MODEL 5100-02-IT
IT Series
COMBUSTIBLE GAS SENSOR MODULE
Version 2.00a
APPLICABILITY & EFFECTIVITY
Effective for all Model 5100-02-IT Modules manufactured after February 15, 2008.
Instruction Manual Part Number T12019
Rev. B1
Model 5100-02-IT Combustible Gas Sensor Module
FM APPROVAL
ONLY THE FOLLOWING ITEMS, FUNCTIONS AND OPTIONS ARE FM* APPROVED
Model 5100-02-IT Combustible Gas Sensor Module
Sensor Module
Model 5100-02-IT Combustible Gas Sensor Module
Model 5100-02-IT-SS Combustible Gas Sensor Module, 316SS
Calibration Equipment
Model 1200-26 Calibration Gas Delivery System
Model 1290-02 Combustible Gas Cylinder
Model 5358-01 Calibration Head, Standard
Model 5360-00 Calibration Gas Delivery Fitting
Model 1260-02 Combustible 50% LEL Gas Cylinder
Model 1260-42 Cylinder H2 50% LEL Type A
Model 1250-01 Gas Sensor Calibrator Kit, Type A
Model 1256-01 Regulator Type A Calibrator
Model 5394-61 Auxiliary Connection Option
Model 5394-62 Auxiliary Relay Option
Model 5394-64 RS-485 Multidrop Option
Model 5394-51 Remote Sensor Option – 5100-02-IT
Notes:
1) FM Approval applies only to conventional (one cable run per sensor
module) or multiplexed (multiple sensor modules per cable) installations.
Apparatus must be installed in accordance with National Electrical Code.
2) FM Comments
*FM Approvals, a subsidiary of FM Global
Project# 3021050
Model 5100-02-IT Combustible Gas Sensor Module
TABLE OF CONTENTS
PRODUCT DESCRIPTION .............................................................................................................................3
1.
1.1 GENERAL........................................................................................................................................................3
1.2 PRODUCT CONFIGURATION........................................................................................................................3
1.3 THEORY OF OPERATION..............................................................................................................................3
1.4 MODES OF OPERATION................................................................................................................................3
1.4.1 SENTRY INTERFACE..............................................................................................................................3
1.4.2 MODBUS OPERATION............................................................................................................................5
1.4.3 ANALOG OPERATION ............................................................................................................................5
1.4.4 AUXILIARY RELAY OPERATION (Appendix E)......................................................................................5
1.4.5 ENHANCED CONNECTION (Appendix F) ..............................................................................................5
1.4.6 AUXILIARY RS-485 MULTIDROP (Appendix G).....................................................................................5
1.4.7 REMOTE SENSOR (Appendix D)............................................................................................................5
1.4.8 REMOTE ALARM RESET........................................................................................................................5
1.5 MECHANICAL .................................................................................................................................................5
1.5.1 ENCLOSURE ...........................................................................................................................................5
1.5.2 TRANSMITTER ELECTRONICS .............................................................................................................5
1.5.3 SENSOR ASSEMBLY ..............................................................................................................................5
1.6 INTERCONNECT WIRING..............................................................................................................................6
1.7 POWER REQUIREMENTS .............................................................................................................................6
2. CAUTIONS & WARNINGS .............................................................................................................................7
2.1 INTRODUCTION .............................................................................................................................................7
2.2 IT MODULES - GENERAL ..............................................................................................................................7
2.3 WIRING............................................................................................................................................................7
2.3.1 CATALYTIC BEAD SENSOR MODULES................................................................................................8
3. INSTALLATION ..............................................................................................................................................9
3.1 SENSOR MODULE LOCATIONS...................................................................................................................9
3.2 WIRING............................................................................................................................................................9
3.2.1 ANALOG 4-20 mA OPERATION..............................................................................................................9
3.2.2 MODBUS OPERATION USING RS-485 CONNECTION ........................................................................9
3.2.3 SENTRY OPERATION USING SMC SENTRY CONNECTION ..............................................................9
3.2.4 GENERAL ................................................................................................................................................9
3.3 ENCLOSURE INSTALLATION......................................................................................................................10
3.4 TRANSMITTER AND SENSOR INSTALLATION ..........................................................................................10
3.5 INSTALLATION CONFIGURATION ..............................................................................................................12
4. INTRODUCTION – HUMAN-MACHINE INTERFACE SYSTEM..................................................................15
4.1 HUMAN-MACHINE INTERFACE ..................................................................................................................15
4.2 MAIN MENU...................................................................................................................................................16
4.3 CONFIGURE SET-POINTS...........................................................................................................................17
4.4 MAINTENANCE FUNCTIONS.......................................................................................................................20
5. CALIBRATION..............................................................................................................................................21
5.1 CALIBRATION FREQUENCY .......................................................................................................................21
5.2 CALIBRATION PREPARATION ....................................................................................................................21
5.2.1 CALIBRATION GAS DELIVERY METHODS.........................................................................................21
5.2.2 CALIBRATION PROCEDURE ...............................................................................................................21
5.2.3 SENSOR EXPOSURE TO GAS.............................................................................................................21
6. SERVICE........................................................................................................................ ...............................23
6.1 SENSOR MODULE CONFIGURATION ........................................................................................................23
Contents
Model 5100-02-IT Combustible Gas Sensor Module
6.2 ENCLOSURE REPLACEMENT ....................................................................................................................23
6.3 TRANSMITTER REPLACEMENT .................................................................................................................24
6.4 SENSOR REPLACEMENT............................................................................................................................24
6.5 INSTALLATION INSPECTION ......................................................................................................................24
CONTROLLER INSTALLATION ............................................................................................................24
CABLING INSTALLATION .....................................................................................................................24
SENSOR MODULE INSTALLATION .....................................................................................................24
MOISTURE TRAPS AND RAINSHIELDS..............................................................................................25
STANDARD VOLTAGES .......................................................................................................................25
INSPECTION AND TROUBLESHOOTING GUIDE ...............................................................................25
IF MODULE DOES NOT RESPOND TO GAS ......................................................................................25
IF THE MODULE DOES NOT COME OUT OF WARM UP...................................................................25
If the module does not display the correct %LEL...................................................................................25
If the display shows ‘NO SENSR’ –Sensor Failing ................................................................................25
IF THE MODULE SHOWS “***Calibration Required***” ........................................................................25
IF THE MODULE SHOWS “***UNCALIB***” .........................................................................................25
If the display shows ‘H’ (OR l) THEN THE LOCAL HIGH OR LOW ALARM IS ACTIVE ......................25
If the display shows ‘w’ – radio freQuency INTERFERENCE................................................................25
If the display shows “C” – calibration mode ...........................................................................................25
other error messages – call factory........................................................................................................25
7. APPENDICES ...............................................................................................................................................26
7.1 APPENDIX A: SPECIFICATIONS..................................................................................................................26
7.2 APPENDIX B: MODEL NUMBERS & PARTS LIST .......................................................................................27
7.3 APPENDIX C: LIMITED WARRANTY............................................................................................................28
7.4 APPENDIX D: REMOTE SENSOR/DISPLAY DRAWING 5394-50 ...............................................................29
7.5 APPENDIX E: AUXILIARY RELAY ASSEMBLY 5394-62..............................................................................30
7.6 APPENDIX F: AUXILIARY CONNECTION ASSEMBLY 5394-61 .................................................................31
7.7 APPENDIX G: AUXILIARY RS-485 MULTIDROP ASSEMBLY 5394-64 ……………………………………..32
7.8
APPENDIX H: MODBUS MEMORY MAP......................................................................................................34
7.9 APPENDIX I: COMBUSTIBLE GAS SCALING FACTORS............................................................................35
7.10 APPENDIX J: MENU KEY FOR 5100-02-IT GAS SENSOR MODULE …………………………….…….......36
Contents
Model 5100-02-IT Combustible Gas Sensor Module
®
1. PRODUCT DESCRIPTION
1.1 GENERAL
The Model 5100-02-IT Catalytic Bead Combustible Gas Sensor Module
is a member of the Sentry Information Technology ”IT” family of gas
sensor transmitter modules. IT modules offer a broad array of features
including:
• Integral Alphanumeric display
• 180 day calibration frequency
• Integral alarm relays (3)
• 4-20 mA output
• Modbus
• SMC Sentry interface
• 316 Stainless steel enclosure option
• Remote alarm reset
®
RTU interface
• Auxiliary relay option
• Remote sensor option
• Auxiliary connector option
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.
