Sierra Monitor Corporation IT Series Instruction Manual

MODEL 5100-02-IT

IT Series

COMBUSTIBLE GAS SENSOR MODULE

Version 3.00A

APPLICABILITY & EFFECTIVITY

Effective for all Model 5100-02-IT Modules manufactured after December 1, 2011.

Instruction Manual Part Number T12019

Rev. D

Model 5100-02-IT Combustible Gas Sensor Module

FM APPROVAL

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


Sensor Module

Model 5100-02-IT

Model 5100-02-IT-SS

Calibration Equipment

Model 1200-26

Model 1290-02

Model 5358-01

Model 5360-00

Model 1260-02

Model 1260-42

Model 1250-01

Model 1256-01

Model 5394-51

Combustible Gas Sensor Module

Combustible Gas Sensor Module, 316SS

Calibration Gas Delivery System

Combustible Gas Cylinder

Calibration Head, Standard

Calibration Gas Delivery Fitting

Combustible 50% LEL Gas Cylinder

Cylinder H2 50% LEL Type A

Gas Sensor Calibrator Kit, Type A

Regulator Type A Calibrator

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.

* FM Approvals, a subsidiary of FM Global

Project# 3021050


TABLE OF CONTENTS

1.

PRODUCT DESCRIPTION ................................................................................................................................. 3

1.1 GENERAL ........................................................................................................................................................ 3

1.2 PRODUCT CONFIGURATION ........................................................................................................................ 3

1.3 THEORY OF OPERATION .............................................................................................................................. 3

1.4 MODES OF OPERATION ................................................................................................................................ 3

1.5 MECHANICAL ................................................................................................................................................. 4

1.6 INTERCONNECT WIRING .............................................................................................................................. 5

1.7 POWER REQUIREMENTS ............................................................................................................................. 5

2.

CAUTIONS & WARNINGS ................................................................................................................................. 7

2.1 INTRODUCTION ............................................................................................................................................. 7

2.2 IT MODULES GENERAL .............................................................................................................................. 7

3.

QUICK START .................................................................................................................................................... 9

............................................................................................................................................................ 9

3.3 MODULE

3.4 TRANSMITTER

3.5 START-UP

INSTALLATION .................................................................................................................... 9

& OPERATION ............................................................................................................................. 9

4.

INSTALLATION ................................................................................................................................................ 10

4.1 SENSOR MODULE LOCATIONS ................................................................................................................. 10

.......................................................................................................................................................... 10

4.3 ENCLOSURE INSTALLATION ...................................................................................................................... 11

4.4 TRANSMITTER AND SENSOR INSTALLATION .......................................................................................... 12

4.5 MODULE ADDRESS SWITCH ...................................................................................................................... 13

5.

OPERATION ..................................................................................................................................................... 18

5.1 DATA ENTRY KEY PAD ................................................................................................................................ 18

5.2 MAIN MENU................................................................................................................................................... 19

5.3 SET-UP .......................................................................................................................................................... 20

5.4 MAINTENANCE FUNCTIONS ....................................................................................................................... 23

6.

CALIBRATION .................................................................................................................................................. 24

6.1 CALIBRATION FREQUENCY ....................................................................................................................... 24

6.2 CALIBRATION PREPARATION .................................................................................................................... 24

6.3 CALIBRATION GAS DELIVERY METHODS ................................................................................................. 24

6.4 CALIBRATION PROCEDURE ....................................................................................................................... 24

6.5 SENSOR EXPOSURE TO GAS .................................................................................................................... 24

6.6 CALIBRATION SUB-MENU ........................................................................................................................... 25

7.

SERVICE ........................................................................................................................................................... 26

7.1 MODULE SUB ASSEMBLY ........................................................................................................................... 26

7.2 ENCLOSURE REPLACEMENT .................................................................................................................... 26

7.3 TRANSMITTER REPLACEMENT ................................................................................................................. 27

7.4 SENSOR REPLACEMENT ............................................................................................................................ 27

7.5 INSTALLATION INSPECTION ...................................................................................................................... 27

Page: 1


8.

