Univex 5100-02-IT User Manual
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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