Sierra Monitor Corporation 5100-06-IT, 5100-05-IT, 5100-04-IT, T12020, 5100-03-IT User Manual
MODEL 5100-XX-IT
IT Series
TOXIC GAS SENSOR MODULE
Version 2.0
APPLICABILITY & EFFECTIVITY
Effective for all Model 5100-XX-IT and 5100-XX-IT-SS Modules manufactured after March 1, 2008
including.
5100-03-IT
5100-04-IT
5100-05-IT
5100-06-IT
Instruction Manual Part Number T12020
Rev A
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Contents
TABLE OF CONTENTS
PRODUCT DESCRIPTION .............................................................................................................................1
1.
1.1 GENERAL........................................................................................................................................................1
1.2 PRODUCT CONFIGURATION........................................................................................................................1
1.3 THEORY OF OPERATION..............................................................................................................................1
1.4 MODES OF OPERATION................................................................................................................................1
1.4.1 SENTRY INTERFACE..............................................................................................................................1
1.4.2 MODBUS OPERATION............................................................................................................................2
1.4.3 ANALOG OPERATION ............................................................................................................................2
1.4.4 REMOTE SENSOR AND DISPLAY (APPENDIX D)................................................................................2
1.4.5 REMOTE ALARM RESET (DIGITAL INPUT) (Figure 3-7) ......................................................................2
1.4.6 OPTIONAL INTEGRAL RELAYS .............................................................................................................2
MECHANICAL ............................................................................................................................................................2
1.4.7 ENCLOSURE ...........................................................................................................................................2
1.4.8 TRANSMITTER ELECTRONICS .............................................................................................................4
1.4.9 SENSOR ASSEMBLY ..............................................................................................................................4
1.5 INTERCONNECT WIRING..............................................................................................................................4
1.6 POWER REQUIREMENTS .............................................................................................................................4
2. CAUTIONS & WARNINGS .............................................................................................................................5
2.1 INTRODUCTION .............................................................................................................................................5
2.2 IT MODULES - GENERAL ...............................................................................................................................5
2.3 WIRING............................................................................................................................................................5
3. INSTALLATION ..............................................................................................................................................7
3.1 SENSOR MODULE LOCATIONS....................................................................................................................7
3.2 WIRING............................................................................................................................................................7
3.2.1 ANALOG 4-20 mA OPERATION..............................................................................................................7
3.2.2 MODBUS OPERATION USING RS-485 CONNECTION ........................................................................7
3.2.3 SENTRY OPERATION USING SMC SENTRY CONNECTION ..............................................................7
3.2.4 GENERAL ................................................................................................................................................7
3.3 ENCLOSURE INSTALLATION........................................................................................................................8
3.4 TRANSMITTER AND SENSOR INSTALLATION ............................................................................................8
3.5 MODULE ADDRESS SWITCH ......................................................................................................................10
4. OPERATION .................................................................................................................................................17
4.1 INTRODUCTION – HUMAN-MACHINE INTERFACE SYSTEM ...................................................................17
4.2 HUMAN-MACHINE INTERFACE ..................................................................................................................17
4.3 MAIN MENU...................................................................................................................................................18
4.4 CONFIGURE SET-POINTS...........................................................................................................................19
4.5 MAINTENANCE FUNCTIONS.......................................................................................................................22
5. CALIBRATION..............................................................................................................................................24
5.1 CALIBRATION FREQUENCY .......................................................................................................................24
5.2 CALIBRATION PREPARATION ....................................................................................................................24
5.2.1 CALIBRATION GAS DELIVERY METHODS.........................................................................................24