APPENDICES ................................................................................................................................................... 29

8.1 APPENDIX A: SPECIFICATIONS.................................................................................................................. 29

8.2 APPENDIX B: MODEL NUMBERS, PARTS LIST & PARAMETERS............................................................. 30

8.3 APPENDIX C: LIMITED WARRANTY ............................................................................................................ 31

8.4 APPENDIX D: REMOTE SENSOR OPTION ................................................................................................. 32

8.5 APPENDIX E: HART ...................................................................................................................................... 33

8.6 APPENDIX F: MODBUS MEMORY MAP ...................................................................................................... 40

8.7 APPENDIX G: COMBUSTIBLE GAS SCALING FACTORS .......................................................................... 41

8.8 APPENDIX H: MENU KEY FOR 5100-02-IT GAS SENSOR MODULE ......................................................... 42

8.9 APPENDIX I: FM APPROVAL ....................................................................................................................... 45

8.10 APPENDIX J: SIL-2 APPROVAL CERTIFICATE ........................................................................................... 47

LIST OF FIGURES

FIGURE 1 - 1: MODEL 5100-02-IT COMBUSTIBLE SENSOR – MOUNTING OPTIONS .................................... 5

FIGURE 1 - 2: MODEL 5100-02-IT COMBUSTIBLE SENSOR – CAST AL ENCLOSURES, DIMENSIONS ....... 6

FIGURE 1 - 3: MODEL 5100-02-IT-SS COMBUSTIBLE SENSOR – 316SS ENCLOSURES, DIMENSIONS ..... 6

FIGURE 4 - 1: TYPICAL MOUNTING OPTIONS ................................................................................................. 10

FIGURE 4 - 2: TRANSMITTER FACE PLATE ..................................................................................................... 14

FIGURE 4 - 3: 4-20 MA CIRCUITS TYPES 5100-02-IT ...................................................................................... 14

FIGURE 4 - 4: 4-20 MA CIRCUITS TYPES 5100-02-IT – CONNECTIONS ........................................................ 15

FIGURE 4 - 6: REMOTE ALARM RESET ............................................................................................................ 16

FIGURE 4 - 5: DIGITAL INTERFACE CONNECTIONS ...................................................................................... 16

FIGURE 4 - 7: TERMINATION DRAWING .......................................................................................................... 17

FIGURE 5 - 1: FACE PLATE WITH DATA ENTRY KEY PAD ............................................................................. 18

FIGURE 6 - 1: MODEL 5358-01 CALIBRATION ADAPTER ............................................................................... 24

FIGURE 7 - 1: MODULE COMPONENTS ........................................................................................................... 26

FIGURE 8 - 1: REMOTE SENSOR OPTION ....................................................................................................... 32

FIGURE 8 - 2: HART ............................................................................................................................................ 33

FIGURE 8 - 3: 4-20 MA CIRCUITS TYPES 5100-02-IT – CONNECTIONS - HART .......................................... 34

LIST OF TABLES

TABLE 4 - 1: MINIMUM WIRE GAUGES ............................................................................................................. 11

TABLE 4 - 2: SENSOR MODULE EXTERNAL INTERFACES ............................................................................ 13

TABLE 4 - 3: SENSOR MODULE ADDRESS SWITCH POSITIONS .................................................................. 13

TABLE 5 - 1: MASTER MENU ............................................................................................................................. 19

TABLE 5 - 2: OPERATION DISPLAY VALUES ................................................................................................... 19

TABLE 5 - 3: SET-UP CONFIGURATION ........................................................................................................... 21

TABLE 5 - 4: MAINTENANCE MENU .................................................................................................................. 23

TABLE 6 - 1: CALIBRATION ................................................................................................................................ 25

TABLE 8 - 1: MODBUS MEMORY MAP .............................................................................................................. 40

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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

• SIL-2

• FM Approved for performance and hazardous locations

• 4-20 mA output

• Modbus

®

RTU interface

• SMC Sentry interface

• 316 Stainless steel enclosure option

• Remote alarm reset

• Optional Alarm Relays

• Remote sensor 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

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 4-1. Figure 4-4 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.