1.3 THEORY OF OPERATION
Catalytic bead gas sensors detect gas by comparing the resistance of two heated elements. One element is
catalytic to enhance the burning of combustible gases, the other element is passive. Electronic circuits are
used to compare the change in the catalytic bead resistance relative to the passive bead. The relative change
is calibrated to determine the concentration of the gas of interest.
1.4 MODES OF OPERATION
1.4.1 SENTRY INTERFACE
All IT gas sensor modules can be installed on Sierra Monitor Sentry Model 5000 controllers. Catalytic bead
modules communicate as a combustible gas sensor module (Type 2 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 rotary switch accessible
from the cover plate as illustrated in Figure 3-1. Figure 3-4 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 alarm relay setup (See section
4.3) should be set to “Sentry”, allowing the Sentry controller to manage alarm relay action rather than the
5100-02-IT Gas Sensor Module.
An available option, applicable only to Sentry installations, is a connector card which allows daisy chain
installation using the Sentry multiplex capability. Use of the connector card reduces 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.
Registered trademark of Schneider Electric.
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Model 5100-02-IT Combustible Gas Sensor Module
Figure 1-1
Model 5100-02-IT Combustible Gas Sensor Module Stainless Steel – Dimensions
Figure 1-2
Model 5100-02-IT Combustible Gas Sensor Module Aluminum – Dimensions
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Model 5100-02-IT Combustible Gas Sensor Module
1.4.2 MODBUS OPERATION
All IT gas sensor modules have a Modbus RTU RS-485 serial interface to allow direct connection to any
standard PLC or DCS. The Module Address Switch (section 3.5) allows the user to select Modbus
addresses 1 thru 15. Switch position “0” allows the user to set addresses up to 254 using the s Menu (See
Table 4-3). Figure 3-4 provides the wiring terminations for Modbus connections.
1.4.3 ANALOG OPERATION
All IT gas sensor modules have a 4-20 mA interface to allow direct connection to standard analog
indicators or PLCs. The standard Model 5100-02-IT provides a 4-20 mA analog interface which allows
power and loop connections. When IT modules are to be operated with analog interface, each module
requires individual home run wiring and no unique address is required. Figure 3-3 provides the wiring
terminations for 4-20 mA connections.
1.4.4 AUXILIARY RELAY OPERATION (APPENDIX E)
While the 5100-02-IT has three internal 0.25 amp relays (high alarm, low alarm and trouble) as standard,
an available option is an Auxiliary Relay Assembly, Part Number 5394-62, which provides 8 amp alarm
relays for each of the two conditions, low alarm and high alarm.
1.4.5 ENHANCED CONNECTION (APPENDIX F)
An Auxiliary Connection Assembly, Part Number 5394-61, applicable to Sentry and RS-485 installations
only, provides connections capable of accepting 12 AWG wire. Additionally, the enhancement acts as a
junction box providing connections for the next module in the run, when utilizing the Sentry multiplexing
capability.
1.4.6 AUXILIARY RS-485 MULTIDROP (APPENDIX G)
The Auxiliary RS-485 Multidrop Connection Assembly, Part Number 5394-64, provides the additional
terminal connectors to enable the user to connect the In/Out terminations of a RS-485 connection.
1.4.7 REMOTE SENSOR (APPENDIX D)
Extension kit 5394-51 can be used to remotely mount the sensor up to 50’ from the transmitter.
1.4.8 REMOTE ALARM RESET
An input is available for connection of remote alarm reset/acknowledge. Figure 3-5 provides the wiring
termination for connecting the remote alarm reset.
1.5 MECHANICAL
The sensor module is comprised of the following three primary components:
1.5.1 ENCLOSURE
Standard on the 5100-02-IT is an explosion-proof, rain-tight cast aluminum electrical housing with three ¾”
FNPT conduit hubs. The 5100-02-IT-SS 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. .
1.5.2 TRANSMITTER ELECTRONICS
Electronic Assembly consisting of one printed circuit board assembly mounted under a cover plate. Wiring
connections for power, signal interface and alarm relays are located on the back side of the display.
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
delivery fitting.
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Model 5100-02-IT Combustible Gas Sensor Module
1.6 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.
1.7 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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Model 5100-02-IT Combustible Gas Sensor Module
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 (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 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
"DO NOT PAINT".
2.3 WIRING
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 instrument
ground.
• 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.
Voltage AC conductors are not to be run in the same conduit as voltage DC
NOTE
conductors.
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Model 5100-02-IT Combustible Gas Sensor Module
2.3.1 CATALYTIC BEAD SENSOR MODULES
Model 5100-02-IT Gas Sensor Modules are FM performance approved for detection of Combustible gas
(methane and hydrogen). The sensor is cross sensitive to the combustible gases indicated in Table 2-1.
Risk management planning should take into consideration the potential for the presence of other gases in
the monitored area.
Note that the 5100-02-IT has a gas factor scaling feature in which a calibration standard of Methane or
Propane may be used in conjunction with scaling factors to cause alarm function in %LEL scale of another
gas. See Appendix I.
