S4100C Hydrocarbon Transmitter Manual

MODEL S4100C
Hydrocarbon Smart Transmitter
The information and technical data disclosed in this
document may be used and disseminated only for the
purposes and to the extent specifically authorized in
General Monitors in writing. Such information and
technical data are proprietary to General Monitors and
may not be used or disseminated except as provided in
the foregoing sentence.
Instruction Manual
02/14
General Monitors reserves the right to change published
specifications and designs without prior notice.
Part No.
Revision
MANS4100C-EU
N/02.14
Model S4100C
Warranty Statement
General Monitors warrants the Model S4100C to be free from defects in workmanship
or material under normal use and service within two (2) years from the date of
shipment. General Monitors will repair or replace without charge any equipment
found to be defective during the warranty period. Full determination of the nature of,
and responsibility for, defective or damaged equipment will be made by General
Monitors’ personnel. Defective or damaged equipment must be shipped prepaid to
General Monitors’ plant or the representative from which shipment was made. In all
cases this warranty is limited to the cost of the equipment supplied by General
Monitors. The customer will assume all liability for the misuse of this equipment by its
employees or other personnel. All warranties 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 General Monitors’ approval or which have been
subjected to neglect, accident, improper installation or application, or on which the
original identification marks have been removed or altered. Except for the express
warranty stated above, General Monitors disclaims all warranties with regard to the
products sold, 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
General Monitors for damages including, but not limited to, consequential damages
arising out of/or in connection with the use or performance of the product.
Warnings
High off scale readings may indicate an explosive concentration of gas at the sensor.
A subsequent fall in indicated gas concentration does not imply that safe working
conditions have been restored.
Install and maintain all hazardous area equipment in accordance with the relevant
regulations and practices of the country concerned. See Section 3 Installation and
Section 5 Maintenance.
The S4100C must be protected by in-line 1A PC> 1500A Char “T” fuse (required if
voltage at unit is between 10VDC and 35VDC) or a 500mA fuse (required if voltage at
unit is between 18VDC and 35VDC) in the 24 VDC supply line. This is necessary to
fully comply with approval requirements and good installation practices.
NOTE: General Monitors series of Trip Amplifiers have the 500mA fuse as standard.
Where application requires 1A fuse, then this must be replaced at time of installation.
The S4100C must be protected by an in-line 63mA; PC> 1500A Char “F” fuse in the
analogue output line. This is necessary to fully comply with approval requirements and
good installation practices.
WARNING - Installation and Maintenance must be carried out by suitably skilled and
competent personnel only.
i
Model S4100C
ii
Model S4100C
Table of Contents
Page
Warranty Statement
..................................................................................................... i
Warnings
..................................................................................................... i
Table of Contents
................................................................................................... iii
1.0
.................................................................................................... 1
Introduction
1.1
2.0
3.0
General Description ................................................................................... 1
Specifications .................................................................................................... 2
2.1
Approvals ................................................................................................... 2
2.2
Functional .................................................................................................. 2
2.3
Mechanical ................................................................................................. 3
2.4
Environmental ............................................................................................ 3
2.5
Electrical .................................................................................................... 3
2.6
Factory default settings .............................................................................. 4
2.7
Sensor Material and Specifications when connected to S4100C ................ 4
2.8
Outline Drawing.......................................................................................... 5
Installation
.................................................................................................... 6
3.1
On Receipt of your Equipment ................................................................... 6
3.2
Smart Transmitter location Guidelines ....................................................... 6
3.3
Sensor Poisons .......................................................................................... 7
3.4
Interconnecting cable Guidelines ............................................................... 8
3.5
Installation of Sensor .................................................................................. 8
3.6
Installation Instructions ............................................................................... 9
3.6.1 Smart Transmitter Cable Termination................................................ 9
3.6.2 Cable Termination in Safe Area ........................................................ 9
3.6.3Cable Termination Drawing .............................................................. 10
4.0
3.7
Interconnection Details ............................................................................. 12
3.8
Power up Routine (see also Section 4.5 and 4.6)..................................... 12
Operating Instructions .................................................................................... 13
4.1
Menu Operation and Display Codes ......................................................... 13
4.2
Tables ...................................................................................................... 15
4.3
Calibration ................................................................................................ 17
4.4
New Sensor Calibration........................................................................... 18
4.5
Calibration Check ..................................................................................... 19
4.6
Power up Routine ..................................................................................... 19
4.7
Special Power up Routine ........................................................................ 20
iii
Model S4100C
5.0
6.0
7.0
8.0
Maintenance .................................................................................................. 21
5.1
Maintenance ............................................................................................ 21
5.2
Storage .................................................................................................... 21
Trouble Shooting ............................................................................................. 22
6.1
Fault codes and Remedies ....................................................................... 22
6.2
Alarms ...................................................................................................... 23
6.3
Modbus RTU Serial Interface problems ................................................... 23
Ancillary Equipment ........................................................................................ 24
7.1
Dust Guard Assembly (P/N 10110) .......................................................... 24
7.2
Sintered Stainless Steel Dust Guard (P/N 1800822-1) ............................. 24
7.3
Splash Guard (P/N 10395-1) .................................................................... 24
7.4
Sensor Flow Chamber (P/N 10066) ......................................................... 24
7.5
Duct Mounting Plate (P/N 10041 Dash-1 or –2) ....................................... 25
7.6
Portable Purge Calibrator – Model 1400150 ............................................ 25
7.7
Remote Test Gas Applicator – TGA-1 ...................................................... 27
7.8
Volatile Liquids and Solvents ................................................................... 28
Modbus RTU Serial Interface .......................................................................... 29
8.1
General .................................................................................................... 29
8.2
Modbus Message Characteristics ............................................................ 29
8.3
Modbus Exception Codes ........................................................................ 29
8.4
Modbus Read/Write - Commands ............................................................ 30
8.5
Modbus Register Configuration ................................................................ 31
8.5.1 Register 3 ........................................................................................ 31
8.5.2 Register 7 ........................................................................................ 32
8.5.3 Register 9 ........................................................................................ 32
8.5.4 Register 10 ...................................................................................... 32
9.0
Apendix A
.................................................................................................. 33
9.1
Maximum Sensor Cable Length ............................................................... 33
9.2
Maximum Smart Transmitter Cable Length .............................................. 33
Customer Satisfaction Questionnaire ......................................................................... 35
iv
Model S4100C
1.0
1.1
Introduction
General Description
The General Monitors Model S4100C Smart Transmitter is a highly reliable, self
contained, microprocessor controlled, Hydrocarbon gas monitor with integral 3-digit
readout. The Transmitter is connected to the user’s indicating and shut-down
equipment by means of a screened and armoured cable.
The S4100C is designed to measure and display concentrations of combustible gases
in the range of: 0-100% Lower Explosive Level (LEL), but will continue to display
concentrations up to 120% LEL.
No user adjustments are required. The instrument will record the number of
successful calibrations, compute the sensor output as a % of the new sensor
reference output during calibration and store in non-volatile memory, along with
calibration and setup parameters.
The entire electronics module is fully encapsulated in compliance with the relevant
standards.
The Smart Transmitter’s user interface is menu driven. In addition the instrument may
be addressed via the Dual Modbus RTU serial interface.
The accuracy of the Smart Transmitter depends upon routine re-calibration which
should be carried out at least every 90 days. This procedure is extremely simple and
may be carried out by one person aided by prompts from the digital display.
Calibration may be completed in less than 2 minutes. All calibration parameters are
tested by advanced software routines before being accepted. Any errors detected will
be shown on the digital display by means of an appropriate fault code.
General Monitors is recognised as a leader in the field of gas detection and a team of
experts is always available to provide advice or service as required.