5.3 CALIBRATION PROCEDURE.......................................................................................................................24
5.3.1 SENSOR EXPOSURE TO GAS.............................................................................................................25
6. SERVICE........................................................................................................................ ...............................26
6.1 SENSOR MODULE CONFIGURATION ........................................................................................................26
6.2 ENCLOSURE REPLACEMENT ....................................................................................................................26
6.3 TRANSMITTER REPLACEMENT .................................................................................................................27
6.4 SENSOR REPLACEMENT............................................................................................................................27
Contents
6.5 INSTALLATION INSPECTION ......................................................................................................................27
6.5.2 INSPECTION AND TROUBLESHOOTING GUIDE ...............................................................................28
6.5.3 IF MODULE DOES NOT RESPOND TO GAS ......................................................................................28
6.5.4 IF THE MODULE DISPLAYS “STARTING” FOR MORE THAN 1 HOUR .............................................28
7. APPENDICES ...............................................................................................................................................29
APPENDIX A - SPECIFICATIONS ...........................................................................................................................29
APPENDIX B: - MODEL NUMBERS & PARTS LIST ................................................................................................31
APPENDIX C: LIMITED WARRANTY ......................................................................................................................32
APPENDIX D: REMOTE SENSOR/DISPLAY DRAWING 5394-52..........................................................................33
APPENDIX E: MODBUS MEMORY MAP.................................................................................................................34
Contents
1. PRODUCT DESCRIPTION
1.1 GENERAL
The Model 5100-XX-IT Toxics Gas Sensor Module is a member of the Information Technology ”IT” family of
gas sensor transmitter modules. Members of the IT Toxics family include:
• 5100-03-IT Oxygen Deficiency Gas Sensor Module
• 5100-04-IT Carbon Monoxide Gas Sensor Module
• 5100-05-IT Hydrogen Sulfide Gas Sensor Module
• 5100-06-IT Chlorine Gas Sensor Module
IT modules offer a broad array of features, including:
• Integral alphanumeric LED display
• 180 day calibration frequency
• 4-20 mA output
• Modbus
• SMC Sentry interface
• 316 Stainless steel enclosure option
®
RTU interface
• Auxiliary integral relay option
• Remote display option
• Low maintenance and operation costs
IT modules are designed, and approved for installation and operation in hazardous locations.
1.2 PRODUCT CONFIGURATION
Various module configuration options are available. Where applicable, these options are factory configured
prior to shipment. Options which can be re-configured by the installer or field technician are fully described in
this manual.
1.3 THEORY OF OPERATION
Electrochemical sensors are fuel cell-like devices consisting of an anode, cathode and electrolyte. The
components of the cell are selected so a subject gas, allowed to diffuse into the cell, will cause a chemical
reaction and generate a current. The cells are diffusion limited so the rate the gas enters the cell is solely
dependent on the gas concentration. The current generated is proportional to the rate of consumption of the
subject gas in the cell.
1.4 MODES OF OPERATION
1.4.1 SENTRY INTERFACE
IT gas sensor modules can be installed on Sierra Monitor Sentry Model 5000 controllers. The gas sensor
module communicates as a toxic gas sensor module (Type 4 – communication) and are automatically
detected by the Sentry controller. When it is installed in a Sentry system the IT module must have a unique
address which can be established by setting an address between 1 and 8 on the Module Address Switch
®
Registered trademark of Schneider Electric
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accessible from the cover plate as illustrated in Figure 3-1. Figure 3-6 in this manual provides the wiring
terminations for connections to the Sentry controller.
When the module is operated in conjunction with a Sentry controller, the alarms outputs in the module can
both be set to “Sentry”, allowing the Sentry controller to manage alarm acknowledge and reset rather than
the sensor module. The alarm relay outputs are triggered by the alarm values established in the module,
and can be independent of the settings in the Sentry controller.
The Sentry configuration allows daisy chain installation using the Sentry multiplex capability, thus reducing
costs by avoiding the requirement for wiring junction boxes. The connector card has two sets of
connections, allowing for a continuous run to the next module.
1.4.2 MODBUS OPERATION
An RS-485 Modbus RTU serial interface allows direct connection to standard PLCs and DCSs. The
Module Address Switch (section 3.5) allows the user to select up to 16 different Modbus addresses. Also,
an additional 238 Modbus addresses (for a total of 254 different Modbus Addresses) are available via
menu selection. Figure 3-6 in this manual provides the wiring terminations for Modbus connections. The
5100-XX-IT provides the additional terminal connectors to enable the user to connect In/Out terminations of
a RS-485 connection.
1.4.3 ANALOG OPERATION
The 4-20 mA interface allows direct connection to standard analog controllers or PLCs. The 5100-XX-IT 420 mA connection can be wired as a Type 3 (3-wire) or Type 4 (4-wire) circuit as described by ANSI/ISA-
50.00.01-1975 Standard (see figure 3-5).
1.4.4 REMOTE SENSOR AND DISPLAY (APPENDIX D)
The Remote Sensor and Display option (5394-52) can be used to remotely mount the sensor up to 100’
from the transmitter.
1.4.5 REMOTE ALARM RESET (DIGITAL INPUT) (Figure 3-7)
An input is available for connection of remote alarm reset/acknowledge. Figure 3-4 provides the wiring
termination for connecting the remote alarm reset. This only resets local alarms, not Sentry alarms. This
input can be wired as supervised or non-supervised.