Acetaldehyde
Acetic Acid
Acetic Anhydride
Acetone
Acetylene
Alkyl Alcohol
Ammonia
n-Amyl Alcohol
Aniline
Benzene
Biphenyl
1,3-Butadiene
n-Butane
iso-Butane
Butene-1
cis-Butene-2
trans-Butene-2
n-Butyl Alcohol
iso-Butyl Alcohol
tert-Butyl-Alcohol
n-Butyl Benzene
iso-Butyl Benzene
n-Butyric Acid
Carbon Disulfide
Carbon Monoxide
Carbon Oxysulphide
Chlorobenzene
Cyanogen
Cyclohexane
Cyclopropane
n-Decane
Diethylamine
Dimethylamine
2,3-Dimethylpentane
2,3-Dimethylpropane
Dimethylsulphide
1,4-Dioxane
Epichlorohydrin
Ethane
Ethyl Acetate
Ethyl Alcohol
Ethylamine
Ethyl Benzene
Ethyl Bromide
Ethyl Chloride
Ethylcyclopentane
Ethylene
Ethylenedichloride
Ethyleneoxide
Diethyl Ether
Dimethoxyethane
Dimethyl Ether
Dimethylformamide
Ethyl Formate
Ethylmercaptan
n-Heptane
n-Hexane
Hydrazine
Hydrogencyanide
Hydrogen
Hydrogen Sulfide
Methane
Methyl Actetate
Methyl Alcohol
Methylamine
Methyl Bromide
Methyl Chloride
Methylcyclohexane
Methylenedichloride
Methylethylether
Methylethylketone
Methyl Formate
Methylmercaptan
Methylpropionate
Methyl n-propylketone
Napthalene
Nitromethane
n-Nonane
n-Octane
n-Pentane
i-Pentane
Propane
n-Propyl Alcohol
n-Propylamine
n-Propylchloride
Propylene
Propyleneoxide
iso-Propylether
Propyne
Toluene
Triethylamine
Trimethylamine
Vinylethylether
o-Xylene
m-Xylene
p-Xylene
JP-4 (Jet Fuel)
Table 2-1
Combustible gases detected by Model 5100-02-IT Combustible Gas Sensor Module
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Model 5100-02-IT Combustible Gas Sensor Module
3. INSTALLATION
All modules are tagged to indicate the configuration including the sensor module number.
All IT modules are factory pre-configured and calibrated.
Identify all components during unpacking and install using the factory configuration.
NOTE
3.1 SENSOR MODULE LOCATIONS
Select locations for each sensor module 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) can 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 5100-02-IT can be either 3-wire (using the 5394-61 Connector Board) 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.
3.2.3 SENTRY OPERATION USING SMC SENTRY CONNECTION
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.
Be sure to follow all local electric code and safety requirements when installing the 5100-02-IT Gas Sensor Module
3.2.4 GENERAL
NOTE:
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.
• Use Auxiliary Connection Assembly, Model 5394-61. The Auxiliary Connection Assembly plugs into
the sensor module transmitter and provides daisy chain wiring.
Installation and wiring must be in accordance with the National Electrical Code. Temperature
The drain wire of shielded cable must NOT be used as one of the conductors.
rating of cable wire must be at least 75oC. If cable runs through higher temperature
environments, it must be specified for that environment.
NOTE
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Model 5100-02-IT Combustible Gas Sensor Module
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 on the face plate.
• Lift the transmitter out of the housing.
• Unplug the sensor cable from transmitter connector J2.
• 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.
When housing earth grounding is required for the installation a grounding lug is located in the
NOTE
base of the enclosure. Install the earth ground to under the green ground lug.
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 transmitter connectors P1 and P2 (Figure 3-2)
according to Figures 3-3 (Analog Output), 3-4 (Digital Interface), 3-5 (Remote Alarm Reset).
3. Connect the sensor assembly cable to transmitter connector J2.
4. Reconnect any required auxiliary wiring to the applicable terminals according to project
requirements and Table 3-2.
5. Connectors P1 and P2 are removable to facilitate wiring termination. When reinstalling the
connectors pay attention to the connector orientation. See Figures 3-2, 3-3, 3-4, 3-5, etc.
Connectors P1 and P2 are removable for easy wiring termination.
NOTE
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Model 5100-02-IT Combustible Gas Sensor Module
6. Carefully return the transmitter to the enclosure installing it over the two standoffs. Tighten the
retaining screws into the standoffs.
P1 FUNCTION P2 FUNCTION
1 High Alarm Relay NC 1 Power
2 High Alarm Relay NO 2 Signal
3 High Alarm Relay COM 3 Ground
4 Low Alarm Relay NC 4 N/A
5 Low Alarm Relay NO 5 N/A
6 Low Alarm Relay COM 6 4-20 mA output -
7 Trouble Relay NC* 7 4-20 mA output +
8 Trouble Relay NO* 8 RS-485 Ground
9 Trouble Relay COM 9 RS-485 (-) (B)
10 Digital Input SW+ 10 RS-485 (+) (A)
11 Digital Input SW-
*Trouble relay is fail safe so it is energized for normal operation. Functions
are labeled for normal operation.
Table 3-1
Sensor Module External Interfaces
7. Establish the module address according to section 3.5.
The warm-up period is 3 minutes from power on.
NOTE
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Model 5100-02-IT Combustible Gas Sensor Module
3.5 INSTALLATION CONFIGURATION
Table 3-3 and Figures 3-1 through 3-4 provide location and installation details.
POSITION ADDRESS POSITION ADDRESS
1 Sensor 1 9 Sensor 09
2 Sensor 2 A Sensor 10
3 Sensor 3 B Sensor 11
4 Sensor 4 C Sensor 12
5 Sensor 5 D Sensor 13
6 Sensor 6 E Sensor 14
7 Sensor 7 F Sensor 15
8 Sensor 8 0 Select
Table 3-2
Sensor Module Rotary Switch Positions
Figure 3-1
Module Address Rotary Switch
For Sentry applications only sensor addresses 1-8 are allowed. If using Modbus output
sensor addresses 1-15 are available. Position 0 allows the Modbus or Sentry address to be
set by software menu, in the range 16-254.
NOTE
Figure 3-2
Connector Locations
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Model 5100-02-IT Combustible Gas Sensor Module
Figure 3-3
4-20 mA Connection
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Model 5100-02-IT Combustible Gas Sensor Module
Figure 3-4
Digital Interface Connections
Figure 3-5
Remote Alarm Reset
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Model 5100-02-IT Combustible Gas Sensor Module
r
4. INTRODUCTION – HUMAN-MACHINE INTERFACE SYSTEM
The Combustible Gas Sensor utilizes a visual menu system operated by means of a magnet. A magnet stick is
supplied for this purpose. The menu system is used to configure alarm set-points, calibrate the sensor
module, and for maintenance procedures and alarms acknowledge.