1
Model S4100C
2.0
2.1
Specifications
Approvals
Hazardous Area Standards
EN 60079-0, EN 60079-7, EN 60079-18, EN 60079-29-1
Code of Protection
Ex emd IIC T5 Gb (Tamb -40C +55C)
Ex emd IIC T4 Gb (Tamb -40C +70C) Cable insulation rated to at
least 110C
Application:
Combustible Gas Monitor
2.2
Functional
Measuring Range:
0-100% LEL
Measuring Resolution
1% LEL
Over-range Indication:
Display flashes for readings greater than 99% LEL, but continues to
display gas concentration up to 120% LEL.
Calibration Level:
User selectable 25% - 90% LEL in 1% LEL increments
A1 Trip Level:
User selectable 10% - 60% LEL in 1% LEL increments
A1 Open Collector Output
User selectable Energised/De-energised and Latching/Non-latching
A2 Trip Level:
User Selectable 10% - 60% LEL in 1% LEL increments
A2 Open Collector Output
User selectable Energised/De-energised and Latching/Non-latching
Fault Open Collector Output
Normally Energised
Analogue Output during Calibration
User selectable 0.0 mA, 1.5 mA and 2.0 mA
Modbus Baud Rate
User selectable 2400, 4800, 9600 and 19200 Baud
Modbus Format
User selectable 1/2 stopbits, odd/even/no parity, 8 databits
Modbus Node Address
User selectable 1 – 255; Address 0 is recognised as broadcast mode
Repeatability, Short Term:
5% LEL over 1 hour
Repeatability, Long Term:
10% LEL over 3 months
Accuracy (Linearity)
5% LEL
Temperature Variation
10% LEL over Temperature Range (-50C to +70C)
Pressure Variation:
10% LEL (950 mBar – 1100 mBar)
Humidity Variation:
10% LEL (20% RH – 90% RH)
Power up Variation:
< 3% LEL after 5 minutes
Response Time (input step)
T50 < 10 seconds
T90 < 23 seconds
2
Model S4100C
2.3
Mechanical
Height excl. Sensor:
150mm (6”)
Height incl. Sensor:
200mm (8”)
Width:
150mm (6”)
Depth:
95mm (3.75”)
Weight including Sensor:
2.5kg (5.5lbs)
Mounting Holes:
4 x 7 mm (0.28”) dia holes
Termination:
Ex e rated Terminal Block
2.4
Environmental
Operating temperature range (continuous) min/max
- 40C to + 70C
Storage temperature range min/max
- 50C to + 70C
Relative humidity min/max:
5% to 95%
Operating Altitude max:
8000 ft
Non-operating Altitude max:
16000 ft
Meets
EMI/RFI Susceptibility;
EN 50270
EN55011: ENV50204
EN 61000-4-2: EN 61000-4-4: EN 61000-4-6
EN 61000-4-3: EN 61000-4-5: EN 61000-4-8
IP Rating:
2.5
IP66/67
Electrical
Supply voltage min/max:
10VDC/35VDC
Supply voltage abs min/max:
8VDC/40 VDC
Supply voltage ripple & noise max.
1Vpp
Supply current consumption, including sensor typ/max:
250mA/310mA @ 24 VDC
500mA/620mA @ 12 VDC
Supply fuse rating:
500mA Chart “T” PC  1500A
1A Chart “T” PC  1500A
18VDC – 35VDC operation
10VDC – 35VDC operation
Supply voltage low detection threshold min/max:
9.20VDC/10.32 VDC
Sensor Bias Current (Rsensor + Rcable = 6ohms –30ohms):
300mA  10mA
Sensor Bias Current (Rsensor + Rcable = zero ohms) max:
410mA
Sensor Cable Resistance per conductor max:
5 ohms
Analogue output Current Range:
0 – 22.0mA
Analogue Signal Startup
4mA  0.2mA
3
Model S4100C
Analogue Signal 0-100% LEL
4-20mA
Analogue Output Current abs max:
22.1mA
Analogue Output Current Ripple and Noise max.
20uApp
Analogue output termination resistance min/max:
(including total cable resistance)
0 – 750 ohms
Analogue output open-circuit detection current range min/max:
1.0mA – 22.0mA
Analogue output fuse rating:
63mA Char “F” PC  1500A
Remote calibration input Isink max
2.7mA
Remote calibration input Vin max:
24VDC
Open collector output Isink max
Note: Inductive loads require an external clamp diode
100mA
Open collector output Vin max:
35VDC
Open collector output Vdrop-out @ 100mA max:
1VDC
2.6
Factory default settings
Calibration level:
50% LEL
A1 Trip Level
20% LEL
A1 Open Collector Output:
De-energised and non-latching
A2 Trip Level:
50% LEL
A2 Open Collector Output
De-energised and non-latching
Analogue output during calibration
1.5mA
Modbus Baud rate:
19200 Baud
Modbus Format:
1 stopbit, no parity, 8 data bits
Modbus Node address;
1
2.7
Sensor Material and Specifications when connected to
S4100C
General Monitors Sensors (11159-X) are constructed from 316 Stainless Steel. The
temperature and classification becomes
Ex emd IIC T5 Gb (Tamb -40ºC to +55ºC)
Ex emd IIC T4 Gb (Tamb -40ºC to +70ºC) when the sensors are fitted to the S4100C
units only.
4
Model S4100C
2.8
Outline Drawing
5
Model S4100C
3.0
Installation
WARNING - Installation and Maintenance must be carried out by suitably skilled and
competent personnel only.
3.1
On Receipt of your Equipment
All instruments shipped by General Monitors are pre-packed in stout containers and
enclosed in a shock absorbing filling which affords a considerable degree of protection
against physical damage. The contents should be carefully removed and checked
against the enclosed packing slip.
All discrepancies between the contents and the packing slip must be reported to
General Monitors within 10 days of receipt of equipment. General Monitors cannot be
held responsible for shortages not reported within this period.
Damage to the contents of a shipment should be brought to the attention of the carrier
immediately and a claim filed.
All subsequent correspondence with General Monitors must specify the equipment
part numbers and serial numbers.
3.2
Smart Transmitter location Guidelines
The following guidelines should be observed with regard to the location in which to
install a Smart Transmitter. Note that the vapour from a flammable liquid should, in
general, be treated in the same manner as a gas, but refer to the additional
precautions listed below:
•
Consider how the leaking gas will disperse. Locate the Smart Transmitter where
prevailing air currents are likely to contain the maximum amount of leaking gas,
but sufficiently distant from minor leak sources so as to avoid spurious alarms.
•
Consider the emission temperature and specific gravity of the gas to be detected.
The Smart Transmitter should be located close to ground level (but out of the
splash zone) for gases which are heavier than air, and close to the ceiling or roof
for gases which are lighter than air. Liquids of low volatility may require the Smart
Transmitter to be sited in the immediate vicinity of the potential leaking points.
•
Site the Smart Transmitter so as to facilitate routine re-calibration; refer to the
Ancillary Equipment Section of the manual for details. Ensure that the mounting
allows for the replacement of a faulty sensor and that access to any accessories
is not restricted. Check that the calibration instructions and display will be visible
under all normal weather conditions whenever required. A combination of rain
and sun guard is recommended for outdoor locations because it protects the
Smart Transmitter against the heat of direct sunlight and the adverse effects of
rain-borne grime whilst simultaneously improving display visibility under sunny
conditions.
6
Model S4100C
3.3
•
Observe the ambient temperature limitations quoted in the specification. If a
sampling preconditioning system is employed, take steps to ensure that vapours
will not condense in the associated pipework.
•
The mounting should be as free from shock and vibration as possible. Avoid
mounting Smart Transmitters directly on structures or process equipment prone
to high levels of vibration or shock.
•
Select sensor accessories so as to protect the sensor against high wind
velocities, rain, dust, hosing down and any other anticipated environmental
hazards.