Page: 3


An RS-485 Modbus RTU serial interface allows direct connection to standard PLCs and DCSs. The

Module Address Switch (section 4.5) allows the user to select up to 15 different Modbus addresses. Also, up to 254 different Modbus Addresses are available via menu selection. Figure 4-5 in this manual provides the wiring terminations for Modbus connections.

The analog 4-20 mA interface allows direct connection to standard controller and distributed system. The module is an active current source.

The standard configuration is set up for a 3-wire non-isolated connection. An optional 4-wire isolated connection is also available and can be enabled by changing JP1 and JP2.

1.4.4 REMOTE SENSOR (APPENDIX E)

The Remote Sensor option enables the remote mounting of the sensor up to 50’ from the transmitter.

1.4.5 HART CONNECTION (APPENDIX F)

A HART interface option is available. Refer to Appendix F for information.

1.4.6 OPTIONAL INTEGRAL RELAYS

The optional relays are integral to the gas sensor module and are rated as SPDT, 250VAC, 5 Amps for the

High Alarm and Low Alarm relays and SPDT, 250VAC, 2 Amp for the Trouble relay.

* HART option, relays are all SPDT, 250VAC, 2 Amp

If the gas sensor module is provided with the optional relays, it will include Terminal P4 on the interface board (Figure 4-3). Relay output connections are on P4.

1.4.7 REMOTE ALARM RESET

An input is available for connection of remote alarm reset/acknowledge. Figure 4-6 provides the wiring termination for connecting the remote alarm reset. This only resets local alarms, not Sentry alarms.

1.5 MECHANICAL

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

 ENCLOSURE

Standard on the 5100-02-IT is an explosion-proof, rain-tight cast aluminum electrical housing (Figure 1-3) with three ¾” FNPT conduit hubs. The 5100-02-IT-SS has a 316 Stainless Steel enclosure (Figure 1-2).

Both enclosure covers have a viewing window. The design of the enclosure allows 3-way mounting choices as shown in figure 1-1.

 TRANSMITTER ELECTRONICS

Electronic Assembly consisting of one printed circuit board assembly mounted under a cover plate, plugged into one field termination board. Connectors for wiring for power, signal interface and alarm relays are located on the bottom of the termination board.

 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.

Page: 4


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 alternatives 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.

(Default)

Figure 1 - 1: Model 5100-02-IT Combustible Sensor – Mounting Options

Page: 5


Figure 1 - 3: Model 5100-02-IT-SS Combustible Sensor – 316SS Enclosures, Dimensions

Figure 1 - 2: Model 5100-02-IT Combustible Sensor – Cast Aluminum Enclosures, Dimensions

Page: 6


2. CAUTIONS & WARNINGS

2.1 INTRODUCTION

Although IT Transmitter Modules are designed and constructed for installation and operation in industrial applications including "hostile" environments, caution should be taken to insure that the installation is made in compliance with this instruction manual and that certain procedures and conditions are avoided. This chapter discusses the necessary cautions.

Read the entire chapter prior to installation of the equipment.

2.2 IT MODULES - GENERAL

Avoid installing sensor modules where they will be unnecessarily exposed to wind, dust, water (esp. direct hose down), shock, or vibration. Observe temperature range limitations.

Sensors may be adversely affected by prolonged exposure to certain materials. Loss of sensitivity, or corrosion, may be gradual if such materials are present in low concentrations. These materials include: silicones, sulfides, Halides (compounds containing chlorine, fluorine, bromine, iodine), acid vapors, caustic liquids or mists.