4.1 HUMAN-MACHINE INTERFACE
The module menu system is operated by means of directing the magnet stick toward each of four independent
hall-effect magnetic switches. Each switch functions as if it is a manually activated panel key. The keys are
located above and below the faceplate display and are labeled
• Key M : MODE
• Key E : ENTER
• Key ▲: UP (+)
M , E , ▲, and ▼as shown in Figure 4-6.
• Key ▼: DOWN (-)
Mode
Ente
Up
Down
Figure 4-6
HMI Switch Locations
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Model 5100-02-IT Combustible Gas Sensor Module
4.2 MAIN MENU
Table 4-1 describes the primary human-machine interface operation.
Function Display Description Reference
Key
M E
ST
M E
ST
ME
S T
ME
S T
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
Mode Switch [M]
Enter Switch [E]
Up Switch [▲] Previous Menu
Down Switch [▼] Next Menu
5100-02 First screen at power up-model
1.Xxa VX.Xxx Second screen at power up-version
Warm.XXX Third screen at start up-warm up
0%LEL Normal condition - default display
Mode ALMRSET: Mode Function -Alarms Acknowledge
SSSSSSSS
Banner: Use <M> switch for different menu items. Select <E> to
enter menu item.
0%LEL Default Display
Mode ALMRSET: Mode Function - Alarms Reset
Mode CALIB: Mode Function - Calibrate Table 5-1
Mode SETUP: Mode Function - Set Point Adjustments Table 4-3
Mode MAINT: Mode Function - Maintenance Table 4-4
Mode EXIT-? Exit Mode
Enter 0%LEL Apply Selected Mode (Exit)
0%LEL Default Display
Table 4-1
Master Menu
Table 4-2 describes the operational display values of the human-machine interface system.
Display Description
STARTING Warm-up at start-up
##%LEL Concent ration
L ##%LEL Low Alarm
H ##%LEL High Alarm
HIGH >100% Full Scale
NO SENSR Sensor Failure
C ##%LEL Calibration Mode
ACK Acknowledged Function
Table 4-2
Operation Display Values
ID THE DISPLAY SHOWS “START” INSTEAD OF “STARTING, THE MODULE MUST BE CALIBRATED BEFORE USING IT.
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Model 5100-02-IT Combustible Gas Sensor Module
4.3 CONFIGURE SET-POINTS
The sensor module set-points menu is used to initially set-up the alarm set points, relay actions, gas type and
range, 4-20 mA action and RS-485/Sentry address and baud rates (See Menu Key in Appendix J).
• Alarm Set-points: Once the Set-up menu is selected, press [E] to activate the Alarm Set-point
screen. Use the [▲] or [▼] keys to select Low Alarm or High Alarm menu. Key [▲] will adjust the
setpoint upwards and Key [▼] will adjust the value downwards. Once it reaches the desired
setpoint, Key [E] will accept it and ACK will appear. Set-points can be configured using this menu to
values between 0 and 60.
• Alarm Relay Set-up: Once the Set-up menu is selected, press key [▼] once and press [E] to
activate the Relay Set-up menu. Use the [▲] or [▼] keys to select High Alarm or Low Alarm relay
menu and press [E]. Use the [▲] or [▼] keys to select the correct alarm relay action for the
application, Latch, Sentry or Non-Latch. Selecting “Sentry” enables the Sentry controller to make all
alarm action decisions. * indicates the current selection.
• Gas Factor: A calibration standard of Methane or Propane may be used in conjunction with scaling
factors to cause alarm function in %LEL scale of another gas. See Appendix I for a list of the scaling
factors. Note that if the 5100-02-IT is interfaced to a Sentry controller that the gas factor can be set in
the Sentry or the Gas Sensor Module but NOT IN BOTH. It is recommended that the gas factor be
adjusted in the Gas Sensor Module so that the display values on both the Gas Sensor Module and
the Sentry are matched. Note that gas factors are not applicable during calibration.
• 4-20mA: Once the Set-up menu is selected, press key [▼] three times and press [E] to activate the
4-20mA Set-up menu. Use the [▲] or [▼] keys to select Calib, or CalibOut TblOut 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 510028-IT and upon selecting the 4 mA output calibration then the [▲] or [▼] keys can be used to adjust
the 4 mA reading on the amp meter until it reads 4 mA. Similar steps can then be performed for the
20 mA output. The CalibOut section allows the user to select the 4-20 mA output action desired
during calibration. * indicates the current selected value. Available selections include:
Track – the 4-20mA value tracks the calibration gas exposed to the gas sensor module
Zero – the 4-20mA value is held at 0mA during calibration
C1.50mA – the 4-20mA value is held at 1.50mA during calibration
C4.00mA – the 4-20mA value is held at 4.0mA during calibration.
The Tbl Out menu enables the user to select the mA output value for the Trouble Alarm. Select
“T2.5mA” to choose the 2.5mA default valve. Or select “User mA” and use the [▲] or [▼] keys to
select any valve between 0.5mA and 3.7mA.
• RS-485 - Once the Set-up menu is selected, press key [▼] four times and press [E] to activate the
RS-485/Sentry Set-up menu. Use the [▲] or [▼] keys to select Address or Baud rate menu and
press [E]. Note that the 5100-28-IT has a rotary switch on the faceplate and it is used to select
addresses 1-15. When connected to Sentry the user can select 1-8 and using Modbus RS-485 the
user can select addresses 1-15. For Modbus addresses above 15, set the rotary switch to 0 and
then use the “Address” menu to select any address between 16 and 254. The Baud rate menu
allows the user to select a baud rate of 38400, 19200, 9600, 4800 or 2400. * indicates current
selection.