•
Avoid locations where the Smart Transmitter will be subjected to strong
electromagnetic interference (greater than 10V/m field strength) such as found in
proximity to radio transmitters, welders, switched mode power supplies, inverters,
battery chargers, ignition systems, generators, switch-gear, arc lights and other
high frequency or high power switching process equipment. Walkie-talkie radios
should not be operated at a distance less than 0.75m from the Smart Transmitter.
Sensor Poisons
HC Sensors may be adversely affected by prolonged exposure to certain
atmospheres. These in the main are chemical poisons, although other substances
such as silicones coat the sensor beads, thus rendering them insensitive to
combustible gases.
Such loss of sensitivity may be gradual, if the poisons are present in very low
concentrations, or rapid in the event of large concentrations of poisons being present.
The most important poisons are:
Halides: Compounds containing fluorine, chlorine, bromine and iodine
Glycols
Sulphur compounds
Compounds that polymerise on the beads
Heavy Metals: e.g. Tetraethyl lead
Silicones contained in grease or aerosols are the most common coating agents that
are not true sensor poisons, but reduce sensor response.
Other materials that have a deleterious effect on HC Sensors include mineral acid
vapours and caustic vapours that attack the sensor physically.
The presence of such poisons and damaging vapours does not imply that the General
Monitors sensor may not be used in these locations. A careful analysis of ambient air
conditions should be undertaken and the customer should be aware that sensor
calibration might need to be repeated at shorter intervals.
7
Model S4100C
3.4
3.5
Interconnecting cable Guidelines
•
The Smart Transmitter requires an interconnecting cable with an overall screen
(shield) and armour. Cables to BS5308 Part 2, Type 2 or equivalent are suitable.
•
Interconnecting cables should be segregated from power and other “noisy”
cables. Avoid proximity to cables associated with radio transmitters, welders,
switched mode power supplies, inverters, battery chargers, ignition systems,
generators, switch gear, arc lights and other high frequency or high power
switching process equipment. In general, maintain a separation of at least 1m
between instrument and other cables. Greater separation is required where long
parallel cable runs are unavoidable. Avoid running instrument cable trenches
close to lightning conductors earthing pits.
•
Complete all cable insulation tests before connecting the cable at either end.
•
General Monitors do not recommend the use of cable shoes or crimps on any
junction box or housing wiring terminals. Poor crimping can cause bad
connection when unit experiences temperature variations. We therefore
recommend good practice is to just terminate cable or sensor wires as is,
especially in remote sensor applications.
Installation of Sensor
General Monitors sensors are machined to a ¾ NPT thread for fixing into the junction
box, through a suitably machined entry. Each sensor requires a suitable O’Ring and
Lock Nut to ensure correct assembly. To assemble the sensor into the junction box
the wires should be placed through the O’Ring, over the ¾ NPT thread until it rests at
the end of the machined thread. The sensor is then placed through the entry of the
junction box and held in place by fitting the ¾ NPT Lock Nut. The sensor should be
tightened sufficiently to ensure a good seal, but not over tightened to damage the
O’Ring. The colour coded wires should then be connected into the corresponding
locations of the connector which is installed and labelled in the junction box. Care
should be taken not to tighten the connection on the insulation of the wires.
8
Model S4100C
3.6
Installation Instructions
3.6.1
Smart Transmitter Cable Termination
•
The Smart Transmitter should be installed in accordance with the certification
documents and the relevant regulations of the country concerned.
•
Ensure that the gas sensor, if used, points downwards so as to protect it from
rain and the accumulation of deposits.
•
Ensure that approved Exe cable glands are used and installed according to the
manufacturer’s instructions.
•
The cable glands must be electrically connected to the continuity plate by means
of a suitable nut. The cable armour must be terminated in the gland to ensure a
positive electrical connection.
•
The cable screens (drain wires) must all be terminated on the isolated terminal in
the transmitter housing (and sensor junction box if the sensor is mounted
remotely). The cable screens must not be connected electrically to the electronic
circuitry of the Smart Transmitter or the sensor.
•
Connect an external earth stud in accordance with local practice if required.
•
Ensure no wires cross over the top of the connector blocks as they may become
trapped between the blocks and the electronics module when the lid is fitted.
•
When fitting the lid, ensure the fly-lead and earth strap from the electronics
module fit freely into the box. Press the lid home and verify it fits snugly against
the box, before tightening the screws.
•
Ensure there is 1mm spacing between insulation of wire and end connector
block. Ensure that insulation is not crimped.
3.6.2
Cable Termination in Safe Area
•
The cable armour must be connected to Safety Earth.
•
The cable screens (drain wire) and power supply return (OV) must be connected
to Instrument Earth.
•
The power supply or power distribution system employed should meet the
requirements of EN5008 I- 1/2 and EN60101-1.
•
Power supply or GM Trip Amplifier Power and analogue output must be
fused in accordance with the Smart Transmitter specification.
9
Model S4100C
3.6.3 Cable Termination Drawing
10
Model S4100C
The electrical rating for all open collector outputs is 100mA @ 35VDC.
The diagram below illustrates some typical open collector external circuits.
11
Model S4100C
3.7
Interconnection Details
Signal
Name
+ 24VDC
SIG
OV
CAL
A2
A1
FLT
MA
MB
GA
GB
SCREEN
12-Way
Terminal
1
2
3
4
5
6
7
8
9
10
11
12
Function
If not used
Power Supply
Analogue output
connect to OV
Power Supply Return
Remote calibration input (Note)
leave unconnected*
Alarm 2 open collector output
leave unconnected*
Alarm 1 open collector output
leave unconnected*
Fault open collector output
leave unconnected*
Modbus 1 serial interface line A
leave unconnected*
Modbus 1 serial interface line B
leave unconnected*
Modbus 2 serial interface line A
leave unconnected*
Modbus 2 serial interface line B
leave unconnected*
Terminate all cable screens (drain wires) at this connection
Module
Fly lead colour
brown
yellow
blue
grey
orange
violet
green/black
red/black
red/green
red/brown
red/blue
NA
Signal
Name
WHT
BLK
RED
GRN
4-Way
Terminal
1
2
3
4
Function
Sensor active bead
Sensor passive bead
Sensor common
NA
Module
Fly lead colour
white
black
red
NA
* Ensure conductor ends have been cut back so that bare conductors do not cause shorts.
NOTE:
If remote calibration is required, connect the Remote Calibration Input to Power
Supply Return via a momentary action-NO-switch in the Safe Area. The switch
should be rated 5V, 5mA or better.
NOTE:
For Smart Transmitter and Sensor Interconnection Cable details consult Appendix A.
3.8
Power up Routine (see also Section 4.5 and 4.6)
When all wiring has been completed and checked, the instrument may be powered up.
Immediately following power-up, the instrument will carry out “Display Test”, then
blank the display for 1 second, display “Software Revision” and then display “Power
up in progress”, followed by normal operation. The analogue output will be at 4.0mA
and the Fault open collector output energised.
The display should read “0” if no gas is present at the sensor.
If the instrument indicates differently from the above, refer to Section 6, Trouble
Shooting.
12
Model S4100C
4.0
Operating Instructions
WARNING – Installation and Maintenance must be carried out by suitably skilled and
competent personnel only.
4.1
Menu Operation and Display Codes
Note: See Table 1 and Table 2 for Display Codes
Menu operation starts at Level 1. To enter the menu, the magnet is applied to the
General Monitors Logo on the Nameplate and held in place. The instrument will
display “- - -“ indicating magnet present. After 5 seconds delay the instrument will start
scrolling through Table 1, Level 1 at the rate of 1 step per 2 seconds, the magnet may
now be removed. In the presence of (latched) Alarms, the delay time will increase to
90 seconds. The scrolling will continue until a selection is made by briefly applying the
magnet. The display will rapid-flash the selection for one second to acknowledge. The
operation will then move to the next level corresponding to that selection, which can
be scrolled in a similar fashion, etc.