Care has been taken by the manufacturer to ship your modules in protective packaging to avoid contamination prior to installation. It is recommended that the modules remain protected during installation and that the covering be removed immediately prior to system start-up.

During normal use the sensor is protected from dirt and oil contamination by a sintered metal cover. If this cover becomes clogged, the response of the sensor will be reduced. Protect the sensor from contamination by careful placement, or by use of rain and dust shields.

Sensor modules must not be painted. Paint may contain compounds which will contaminate the sensor. Paint will cause clogging of the sintered metal cover and will cause difficulties during attachment of the calibration head or other maintenance activity. It is recommended that the module be tagged

"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.

• Unit is shipped with RF filter that is clipped onto the sensor assembly connector.

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

• All splices must be via either a termination hardware system or soldered. Improperly spliced cable can result in corrosion, resistance changes and system errors. The use of wire nuts and crimp-on connectors is unacceptable.

NOTE

Installation and wiring must be in accordance with the National Electrical Code.

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

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.

Page: 7


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 G.

Acetic Acid

Acetic Anhydride

2,3-Dimethylpropane

Dimethylsulphide

Methylcyclohexane

Methylenedichloride

Alkyl Alcohol Ethane Methyl Formate n-Amyl Alcohol Ethyl Alcohol Methylpropionate

Aniline Ethylamine n-propylketone iso-Butane Ethylene n-Pentane trans-Butene-2 n-Butyl Alcohol iso-Butyl Alcohol

Diethyl Ether

Dimethoxyethane

Dimethyl Ether n-Propyl Alcohol n-Propylamine n-Propylchloride n-Butyl Benzene iso-Butyl Benzene n-Butyric Acid

Carbon Disulfide

Carbon Monoxide

Ethyl Formate n-Heptane n-Hexane

Hydrazine

Propyleneoxide

Ethylmercaptan iso-Propylether

Propyne

Toluene

Triethylamine

Carbon Oxysulphide Hydrogencyanide Trimethylamine

Chlorobenzene Hydrogen Vinylethylether

Cyclohexane Methane m-Xylene n-Decane Methyl Alcohol JP-4 (Jet Fuel)

Diethylamine Methylamine

Table 2 - 1: Combustible gases detected by Model 5100-02-IT Combustible Gas Sensor Module

Page: 8


3. QUICK START

3.1 OVERVIEW

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

3.2 WIRING

See section 4.2 to determine if 3-wire or 4-wire operation is necessary.

Provide twisted shielded wiring from the power supply/control device to the sensor module location. Use stranded wire that is 18 AWG or larger.

3.3 MODULE INSTALLATION

The sensor module can be mounted in a variety of configurations supported by the conduit. See figure 1-1 to determine which configuration is best for your specific application. The default configuration enables the modules to be put in line with other modules with the sensor element below the transmitter. To change the configuration simply remove the transmitter and rotate to the appropriate configuration and remount the standoffs and transmitter.

The module is designed to be installed on a ¾” conduit. Two important warnings:

•

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

•

The sensor module enclosure mounting must be spaced far enough from any vertical surface to allow removal and replacement of the sensor assembly which is threaded into one ¾” conduit entry.

•

Sensor housing must be oriented vertically pointing downward.

•

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

3.4 TRANSMITTER INSTALLATION

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

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

•

If the transmitter is installed in a classified hazardous area, replace the threaded cover prior to providing power.

3.5 START-UP & OPERATION

To begin operation of the sensor module activate the instrument loop with 10-30 VDC. Each time the sensor module is powered up it will perform a warm-up for approximately 5-10 minutes. During this time the display will read “Starting”. The loop output will be held at 4 mA.

NOTE:

If the sensor is uncalibrated, the startup display will state “START” instead of “STARTING”

After the warm-up period has expired, the display will indicate the gas concentration. Also, the instrument loop will be released to output current in the range of 4 to 20 mA. The actual current is linear with the gas concentration.

