vertical surface to allow

removal and replacement of the sensor assembly which is threaded into one ¾” conduit entry.

• Sensor housing must be oriented vertically pointing downward.

• If module is installed outdoors it is recommended that it be sheltered from direct sunlight.

3.4 Transmitter Installation

To install the transmitter printed circuit assembly into the housing, carefully turn the faceplate so that the printing is in the correct horizontal position for the mounting configuration and slide the assembly over the two stand-offs in the enclosure.

Hand tighten the two captive panel thumb screws into the stand-offs. Replace the enclosure cover prior to providing power to the transmitter.

NOTE: If the transmitter is installed in a classified hazardous area, replace the threaded cover prior to

providing power.

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3.5 Startup and Operation

To begin operation of the sensor module, activate the instrument loop with 10-30V DC. Each time the sensor module is powered up it will perform a warm-up for approximately 1.0 minutes (60 seconds). During this time the

display will read “Starting”. The loop output will be held at 4 mA.

NOTE: If the sensor is uncalibrated, the startup display will state “UNCALIB” instead of “STARTING”. NOTE: The 5100-06-IT, 5100-08-IT, 5100-25-IT, 5100-26-IT and 5100-88-IT require 300 seconds warm-up

period. After the warm-up period has expired, the display will indicate the gas concentration. Also, the instrument loop will be released to output current in the range of 4 to 20 mA. The actual current is linear with the gas concentration and depends on the selected range. For instance, when the range of 0 to 50 PPM has been selected, a current of 4 mA corresponds to 0 PPM and a current of 20 mA corresponds to 50 PPM.

3.6 Zero Stabilization

All electrochemical sensors require at least 30 minutes on power prior to calibration. This allows the electrode potentials to equilibrate, resulting in a stable zero signal level.

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INSTALLATION

4.1 Sensor Module Locations

NOTE: All IT modules are factory pre-configured and calibrated. All modules are tagged to indicate the

configuration including the sensor module number Identify all components during unpacking and install using the factory configuration.

The gas sensor module utilizes a diffusion type sensor which should be located close to either the expected source or destination of the gas hazard. If the gas is heavier than air, the sensor module should be installed within 24 inches of the ground or floor. If it is lighter than air, move it above 6’.

After optimum locations are determined based on the above recommendations, consideration should be given to placing the sensor modules in locations which are accessible for calibration service. Slight adjustments to the location of the sensor module may have little impact on effectiveness but major effect on accessibility.

• 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.

Model

Gas

Gas Density

N/A

Air

1.00

5100-04-IT

0.97

5100-05-IT

H2S

1.19

5100-06-IT

Cl2

2.49

5100-08-IT

ClO2

3.09

5100-10-IT

SO2

2.26

5100-12-IT

NO2

2.12

5100-21-IT

HCl

1.27

5100-25-IT

NH3

0.60

5100-26-IT

1.86

5100-88-IT

CO2

1.53

Figure 4: Specific Gravities

Figure 5: Typical Mounting Options

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4.2 Wiring

4.2.1 Analog 4-20 mA Operation

For a 3-wire non-isolated connection, set jumpers, located on the bottom of the transmitter board, to the lower position as illustrated in Figure 12. Verify that both jumpers are in the position marked by 3-wire. When using a 3-wire connection, a minimum of an 18 AWG, 3-conductor shielded cable must be used. A cable shield must never be used as a conductor. Larger gauge wire is recommended with distances over 1000’. Connect wires as shown in Figure 10.

For a 4-wire isolated connection, set jumpers, located on the bottom of the transmitter board, to the upper position as illustrated in Figure 10. Verify that both jumpers are in the position marked by 4-wire. When using a 4-wire connection, a minimum of 2 each of an 18 AWG, 2 conductor twisted/shielded pair cable must be used. A cable shield must never be used as a conductor. Larger gauge wire is recommended with distances over 1000’. Connect wires as shown in Figure 10.

4.2.2 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 RS485 half-duplex communication. The installation may be planned in a manner which provides up to 32 sensor modules on a single home run.

Standard default RS485 Settings are: 38,400 baud, 8 bits, 1 stop bit, no parity

4.2.2.1 Termination Resistor Jumpers

Termination resistors are used in RS-485 wire runs to provide impedance matching. The IT series modules use a 120 Ohm resistor for this function. The cable being used for this RS-485 connection must have a minimum of 100 Ohm impedance with a maximum of 120 Ohms.

Installations where the cable length is under 100’, termination resistors may not be required. In installations where

the cable length is greater than 100’, it is recommended to place the termination jumpers on the first device and

last device on the RS-485 wire run. Termination jumpers must be removed from all other modules connected between the first and last device. The first device in the RS-485 multiplexed bus is usually a gas controller or PLC. Factory term resistor setting is “not enabled.”

4.2.2.2 Bias Jumpers (BIAS A, BIAS B)

Bias resistors are used to force RS-485 receiver outputs to a known (fail-safe) state, when the bus is idle. Bias jumpers are always installed in pairs as the bias must be placed on both the TX A and TX B lines. Sierra Monitor’s IT series of toxic gas sensors automatically apply the bias jumpers, and are factory installed so that the bias is always enabled.

4.2.3 Sentry Operation Using Sentry Connection

See Figure 13. Use a minimum of 18 AWG, 3-conductor cable up to 2000’. The cable may or may not be shielded. We recommend shielded cable in circumstances that there could be RF or EM interference present. Shield to be terminated and grounded only at the Sentry controller. Shield must be cut and dressed at the module end so that no part of it comes in contact with the conduit or ground.

NOTE: Be sure to follow all local electric code and safety requirements when installing the 5100-XX-IT

Gas Sensor Module.

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4.2.4 General

Install conduit as required by local code or construction specifications. Provide for splice boxes where multiple modules will be wired to a single run. Pull conductors of the correct gauge wire from the controller to each splice box and from the respective splice box to each planned module location. See for proper wire termination in the splice box. Twisted wire secured with wire nuts is not an acceptable splice.

NOTE: 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 75°C. If cable runs through higher temperature environments, it must be specified for that environment.

4.3 Enclosure Installation

To protect the transmitter and sensor assembly they should be removed from the enclosure and preserved until final installation and wiring termination.

Number

Modules

Maximum Length of Wire Run (feet)

500

1,000

2,000

3,000

5,000

14 2 18

xx 3 18

Figure 6: Minimum Wire Gauges

Prior to installation and wiring complete the following steps.

1. Remove the transmitter from the module housing by:

a) Unscrew the two captive panel screws on the faceplate. b) Lift the transmitter out of the enclosure. c) Unplug the sensor cable from transmitter connector P2. d) Remove the sensor assembly from the enclosure hub.

2. Install the module enclosure onto the end of the supply conduit and/or bolt into position as required.

NOTE: When enclosure earth grounding is required for the installation a grounding lug is located in the

base of the enclosure. Install the earth ground under the green ground screw.

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4.4 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 9 and as detailed in the connector tables below.

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 then push together.

5. Turn the rotary switch to correct sensor address if required.

6. Carefully return the transmitter to the enclosure, installing it over the two stand-off’s. Tighten the retaining screws into the stand-offs.

7. Cycle power to accept module address change.

8. Establish the module address according to Section 4.5.

NOTE: The starting delay period normally takes approximately 3 minutes but under some circumstances

can take longer. For optimum performance, it is recommended that a calibration be performed after 24 hours of operation.