At all menu levels, the instrument will start “10 second menu timeout”, 30 seconds
after the last selection was made, allowing the user to re-enter the menu while the
analogue output is still at cal level (0.0, 1.5 or 2.0mA). Once “10 second menu
timeout” has expired, menu data is written to EEPROM, following which the
instrument returns to normal operation.
Calibration and Check Calibration mode will be terminated upon completion of the
corresponding calibration or calibration check procedure. The unit expects to “see”
calibration gas within 6 minutes following selection and will display the appropriate
fault code if no gas has been applied and exit the menu. Similar action occurs if the
calibration gas supply is interrupted during “Calibration in progress” or if the calibration
gas is not removed within 6 minutes following “Calibration completed.”
While in Check Calibration mode, Calibration mode may be activated by entering the
menu as normal.
When A1 alarm trip level, A2 alarm trip level or Calibration is selected, the current
value is shown on the display. The most significant digit will scroll and the desired
value is acknowledged by briefly applying the magnet, following which the next lower
significant digit will scroll and is acknowledged in similar fashion. The display will
rapid-flash each selection for one second to acknowledge. If the current value is
acceptable, two or three subsequent “acknowledge” commands, (one for each digit)
will allow the user to continue.
Setting A1 alarm trip level higher than the current A2 alarm trip level causes the A2
alarm trip level to be set to the same level as A1 alarm trip level and following
acknowledge of A1 alarm trip level the menu automatically jumps to “A2 alarm set up”
to alert the user and allow re-adjustment of A2 alarm trip level. Similar action occurs if
A2 alarm trip level is set lower than the current A1 alarm trip level.
Change of Calibration level causes the instrument to enter Calibration mode
immediately, alleviating the necessity of a password option.
13
Model S4100C
Faults and Alarm status and LEL level determine which Level 1 menu selections are
available. Any Fault except F08 inhibits menu operation.
Menu Selection Availability:
Faults?
No
No
No
No
No
No
Yes
Alarms?
No
No
No
No
Yes
Yes
NA
Latched
Alarms?
No
No
Yes
Yes
No
Yes
NA
LEL<10%
Yes
No
Yes
No
NA
NA
NA
14
Level 1 menu selections
available
ACA, CCA, ASU, CSU & ncl
ACA, ASU, CSU & ncl
ACA, & CCA
ACA & ncl
ACA & ncl
ACA & ncl
None
Menu entry
delay
5 sec
5 sec
90 sec
90 sec
90 sec
90 sec
NA
Model S4100C
4.2
Tables
TABLE 1 – MENU DISPLAY CODES
Level 1
ACA
Cca
Asu
Level 2
Activate calibration
mode
Check calibration mode
Activate setup mode
AC
CP
Cc
Aca
Ga1
Ta2
O--
R--
LKJ
Level 3
Level 4
Activate calibration,
Apply calibration gas
Calibration in progress
Calibration completed,
Remove calibration gas
Activate calibration mode
A1 alarm setup
A2 alarm setup
Analogue output setup
Calibration level setup
Return to level 1
15
GeJ
GIE
GQA
GJQ
GKP
Ta2
LKJ
TeJ
TIE
TQA
TJQ
TKP
O-LKJ
O0.0
O1.5
O2.0
R-LKJ
R??
GA1
LKJ
Open collector output
normally energized
Open collector output
normally de-energized
Open collector output
latching
Open collector output
non-latching
Triplevel setup
G??
Triplevel adjustable
10% LEL to 60% LEL
T??
Triplevel adjustable
10% LEL to 60% LEL
A2 alarm setup
Return to level 2
Open collector output
normally energized
Open collector output
normally de-energized
Open collector output
latching
Open collector output
non-latching
Triplevel setup
Analogue output setup
Return to level 2
Analogue output 0mA
during calibration
Analogue output 1.5mA
during calibration
Analogue output 2.0mA
during calibration
Calibration level setup
Return to level 2
Cal. Level adjustable
25% LEL to 90% LEL
A1 alarm setup
Return to level 2
Model S4100C
TABLE 1 – MENU DISPLAY CODES
Level 1
CSU
Level 2
Check setup mode
???.
Note: decimal point
JOR
New sensor calibration
G??
G??
G??
T??
T??
T??
O?.?
R??
???.
???
???.
???
Response reference in
mV
Nr. Of successful
calibrations
Modbus port 1 & 2 node
address
LKJ
JOR
Return to level 1
LKJ
KNM
Terminate menu
KNM
Slow Flash (2/sec)
Level 3
A1 open collector output
norm. (de)-energized
A1 open collector output
(non)-latching
Level 4
A1 alarm triplevel % LEL
A2 open collector output
norm. (de)-energized
A2 open collector output
(non)-latching
A2 alarm triplevel % LEL
Analogue output current
during calibration in mA
Calibration level % LEL
Response @ cal in % of
mV reference
New sensor calibration
AC
CP
Cc
Activate calibration,
Apply calibration gas
Calibration in progress
Calibration completed,
Remove calibration gas
Return to level 1
“10 sec Menu Timeout in progress”. This timeout starts 30 sec after the last menu selection was made.
Apply magnet to re-enter at Level 1. The analogue output remains at calibration level in this mode.
If magnet not applied, the instrument will write menu parameters to EEPROM,
exit menu and revert to normal operation following timeout.
TABLE 2 – DISPLAY CODES
8.8.
8.
L??
SU
G??
T??
???
???
EE
f??
DDD
Display Test (1 sec)
Software Revision (1 sec)
Power up in progress (58 sec)
Gas measurement with A1 alarm condition present, or latched A1 alarm pending
Gas measurement with A2 alarm condition present, or latched A2 alarm pending
Slow Flash (2/sec) “Overrange” if display > 99% LEL or “Check Calibration Mode active”
Rapid Flash (8/sec) “Acknowledgement of menu selection” or “Magnet present” during alarm or fault indication
EEPROM write activity
Fault Codes
“Magnet present”
16
Note: This operation sets
nr. of calibrations to
1 and redefines
sensor mV reference
when successful
Model S4100C
4.3
Calibration
Calibration may be carried out as follows:
•
Ensure that the instrument has stabilised for at least 1 hour and that there is no
combustible gas present at the sensor. If the background levels of gas are
suspected, their presence may be confirmed by capping the sensor and
observing a fault in indicated gas concentration as the sensor oxidises the
entrapped gas. A true zero reading will be obtained when the reading stabilises
at the lower value.
•
Place the magnet on the General Monitors Logo on the Nameplate. The
instrument will display “ - - - “ for 5 seconds and then enter the menu routine.
Remove the magnet. Select “ACA” by briefly re-applying the magnet when the
display scrolls around. The instrument will acknowledge the selection by rapid
flashing “ACA” for 1 second and continue to display “ACA” for another 7 seconds
while it takes the zero gas reading. The instrument will then display “AC”.
NOTE: Calibration mode may be terminated at this point by briefly re-applying
the magnet.
•
Use General Monitors Portable Purge with flow rate of 300-400ml/min, or
Calibration Chamber to apply gas at the required concentration level. When the
instrument detects the gas it will display “CP”.
•
When the instrument displays “CC”, normally within 2 minutes, remove the
calibration gas.
•
As the remaining gas in the sensor disperses, the instrument will exit Calibration
mode and return to normal operation. The display should read “0”.
If the above procedure is unsuccessful, refer to the Trouble Shooting section in
this manual.