Page: 9


4. INSTALLATION

NOTE

All IT modules are factory pre-configured and calibrated.

All modules are tagged to indicate the configuration including the sensor module number

Identify all components during unpacking and install using the factory configuration.

4.1 SENSOR MODULE LOCATIONS

Select locations for each sensor modules based on the following:

• Modules should be placed close to the potential source of gas.

• Modules should be placed in areas accessible for calibration.

• Sensors should be pointed down and the conduit should include an inverse trap to reduce moisture

(condensation) from accumulating in the electronics enclosure.

• Remote calibration fitting (5360-00) should be used to facilitate calibration gas delivery. Run polyurethane tubing (1/4” O.D. x 1/8” I.D.) from fitting to an accessible location.

Figure 4 - 1: Typical Mounting Options

NOTE

Module must always be installed vertically with sensor pointing down.

4.2 WIRING (Figure 4-2 refers to Analog, Modbus and Sentry operation)

4.2.1 ANALOG 4-20 MA OPERATION

The 4-20 mA output for the 5100-02-IT can be either 3-wire (ISA Type 3 Circuit) or standard (ISA Type 4

Circuit 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’.

Page: 10


4.2.2 MODBUS OPERATION USING RS-485 CONNECTION

Use a minimum of 18 AWG, 2 conductor for DC power connection. No shield required. In addition use a minimum of 24 AWG, low capacitance, shielded data cable for RS485 half duplex communication. The installation may be planned in a manner which provides up to 32 sensor modules on a single home run.

TERMINATION RESISTOR JUMPERS:

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

Installations where the cable length is under 100’, termination resistors may not be required. In installations where the cable length is greater than 100’, it is recommended to place the termination jumpers on the first device and last device on the RS-485 wire run. Termination jumpers must be removed from all other modules connected between the first and last device. The first device in the RS-485 multiplexed bus is usually a gas controller or PLC. Factory term resistor setting is “not enabled.”

BIAS JUMPERS: (BIAS A, BIAS B)

Bias resistors are used to force RS-485 receiver outputs to a known (fail-safe) state, when the bus is idle.

Bias jumpers are always installed in pairs as the bias must be placed on both the TX A and TX B lines.

Sierra Monitor’s IT series of combustible gas sensors automatically apply the bias jumpers, and are factory installed so that the bias is always enabled.

4.2.3 SENTRY OPERATION USING SENTRY PSG 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.

NOTE:

Be sure to follow all local electric code and safety requirements when installing the 5100-02-IT Gas Sensor Module

4.2.4 GENERAL

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

NOTES

RFI Noise Suppressor must be added to power/ground as per Appendix D.

The drain wire of shielded cable must NOT be used as one of the conductors.

Installation and wiring must be in accordance with the National Electrical Code. Temperature rating of cable wire must be at least 75 o

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

4.3 ENCLOSURE INSTALLATION

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

Number of modules

1

2

3

4

Maximum length of wire run (feet)

500 1,000 2,000 3,000 5,000

18 18 16 16 14

18 18 14 12 xx

18 16 12 xx xx

16 14 12 xx xx

Table 4 - 1: Minimum Wire Gauges

Page: 11


Prior to installation and wiring.

1. Remove the transmitter from the module housing by:

• Unscrew the two captive panel screws in the face plate.

• Lift the transmitter out of the enclosure housing.

• Unplug the sensor cable from transmitter assembly connector J1.

• Remove the sensor assembly from the enclosure hub.

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

NOTES

When housing earth grounding is required for the installation a grounding lug is located in the base of the enclosure. Install the earth ground wire under the green lug.

4.4 TRANSMITTER AND SENSOR INSTALLATION

When all pre-wire is complete:

1. Install sensor assembly in the open hub on the module enclosure. The sensor assembly thread must be fully seated into the hub and tightened to maintain explosion proof assembly.