Page: 17
Model 5100-02-IT Combustible Gas Sensor Module
Function Display Description Reference
Key
--0%LEL- Default Display
M E
ST
M E
ST
M E
ST
M E
ST
ME
S T
ME
S T
ME
S T
ME
S T
M E
ST
M E
ST
ME
S T
M E
ST
Mode ALMRSET: Mode Function - Alarm Reset
Mode CALIB:-- Mode Function - Calibrate
Mode SETUP:--- Mode Function - Set Point Adjustments
Enter Alarms S.P. Function - Alarm Adjust * A Below
Down Relays S.P. Function - Relays Adjust * B Below
Down GasFactr S.P. Function - Gas Factor Adjust * C pg. 19
Down 4-20mA S.P. Function - 4-20 mA Adjust * D pg. 19
Down RS-485 S.P. Function - RS-485/Sentry Output Adjust * E pg. 19
High Alarm Set Point Adjustment Example
Enter H.Alarm S.P. Function - High Alarm Adjust *A
Enter HASP:60- High Alarm Set Point: current = 60
Use S or T keys to adjust to new set point
Down (x5) HASP:55- High Alarm Set Point: new = 55
Enter ACK Momentary Acknowledge of new Set Point
H.Alarm S.P. Function - High Alarm Adjust
M E
ST
ME
S T
M E
ST
ME
S T
ME
S T
Relays Set Point A djustment Example
Enter H. Relay S.P. Function - High Alarm Relay Adjust *B
Down L.Relay S.P. Function - Low Alarm Relay Adjust
Enter Latch
Down Sentry
Use S or T keys to adjust to new relay action
(Latch, Sentry, NonLatc) * indicates current
NOTE: Sentry indicates that Sentry controls relay
action and not the IT Sensor Module
Down *Sentry High Alarm Relay set to Sentry
Table 4-3A Set-Up Configuration
Page: 18
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
ME
S T
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
ME
S T
M E
ST
Model 5100-02-IT Combustible Gas Sensor Module
Gas Factor Example
Enter GasFactr S.P. Function - Gas Factor Adjust *C
Enter Factr100
Enter ACK Acknowledgement of new Gas Factor Value
Enter Calib S.P. Function - Calib Adjust *D
Enter Out: 4mA Use S or T keys to select 4 mA or 20mA
Enter 4mA Selects 4 mA
Enter ACK Momentary Acknowledge of new Set Point
Mode Calib S.P. Function - Calib Adjust
Down CalibOut S.P. Function - Output during Calibration Adjust
Enter Track Use S or T keys to select Track, Zero, C1.50mA, C4.00mA
Enter *Track * = Current selection
Mode
Calib S.P. Function - Calib Adjust
Down Tbl Out S.P. Function - output during Trouble Alarm
Enter *T2.50mA Current Valve 2.5mA for Trouble
Down User mA S.P. Function - User Selectable mA Valve
Enter *T2.50mA
Enter *T1.75mA Selctd 1.75mA for volume during trouble
Enter Address S.P. Function - RS-485 Address Adjust *E
Enter Addr:016 Use S or T keys to enter new address
Enter ACK New address selected
Enter Address S.P. Function - RS-485 Address Adjust
Down Baud S.P. Function - RS-485 Baud Rate Adjust
Enter *38400 Press [E] to select or [S] or [T] to select another
Select [E] to select or S or T to adjust factor
number and press [E]
4-20 mA Adjustment Example
Track = Output during calibration tracks the calibration gas,
Zero = Output is Zero during calibration,
C1.50mA = Output during calibration is 1.50 mA, C4.00mA =
Output during calibration is 4.0 mA
Use S or T keys to select mA Valve between 0.5
and 0.7mA
RS-485 Adjustment Example
Table 4-3B
Set-Up Configuration
Page: 19
Model 5100-02-IT Combustible Gas Sensor Module
4.4 MAINTENANCE FUNCTIONS
The maintenance menu allows the operator to monitor certain Sensor values, and select the required analog or
digital communication interface. The maintenance menu operation is described in Table 4-4.
Function Display
Key
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
Mode ALMRSET: Mode Function - Alarm Reset
Mode CALIB: Mode Function - Calibration
Mode SETUP: Mode Function - Set Point Adjustments
Mode MAINT: Mode Function - Maintenance
Enter V2.00aA Module Version
0%LEL Default Display
Description
Table 4-4
Maintenance Menu
Reference
Page: 20
Model 5100-02-IT Combustible Gas Sensor Module
5. CALIBRATION
5.1 CALIBRATION FREQUENCY
The manufacturer specifies that sensor modules must be calibrated every 180 days. Periodic functional tests are
advisable for critical applications and hostile environments.
The sensor module microprocessor software includes high level self checking algorithms which provide continuous
sensor diagnostic and self adjustment. Users may elect to increase calibration periods based on low drift
experience during the first two calibration periods.
CALIBRATION PREPARATION
5.2
Calibration of the sensor is accomplished by simple menu based steps and application of span gas.
If an error is made during any stage of the calibration process, hold the magnet stick at the
Switch 1 for 10 seconds. A scrolling display will indicate “Operate Mode” and the sensor module
will exit the calibration activity and return to normal operating mode. The calibration procedure
NOTE
can then be restarted.
Calibration must be performed only when the area is known to be clear of combustible gas. If necessary, use a
portable instrument to confirm that there is no background combustible gas.
For compliance with Factory Mutual (FM) Approvals, the Sierra Monitor Model 1200-26, 1250-01, 1256-01, 1260 02 and 1260-42 are the FM Approved calibration gas delivery devices. Use Model 5358-01 Calibration Adapter or
Model 5360-00 Gas Delivery Fitting.
5.2.1 CALIBRATION GAS DELIVERY METHODS
Calibration gas can be delivered to the sensors via the following delivery devices:
Model 5358-01: Calibration Adapter - use with portable calibrators. See Fig 5-1.
Model 5360-00: Calibration Gas Delivery fitting - permanently installed fitting
which allows tubing to be run to a convenient delivery location.
5.2.2 CALIBRATION PROCEDURE
Table 5-1 shows the step by step process of the calibration procedure.
The procedures requires that the menu “keys” be activated using the magnet
stick. Each key press steps through the process of setting the zero value for
clean air and then setting the span value.
At each of these steps, apply calibration gas of the value corresponding to the
setting accepted on the sensor module display.
Model 5358-01 Calibration Adapter
Figure 5-1
5.2.3 SENSOR EXPOSURE TO GAS
Calibration gas must be delivered to the sensor using the flow rate and duration listed in below:
Model Gas Flow Period
5100-02-IT Combustible 100-300 cc/min Until Stable (minimum 3 minutes.)
Following calibration, the module counts down for 300 seconds. During this time the module is updating its internal memory and it
is very important that its power not be interrupted
NOTE:
Page: 21
Key
M E
ST
M E
ST
M E
ST
M E
ST
M E
ST
Model 5100-02-IT Combustible Gas Sensor Module
FunctionDisplay Description Reference
0%LEL Default Display
Mode ALMRSET: Mode Function - Alarms Reset
Mode CALIB: Mode Function - Calibrate or Sub Routine A
Enter CAL-0%
Enter ACK Zero gas setting acknowledged
50%-SPAN
Enter CAL-50%
C 0%LEL
Banner: Apply zero gas, enter <E> when done
Operation: Confirm area clear of gas, or apply zero air to sensor.
Banner: Select span, enter <E> when done
Banner: Apply 50% gas, then enter <E> to calibrate gas sensor
Operation: Apply calibration gas.
use Sub Routine B
M E
ST
M E
ST
ME
S T
ME
S T
M E
ST
ME
S T
M E
ST
Enter CAL-OK Calibration Passed - now remove gas
Mode (Any)
Down 25%-SPAN
Down Adj-SPAN
Enter 25%-SPAN
Up (x5) 30%-SPAN
Enter CAL-FAIL
CXX%LEL
WAIT-300
Operation: As gas is applied the reading will increase - wait 3 minutes
Operation: Five minute time out before sensor is returned to service.