17
Model S4100C
4.4
New Sensor Calibration
New sensor calibration may be carried out as follows:
•
Ensure that the instrument has stabilised for at least 1 hour and that there is no
combustible gas present at the sensor. If the background levels of gas are
suspected, their presence may be confirmed by capping the sensor and
observing a fault in indicated gas concentration as the sensor oxidises the
entrapped gas. A true zero reading will be obtained when the reading stabilises
at the lower value.
•
Place the magnet on the General Monitors Logo on the Nameplate. The
instrument will display “ - - -“ for 5 seconds and then enter the menu routine.
Remove the magnet. Select “ncl” by briefly re-applying the magnet when the
display scrolls around. The instrument will acknowledge the selection by rapid
flashing “ncl” for 1 second. Re-confirm by briefly re-applying the magnet when the
display shows “ncl” or return to the previous level by briefly applying the magnet
when the display shows “rtn”. The unit will continue to display “ncl” for another 7
seconds while it takes the zero gas reading. The instrument will then display
“AC”.
NOTE: Calibration mode may be terminated at this point by briefly re-applying
the magnet.
•
Use General Monitors Portable Purge with flow rate of 300-400ml/min., or
Calibration Chamber to apply gas at the required concentration level. When the
instrument detects the gas it will display “CP”.
•
When the instrument displays “CC”, normally within 2 minutes, remove the
calibration gas.
•
As the remaining gas in the sensor disperses, the instrument will exit Calibration
mode and return to normal operation .The display should read “0”.
•
This calibration procedure resets “number of successful calibrations” to 1 and redefines the “sensor response reference” parameter from which all subsequent
“sensor response during calibration” percentages are computed.
When cross-calibrating, verify a “new sensor calibration” was carried out with the
reference gas, as this may be different from the gas used during factory
calibration, leading to incorrect “sensor response during calibration” percentages.
If the above procedure is unsuccessful, refer to the Trouble Shooting section in
this manual.
18
Model S4100C
4.5
Calibration Check
•
Place the magnet on the General Monitors Logo on the Nameplate. The
instrument will display “ - - -“ for 5 seconds and then enter the menu routine.
Remove the magnet. Select “CCA” by briefly reapplying the magnet when the
display scrolls around. The instrument will acknowledge the selection by rapid
flashing “CCA” for 1 second and continue to display “CCA” for another 7 seconds
while it takes a zero gas reading. The display will then slow-flash the gas
concentration. The analogue output will remain at calibration level.
NOTE: The sensor should be exposed to clean air conditions for at least 2
minutes prior to entering Calibration check mode, such that the zero reading
taken by the instrument is valid.
NOTE: Calibration Check mode may be terminated at this point by briefly reapplying the magnet.
•
Use General Monitors Portable Purge with flow rate 300-400ml/min, or
Calibration Chamber to apply gas at the required concentration level. The
instrument will measure and display gas concentrations. Observe that the gas
reading settles at the required level. Should the final reading fall outside the
required limits, a full calibration is required. If so proceed as follows:
•
Place the magnet on the General Monitors Logo on the Nameplate. The
instrument will display “- - -“ for 5 seconds and then show “ACA”. Select by briefly
re-applying the magnet. The instrument will acknowledge the selection by rapid
flashing “ACA” for 1 second. The instrument will then display “AC” followed
shortly by “CP”. Continue as described in Calibration.
•
While in Calibration Check the display will continue to slow-flash the reading and
the analogue output remains at calibration level until the gas has been removed
and the concentration at the sensor has dropped below 3.5% LEL, when the
instrument will exit Calibration Check mode and return to normal operation.
If the above procedure is unsuccessful, refer to the Trouble Shooting section in
this manual.
4.6
Power up Routine
Immediately following power-up, the instrument will carry out “Display Test”, then
blank the display for 1 second, display “Software Revision” and then display “Power
up in progress” followed by normal operation. The analogue output will be at 4.0mA
and the Fault open collector output energised.
19
Model S4100C
4.7
Special Power up Routine
If the instrument is powered up with the magnet present it will display “EEPROM write
activity” for 1 second, followed by “Power up in progress” as above. The magnet
present will cause the Modbus Parameters to be reset to factory default. The magnet
may be removed immediately.
If the instrument is powered up with the magnet Present AND the Remote Calibration
input active it will display “EEPROM write activity” for 1 second, followed by “Power up
in progress” as above. This condition will cause the Power-up EEPROM CRC check
to be bypassed and the Modbus Parameters, all calibration and menu parameters to
be reset to factory default. On exit from Power up, the instrument will enter Calibration
mode. This feature is available to allow recovery in the field, should the EEPROM
contents have been corrupted due to a power failure coinciding with an EEPROM
write cycle. The magnet may be removed and the Remote Calibration input deactivated immediately.
20
Model S4100C
5.0
Maintenance
WARNING - Installation and Maintenance must be carried out by suitably skilled and
competent personnel only.
5.1
Maintenance
Once correctly installed, systems require very little maintenance other than Routine
Re-calibration (see section 4) and periodic inspection.
Sensors exposed to the elements may require a little grease on the accessory
mounting threads. The grease must be free from silicones (Refer to Sensor Poisons)
and have a high melting point. Alternatively P.T.F.E. tape may be used.
The removal of particulate matter from sensor accessories may be facilitated by the
use of an appropriate halogen-free solvent. The accessories should be thoroughly
dried, with compressed air if necessary, before refitting to the sensor body.
General Monitors strongly recommends that the complete system, including all alarm
circuitry be tested at least annually and that the following checks be carried out:
5.2
•
All Smart Transmitter assemblies for suitability of mounting positions so that
modifications to plant layout have not affected these.
•
Security of mounting
•
Sensor flame arrestors for clogging due to water, oil, dust, paint or other
contaminants.
•
Sensor accessories where fitted
•
Condition of fastening of cables.
•
Air filters, where fitted
•
Operation of complete system on stand-by supplies, where fitted, for the full
prescribed time.
Storage
Modules should be stored in a clean dry area and within the temperature range
quoted in the Specification (see Section 2):
When prolonged storage is anticipated, modules should be sealed, together with a
desiccant, into plastic bags and double wrapped for protection.
21
Model S4100C
6.0
6.1
Trouble Shooting
Fault codes and Remedies
Faults are stacked according to priority, i.e.: if more than one Fault exists at a
particular time, the display will show the Fault with the highest priority (lowest number
in priority column). As the Faults are being cleared, the Fault with the next highest
priority will be displayed, until all Faults have been cleared.
Latching Faults, except for F07, may be cleared by briefly applying the magnet to the
General Monitors Logo on the Nameplate if the Fault condition no longer exists. Nonlatching Faults will clear automatically once the Fault condition ceases to exist.
Recovery from F04, F05 and F06 will cause the unit to enter Power up mode as the
sensor may have been disconnected or insufficiently biased during the fault condition.
Fault
Code
F01
F02
Function
Priority
Mode
Remedy
Analogue output open circuit
Fail to calibration
6
9
non-latching
latching
F03
Low response
8
latching
F04
Sensor open circuit
5
non-latching
F05
Sensor short circuit
4
non-latching
F06
Power low
3
non-latching
F07
EEPROM CRC error
2
latching
F08
Negative drift>9.5% LEL
1
non-latching
F09
Calibration (check) time-out
7
latching
Check wiring and fuse.
Ensure calibration gas supply is adequate.
Re-calibrate. If persistent, replace sensor.
Ensure calibration gas supply is adequate.
Re-calibrate. If persistent replace sensor.
Check wiring and sensor. Replace sensor if
necessary.
Check wiring and sensor. Replace sensor if
necessary.
Ensure power supply voltage at the
instrument’s terminal block is within
specification.
Ensure 50% LEL calibration gas is available.
Power down the instrument. Activate the
Remote Cal input and place the magnet on
the General Monitors Logo on the
Nameplate. Re-apply power, remove the
magnet and de-activate Remote Cal. Wait for
the instrument to complete its power-up
routine. The instrument will automatically
enter calibration mode. Calibrate as normal.