PCB Label

Function

Switch

IN +

Digital Input SW +

IN -

Digital Input SW -

4-20

IN +

4-20 mA Input +

IN -

4-20 mA Input -

GND

Ground

4-20

OUT +

4-20 mA Output +

OUT -

4-20 mA Output -

RS 485

RS 485 (+) (A)

2 - RS 485 (-) (B)

3 S RS 485 shield (Isolated GND)

RS 485 (+) (A)

5 - RS 485 (-) (B)

6 S RS 485 shield (Isolated GND)

P3B

1 P V DC Power

Sentry Signal or Communication

3 G V DC Ground

P3A

4 P V DC Power

Sentry Signal or Communication

6 G V DC Ground

P4*

PCB Label

Function

WARNING

N/C

Low Alarm Relay NC

COM

Low Alarm Relay COM

N/O

Low Alarm Relay NO

ALARM

N/C

High Alarm Relay NC

COM

High Alarm Relay COM

N/O

High Alarm Relay NO

TRBL**

N/C

Trouble Alarm Relay NC

COM

Trouble Alarm Relay COM

N/O

Trouble Alarm Relay NO

* P4 Connections are installed only when the optional

Relays are included

** Trouble relay is a fail-safe so it is energized for normal operation, functions are labeled for normal operation.

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4.5 Module Address Switch

For digital interface applications the module address switch (or Modbus node) Figure 8 must be set per the table below.

Position

Address

Position

Address

Sensor 1

Sensor 09

Sensor 2

Sensor 10

Sensor 3

Sensor 11

Sensor 4

Sensor 12

Sensor 5

Sensor 13

Sensor 6

Sensor 14

Sensor 7

Sensor 15

Sensor 8

Software Menu

Figure 7: Sensor Module Address Switch Positions

NOTE: For Sentry (PSG) 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 8: Transmitter Face Plate

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Figure 9: Interface Board Connectors

Figure 10: RS-485 – Termination, BIAS Jumper

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Figure 11: mA Circuit Types

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Figure 12: 4-20 mA Circuit Type Connections for 5100-XX-IT

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5100-XX-IT TO MODBUS DEVICE

5100-XX-IT TO SENTRY

Figure 13: Wiring Connections for Modbus and Sentry Interface

(dry contact only unpowered)

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Figure 14: Wiring Connections for Remote Alarm Reset

5100-XX-IT Remote Alarm Reset (Unsupervised)

(dry contact only unpowered)

SWITCH IN

GND

- -

IN IN

OUT

SWITCH

4-20 4-20

4.7K OHM (CUSTOMER SUPPLIED)

5100-XX-IT Remote Alarm Reset (Supervised)

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OPERATION

5.1 Introduction

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.

5.2 Data Entry Keypad

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 under the faceplate above and below the LED display and are labeled M , E ,  and  as shown in

Figure 15.

Figure 15: Face Plate with Operator Keypad

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5.3 Main Menu

Key

Function

Display

Description

Reference

Mode

Switch [M]

▲

▼

Enter

Switch [E]

▲

▼

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

XXX PPM

Normal condition - default display

Mode

ALMRSET:

Mode Function - Alarm Reset

▲

▼

Banner: "Press [E] to reset alarm"

RESET

Alarm Reset

▲

▼

XXX PPM

Default Display

Mode

ALMRSET:

Mode Function - Alarm Reset

▲

▼

Mode

CALIB:--

Mode Function - Calibrate

Figure 21

▲

▼

Mode

SETUP:--

Mode Function - Set up alarms, relays, etc

Figure 18 & Figure 19

▲

▼

Mode

MAINT:--

Mode Function - Maintenance

Figure 20

▲

▼

Mode

EXIT-?--

Exit Menu

▲

▼

Enter

XXX PPM

Apply Selected Mode (Exit)

▲

▼

XXX PPM

Default Display (Once a minute the sensor displays module address)

Figure 16: Master Menu

Figure 17 defines the key operational displays on the operator interface.

Display

Description

STARTING

Delay from loss of power at start-up

XXX PPM

Concentration

LXXX PPM

Low Alarm (Warning)

HXXX PPM

High Alarm (Alarm)

HIGH

Measures gas, concentration exceeds 100% of Full Scale

CXXX PPM

Calibration Mode

ACK

Acknowledged Function

Figure 17: Operation Display Values

NOTE: If display shows “Start” instead of “Starting”, the module must be calibrated before using it.

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5.4 Set-Up

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 or RS-485/Sentry address and baud rates, Digital Input and Warm-up time. Use the [▲] or [▼] keys to select following menus and press [E] to select.

• Alarms – U se the [▲] or [▼] keys to select Low Alarm (Warning) or High Alarm (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:

Factory Alarm Set Points

Model

Warning

Alarm

5100-03-IT

19.5%

16.5%

5100-04-IT

50 PPM

100 PPM

5100-05-IT

10 PPM

20 PPM

5100-06-IT

2.0 PPM

5.0 PPM

5100-08-IT

0.3 PPM

1.0 PPM

5100-10-IT

10 PPM

20 PPM

5100-12-IT

2 PPM

4 PPM

5100-21-IT

5 PPM

10 PPM

5100-25-IT

25 PPM

50 PPM

5100-26-IT

2.0 PPM

5.0 PPM

5100-88-IT

1000 PPM

2500 PPM

NOTE: To enable rising O2 Alarm set warning setpoint higher than 20.9%

• Relays – Use the [▲] or [▼] keys to select High Alarm (Alarm) or Low Alarm (Warning) 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 – 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.

Factory Range Set-up

Model

Range

Other Available

5100-03-IT

5-25%

0-25%

5100-04-IT

0-500 PPM

Variable

5100-05-IT

0-100 PPM

Variable

5100-06-IT

0-10 PPM

None

5100-08-IT

0-3 PPM

None

5100-10-IT

0-100 PPM

Variable

5100-12-IT

0-20 PPM

None

5100-21-IT

0-20 PPM

None

5100-25-IT

0-100 PPM

Variable

5100-26-IT

0-10 PPM

None

5100-88-IT

0-5000 PPM

Variable

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• 4-20mA – 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 5100-XX-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:

o Track – the 4-20mA value tracks the calibration gas exposed to the gas sensor module o C2.50mA – the 4-20mA value is held at 2.50mA during calibration o C4.00mA – the 4-20mA value is held at 4.0mA during calibration

• RS-485 – 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 when 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. The Sentry default is 9600.

• DigInput – Use the [▲] or [▼] keys to select supervised or Non-supervised digital input and then press

[E] to change.

Key

Function

Display

Description

Reference

--0%LEL-

Default Display

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

Relays

S.P. Function - Range Adjust

* C Below

▲

▼

Down

4-20mA

S.P. Function - 4-20 mA Adjust

* D Below

▲

▼

Down

Dig Input

S.P. Function - RS-485/Sentry Output Adjust

* E Below

▲

▼

High Alarm Set Point Adjustment Example

Enter

H.Alarm

S.P. Function - High Alarm Adjust

▲ ▼ M

Enter

HASP:60-

High Alarm Set Point: current = 60

▲

▼

Use ▲ or ▼ keys to adjust to new set point

Down (x5)

HASP:55-

High Alarm Set Point: new = 55

▲ ▼ M

Enter

ACK

Momentary Acknowledge of new Set Point

▲

▼

H.Alarm

S.P. Function - High Alarm Adjust

Relays Set Point Adjustment Example

Enter

H. Relay

S.P. Function - High Alarm Relay Adjust

▲ ▼ M

Down

L.Relay

S.P. Function - Low Alarm Relay Adjust

▲

▼

Enter

Latch

Use ▲ or ▼ keys to adjust to new relay action (Latch, Sentry, NonLatc) * indicates current

▲

▼

Down

Sentry

NOTE: Sentry indicates that Sentry controls relay action and not the IT Sensor Module