2. Connect the sensor assembly cable to top transmitter board connector J1.

3. Align the headers between the top transmitter board and the lower termination board and push together.

4. Turn rotary switch to correct sensor address if required.

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

6. Cycle power to accept module address change.

P1

1

2

3

4

PCB Label

Switch

4-20

IN +

IN -

IN +

IN -

5 GND

6

4-20

OUT +

7 OUT -

Function

Digital Input SW +

Digital Input SW -

4-20 mA Input +

4-20 mA Input -

Ground

4-20 mA Output

4-20 mA Output

4

5

6

P2

1

2

3

PCB Label

RS 485

RS 485

+

-

S

+

-

S

Function

RS 485 (+) (A)

RS 485 (-) (B)

RS 485 shield (Isolated GND)

RS 485 (+) (A)

RS 485 (-) (B)

RS 485 shield (Isolated GND)

P3B PCB Label

1 P

2 S

3 G

P3A

4 P

5 S

6 G

Function

Sentry Signal or Communication

Sentry Signal or Communication

Page: 12


P4 Connections are only available when the optional Relays are included

P4 PCB Label Function

1

2

WARN

N/C

COM

Low Alarm Relay NC

Low Alarm Relay COM

3

4

N/O

N/C

Low Alarm Relay NO

High Alarm Relay NC

5

ALARM

COM High Alarm Relay COM

6

7

N/O

N/C

High Alarm Relay NO

Trouble Alarm Relay NC *

8

TRBL

COM Trouble Alarm Relay COM*

9 N/O Trouble Alarm Relay NO*

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

Table 4 - 2: Sensor Module External Interfaces

7. Establish the module address according to section 4.5.

NOTES

The starting delay period normally takes approximately 3 minutes but under some circumstances can take longer.

4.5 MODULE ADDRESS SWITCH

For digital interface applications the module address switch (or Modbus node) must be set per Table 4-2:

P

OSITION

A

DDRESS

P

OSITION

7

8

5

6

3

4

1

2

Sensor 1

Sensor 2

Sensor 3

Sensor 4

Sensor 5

Sensor 6

Sensor 7

Sensor 8

D

E

F

0

9

A

B

C

A

DDRESS

Sensor 09

Sensor 10

Sensor 11

Sensor 12

Sensor 13

Sensor 14

Sensor 15

Software Menu

Table 4 - 3: Sensor Module Address Switch

Positions

N OTE

For Sentry applications only sensor addresses 1-8 are allowed. If using Modbus output sensor addresses 1-15 are available. Position 0 allows the Modbus Address to be set by software menu, in the range 16-254.

Page: 13


Figure 4 - 2: Transmitter Face Plate

Figure 4 - 3: 4-20 mA Circuits Types 5100-02-IT

Page: 14


7

(DEFAULT)

Figure 4 - 4: 4-20 mA Circuits Types 5100-02-IT – Connections

Page: 15


-

+

Figure 4 - 5: Digital Interface Connections

Figure 4 - 6: Remote Alarm Reset

Page: 16


Figure 4 - 7: Termination Drawing

Page: 17


5. OPERATION

The Combustible Gas Sensor utilizes a visual menu system operated by means of a magnet. A magnet stick is supplied for this purpose. The menu system is used to configure alarm set-points, calibrate the sensor module, and for maintenance procedures and alarms acknowledge.

5.1 DATA ENTRY KEY PAD

The module menu system is operated by means of directing the magnet stick toward each of four independent hall-effect magnetic switches. Each switch functions as if it is a manually activated panel key. The keys are located above and below the faceplate display and are labeled

M

,

E

, ▲ , and ▼ as shown in Figure 5-1.

• Key : MODE

• Key : ENTER

• Key : UP (+)

• Key : DOWN (-)

Mode Enter

Up Down

Figure 5 - 1: Face Plate with Data Entry Key Pad

Page: 18


Table 5-1 describes the primary human-machine interface operation.