All user selectable parameters will have
returned to their factory default settings
and must be re-programmed as required.
If F07 persists, the fault condition is terminal
and requires the instrument to be returned to
General Monitors.
Re-calibrate. Ensure sensor “sees” no gas
when zero reading is taken. If persistent,
replace sensor.
Ensure calibration gas supply is adequate.
Re-calibrate and apply or remove calibration
gas in timely fashion as prompted by the
display. If persistent, replace sensor.
22
Model S4100C
6.2
Alarms
Alarms are stacked below Faults according to priority i.e.: if a Fault and (latched)
Alarm(s) exist at a particular time, the display will show the Fault. As the Fault is
cleared, the Alarm with the next highest priority will be displayed.
Latched Alarms may be cleared by briefly applying the magnet to the General
Monitors Logo on the Nameplate if the Alarm condition no longer exists. Non-latching
Alarms will clear automatically once the Alarm condition ceases to exist.
6.3
Modbus RTU Serial Interface problems
If the Modbus Node Address or any other Modbus parameter of the instrument is
unknown, proceed as follows:
Power down the instrument. Place the magnet on the General Monitors Logo on the
Nameplate. Ensure the Remote Cal input is NOT activated. Re-apply power and
remove the magnet. Wait for the instrument to complete its power up routine. All user
selectable Modbus parameters will have returned to their factory default settings and
may be re-programmed as required.
23
Model S4100C
7.0
7.1
Dust Guard Assembly (P/N 10110)
Dust Guard Kit
(with 12 replaceable
screens)
7.2
Ancillary Equipment
The dust guard is a simple, threaded (1 3/16-18 UNEF 2B) stainless steel
cylinder with a wire screen at one end. It is easily unscrewed for cleaning
and/or replacement of the disposable screen. The screen material is stainless
steel with a nominal 40 micron mesh. This General Monitors accessory is
specially designed to prevent dust and particulate matter from reaching the
sensor flame arrestor. Such debris can plug the sinter and limit the amount of
gas reaching the active surface of the sensor, thereby creating a potentially
hazardous situation. When the dust guard is installed, this problem is
eliminated and sensor response is virtually unchanged. The dust guard is
also available in a kit (PIN 10044) with twelve replaceable screens. It can be
used as an effective windscreen, and is recommended for corrosive, windy or
high temperature environments. A typical application would be in the area
surrounding a drying oven.
Sintered Stainless Steel Dust Guard (P/N 1800822-1)
The construction of this accessory is similar to P/N 10110, but with 3mm
(1/8”) thick sintered stainless steel disc at one end. The body material is
stainless steel with an internal 3/16 UNEF 2B thread for installation on the
sensor body. This dust guard provides protection from fine particulates and
windy environments. It should be used only in dry locations because of the
tendency of the sintered disc to absorb water which will then act as a gas
diffusion barrier until the disc has dried out again. Sensor response time is
affected by the dust guard. It should not be removed during sensor
calibration.
7.3
Splash Guard (P/N 10395-1)
The Splash Guard is a rugged thermoplastic polyester (Valox) plastic cylinder
which screws into place over the sensor body. It contains a series of internal
baffles which are designed to deflect water spray away from the sensor flame
arrestor. The splash guard is recommended for areas where heavy rain or
frequent equipment hosedowns occur. It also makes an effective barrier
against high winds. Sensor response time is affected by the splash
guard. It should not be removed during sensor calibration.
7.4
Sensor Flow Chamber (P/N 10066)
The General Monitors Sensor Flow Chamber is constructed of 2024T
aluminium (optional stainless steel type 316, P/N 10066-SS). The chamber
has an internal thread 1 3/16-18 UNEF 2B, into which a sensor may be
screwed, and two threaded ports (1/8 27 NPT L1 NOM) which accept 1/4”
tube fittings (P/N 925-029). The chamber is designed for insertion into a
sampling system and the recommended flow rate is 0.47 litres per minute (1
cu. ft/hr.)
24
Model S4100C
7.5
Duct Mounting Plate (P/N 10041 Dash-1 or –2)
The Duct Mounting Plate is a rectangular plate measuring 73 x 116mm (2.88” x 4.56”)
containing four captive mounting screws (6-32 UNC), and fitted with a Neoprene Oring seal. The sensor is mounted in a 1 3/16-18 UNEF threaded hole in the centre of
the plate. The assembly is ideally suited to the monitoring of ducted air for living
quarters in large offshore modules. Note that the sensor should be mounted pointing
down, protected for excessive air velocity and in a position to facilitate recalibration.
7.6
Portable Purge Calibrator – Model 1400150
General Monitors Portable Purge Calibrator is a compact, accurate and safe field
calibration system.
No hazardous gas to handle – The Calibrator is filled with a Gas/Air mixture below the
Lower Explosion Level. (Standard mixture is 50% LEL).
Known Gas/Air Mixture – Eliminate the chance of error in field calibration
Hose and Cup Adapter – Permits you to calibrate your sensors without dismounting
them.
Available Gases – Premixed calibration gases at approximately 50% LEL.
Butane
Hydrogen
Methane
Propane
C4H10
H2
CH4
C3H8
Maximum Permissible Pressure in the lecture bottle is 1200 psia
Spare Gas Bottles – Order Part No. 1400155 and specify gas. Bottles are
inexpensive and may be returned for refilling.
25
Model S4100C
Available from stock
Portable Purge Calibrator
Methane Gas 50% LEL
1400150-M
Replacement Cylinder
Hydrogen 50% LEL
140155-H
Portable Purge Calibrator
Hydrogen Gas 50% LEL
1400150-H
Replacement Cylinder
Butadine Gas 50% LEL
140155-BD
Portable Purge Calibrator
Butadine Gas 50% LEL
1400150-BD
Replacement Cylinder
Butane Gas 50% LEL
140155-B
Portable Purge Calibrator
Butane Gas 50% LEL
1400150-B
Replacement Cylinder
Ethane Gas 50% LEL
140155-E
Portable Purge Calibrator
Ethane Gas 50% LEL
1400150-E
Replacement Cylinder
Propane Gas 50% LEL
140155-P
Portable Purge Calibrator
Propane Gas 50% LEL
1400150-P
Cylinder Refill
Methane Gas 50% LEL
140015-M
Small Calibration Cup
1400152-1
Cylinder Refill
Hydrogen Gas 50% LEL
140015-H
Large Calibration Cup
1400154
Regulator, Pressure Guage
922-009
Cylinder Refill
Propane Gas 50% LEL
140015P
Replacement Cylinder
Methane Gas 50% LEL
140155-M
Cylinder Refill
Butane Gas 50% LEL
140015-B
Portable Purge Calibrator Operating Instructions
1.
Allow the Model S4100C to stabilise for 1 hour. Ensure that the sensor is in clean air i.e.
there is no gas present. Put the unit into Calibration Mode, wait until “AC” is displayed.
2.
Turn the main valve on the lecture bottle counter clockwise until pressure is indicated
on the gauge. Gas flow is now controlled by the low pressure, lever operated valve.
Turn the gas ”on” by means of valve.
3.
Place the plastic cup over the outer sensor guard (Two cup sizes are supplied; cup
should fit closely but not seal).
CAUTION: DO NOT ADJUST THE REGULATOR. IT IS FACTORY ADJUSTED FOR OPTIMUM FLOW.
4.
Wait until “CC” is displayed.
5.
Release the lever-operated valve, stopping the flow of gas through the plastic tube.
Remove the cup from the sensor (Reading should return to zero)
6.
Turn off gas by valve, then turn the main valve clockwise to turn the gas off.
7.