▲

▼

Down

*Sentry

Low Alarm Relay set to Sentry

▲

▼

Figure 18: Set-Up Configuration Part 1

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Gas Range Adjustment Example

Enter

Range

S.P. Function - Range Adjust

▲

▼

Enter

*100 PPM

Select [E] to select or ▲ or ▼ to select another and press [E]

▲ ▼ M

Down

10 PPM

Press [E] if selecting 0-10 PPM range

▲

▼

Down

USER

Press [E] if selecting User adjustable range

▲

▼

Enter

100 PPM

Select [E] to select or ▲ or ▼ to select another and press [E]

▲

▼

4-20 mA Adjustment Example

Enter

Calib

S.P. Function - Calib Adjust

▲

▼

Enter

Out: 4mA

Use ▲ or ▼ keys to select 4 mA or 20mA

▲

▼

Enter

4mA

Selects 4 mA

▲ ▼ M

Enter

ACK

Momentary Acknowledge of new Set Point

▲

▼

Mode

Calib

S.P. Function - Calib Adjust

▲

▼

Down

CalibOut

S.P. Function - Output during Calibration Adjust

▲ ▼ M

Enter

Track

Use ▲ or ▼ keys to select Track, C2.50mA, C4.00mA

▲

▼

Track = Output during calibration tracks the calibration gas, C2.50mA = Output during calibration is 2.50 mA, C4.00mA = Output during calibration is 4.0 mA

Enter

*Track

* = Current selection

▲

▼

RS-485 Adjustment Example

Enter

Address

S.P. Function - RS-485 Address Adjust

▲

▼

Enter

Addr:016

Use ▲ or ▼ keys to enter new address

▲

▼

Enter

ACK

New address selected

▲ ▼ M

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 ▲ or ▼ to select another

▲

▼

Figure 19: Set-Up Configuration Part 2

5.5 Maintenance Sub-Menu

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 Figure 20.

Key

Function

Display

Description

Reference

XXXPPM

Default Display

Mode

ALMRSET:

Mode Function - Alarm Reset

▲ ▼ M

Mode

CALIB:--

Mode Function - Calibrate

▲

▼

Mode

SETUP:-

Mode Function - Set Point Adjustments

▲

▼

Mode

MAINT:--

Mode Function - Maintenance

▲ ▼ M

Enter

3.XX

Module Software Version Number

▲

▼

Enter

CCC001

Module Custom Configuration Control number

▲

▼

Figure 20: Maintenance Menu

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CALIBRATION

6.1 Calibration Frequency

The Gas Sensor Module has been calibrated in the factory prior to shipment. It is recommended that the user calibrate before placing into service. The sensor module must be calibrated every 180 days at a minimum. Periodic functional tests are advisable for critical applications and hostile environments. Oxygen sensors will require more frequent adjustment.

The sensor module microprocessor software includes high-level self-checking algorithms which provide continuous sensor diagnostic and self-adjustment. Users may select to increase calibration frequencies based on low-drift experience during first two calibration periods.

6.2 Calibration Preparation

Calibration of the sensor is accomplished by simple menu based steps and application of span gas.

NOTE: If an error is made during any stage of the calibration process, hold the magnet stick at the [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.

Calibration must be performed only when the area is known to be clear of the gas of interest. When in doubt, use a portable instrument to confirm that there is no background.

For compliance with Factory Mutual (FM) Approvals, the Sierra Monitor Model 1250-01, 1260 -05 and 1260-45 are the FM Approved calibration gas delivery devices. Use the Model 5358-01 Calibration Adapter delivery fitting.

NOTE: Refer to Appendix H.1 for information on use of permeation tube for 5100-25-IT and Appendix H.2

for 5100-26-IT calibration.

6.3 Calibration Gas Delivery Methods

Calibration gas can be delivered to the sensors via the Model 5358-01: Calibration Adapter (Figure 21) - used with portable calibrators.

Calibration Procedure

The Calibration Menu is described on Figure 22. The procedure 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.

Figure 21: Model 5358-01

Calibration Adapter

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6.4 Sensor Exposure to Gas

Calibration gas must be delivered to the sensor using the flow rate and duration listed below:

Model

Calibration Gas

Flow

Period

5100-03-IT

Air

300 cc of Zero Air or exposure to Ambient Air (3 minutes)

5100-04-IT

Carbon Monoxide

300 cc/min

Until Stable (minimum 3 minutes)

5100-05-IT

Hydrogen Sulfide

300 cc/min

Until Stable (minimum 3 minutes)

5100-06-IT

Chlorine

300 cc/min

Until Stable (minimum 3 minutes)

5100-08-IT*

Chlorine Dioxide

300 cc/min

Until Stable (minimum 3 minutes)

5100-10-IT

Sulfur Dioxide

300 cc/min

Until Stable (minimum 3 minutes)

5100-12-IT

Nitrogen Dioxide

300 cc/min

Until Stable (minimum 3 minutes)

5100-21-IT

Hydrogen Chloride

300 cc/min

5100-25-IT

Ammonia

See Appendix H.1

5100-26-IT

Hydrogen Fluoride

See Appendix H.2

5100-88-IT

Carbon Dioxide

300 cc/min

Until Stable (minimum 3 minutes)

5100-04-IT

Carbon Monoxide

300 cc/min

Until Stable (minimum 3 minutes)

* Use 5PPM Cl2 to calibrate (set module to 1.5 PPM ClO2)

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6.5 Calibration Sub-Menu

Key

Function

Display

Description

Reference

XXXPPM

Default Display

Mode

ALMRSET:

Mode Function - Alarm Reset





Mode

CALIB:--

Mode Function - Calibrate





Enter

CAL-0PPM--

Banner: Apply zero gas, enter <E> when done (not applicable for 5100-03-IT)





Operation: Confirm area clear of gas, or apply zero air to sensor

Enter

ACK

Zero gas setting acknowledged





10PPM-SP

Banner: Select span, enter <E> to calibrate sensor Banner: (5100-03-IT) Specify Cal gas <E> when done

Sub A



Enter

C 4 PPM

Banner: Apply span gas, then enter <E> to calibrate gas sensor

Sub B





C 4 PPM

Operation: Apply calibration gas

CXXXPPM

Operation: As gas is applied the reading will increase - wait 3 minutes

Enter

CAL-OK

Calibration Passed - now remove gas





WAIT-300

Operation: Five minute time out before sensor is returned to service.

Sub-Routines

10PPM-SP

Banner: Select span, enter <E> when done

Sub A

Down

25PPM-SP

Operation: Change Span Gas Value to 25PPM





Down

Adj-SPAN

Operation: User adjustable value





Enter

25PPM-SP

Operation: Ready for user adjustment





Enter

C 25PPM

Banner: Apply 25PPM gas, then enter <E> to calibrate gas sensor

Sub B





C 25PPM

Operation: Apply calibration gas

Enter

CAL-FAIL

Operation: No calibration gas applied, or sensor did not respond correctly.





WAIT-300

Operation: Five minute time out before sensor is returned to service.

Mode

(Any)

Operation: Hold magnet over Mode Switch for ten seconds to abort calibration

Sub C





Banner: Calibration Aborted

XXXPPM

Default Display

Figure 22: Calibration Sub-Menu

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6.5.1 5100-03-IT Oxygen Deficiency

It is recommended to use fresh Air as the calibration source for the Oxygen detector. If the area is known to be safe with adequate air flow, you may use the surrounding Air to set the instrument span at 20.9 %. If the condition of the environment is unknown, then the customer may use a cylinder of Zero Air as the span gas. Please note that the Oxygen concentration contained in Zero Air cylinders may have anywhere from 20.0 to 21.0 % Oxygen as it is not a precise standard.