Sub-Routine A - Abort Calibration
Operation: Hold magnet over Mode <SW1> for ten sec onds to abort
calibration
Banner: Operate mode
0%LEL Default Display
50%-SPAN
Banner: Select span, enter <E> when done
Operation: Change Span Gas Value to 25%
Operation: User adjustable value
Operation: Ready for user adjustment
Operation: User adjustment to new val ue 30%
Sub-Routine C - Calibration 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.
Sub-Routine B - Select Span
Table 5-1
Calibration
use Sub Routine C
Page: 22
Model 5100-02-IT Combustible Gas Sensor Module
6. SERVICE
6.1
SENSOR MODULE CONFIGURATION
The gas sensor module is comprised of the following sub-assemblies (Figure 6-1):
5100-02-IT Gas Sensor Module
SPL21810 Alluminum Enclosure (SPL32178 316SS Enclosure)
SPL21813 Transmitter Assembly
5200-02 Sensor Assembly
There are no field serviceable components below the sub assembly level.
6.2
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.
Page: 23
Figure 5-1
Module Components
Model 5100-02-IT Combustible Gas Sensor Module
TRANSMITTER REPLACEMENT
6.3
The transmitter assembly should be replaced when it is determined that it is unreliable, noisy or cannot be
calibrated. This may occur due to age, corrosion or failed components.
To replace the transmitter assembly:
a. Remove the cover of the main enclosure
b. Unscrew the two thumb screws in the top of the cover plate, lift the assembly and rotate 90
wiring service loop
c. Unplug the sensor connector from the transmitter
d. Plug connector into new transmitter (be sure to match numbers between connector and socket).
e. Restore power and allow a minimum of 3 hours for stabilization before re-calibration
6.4
SENSOR REPLACEMENT
The gas sensor which is located inside the sensor assembly housing can be replaced without replacement of the
housing. The gas sensor needs replacement when:
The “CAL-FAIL” message appears after calibration
The sensor output signal is noisy, causing erroneous gas level readings
To replace the sensor:
a. Confirm that system power has been removed
b. Remove the gas sensor module enclosure cover,
c. Unscrew the two thumb screws in the top of the faceplate, lift the transmitter assembly and rotate 90
relieve the wiring service loop.
d. Unplug the sensor connector from the transmitter
e. Unscrew the old sensor assembly from the enclosure conduit hub. Remove the sensor assembly with its
harness
f. Unscrew sensor housing cover from the sensor (be sure to loosen the set screw first)
g. Carefully pull the old sensor straight up from the socket
h. Press the new sensor into the socket.
i. Reverse the preceding steps to install the sensor assembly.
j. Allow the new sensor to stabilize for a minimum of 3 hours and then calibrate using the procedure in Section
5.
6.5
INSTALLATION INSPECTION
o
to relieve the
o
to
Prior to system start-up or trouble shooting, the entire system should be visually inspected. The following are
guidelines for that inspection:
6.5.1 CONTROLLER INSTALLATION
• Controller installed in conformance to instruction manual recommendations.
• AC power is correctly grounded.
• Hot AC and relay connections have safety covers installed.
6.5.2 CABLING INSTALLATION
• All splices are soldered or via terminal block.
• Cabling is away from sources of electrical noise where possible.
• Connector P2, terminals P2 1, 2, 3 on sensor module are connected to Sentry controller as Power, Signal,
Ground, respectively.
6.5.3 SENSOR MODULE INSTALLATION
• Module installation in conformance with this manual.
• Modules accessible for calibration.
Page: 24
Model 5100-02-IT Combustible Gas Sensor Module
• Wiring terminations clean and correct.
6.5.4 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.
6.5.5 STANDARD VOLTAGES
• Regulated DC Voltage to be applied to the sensor module must be between 10 VDC and 30 VDC.
6.5.6 INSPECTION AND TROUBLESHOOTING GUIDE
The inspection and troubleshooting guide can be used to step through the system start-up and to determine the
corrective action if a fault occurs.
6.5.7 IF MODULE DOES NOT RESPOND TO GAS
1. Repeat calibration procedure.
2. Remove the gas and wait for the timer to completely count down.
3. Apply 50%LEL and verify that the sensor sees 50% LEL gas after calibration.
4. If the sensor still does not see gas, power cycle the unit and repeat calibration.
6.5.8 IF THE MODULE DOES NOT COME OUT OF WARM UP
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 combustible gas during warm-up.