Note that when the Remote Alarm Reset is operated in a supervised mode that both the switch and resistor
must be present as outlined in Figure 3-7.
1.4.6 OPTIONAL INTEGRAL RELAYS
The optional relays are integral to the gas sensor module and are rated as SPDT, 250VAC, 8 Amps for the
High Alarm and Low Alarm relays and SPDT, 250 VAC, 2 Amp for the Trouble relay.
If the gas sensor module is provided with the optional relays, it will include Terminal P4 on the interface
board (Figure 3-2). Relay output connections are on P4.
MECHANICAL
The sensor module of comprised of the following three primary components:
1.4.7 ENCLOSURE
Standard on the 5100-XX-IT is an explosion-proof, rain-tight cast aluminum electrical housing (Figure 1-1)
with three ¾” FNPT conduit hubs. The 5100-XX-IT-SS (Figure 1-2) has a 316 Stainless Steel enclosure.
Both enclosure covers have a viewing window. The design of the enclosure allows 3-way mounting choices
as shown in figure 1-3.
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Model 5100-05-IT Toxic Gas Sensor Module – Aluminum Enclosures, Dimensions
Figure 1-1
Figure 1-2
Model 5100-05-IT Toxic Gas Sensor Module – 316 Stainless Steel Enclosures, Dimensions
.
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Figure 1-3
Model 5100-XX-IT Toxic Gas Sensor Module – Mounting Options
1.4.8 TRANSMITTER ELECTRONICS
Electronic Assembly consist of one top transmitter board (connected to the cover plate) and on lower
interface board. Connectors for wiring for power, signal interface and alarm relays are located on the
interface board assembly
1.4.9 SENSOR ASSEMBLY
The sensor assembly includes an explosion proof housing containing the gas sensor and a wiring harness
for connection to the transmitter. The sensor assembly threads into one hub of the enclosure. The
exposed end of the sensor assembly is threaded to allow connection of a rain-shield or calibration gas
delivery fitting.
1.5 INTERCONNECT WIRING
Not supplied with the sensor module, but necessary to the installation and operation is the multi conductor
wiring which connects the module to its power source and controller. Before this wiring is installed it is
important to read and understand the control system installation instructions to determine wiring requirements
and alternatives.
1.6 POWER REQUIREMENTS
IT modules operate on DC power between 10 VDC and 30 VDC. Regulated DC power must be supplied from
a separate source, or from an approved Sentry or IT controller.
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2. CAUTIONS & WARNINGS
2.1 INTRODUCTION
Although IT Transmitter Modules are designed and constructed for installation and operation in industrial
applications including "hostile" environments, caution should be taken to insure that the installation is made in
compliance with this instruction manual and that certain procedures and conditions are avoided. This chapter
discusses the necessary cautions. Read the entire chapter prior to installation of the equipment.
2.2 IT MODULES - GENERAL
Avoid installing sensor modules where they will be unnecessarily exposed to wind, dust, water (esp. direct
hose down), shock, or vibration. Observe temperature range limitations.
Sensors may be adversely affected by prolonged exposure to certain materials. Loss of sensitivity, or
corrosion, may be gradual if such materials are present in low concentrations. These materials include:
Halides (compounds containing chlorine, fluorine, bromine, iodine), acid vapors, caustic liquids or mists.
Care has been taken by the manufacturer to ship your modules in protective packaging to avoid contamination
prior to installation. It is recommended that the modules remain protected during installation and that the
covering be removed immediately prior to system start-up.
During normal use the sensor is protected from dirt and oil contamination by a sintered metal cover. If this
cover becomes clogged, the response of the sensor will be reduced. Protect the sensor from contamination
by careful placement, or by use of rain and dust shields.
Sensor modules must not be painted. Paint may contain compounds which will contaminate the sensor. Paint
will cause clogging of the sintered metal cover and will cause difficulties during attachment of the calibration
head or other maintenance activity. It is recommended that the module be tagged
2.3 WIRING
"DO NOT PAINT".
The manufacturer recommends that extra caution be taken where the installation is near any sources of
electromagnetic or radio frequency interference. Precautions include:
• Avoid running sensor module cable close to high power cables, radio transmission lines, or cables
subject to pulses of high current.
• Avoid running cables near large electric motors or generators.
• When the sensor module is to be operated in analog (4-20mA output) mode shielded cable is required.
• When the risk of interference is present use shielded cables. In conduit installations the shield should
be connected to the conduit. In cable applications the shield should be connected to the cable
connector.