To calibrate the Oxygen sensor module, place the module into the calibration mode using the magnetic wand. Press the Mode key until CALIB is displayed. Press Enter to begin. Select Calibration value to be 20.9%. Press Enter to confirm. Apply span gas or use the surrounding Air then press Enter to complete procedure.

6.5.2 5100-88-IT Carbon Dioxide

The CO2 transmitter also has a span only calibration adjustment. There is no zero adjustment or requirement to apply Zero gas. To calibrate the CO2 detector, place the module into the calibration mode using the magnetic wand. Press the Mode key until CALIB is displayed. Press Enter to begin. Select calibration value, typical 2500 ppm, and press Enter to confirm. Apply span gas for at least 3 minutes or until stable. Press Enter to complete procedure.

NOTE: The Analog output values to be transmitted during the calibration procedure are selected in the

maintenance configuration. Normal 20.9% value provides 17.3 mA.

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Appendix A. Service

Appendix A.1. Sensor Module Configuration

The gas sensor module is comprised of the following sub-assemblies (Figure 23):

5100-XX-IT Gas Sensor Module (See Appendix C)

SPL21810 Aluminum Enclosure SPL21823 316SS Enclosure XXXXXXX Transmitter Assembly (See Appendix C) XXXXXXX Sensor Assembly (See Appendix C) 5200-XX-IT Sensor (See Appendix C)

Appendix A.2. Enclosure Replacement

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 continue the transmitter and sensor assembly replacement instructions.

Figure 23: Module Components

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Appendix A.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:

1. Remove the cover of the main enclosure.

2. Unscrew the two thumb screws in the top of the cover plate, lift the assembly and rotate 90o to relieve the

wiring service loop.

3. Remove all wires from bond, marking them carefully so they can be correctly replaced.

4. Unplug the sensor connector from the transmitter.

5. Reverse the preceding steps to install the new transmitter.

6. Restore power and allow a minimum of 30 minutes for stabilization before re-calibration.

Appendix A.4. Sensor Replacement

NOTE: Refer to Appendix H for information on sensor electrolyte replacement for 5100-25-IT and

5100-26-IT.

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.

• The “Sensor Failure” message displays.

To replace the sensor:

1. Confirm that system power has been removed.

2. Remove the gas sensor module enclosure cover.

3. Unscrew the two thumb screws in the top of the faceplate, lift the transmitter assembly and rotate 90o to

relieve the wiring service loop.

4. Unplug the sensor connector from the transmitter.

5. Unscrew the old sensor assembly from the enclosure conduit hub.Remove the sensor assembly with its

harness.

6. Unscrew sensor housing cover from the sensor.

7. Carefully pull the old sensor straight up from the socket.

8. Press the new sensor into the socket.

9. Reverse the preceding steps to install the sensor assembly.

10. Allow the new sensor to stabilize for a minimum of 60 minutes and then calibrate using the procedure in

Section 6.

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Appendix A.5. Installation Inspection

Prior to system start-up or trouble shooting, the entire system should be visually inspected. The following are guidelines for that inspection.

Appendix A.5.1. Controller Installation

• Controller installed in conformance to instruction manual recommendations.

• AC power is correctly grounded.

• Hot AC and relay connections have safety covers installed.

Appendix A.5.2. Cabling Installation

• All splices are soldered or via terminal block.

• Cabling is away from sources of electrical noise or RFI where possible.

Appendix A.5.3. Sensor Module Installation

• Module installation in conformance with this manual.

• Modules accessible for calibration.

• Wiring terminations clean and correct.

Appendix A.5.4. 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.

Appendix A.5.5. Standard Voltages

• Regulated DC voltage to be applied to the sensor module must be between 10 VDC and 30 VDC.

Appendix A.6. Inspection and Troubleshooting Guide

The inspection and troubleshooting guide can be used to step through the system startup and to determine the appropriate corrective action if a fault occurs.

Appendix A.6.1. Ir 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 calibration gas and verify that the sensor sees calibration gas after calibration.

4. If the sensor still does not see gas, power cycle the unit and repeat calibration.

Appendix A.6.2. 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 gas of interest during warm-up.

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Appendix A.6.3. Module Does Not Display the Correct %PPM

1. Power cycle the unit.

2. Recalibrate the sensor.

Appendix A.6.4. Display Shows ‘F’ – Sensor Missing or Bad Sensor

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. Check all other connections.

5. Power up the unit.

Appendix A.6.5. Module Shows “***Calibration Required***”

Calibrate the module.

Appendix A.6.6. Display Shows “H” or “L”

This means the local high or low alarm is active.

Appendix A.6.7. Display Shows “M” – Not Calibrated

Calibrate the module.

Appendix A.6.8. Display Shows “C” – Calibration Mode

Complete calibration and exit to operating mode.

Appendix A.6.9. Display Shows “S” – Sentry Connection

Check connections with Sentry Controller

Appendix A.6.10. Diagnostic LEDs

LEDs 1 = 1 Hz Heartbeat normal, 2 Hz Panic Error 2 = Computation process 3 = 1 Hz Heartbeat normal 4 = HART or Sentry comms activity

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Appendix B. Specifications

Sensor

Type Electrochemical

Standard

Range

(1)

Optional

Max Range

Zero Drift

Repeatability

Linearity

Resolution

Response

Time

(2)

Accuracy

Sensor

Life

(3)

5100-03-IT O2

5-25% Vol

0-25% Vol

+/- 0.1%

+/- 0.2%

+/- 0.1%

<10 sec.

+/- 0.2%

2 years

5100-04-IT CO

0-500 PPM

1200 PPM

+/- 1 PPM

0.5 PPM

<35 sec.

+/- 1 PPM

2 years

5100-05-IT H2S

(5)

0-100 PPM

100 PPM

+/- 0.5 PPM

+/- 1 PPM

0.1 PPM

<44 sec.

+/- 3 PPM

(6)

2 years

5100-06-IT Cl2

0-10.0 PPM

10.0 PPM

+/- 0.5 PPM

0.1 PPM

<60 sec.

+/- 0.5 PPM

2 years

5100-08-IT ClO2

0-3.0 PPM

3.0 PPM

+/- 0.5 PPM

0.1 PPM

<60 sec.

+/- 0.5 PPM

2 years

5100-10-IT SO2

0-100 PPM

100 PPM

+/- 0.5 PPM

+/- 1 PPM

0.5 PPM

<20 sec.

+/- 0.5 PPM

2 years

5100-12-IT NO2

0-20 PPM

20.0 PPM

+/- 0.5 PPM

0.2 PPM

<35 sec.

+/- 0.5 PPM

2 years

5100-21-IT HCl

0-20 PPM

20.0 PPM

+/- 0.5 PPM

0.2 PPM

<35 sec.

+/- 0.5 PPM

2 years

5100-25-IT NH3

(4)

0-100 PPM

100 PPM

+/- 1.0 PPM

+/- 1 PPM

<30 sec.

+/- 1 PPM

1 year

(7)

5100-26-IT HF

(4)

0-10 PPM

10 PPM

0.5 PPM

<30 sec.

+/- 1 PPM

1 year

(7)

5100-88-IT CO2

(8)

0-5000 PPM

5000 PPM

+/- 1.0 PPM

+/- 1 PPM

<20 sec.