6.5.9 IF THE MODULE DOES NOT DISPLAY THE CORRECT %LEL
1. Power cycle the unit.
2. Recalibrate the sensor.
6.5.10 IF THE DISPLAY SHOWS ‘NO SENSR’ –SENSOR FAILING
1. Power down the unit
2. Open the enclosure and unplug the sensor from the transmitter board.
3. Plug the sensor back into the transmitter board carefully and ensure a secure fit.
4. Power up the unit.
6.5.11 IF THE MODULE SHOWS “***CALIBRATION REQUIRED***”
1. Calibrate the module
6.5.12 IF THE MODULE SHOWS “***UNCALIB***”
1. Hold magnet to any key to acknowledge message
2. Calibrate the module
6.5.13 IF THE DISPLAY SHOWS ‘H’ (OR L) THEN THE LOCAL HIGH OR LOW ALARM IS ACTIVE
6.5.14 IF THE DISPLAY SHOWS ‘W’ – RADIO FREQUENCY INTERFERENCE
1. Remove source of interference.
6.5.15 IF THE DISPLAY SHOWS “C” – CALIBRATION MODE
1. Complete calibration or exit to operating mode.
6.5.16 OTHER ERROR MESSAGES – CALL FACTORY
1. E: OSC F1 Oscillator Fail
Page: 25
Model 5100-02-IT Combustible Gas Sensor Module
7. APPENDICES
7.1 APPENDIX A: SPECIFICATIONS
Specifications:
Sensor:
Type: Catalytic Bead
Range: 0-100% LEL Combustible
Repeatability: +/-1% LEL
Response time: < 12 sec to 60% full scale
Accuracy: +/- 1% for 0-50% LEL range
+/- 2% for 51-100% LEL range
Sensor Life: Typically >3 years
Output:
Display: Fixed and Scrolling LED
Relays (Standard): High Alarm, Low Alarm, Trouble (SPDT Form C, 0.25 Amp@ 250VAC)
Signal Output: Sentry Digital Bus
Relays (Option): High Alarm, Low Alarm (8 Amp, 250VAC)
420 mA: 3-wire sensor powered analog 4-20 mA or optically isolated (Calibration: 4.0
mA (default) or 1.5 mA. or Normal)
RS485: Serial RS-485 Modbus RTU
Input:
Remote Alarm Reset: Normally open digital input
Electrical Data:
Power consumption: 3 watts
Connection type: 3 wire
Input voltage: 24 VDC nominal: 10-30VDC
RFI/EMI Protection: EN50081-2, EN50082-2
Operating Range:
Ambient Temperature Range: -40o to 176 oF(-40o to 80oC)
Relative Humidity: 0-99%
Enclosure:
Dimensions: 7.5 x 5.0 x 4.8 inches (H x W x D)
(21.6 x 12.7 x 12.2 cm)
Weight: 2.7 lb. (1.3 Kg)
Housing: NEMA 4X
Electrical Classification:
Performance: Explosion proof, Class 1, Div. I, Groups B, C, D
Class 1, Zone 1, Group IIB+H2 IP66
Approvals:
FM Approved: Approval Standards: 6320, 3600
Modbus:
Baud: 38400 (Adjustable 2400 to 38400 baud)
Parity: None
Stop bit: 1
Data bits: 8
Flow Control: None
Memory map: Available upon request
Warranty:
Limited warranty: 2 years
Specifications subject to change without notice
Page: 26
7.2 APPENDIX B: MODEL NUMBERS & PARTS LIST
Sensor Module
5100-02-IT-AL Sensor Module, Combustible, Aluminum housing
5100-02-IT-SS Sensor Module, Combustible, 316SS housing
Model 5100-02-IT Combustible Gas Sensor Module
Options
5311-00 Rainshield
5394-51 Remote Sensor/Display Option
5394-61 Auxiliary Connection Assembly
5394-62 Auxiliary Relay Assembly
Calibration Items
1200-26 Gas Sensor Calibrator w/2 Gas Cylinders
1250-01 Gas Sensor Calibrator Kit
1256-01 Regulator Type A Calibrator
1260-00 Gas Cylinder – Air (Type A), 105 liters
1260-02 Gas Cylinder – Methane 50% LEL, (type A), 105 liters
1260-42 Gas Cylinder - Hydrogen, 50% LEL, (Type A), 105 liters
1290-02 Gas Cylinder - Combustible, CH4, 50% L.E.L.
5358-01 Calibration Adapter - Direct, Standard
5358-50 Calibration/Configuration Magnetic Tool
Spare Parts
SPL21813 Transmitter for 5100-02-IT
5200-02-IT Sensor Assy for 5100-02-IT
Page: 27
Model 5100-02-IT Combustible Gas Sensor Module
7.3 APPENDIX C: LIMITED WARRANTY
SIERRA MONITOR CORPORATION warrants its products to be free from defects in workmanship or material
under normal use and service for two years after date of shipment. SMC will repair or replace without charge any
equipment found to be defective during the warranty period. Final determination of the nature and responsibility
for defective or damaged equipment will be made by SMC personnel.
All warranties hereunder are contingent upon proper use in the application for which the product was intended and
do not cover products which have been modified or repaired without SMC approval or which have been subjected
to accident, improper maintenance, installation or application, or on which original identification marks have been
removed or altered. This Limited Warranty also will not apply to interconnecting cables or wires, consumables (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.
Page: 28
Model 5100-02-IT Combustible Gas Sensor Module
7.4 APPENDIX D: REMOTE SENSOR DRAWING 5394-50
Page: 29
Model 5100-02-IT Combustible Gas Sensor Module
7.5 APPENDIX E: AUXILIARY RELAY ASSEMBLY 5394-62
Page: 30
Model 5100-02-IT Combustible Gas Sensor Module
7.6 APPENDIX F: AUXILIARY CONNECTION ASSEMBLY 5394-61
Page: 31
Model 5100-02-IT Combustible Gas Sensor Module
7.7 APPENDIX G: AUXILIARY RS-485 MULTIDROP ASSEMBLY 5394-64
Page: 32
Model 5100-02-IT Combustible Gas Sensor Module
Page: 33
Model 5100-02-IT Combustible Gas Sensor Module
7.8 APPENDIX H: MODBUS MEMORY MAP
Read Register Table
Register Description Comments
40001 Concentration Gas Concentration multiplied by 100
40002 Temperature Temperature in degrees Celsius scalled by a factor of 100
40003 High Alarm Relay Boolean indicating the High Alarm Status, 0 No Alarm, 1 High Alarm
40004 Low Alarm Relay Boolean indicating the Low Alarm Status, 0 No Alarm, 1 Low Alarm
40005 Low Alarm Value Low alarm set point, used for activating Alarms
40006 High Alarm Value High alarm set point, used for activating High Alarms
40007 Reserved
40008 Reserved
40009 Reserved
40010 Reserved
40011 Trouble Bits 0 for no trouble
40012 Trouble 1 for any trouble, 0 for no trouble
40013 High Alarm Immediate Like 40003. but never latched
40014 Low Alarm Immediate Like 40004, but never latched
40015 Random ID Randomly generated permanent ID of sensor
40016 Restart Count
40017 Run time – high In minutes
40018 Run time – low In minutes
40019 Max. gas value *scale ((see 40024)
40020 Model 51002
40021 Range *scale (see 40024)
40022 Units 1 is %LEL
40023 Temperature Units 0 is C, 1 is F
40024 Gas Scale Value like 1 or 100
40025 Temperature Scale Value like 1 or 100
Page: 34
Model 5100-02-IT Combustible Gas Sensor Module
7.9 APPENDIX I: COMBUSTIBLE GAS SCALING FACTORS
For combustible gas monitoring, a calibration standard of Methane may be used in conjunction with scaling
factors to cause Sentry concentration display and alarm function in %LEL scale of another gas as follows:
GAS METHANE
FACTOR
Acetaldehyde 60
Acetic Acid 54
Acetic Anhydride 46
Acetone 52
Acetylene 57
Alkyl Alcohol 51
Ammonia 126
n-Amyl Alcohol 33
Aniline 39
Benzene 41
Biphenyl 25
1,3-Butadiene 56
n-Butane 58
iso-Butane 52
Butene-1 45
cis-Butene-2 48
trans-Butene-2 51
n-Butyl Alcohol 34
iso-Butyl Alcohol 53
tert-Butyl-Alcohol 74
n-Butyl Benzene 31
iso-Butyl Benzene 32
n-Butyric Acid 38
Carbon Disulfide 18
Carbon Monoxide 75
Carbon Oxysulphide 93
Chlorobenzene 34
Cyanogen 89
Cyclohexane 41
Cyclopropane 62
n-Decane 33
Diethylamine 49
Dimethylamine 58
2,3-Dimethylpentane 40
2,3-Dimethylpropane 40
Dimethylsulphide 43
1,4-Dioxane 45
Epichlorohydrin 45
Ethane 68
Ethyl Acetate 51
Ethyl Alcohol 73
Ethylamine 53
Ethyl Benzene 36
Ethyl Bromide 91
Ethyl Chloride 57
Ethylcyclopentane 40
Ethylene 71
Ethylenedichloride 66
Ethyleneoxide 52
NOTES:
Diethyl Ether 46
Dimethoxyethane 42
Dimethyl Ether 63
Dimethylformamide 46
Ethyl Formate 44
Ethylmercaptan 56
n-Heptane 39
n-Hexane 37
Hydrazine 45
Hydrogencyanide 48
Hydrogen 77
Hydrogen Sulfide 41
Methane 100
Methyl Actetate 50
Methyl Alcohol 86
Methylamine 77
Methyl Bromide 90
Methyl Chloride 102
Methylcyclohexane 44
Methylenedichloride 93
Methylethylether 44
Methylethylketone 41
Methyl Formate 67
Methylmercaptan 61
Methylpropionate 51
Methyl n-propylketone 40
Napthalene 34
Nitromethane 34
n-Nonane 31
n-Octane 37
n-Pentane 46
i-Pentane 46
Propane 55
n-Propyl Alcohol 47
n-Propylamine 48
n-Propylchloride 50
Propylene 52
Propyleneoxide 46
iso-Propylether 44
Propyne 42
Toluene 40
Triethylamine 40
Trimethylamine 48
Vinylethylether 42
o-Xylene 36
m-Xylene 39
p-Xylene 39
JP-4 (Jet Fuel) 41
GAS METHANE
FACTOR
1. Scaling factors are not FMRC approved.
2. Base data source: EEV sensor specification catalog. (EEV claims some data is the result of specific
tests, other data is empirically derived).
Page: 35
Model 5100-02-IT Combustible Gas Sensor Module
7.10 APPENDIX J: Menu Key for 5100-02-IT Gas Sensor Module
• Key M : MODE
• Key E : ENTER
• Key ▲ UP (+)
• Key ▼ DOWN (-)
MAIN MENU
Use the M key to access each of the 4 main sections of the menu.
M M M M M
| | | | |
|- ALMRSET: |- CALIB: |- SETUP: |- MAINT: |- EXIT?
ALARM RESET MENU
ALMRSET:
|
E– RESET (Resets current alarm)
CALIB MENU
CALIB:
|
E – CAL-0% (Calibrate Zero)
|
E – Ack (Acknowledges Zero)
|
*50%-SPAN (Last span gas used – initially set at 50%)
| |
| ▲ 25%-SPAN
| ▲ 50%-SPAN (Select Span gas value from below)
| ▲ 75%-SPAN
| ▲ Adj-SPAN (To select an alternate span gas value)
| |
| E 50%-SPAN
| |
| ▲ 51%-SPAN (Change span value to desired, once completed E starts calibration)
|
E C XX%LEL (Reading the value of the calibration gas being applied)
|
|- CAL-OK (if successful) or CAL-FAIL (if unsuccessful)
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Model 5100-02-IT Combustible Gas Sensor Module
SETUP MENU
Once in the SETUP menu use the ▲ or ▼ keys to access each of the 5 main sections of the SETUP menu.
▼ ▼ ▼ ▼ ▼
| | | | |
|- Alarms: |- Relays: |- GasFactr: |- 4-20mA: |- RS-485
SETUP:
|
E – Alarms (Alarms Set-Point Adjustment)
| |
| E – H.Alarm (High Alarm Setup)
| |
| E --------------------------- OR---------------------------------------▼
| | |
| |- HASP: 60 (Current Hi Alarm set-point |- L. ALARM (Low Alarm Setup)
| | |
| ▲ or ▼ (To adjust to desired set-point) E LASP:20 (Current Lo Alarm Set-point)
| | |
| E – Ack (Accepts set-point) ▲ or ▼ (To adjust to desired set-point)
| |
| E – Ack (Accepts set-point)
|
|
|----▼ Relays (Relay Set Point Adjustment)
| |
| E ----------------------------- OR-----------------------------------------▼:
| | |
| |- H. Relay (High Relay Setup) |- L. Relay (Low Relay Setup)
| | |
| E – Latch E – Latch
| | |
| ▲ or ▼ (To adjust to desired condition) ▲ or ▼ (To adjust to desired condition)
| (Selections are Latch, NonLatc, or Senty)
| (* indicates current status, Sentry = Sentry controller controls alarm relay action)
|
|----▼ Gas Factr (Gas Factor Adjustment)
| |
| E *Factr100 (* = current selection)
| |
| ▲ or ▼ (To adjust to desired factor)
| If USER is selected use the ▲ or ▼ keys to change to desired value
|
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Model 5100-02-IT Combustible Gas Sensor Module
|
|----▼ 4-20mA (Verifies 4mA or 20mA output and selects condition of output during calibration)
| |
| ▼ -------or--------------- E Calib
| | |
| | |- Out: 4mA
| | |
| | ▼ --or—E (To calibrate analog output 4mA, |▲ or ▼ to adjust level,
| | | then E t o accept)
| | |- Out: 20mA
| | ▼ --or--E (To calibrate analog output 20mA, |▲ or ▼ to adjust level,
| | | then E to accept)
| | |- In: 4mA
| | ▼ --or—E (To calibrate analog input 4mA, |▲ or ▼ to adjust level,
| | | then E to accept)
| | |- In: 20mA
| | ▼--or--E (To calibrate analog input 20mA, |▲ or ▼ to adjust level,
| | then E to accept)
| |
| ▼ -------or--------------- E CalibOut (Adjust 4-20mA output during Calibration)
| | |
| | |- Track: (▲ or ▼ (To adjust action/mA value during calibration
| | Track = mA value tracks Gas value
| | Hold = holds mA value existing prior to calibration
| | C1.50mA = 1.50 mA during calibration
| | C4.00 mA = 4.00 mA during calibration
| | User mA = |▲ or ▼ to adjust to desired mA value
| |
| ▼ -------or--------------- E Tbl Out (Adjust 4-20mA output during Trouble condition)
| | |
| | |- T2.50mA: (▲ or ▼ (To select 2.50mA or User mA, * = current value)
| | User mA = |▲ or ▼ to adjust to desired mA value
| |
| |
|----▼ RS-485 (Select RS-485 address and baud rate)
| |
| | - Address
| |
| ▼ | -------or--------------- E Addr:016 (Use (▲ or ▼ and E to select module address – 016 to 254)
| |
| |- Baud --------------- E *38400 (Use |▲ or ▼ and E to select baud rate, * = current selection)
MAINT MENU
MAINT::
|
E – V2.00aB (Software version installed on module)
|
E – CCC001 (Configuration number)
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Model 5100-02-IT Combustible Gas Sensor Module
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