Your Combustible gas detection system is now calibrated to the LEL mixture of the
Portable Purge Calibrator.
26
Model S4100C
7.7
Remote Test Gas Applicator – TGA-1
The Remote Test Gas Applicator, (TGA-1) is designed to be permanently installed on
a combustible gas sensor. The TGA-1 provides protection from outside elements,
such as splashing water, and it allows the user to apply test gas from a remote
source.
Special Instructions
1.
For best results when using the TGA-1, test gas readings should not be accepted
unless the surrounding air is essentially motionless. If used outdoors, wind may
considerably reduce gas concentration. With wind speeds up to 13mph, the
accuracy of the test gas and/or calibration will be within approximately 20% of
the applied gas.
2.
The flow rate of the applied gas should be set at approximately 400ml/minute.
3.
Allow adequate time for the air to be displayed from any interconnecting pipe
before noting test gas readings.
4.
Calibration should be checked periodically using portable purge calibrator, Part
No. 1400150.
Part Numbers
10460-1 TGA-1
10460-2 TGA-1
10460-3 TGA-1
1/4” Brass fitting
1/4” Stainless Steel Fitting
6mm Stainless Steel Fitting
27
Model S4100C
7.8
Volatile Liquids and Solvents
Volatile liquids and solvents are not supplied by General Monitors. This page provides
a listing of some volatile liquids and solvents and the respective volumes required (in
microlitres) to produce a 50% LEL vapor concentration in the 3 Litre Portable
Calibration Chamber (P/No. 10543-1) – a hypodermic syringe is provided for the
accurate measurement and insertion of the precise volumes into the Chamber. (These
volumes are correct at 25ºC and 1 Atmosphere pressure. If using significantly outside
these “STP” values, please consult the factory.)
Acetaldehyde ........................... 136
Acetic Acid ............................... 140
Acetone .................................... 112
Acetonitrile ................................. 96
Acrylonitrile .............................. 120
Amyl Acetate ............................ 100
Benzene ..................................... 65
Butyl Acetate ............................ 137
Butyl Alcohol (1-Butanol) ............ 78
sec-Butyl Alcohol (2-Butanol) ..... 95
tert-Butyl Alcohol ...................... 138
Butyraldehyde .......................... 102
Cyclohexane .............................. 86
Diethyl Ketone (3-Pentanone) .. 103
p-Dioxane................................. 104
Ethanol (Ethyl Alcohol) ............. 118
Ethyl Acetate ............................ 119
Ethyl Amine .............................. 140
Ethyl Benzene ............................ 60
Ethyl Ether ............................... 120
Gasoline ................................... 107
Heptane ..................................... 94
Hexane ...................................... 86
Isopentane (2-Methylbutane) ..... 99
28
Isoprene (2-Methyl-1,3-Butadiene)89
JP-4, Jet Fuel mainly Kerosene) 183
Methanol (Methyl Alcohol) .......... 148
Methyl Ethyl Ketone (MEK) .......... 76
Methyl Metacrylate ..................... 111
Methyl-t-Butyl Ether (MTBE)....... 109
Naptha (Petroleum Ether) ............ 96
Octane ......................................... 99
Pentane, Normal ........................ 105
Isopropyl Alcohol (IPA) ................. 93
n-Propanol.................................. 100
Propylacetate ............................. 120
Propylamine ............................... 103
Propylene Oxide ........................... 98
Styrene (Vinly Benzene) ............... 63
Tetrahydrofuran ............................ 99
Toluene (Methylbenzene, Toluol) . 78
Triethylamine.............................. 102
o-Xylene ....................................... 68
p-Xylene ....................................... 83
m-Xylene ...................................... 83
Xylenes ........................................ 83
Model S4100C
8.0
8.1
Modbus RTU Serial Interface
General
The Modbus communications interface is based on the RS485 standard. It is
implemented as a 2 wire, half-duplex, balanced differential interface which conforms
to the EIA-485 specification. Each slave device must have its unique address so that
more than one device can be connected to an independently addressed on the same
RS485-link.
The Smart Transmitter Interface implements the RTU protocol as described in the
“Modicon Protocol Reference Guide PI-MBUS-300 Rev. G. The Modbus RTU is an
asynchronous NRZ format. The RTU mode and serial format must be the same for all
devices on a Modbus network. The instrument acts as a Modbus communications
“Slave”.
Two Modbus connections (Modbus 1 and Modbus 2), are provided, sharing the node
address and all other Modbus parameters.
The device receives and transmits on both connections simultaneously, requiring the
host for Modbus 2 to be quiescent when Modbus 1 connection is active and vice
versa.
The Modbus interface factory defaults are set to Node Address 1, 19K2 baud, no
parity and 1 stop bit. When the instrument is powered up, the Modbus setup defaults
to the settings used before it was powered down. The interface supports a maximum
of 2 bits for stop bit and parity information. A selection of 2 stop bits causes no parity
to be implemented.
The Modbus Interface and Menu Interface can be used simultaneously for Modbus
read commands only. For write commands, the operation is mutually exclusive. Any
attempts to perform a Modbus write are inhibited while the Menu Interface is active.
This is indicated by returning the Slave Device Busy response (Exception Code 6).
8.2
Modbus Message Characteristics
Baud rate
Byte length (11 bits) max
Inter message spacing or Modicon specification min
Inter byte spacings per Modicon specification min/max
Number of Bytes per message min/max
8.3
Code Name
Illegal function
Illegal data address
Illegal data value
Slave device busy
2K4, 4K8, 9K6 or 19K2
11 / (Baud rate) ms
3.5 bytes
0 bytes / 1.5 bytes
7 / 15
Modbus Exception Codes
Description
Function code is not recognised by the slave
Data address specified is not supported by the slave
Data value specified is not supported by the slave
The slave is engaged in completing a long duration
programme command
29
Hex value
01
02
03
06
Model S4100C
8.4
Function Code
1
2
3
4
5
6
15
16
Modbus Read/Write - Commands
Description
Read coil status
Read input status
Read holding registers
Read input registers
Force single coil
Preset single register
Force multiple coils
Preset multiple registers
Access Type
Read
Read
Read
Read
Write
Write
Write
Write
Any of commands with Function Code 1, 2, 3, 4 allow data to be read from the
instrument. The message structure for each read command specifies a start register
address. A maximum of 5 consecutive registers can be accessed including the start
register address. Each register configures the data as 2 bytes with the most significant
byte first. If more than 5 registers are addressed or if there is an attempt to access
any register outside the valid read register address space, the Illegal Data Address
response (Exception Code 2) is returned.
Any of the commands with Function Code 5, 6 15, 16 allow write data to be written to
the instrument. The message structure for each write command specifies a register
address to which data is written. The message structure for each multiple write
command (15, 16) specifies a register address with the byte count set at 2 to allow
single register access. If more than 1 register is addressed or if there is an attempt to
access any register outside the valid write register address space, the Illegal Data
Address response (Exception Code 2) is returned. Broadcast mode uses address 0
and sends the same data to all attached slaves.
The issue of a write command to a single valid write register normally causes all of the
data specified to be overwritten. In certain situations, it is impossible to force a
condition due to the presence of an external event e.g. attempts to clear a fault while
the fault condition is still present results in the fault not being cleared. For other
situations, any attempts to assign unused, read-only or out of range values will have
no effect. It is advisable to issue a read of the same register range to verify the
true data value present subsequent to the write cycle.
30
Model S4100C
8.5
Modbus Register Configuration
Registers 1, 2, 4, 5, 6, 8 & 11 contain the value of the single parameter specified, the
remaining registers contain composite parameters. Attempts to write a data value out
of range for these parameters will result in the Illegal Data Value response (Exception
Code 3). Unused bits are set to 0.