+/- 2%

2 years

(1) Optional ranges available (2) Response time to 90% full signal value for applied concentration (3) Sensor life typical for use at standard temperature and pressure with occasional exposure to gas of interest (4) Diffusion via membrane. Requires electrolyte (5) Max range, zero drift, linearity, resolution, and sensor life, have not been verified by FM Approvals (6) Or +/- 10% of reading, whichever is greater (7) Electrolyte recharge only (8) Infrared

Output

Display Fixed and Scrolling LED Relays Option 5 Amp, High Alarm, Low Alarm, .25 Amp Trouble all SPDT Analog Output Analog 4-20 mA (Trouble 1.5mA, Calibration 2.5mA) Loop Resistance 800 ohm Signal Output Sentry digital bus Analog 4-20 mA 3-wire Non-Isolated 4-wire Isolated Serial RS-485 Modbus RTU HART

Input

Remote Alarm Reset Normally open digital input

Power

Power consumption 2 watts (4 watts for 5100-88-IT) Input voltage 24 VDC nominal: 10-30 VDC

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Operating Range

Ambient Temp (oF)

Ambient Temp (oC)

Relative Humidity

5100-03-IT O2

5 to 122 oF

-15 to 50 oC

15 – 90%

5100-04-IT CO

- 4 to 122 oF

-20 to 50 oC

15 – 90%

5100-05-IT H2S

(1)

- 40 to 122 oF

-40 to 50 oC

15 – 90%

5100-06-IT Cl2

- 4 to 122 oF

-20 to 50 oC

15 – 90%

5100-08-IT ClO2

- 4 to 122 oF

-20 to 50 oC

15 – 90%

5100-10-IT SO2

- 4 to 122 oF

-20 to 50 oC

15 – 90%

5100-12-IT NO2

- 4 to 122 oF

-20 to 50 oC

15 – 90%

5100-21-IT HCl

- 4 to 122 oF

-20 to 50 oC

15 – 90%

5100-25-IT NH3

+14 to 113 oF

-10 to 45 oC

20 – 95%

5100-26-IT HF

+14 to 113 oF

-10 to 45 oC

20 – 95%

5100-88-IT CO2

- 4 to 140 oF

-20 to 60 oC

15 – 90%

(1) Performance tested by FM Approvals to -40oC/oF

Enclosure

Material - Aluminum Polyester powder-coated, sand-cast, copper-free aluminum Material - Stainless Steel 316 Stainless Steel Dimensions (HxWxD) (differs for 5100-25-IT & 5100-26-IT)

(A1 & A2) 7.9 x 5.7 x 3.9 in. (20.1 x 14.5 x 9.9 cm)

(S1 & S2) 7.6 x 4.4 x 4.9 in. (19.3 x 11.2 x 12.4 cm)

Weight (A1 & A2) 3.4 lb. (1.5 Kg) (S1 & S2) 7.2 lb. (3.3 Kg) Housing NEMA 4X, NEMA 7 Hazardous Area Approval Explosion proof, Class 1, Div. I, Groups B, C, D Group IIB + H2 IP66, IP65, NEMA 4X

Electrical Approvals

Factory Mutual (FM) Class 1, Div. I, Groups B, C, D FM Standards 3600, 3615, 3810 UL UL Standard 508A ATEX (5100-XX-IT) II 2 G Ex d IIB+H2 T6 Gb Ta = -40oC to +50oC

Performance Approvals

FM Performance Approval FM Performance Approval (5100-05-IT) (Appendix J) SIL-2 Certified (5100-04-IT, 5100-05-IT, 5100-06-IT)

CE Mark (5100-05-IT) ABS (5100-05-IT) CQST

Remote Sensor Option (Appendix E)

Distance between sensor and transmitter

5100-03-IT

10 feet

5100-06-IT

10 feet

5100-04-IT

15 feet

5100-08-IT

10 feet

5100-05-IT

15 feet

5100-10-IT

15 feet

Warranty

Limited Warranty 2 years

Specifications subject to change without notice

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Cross Sensitivity Data

5100-04-IT Carbon Monoxide

Gas

Conc.

Response

15 PPM

~38 PPM

SO2

5 PPM

~3 PPM

35 PPM

~10 PPM

NO2

5 PPM

~-3 PPM

100 PPM

<60 PPM

C2H4

100 PPM

<100 PPM

HCN

10 PPM

~5 PPM

HCl

5 PPM

0 PPM

5100-05-IT Hydrogen Sulfide

Gas

Conc.

Response

400 PPM

<.1 PPM

SO2

20 PPM

<10 PPM

50 PPM

<3 PPM

NO2

10 PPM

<-30 PPM

Cl2

10 PPM

<-25 PPM

400 PPM

1 PPM

C2H4

400 PPM

<0.1 PPM

NH3

20 PPM

<0.1 PPM

5100-06-IT Chlorine & 5100-08-IT Chlorine

Dioxide

Gas

Conc.

Response

300 PPM

0 PPM

H2S

15 PPM

0 to -3.38 PPM

SO2

5 PPM

-0.05 PPM

35 PPM

0 PPM

NO2

5 PPM

~5 PPM

100 PPM

0 PPM

C2H4

100 PPM

0 PPM

HCN

10 PPM

0 PPM

HCl

5 PPM

0 PPM

ClO2

3 PPM

10 PPM

5100-10-IT Sulfur Dioxide

Gas

Conc.

Response

H2S

15 PPM

0 PPM

35 PPM

-7 to 0 PPM

NO2

5 PPM

-5 PPM

Cl2

5 PPM

-1.5 to 0 PPM

NO2

5 PPM

~5 PPM

100 PPM

0 PPM

HCN

10 PPM

<5 PPM

HCl

5 PPM

0 PPM

C2H4

100 PPM

0 PPM

5100-12-IT Nitrogen Dioxide

Gas

Conc.

Response

300 PPM

0 PPM

H2S

15 PPM

-1.5 to 0 PPM

SO2

5 PPM

-0.05 to 0 PPM

35 PPM

0 PPM

Cl2

1 PPM

~1 PPM

100 PPM

0 PPM

HCN

10 PPM

0 PPM

HCl

5 PPM

0 PPM

C2H4

100 PPM

0 PPM

5100-21-IT Hydrogen Chloride

Gas

Conc.

Response

300 PPM

<3 PPM

H2S

15 PPM

27 to 45 PPM

SO2

5 PPM

1.5 to 3.5 PPM

35 PPM

0 PPM

NO2

5 PPM

0.5 to 1 PPM

Cl2

1 PPM

-0.05 to 0.1 PPM

100 PPM

<0.5 PPM

HCN

10 PPM

<0.3 PPM

5100-25-IT Ammonia

Gas

Conc.

Response

1000 PPM

0 PPM

SO2

15 PPM

>40 PPM

100 PPM

0 PPM

NO2

60 PPM

0 PPM

CH4

0 PPM

HCN

10 PPM

75 PPM

H2S

3 PPM

75 PPM

5100-26-IT Hydrogen Fluoride

Gas

Conc.

Response

Cl2

5 PPM

8 PPM

HCl

5 PPM

9 PPM

NH3

75 PPM

0 PPM

SiH4

15 PPM

0 PPM

1000 PPM

0 PPM

SO2

5 PPM

9 PPM

100 PPM

0 PPM

NO2

15 PPM

2 PPM

0 PPM

H2S

30 PPM

0 PPM

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Appendix C. Model Numbers and Parts List

Sensor Module

Ordering Information: The following part number is essential in selection of the correct product. Please build up the desired part by inserting the code for each element

into the appropriate space (ie. 5100-12-IT-S1-02-00-0-C).