• All splices must be via either a termination hardware system or soldered. Improperly spliced cable can
result in corrosion, resistance changes and system errors.
Installation and wiring must be in accordance with the National Electrical Code.
AC Voltage conductors are not to be run in the same conduit as DC voltage
NOTE
conductors.
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3. INSTALLATION
All modules are tagged to indicate the configuration including the sensor module number.
All IT modules are factory are pre-configured and calibrated.
Identify all components during unpacking and install using the factory configuration.
3.1 SENSOR MODULE LOCATIONS
NOTE
Select locations for each sensor modules based on the following:
• Modules should be placed close to the potential source of gas.
• Modules should be placed in areas accessible for calibration.
• Sensors should be pointed down and the conduit should include an inverse trap to reduce moisture
(condensation) from accumulating in the electronics enclosure.
• Remote calibration fitting (5360-00) should be used to facilitate calibration gas delivery. Run
polyurethane tubing (1/4” O.D. x 1/8” I.D.) from fitting to an accessible location.
3.2 WIRING
3.2.1 ANALOG 4-20 mA OPERATION
The 4-20 mA output for the 5100-XX-IT can be either 3-wire or 4-wire operation. If using 3-wire operation,
use a minimum of 18 AWG, shielded, 3-conductor cable up to 2000’. For 4-wire operation, use a minimum
of 2 each, 18 AWG, twisted, shielded, pair up to 2000’.
3.2.2 MODBUS OPERATION USING RS-485 CONNECTION
Use a minimum of 18 AWG, 2 conductor for DC power connection. No shield required. In addition use a
minimum of 24 AWG, low capacitance, shielded data cable for RS-485 half duplex communication. The
installation may be planned in a manner which provides up to 32 sensor modules on a single home run.
Refer to Figure 3-3 units ship with BIAS jumpers connected. For all installations, except very long cable
runs, these jumpers connected. The TERM jumpers should be installed in the last (furthest) module of
every loop.
3.2.3 SENTRY OPERATION USING SMC SENTRY CONNECTION
Wire shall be rated as 600 volt tray cable, such as Belden (or equivalent) 27331 or 27331 AS (shielded). If
high RFI or EMI levels exist wiring should be protected by conduit or shield. The installation may be
planned in a manner which provides up to 4 sensor modules on a single home run to a Sentry controller.
NOTE:
Be sure to follow all local electric code and safety requirements when installing the 5100-XX-IT Gas Sensor Module
3.2.4 GENERAL
Install conduit as required by local code or construction specifications. When sensor modules are to be
multiplexed for Sentry or RS-485 communication two alternatives may be planned:
• Install splice boxes above each sensor module. Use multi-position positive contact terminals to
connect daisy chain wiring and provide a pigtail to connect to the sensor module transmitter board.
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NOTES
The drain wire of shielded cable must NOT be used as one of the conductors.
Installation and wiring must be in accordance with the National Electrical Code. Temperature
rating of cable wire must be at least 75oC. If cable runs through higher temperature
environments, it must be specified for that environment.
3.3 ENCLOSURE INSTALLATION
To protect the transmitter and sensor assembly they should be removed from the enclosure and preserved
until final installation and wiring termination.
Prior to installation and wiring.
1. Remove the transmitter from the module housing by:
• Unscrew the two captive panel screws in the face plate.
• Lift the transmitter out of the housing.
• Unplug the sensor cable from transmitter connector P2.
• Remove the sensor assembly from the enclosure hub.
2. Install the module housing onto the end of the supply conduit and/or bolt into position as required.
NOTES
When housing earth grounding is required for the installation a grounding lug is located in the
base of the enclosure. Install the earth ground wire under the green lug.
When installing the enclosure be sure to mount the FM Approved plate near the sensor
enclosure. This plate states “Caution: this area must be known to be free of flammable
concentrations prior to opening the enclosure.”
3.4 TRANSMITTER AND SENSOR INSTALLATION
When all pre-wire is complete:
1. Install sensor assembly in the open hub on the module enclosure. The sensor assembly thread
must be fully seated into the hub and tightened to maintain explosion proof assembly.
2. Connect the wires which return to the controller to interface board connectors P1, P2, P3 and P4
according to Figure 3-2.
3. Connect the sensor assembly cable to top transmitter board connector P2.
4. Align the headers between the top transmitter board and the lower interface board and push
together.
5. Turn rotary switch to correct sensor address.
The interface board should be wired to remote controllers first before installing the front
NOTE
transmitter board.
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