Register
1
Function
Analogue output current
Access Type
Read
Hex address
00
2
Read
01
Read
02
4
Sensor response at calibration
in % of reference
Alarm, fault and analogue
output status
Calibration level setup
Read
03
5
A1 alarm trip level setup
Read/write
04
6
A2 alarm trip level setup
Read/write
05
7
Open collector outputs and
analogue output current at
calibration setup
Number of successful
calibrations
Modbus setup
Clear latched alarms and faults
Sensor response at calibration
reference in mV
Read/write
Read/write
06
07
Read/write
Write
08
09
Read
10
3
8
9
10
11
8.5.1
Scaling
0mA
20mA
0%
1000%
NA
=0x8000
=0xFFFE
=0x8000
=0xFFFE
0
100
0
100
0
100
=0x8000
=0xFFFE
=0x8000
=0xFFFE
=0x8000
=0xFFFE
NA
0
65535
NA
NA
0V
10V
=0x0000
=0xFFFF
=0x8000
=0xFFFE
Register 3
A bit value of 1 denotes that the corresponding element is active. A bit
value of 0 denotes that the corresponding element is inactive. All of the 16
bits in the register are simultaneously accessed during a read.
Description
A2 Alarm
A1 Alarm
Analogue output at cal level
F09 calibration (check) time-out
F08 Negative drift > 9.5% LEL
F07 EEPROM CRC error
F06 Power low
F05 Sensor short circuit
F04 Sensor open circuit
F03 Low response
F02 Fail to calibrate
F01 Analogue output open circuit
-
Alarm/Fault Type
Latching/Non-latching
Latching/Non-latching
Latching
Non-latching
Latching
Non-latching
Non-latching
Non-latching
Latching
Latching
Non-latching
31
Bit Position
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
Model S4100C
8.5.2
Register 7
Description
Bit position
-
15-6
0
-
Analogue output at
calibration
5-4
0
1
2
0.0mA
1.5mA
2.0mA
A2 alarm open collector
output normally
energised/de-energised
3
0
1
De-energised
Energised
A1 alarm open collector
output normally
energised/de-energised
2
0
1
De-energised
Energised
A2 alarm open collector
output normally
latching/non-latching
1
0
1
Non-latching
Latching
A1 alarm open collector
output normally
latching/non-latching
0
0
1
Non-latching
Latching
8.5.3
Dec. value
Function
Register 9
Description
Bit position
Dec. value
Node address
15-8
1-255
1 stop bit
2 stop bits
7
0
1
No parity
Odd parity
Even parity
6-5
0
1
2
-
4-2
0
Baud rate 19200
Baud rate 9600
Baud rate 4800
Baud rate 2400
1-0
0
1
2
3
The Node address specified in the high data byte is not written during a
broadcast write of the register.
8.5.4
Register 10
The clear register is written a value of 1 to clear a latched Fault or Alarm
indicated in the status register. Each issue of the clear command clears a
single latched Fault or Alarm in order of priority, provided the Fault or
Alarm condition no longer exists.
32
Model S4100C
9.0
9.1
Appendix A
Maximum Sensor Cable Length
Note: Cables to be screened and armoured to BS5308 Part 2 or equivalent.
References to Sq. mm and AWG are not to be taken as direct equivalents.
Maximum Sensor Cable length for various conductor sizes:
Conductor Size
Sq. mm
0.75
1.0
1.5
2.0
2.5
Maximum Cable Length
metres
feet
185
500
250
780
370
1000
500
1580
620
2400
AWG
20
18
16
14
12
9.2
Maximum Smart Transmitter Cable Length
Maximum Smart Transmitter Cable Length for various conductor sizes and power
supply voltages with a 100mA load on each of the three open collector outputs:
Note: When open collector outputs are not connected, use values in parenthesis.
Conductor Size
sq mm
0.75
1.0
1.5
2.0
2.5
AWG
20
18
16
14
12
0.75
1.0
1.5
2.0
2.5
Maximum Cable Length
VDC
35.0
mA max
575
(275)
Cable
Drop
total VDC
5.0
(1520)
(2375)
(3025)
(4800)
(7380)
35.0
630
(330)
10.0
1050
1650
2110
3350
5150
(1850)
(2850)
(3670)
(5775)
(8850)
35.0
710
(410)
15.0
(550)
(750)
(1100)
(1500)
(1875)
800
1220
1600
2500
3800
(1520)
(2375)
(3025)
(4800)
(7380)
30.0
630
(330)
5.0
(680)
1050
(1850)
30.0
710
(410)
10.0
160
215
320
430
535
metres
(330)
(450)
(660)
(900)
(1125)
440
680
860
1375
2100
feet
(910)
(1420)
(1820)
(2850)
(4400)
20
18
16
14
12
290
390
580
780
975
(550)
(750)
(1100)
(1500)
(1875)
800
1220
1600
2500
3800
0.75
1.0
1.5
2.0
2.5
20
18
16
14
12
390
520
780
1040
1300
(680)
(900)
(1360)
(1800)
(2250)
0.75
1.0
1.5
2.0
2.5
20
18
16
14
12
290
390
580
780
975
0.75
20
390
33
Power Supply Rating
Model S4100C
Conductor Size
Maximum Cable Length
sq mm
1.0
1.5
2.0
2.5
0.75
1.0
1.5
2.0
2.5
AWG
18
16
14
12
20
18
16
14
12
520
780
1040
1300
430
575
860
1150
1435
0.75
1.0
1.5
2.0
2.5
20
18
16
14
12
125
165
250
330
410
0.75
1.0
1.5
2.0
2.5
20
18
16
14
12
1.0
1.5
2.0
2.5
4.0
1.0
1.5
2.0
2.5
4.0
metres
(900)
(1360)
(1800)
(2250)
(675)
(900)
(1350)
(1800)
(2250)
1650
2110
3350
5150
1190
1850
2350
3730
5725
feet
(2850)
(3670)
(5775)
(8850)
(1825)
(2850)
(3650)
(5775)
(8850)
(215)
(280)
(430)
(560)
(700)
325
525
675
1050
1650
210
275
420
550
675
(315)
(420)
(630)
(840)
(1050)
18
16
14
12
--
23
34
46
57
92
18
16
14
12
--
44
66
88
110
176
Power Supply Rating
VDC
mA max
Cable
Drop
total VDC
30.0
850
(550)
15.0
(575)
(900)
(1150)
(1825)
(2825)
24.0
730
(430)
5.0
550
875
1125
1175
2750
(850)
(1325)
(1700)
(2700)
(4150)
24.0
885
(585)
10.0
(32)
(48)
(64)
(80)
(128)
73
94
150
230
--
(100)
(130)
(210)
(325)
--
12.0
1044
(744)
1.0
(60)
(90)
(120)
(150)
(240)
135
175
280
430
--
(190)
(240)
(380)
(590)
--
12.0
1118
(818)
2.0
34
Model S4100C
Customer Satisfaction Questionnaire
Attention Field Operations:
We would appreciate your help in assessing and thus improving the quality of our Equipment and Service
and would therefore be grateful if you would complete the Questionnaire below and return it to:
General Monitors Ireland Ltd,
Ballybrit Business Park,
Galway,
Republic of Ireland.
Thank you for your assistance
Client ______________________________________________________________________________
Client Order No. ______________________________________________________________________
General Monitors Sales Order No. ________________________________________________________
(Please tick appropriate box)
Yes
No
1. Was the equipment the correct option?
2. Are sensors correct type and range?
3. Is mechanical assembly good?
(everything proper fit and tight)
4. Did you receive the necessary accessories
to commission the equipment?
5. Has the equipment been commissioned?
6. Any problems encountered during commissioning?
7. Is the equipment functioning correctly at present?
If you have answered NO to any of the above, please provide further details overleaf. Thank you.
Completed by: ____________________________________
35
Date: _______________________