Model Gas

Series Enclosure

Relay/Connection

Output

XX Sensor Protection

Remote

Option

ATEX

5100

  

   

- 03 = O2 - 10 = SO2

-IT

- A1 = AL ¾” NPT

- 01 = No Relays (std)

- 0 = Standard

- 0 = None

- C = ATEX/IECEX

- 04 = CO - 12 = NO2

- A2 = AL M20x1.5

- 02 = Relays Option

- 1 = Conformal

- 1 = Remote

(5100-05-IT only)

- 05 = H2S - 21 = HCl

- S1 = SS ¾” NPT

- 05 = HART Option

Sensor

- 06 = Cl2 - 25 = NH3

- S2 = SS M20x1.5

- 08 = ClO2 - 26 = HF

- 27 = ETO

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 / 5100-08-IT

5200-10-IT

Sensor, for 5100-10-IT

5200-12-IT

Sensor, for 5100-12-IT

5200-21-IT

Sensor, for 5100-21-IT

SPL21834

Sensor Assembly, Aluminum, for 5100-03-IT Oxygen

SPL21832

Sensor Assembly, Aluminum, for 5100-04-IT - CO

SPL21830

Sensor Assembly, Aluminum, for 5100-05-IT H2S

SPL21833

Sensor Assembly, Aluminum, for 5100-06-IT / 5100-08-IT - Cl2 & ClO2

SPL21844

Sensor Assembly, Aluminum, for 5100-10-IT SO2

SPL21845

Sensor Assembly, Aluminum, for 5100-12-IT – NO2

SPM21878

Sensor Assembly, Plastic, for 5100-26-IT

SPM27082

Sensor Assembly, 316SS, for 5100-03-IT Oxygen

SPM27083

Sensor Assembly, 316SS, for 5100-04-IT - CO

SPM27074

Sensor Assembly, 316SS, for 5100-05-IT - H2S

SPM27084

Sensor Assembly, 316SS, for 5100-06-IT / 510008-IT - Cl2 & ClO2

SPM27087

Sensor Assembly, 316SS, for 5100-10-IT - SO2

SPM27088

Sensor Assembly, 316SS, for 5100-12-IT - NO2

SPL21824

Transmitter

SPL21810

Enclosure, Transmitter, Aluminum

SPL21823

Enclosure Transmitter, 316SS

SPL21825

Interface Board without Relay

SPL21829

Interface Board with Relay

Options

5311-00

Rainshield

5311-02

Rainshield with calibration port

Calibration Items

1250-01

Gas Sensor Calibration Kit, Type A (CO, H2S, Air)

1250-02

Gas Sensor Calibration Kit, Type B (SO2, NO2)

1250-03

Gas Sensor Calibration Kit, Type C (Cl2)

1260-00

Gas Cylinder, Air, (Type A), 105 liters

1260-04

Gas Cylinder, CO 100 PPM, (Type A) 57 liters

1260-05

Gas Cylinder, H2S in N2, 25 PPM, (Type A) 57 liters

1260-06

Gas Cylinder, Cl2, 5 PPM, (Type C) 104 liters

1260-10

Gas Cylinder, SO2, 50 PPM, (Type B) 74 liters

1260-12

Gas Cylinder, NO2, 10 PPM, (Type B) 74 liters

1260-13

Gas Cylinder, CO, 1000 PPM, (Type A), 105 liters

5360-00

Calibrator Head Standard

1256-01

Regulator Type A Calibrator

1256-02

Regulator Type B Calibrator

1265-03

Regulator Type C Calibrator

5358-01

Calibration Adapter - Direct, Standard

5358-51

Calibration/Configuration Magnetic Tool, 4501-XX

9210-00

Calibrator, Permeation Tube

9211-09

Permeation Tube, Ammonia, NH3

SPX27057

Kit, Sensor Recharge, for 5100-25-IT

SPX27061

Kit, Sensor Recharge, for 5100-26-IT

See Appendix E for 5100-25-IT and 5100-26-IT

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Appendix D. Limited 2 Year 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 (i.e. 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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Appendix E. Remote Sensor Drawing

NOTE: Drawing using aluminum enclosure available from Sierra Monitor.

Unless otherwise specified, NOTE the following:

• Provide access for sensor replacement during installation.

• For field upgrade, relocate 5100-XX-IT-A1/A2 Sensor to 5394-50 as shown in Detail A (Figure 24).

• Use belden cable #9925 or SMC P/N 53056 (see in Figure 24).

• Terminal blocks float in each enclosure.

• The remote sensor assembly is meant to be supported by rigid conduit.

• Calibrate post installation.

• For conduit with M20 thread, install adapter 39218 (2X) where shown (see in Figure 24).

NOTE: The distance between the sensor and transmitter is 15 feet for models 5100-04/05/10-IT. However,

the distance is 10 feet for Model 5100-03-IT.

Typical Wire Connections at all Terminations:

Color

Position

Red

Black

White

Bare Wire

Figure 24: Remote Sensor Drawing

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Appendix F. Modbus Memory Map

Write

40001 Concentration R Gas concentration multipl ied by Gas Scale (e .g. 209 = 20.9%) 40002 Temperature R Temperature in degrees Cel cius scaled by a factor of 10

40003 Alarm Relay R/W

Boolean indi cating the Al arm relay status (0 = No Alarm, 1 - (High) Alarm). Clearing bit wi ll reset alarm.

40004 Warning Relay R/W Boolean indi cating the Warning relay status (0 = No Alarm, 1 - Warning Al arm). Clearing bit wil l reset alarm. 40005 Warning Setpoint R/W Warning Alarm set point, used for activating Low Alarm multiplie d by Gas Scale 40006 Alarm Setpoint R/W Al arm set point, used for activating High Alarm multipl ied by Gas Scale 40007 CCC detail R e .g. 0001, 0007, etc 40008 Software Revision U R e .g. 201 denote s ve rsi on 2.01 40009 Software Revision L R e .g. version aA is denoted by 0x6141 40010 Modbus Map Revi sion R e .g. version 2 is denoted as v2 = 0x7602 40011 Trouble Bits R 0 = no trouble 40012 Trouble R 1 for any trouble, 0 = no trouble 40013 Alarm Immediate R Like 40003, but neve r latched 40014 Warning Immediate R Like 40004, but never latched 40015 Serial Numbe r U R Se rial Number - 24 bits (presently set to Random ID) 40016 Serial Numbe r L R 40017 Run time U R In seconds 40018 Run time L R In se conds 40019 Gas (MAX) value R Gas concentration multipl ied by Gas Scale 40020 Model R Read as 51028 for IR, 51002 for Cat Bead, 51005 for TOXIC H2S etc. 40021 Range RW 40022 Units RW 1 = %LEL, 2 = %VOL

40023 Module Status R

A bit is defi ned for each of the following states: (no bit set also means some sort of trouble) Module State - In Calibration (0x40) = cal failed Module State - In Calibration (0x20) = cal passed Module State - In Calibration (0x10) Module State - Trouble (0x08) Module State - Warming (0x04) Module State - RUN (ALARM) (0x02) Module State - RUN (0x01)

40024 Gas Scale R V alue li ke 1, 10 or 100 40025 Cal Concentration leve l R/W Gas concentration value used during calibration, multiplied by Gas Scale 40026 Calibration due, in days R Gets rese t to 365 / 180 if cal successful , Less then 0 = calibration due 40027 Calibration Count R Counter increments if cal successful (0 = not cali brated) 40028 Display Gas Output R Gas value seen on display (i.e. use ful during calibration) 40029 Gas (MIN) value R Minimum gas value multi plied by Gas Scale 40030 Alarm Time U R In seconds 40031 Alarm Time L R 40032 Warning Time U R In seconds 40033 Warning Time L R 40034 Trouble Time U R In se conds 40035 Trouble Time L R 40036 Max Gas Time U R I n seconds 40037 Max Gas Time L R 40038 Min Gas Time U R In seconds 40039 Min Gas Time L R 40040 Rotary Switch R Module address (If val ue < 16, the value refle cts positi on of rotary switch) 40041 Restart Count R Restart count 40042 Alarm Relay Action Setup RW Alarm Relay Action Setup - Latch/Sentry/Non-l atch 40043 Warning Relay Action Setup RW Warning Rel ay Action Setup - Latch/Sentry/Non-l atch 40044 4-20mA Cal ibOut Value R 40045 4-20mA TroubleOut Value R 40046 Gas Factor RW Applies only to -02 40047 Force Value RW 40048 Module Number RW

40049 Command Register RW

0 indicates command failed, 1 = passed, supported commands: Lock keys = 101 Unlock keys = 102 Abort calibration = 103 Apply zero gas = 104 Apply span gas = 105 Ack alarms = 106 Reset sensor = 107 Clear mem = 108 Speed up startup = 109 Clear eeprom = 110 Force address disp= 111 Clear address disp= 112

40050 Last command executed R Displays last exe cuted command from register 40049

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Appendix G. HART

Figure 25: Wiring Connections Table

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Figure 26: 4-20 mA Circuits Types 5100-XX-IT – Connections - HART

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Hart Protocol Menu

HART (Highway Addressable Remote Transducer) Protocol is the global standard for sending and receiving digital information across analog wires between smart devices and control or monitoring system. HART is a bidirectional communication protocol that provides data access between intelligent field instruments and host systems. A host can be any software application from technician's hand-held device or laptop to a plant's process control, asset management, safety or other system using any control platform. The HART protocol used on this gas sensor module has been developed to comply fully with the HART specifications outlined by the HART Communication Foundation (HCF).

If the HART interface board has been provided with the gas sensor module, then HART will operate via the 4-20 mA interface automatically. While no specific handheld device is necessary for HART operation, the gas sensor module does comply with the HART standard so any handheld or PC-based HCF certified tool will work.

The information below provides the operator instructions on connecting HART and the HART Protocol Menu.

Common Practice Commands

The following Common Practice commands are implemented.

Command

Number

Byte Number

Description

N/A

Reset Configuration Changed Flag

Returns Module Status: Module State - In Calibration (0x10) (0x30 = cal passed) (0x50 = cal failed) Module State - Trouble (0x08) Module State – Warming (0x04) Module State - RUN (ALARM) (0x02) Module State – RUN (0x01)

Returns Alarm Relay Status: 0x01 = Alarm Relay ON 0x02 = Warning Relay ON 0x03 = Both Relays ON

Returns Trouble Status (non-zero value indicates Trouble)

Returns maximum gas value

Returns gas value used during calibration

Returns IT-Series Model Number: 0x28 = 5100-IT-28

Device Specific Commands

The Device Specific commands are used for accessing the unique features of the 5100-IT Series of gas sensor modules.

A response code of 0 indicates SUCCESS. This applies to all commands. As per HART specification, all command responses will have a response code and status byte, plus any command specific data bytes as indicated in the following tables.

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Device Specific Commands Summary

Command

Number

Description

130

Key Press

131

Set Alarm Level

132

Set Warning Level

133

Set Alarm Relay Action

134

Set Warning Relay Action

135

Reset Alarms

136

Abort Calibration

137

Set Calibration Gas Level

138

Apply ZERO Gas

139

Apply SPAN Gas

140

RESERVED

141

Force Gas Value

142

Reset Force Gas Value

143

Read MODBUS RTU Register

144

Set Transducer Serial Number

145

Set Calibration Mode output current

146

Set Trouble Mode output current

147

RESERVED

148

RESERVED

149

Set Gas Factor

150

Write MODBUS RTU Register

Command 130: Key Press

This command mimics the front plate key inputs.

Request Data Bytes:

Byte

Format

Description

Unsigned-8

1=Enter 2=Down 4=Up 8=Menu

Command Specific Response Data Bytes:

Byte

Format

Description

Unsigned-8

Returns same value as passed

Command 131: Set Alarm Level

Request Data Bytes:

Byte

Format

Description

Unsigned-8

Alarm level, range 0 to 60. Default is 60

Command Specific Response Data Bytes:

Byte

Format

Description

Unsigned-8

Returns new Alarm Level

Command 132: Set Warning Level

Request Data Bytes:

Byte

Format

Description

Unsigned-8

Warning level, range 0 to 60. Default is 20.

Command Specific Response Data Bytes:

Byte

Format

Description

Unsigned-8

Returns new Warning Level.

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Command 133: Set Alarm Relay Action

Request Data Bytes:

Byte

Format

Description

Unsigned-8

0=Latching (default) 2=Non-Latching

Command Specific Response Data Bytes:

Byte

Format

Description

Unsigned-8

Returns new Alarm Relay Action value

Command 134: Set Warning Relay Action

Request Data Bytes:

Byte

Format

Description

Unsigned-8

0=Latching 2=Non-Latching (default)

Command Specific Response Data Bytes:

Byte

Format

Description

Unsigned-8

Returns new Warning Relay Action value

Command 135: Reset Alarms

This command will reset any alarm relays that have been latched, providing the alarm condition is no longer present on the sensor.

Request Data Bytes: None Command Specific Response Data Bytes: None

Command 136: Abort Calibration

This command aborts the calibration procedure. Request Data Bytes: None Command Specific Response Data Bytes: None

Command 137: Set Calibration Gas Level

Request Data Bytes:

Byte

Format

Description

Unsigned-8

Calibration Gas Level, range 0 to 100

Command Specific Response Data Bytes:

Byte

Format

Description

Unsigned-8

Returns new Calibration Gas Level

Command 138: Apply ZERO Gas

This command will signal the module to accept the present sensor output to as the ZERO gas condition.

Request Data Bytes: None Command Specific Response Data Bytes: None

Command 139: Apply SPAN Gas

This command will signal the module to accept the present sensor output to as the SPAN gas condition.

Request Data Bytes: None Command Specific Response Data Bytes: None

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Command 141: Force Gas Value

Request Data Bytes:

Byte

Format

Description

Unsigned-8

Sets the Force Gas Value, range 0 to 100

Command Specific Response Data Bytes:

Byte

Format

Description

Unsigned-8

Returns new Force Gas Value

Command 142: Reset Force Gas Value

This command will signal the module to set the Force Gas Value to 0.

Request Data Bytes: None Command Specific Response Data Bytes: None

Command 143: Read MODBUS RTU Register

This command allows the reading of sensor module data as defined in the MODBUS RTU register map.

Request Data Bytes:

Byte

Format

Description

0-1

Unsigned-16

Address of Requested Modbus Register 40001 = lowest address 65535 = highest address

Command Specific Response Data Bytes:

Byte

Format

Description

0-1

Unsigned-16

Returns contents of selected Modbus Register

Command 144: Set Transducer Serial Number

This command allows user to add a device specific serial number, if required. This is different from the serial number assigned by the Manufacturer.

Request Data Bytes:

Byte

Format

Description

0-2

Unsigned-24

Serial Number

Command Specific Response Data Bytes:

Byte

Format

Description

0-2

Unsigned-16

Returns new Serial Number

Command 145: Set Calibration Mode output current

Request Data Bytes:

Byte

Format

Description

0-1

Unsigned-16

Current output required during calibration, in microamperes

Command Specific Response Data Bytes:

Byte

Format

Description

0-1

Unsigned-16

Returns new Calibration current value

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Command 146: Set Trouble Mode Output Current

Request Data Bytes:

Byte

Format

Description

0-1

Unsigned-16

Current output required to indicate Trouble, in microamperes

Command Specific Response Data Bytes:

Byte

Format

Description

0-1

Unsigned-16

Returns new Trouble current value

Command 149: Set Gas Factor

Request Data Bytes:

Byte

Format

Description

Unsigned-8

Sets the Gas Factor value, range 30-200

Command Specific Response Data Bytes:

Byte

Format

Description

Unsigned-8

Returns new Gas Factor value

Command 150: Write MODBUS RTU Register

This command allows the writing of sensor module data as defined in the MODBUS RTU register map.

Request Data Bytes:

Byte

Format

Description

0-1

Unsigned-16

Address of Designated Modbus Register 40001 = lowest address 65535 = highest address

2-3

Unsigned-16

Data for Designated Modbus Register

Command Specific Response Data Bytes:

Byte

Format

Description

0-1

Unsigned-16

Returns MODBUS register value

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Appendix H. Gas Sensor Module Calibration

Appendix H.1. Calibration for 5100-25-IT

NOTE: Supplement to Instructions in Section 6.

1. Equipment Required

The following tools and equipment will be required for calibration:

• Permeation Device Calibrator (Model 9210-00), with Ammonia

Permeation Tube (Model 9211-09).

• Calibration Adapter (Model 5358-01)

2. Permeation Device Calibrator Operation

The calibrator is a portable device with a pump that operates from a 1.5 V alkaline size D battery. A fresh battery should allow 8 hours of continuous operation. The permeation device will probably be shipped separately, usually in a pipe with screw cap ends, one of which will be marked for opening. The permeation device should come fitted with a scrubber, but, as a precaution, open the pipe and remove the permeation device in a well ventilated area.

a) Remove the scrubber from the permeation device and attach the device

to the stainless steel “Tee” assembly inside the calibrator box. Tighten the connection with a wrench, with the device resting inside one of the

openings in the rack. b) Close the door of the calibrator and turn on the pump switch. c) Set the flow rate for the desired ppm of ammonia. The desired flow rate

for calibration of the Model 5100-25-IT is 300-500 cc/min. and the

concentration range should be set between the high alarm point and

100 ppm full scale.

The carrier gas flow rate can be calculated from the formula:

P = (CxF)/K

Where P = the permeation rate in nanograms/min., and C = ppm of span gas, F = carrier gas flow rate in

ml./min. and K = 1.437 for ammonia. The permeation rate for the temperature read on the front of the calibrator can be obtained from permeation rate vs. temperature chart.

d) Run the gas calibrator for 30 min. before attaching the output hose to the ammonia sensor. e) When the use of the calibrator is completed, do not turn off the pump unit until the permeation device has

been removed from the “Tee” and the gas scrubber reattached. Failure to remove the permeation device

when the pump has been turned off will contaminate the system with high amounts of the permeating gas

and result in erroneous concentrations. The device, with scrubber, can be stored in the storage rack

overnight, but should not stay in the gas calibrator for longer storage periods.

3. Sensor Assy. Rebuild Procedure

Follow procedures outlined in Electrolyte/Membrane Replacement (Figure 28). The electrolyte needs to be replaced at least every six months, or if there is evidence of low sensor

output. The membrane and O-Ring should be replaced at the same time that the electrolyte is replaced.

Figure 27: Electrolyte

Replacement

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4. Equipment Required

• Electrolyte Recharge Kit (SPX27057 for Model 5100-25-IT and SPX27061 for Model 5100-26-IT)

consisting of the electrolyte, package of 5 membranes, 5 0-Rings and alcohol wipes to clean the

electrode.

• Tweezers to aid in removing and replacing the membrane.

5. Preparation

a) Transfer the necessary electrolyte into a plastic wash bottle. b) Confirm that system power has been removed. c) Remove the transmitter electronics board from the main housing and unplug the sensor harness from the

transmitter electronics. d) Unscrew the sensor assembly from the bottom of the enclosure. e) Remove the assembly cover from the sensor assembly.

CAUTION: Only remove the sensor cover from the assembly, DO NOT attempt to unscrew the sensor

from the mounting assembly or you could damage the wiring.

6. Electrolyte Replacement (Figure 27)

a) Invert the sensor assembly so that the membrane is upward. b) Insert the sensor assembly in a clamp, if available, and unscrew the box nut counterclockwise, and take

out the hold-down ring, membrane and O-Ring. Then pour out the old electrolyte into a beaker for

disposal.

CAUTION: Avoid contact of the electrolyte with skin, eyes and clothing. In case of contact wash

immediately - rubber gloves and safety glasses are recommended.

c) Clean the electrode with the alcohol wipes included in the electrolyte replacement kit. All oxidation

residue must be removed before re-assembly. When dirt is found inside the sensor assembly, wash the

dirt off with electrolyte. d) Hold the sensor assembly with the sensing electrode up. Close the pressure compensation port with a

tissue. Pour approximately 10cc of fresh electrolyte from the wash bottle into the sensor, and rinse the

inside of the sensor. Empty the electrolyte into the beaker. e) Place the O-ring on top of the washer. Then transfer one drop of electrolyte from the plastic wash bottle to

the exposed electrode surface. f) Place a new membrane into the hold-down ring and carefully place the plastic hold-down ring on top of

the sensor body with the ring ears in the slots of the sensor body. Then fasten the sensor cover over the

assembly.

CAUTION: Never touch the membrane with your hands. Use rubber gloves or tweezers.

g) Invert the sensor so that the membrane is down. If this is the first time that electrolyte has been replace,

there should be a round Mili-Seal covering the pressure compensation screw. This Mili-Seal prevented

loss of electrolyte during shipment. Remove and discard the round Mili-Seal and remove the screw to

expose the electrolyte supply port. h) Transfer electrolyte from the plastic wash bottle into the electrolyte supply port (Figure 27) until the level

is at the maximum level line on the side of the sensor body. i) Replace the pressure compensation screw into the electrolyte supply port. j) Replace the sensor housing cover. k) Install the sensor assembly into the enclosure hub and tighten firmly. l) Reconnect the sensor harness to the transmitter, carefully install the transmitter into the housing and

restore system power.

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m) Recalibrate the transmitter following the instructions in Section 6.

Spare Parts

SPX27057 Recharge Kit NH3 SPX27061 Recharge Kit HF SPX57009 Membrane Kit (both) SPX99017 Electrolyte NH3 SPX99018 Electrolyte HF 5200-25-IT Sensor Assy NH3 5200-26-IT Sensor Assy HF

Figure 28: Sensor Assembly – Exploded View

(WHITE)

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Figure 29: Model 5100-25-IT-A1/A2 and Model 5100-26-IT-A1/A2

Figure 30: Model 5100-25-IT-S1 and Model 5100-26-IT-S1

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Appendix H.2. Calibration for 5100-26-IT

NOTE: Supplement to Instructions in Section 6.

1. The calibration of the Model # 5100-26-IT HF gas sensor module is accomplished by using a 5 ppm Chlorine standard (Type C kit with # 1260-06 cylinder). Scale range is 0-10 ppm with 5 ppm being mid-scale. 5 ppm Cl2 is equivalent to 5 ppm HF.

2. Reference Figure 22 for the calibration procedure sub menu. This procedure requires the use of the magnetic wand to activate the keys and confirm each entry step. Follow prompts on the module display as navigation is detailed in Figure 22.

3. Enter actual span gas concentration that is printed on the cylinder being used when prompted.

4. Refer to the sensor rebuild and electrolyte replacement procedure as detailed in Appendix H.1.

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