M E

S T

M E

S T

M E

S T

M E

S T

M E

S T

M E

S T

Key

M E

S T

M E

S T

M E

S T

M E

S T

Function Display

Mode

Enter

Up

Down

5100-02

1.Xxa

VX.Xxx

M E

S T

Switch [M]

Switch [E]

Description

Switch [ ▲ ] Previous Menu

Switch [ ▼ ] Next Menu

First screen at power up-model

Second screen at power up-version

Warm.XXX

Third screen at start up-warm up

0%LEL Normal condition - default display

Mode ALMRSET: Mode Function -Alarms Acknowledge

SSSSSSSS

0%LEL

Banner: Use <M> sw itch for different menu items. Select

<E> to enter menu item.

Default Display

Mode

Mode

Mode

Mode

Mode

Enter

ALMRSET:

CALIB:

SETUP:

MAINT:

EXIT-?

0%LEL

0%LEL

Mode Function - Alarms Reset

Mode Function - Calibrate

Mode Function - Module Set-up

Mode Function - Maintenance

Exit Mode

Apply Selected Mode (Exit)

Default Display

Table 5 - 1: Master Menu

Table 5-2 describes the operational display values of the human-machine interface system.

Display Description

STARTING Warm-up at start-up

##%LEL Concentration

L ##%LEL Low Alarm (Warning)

H ##%LEL High Alarm (Alarm)

HIGH

NO SENSR

C ##%LEL

ACK

>100% Full Scale

Sensor Failure

Calibration Mode

Acknowledged Function

Table 5 - 2: Operation Display Values

Reference

Table 6-1

Table 5-3

Table 5-4

ID THE DISPLAY SHOWS “S TART ” INSTEAD OF “S TARTING , THE MODULE MUST BE CALIBRATED BEFORE USING IT .

Page: 19


5.3 SET-UP

The sensor module set-points menu is used to initially set-up the alarm set points, relay actions, gas type and range, 4-20 mA action and RS-485/Sentry address and baud rates (See Menu Key in Appendix J). When in the SETUP screen use the [ ▲ ] or [ ▼ ] keys to select submenu and use [E] to enter.

•

Alarms: Use the [ ▲ ] or [ ▼ ] keys to select Low Alarm (Warning) or High Alarm (Alarm) menu. Key

[ ▲ ] will adjust the setpoint upwards and Key [ ▼ ] will adjust the value downwards. Once it reaches the desired setpoint, Key [E] will accept it and ACK will appear. Set-points can be configured using this menu to values between 0 and 60.

•

Relays: Use the [ ▲ ] or [ ▼ ] keys to select Low Alarm (Warning) or High Alarm (Alarm) relay menu and press [E]. Use the [ ▲ ] or [ ▼ ] keys to select the correct alarm relay action for the application,

Latch, Sentry or Non-Latch. Selecting “Sentry” enables the Sentry controller to make all alarm action decisions. * indicates the current selection.

•

Gas Factor: A calibration standard of Methane may be used in conjunction with scaling factors to cause alarm function in %LEL scale of another gas. See Appendix I for a list of the scaling factors.

Note that if the 5100-02-IT is interfaced to a Sentry controller that the gas factor can be set in the

Sentry or the Gas Sensor Module but NOT IN BOTH. It is recommended that the gas factor be adjusted in the Gas Sensor Module so that the display values on both the Gas Sensor Module and the Sentry are matched. Note that gas factors are not applicable during calibration.

•

4-20mA: Use the [ ▲ ] or [ ▼ ] keys to select Calib, or CalibOut TblOut menu and press [E]. The

“Calib” section of the menu allows the user to calibrate the 4 mA and 20 mA outputs. To calibrate the 4 mA and 20 mA outputs it is necessary to have an amp meter connected to the 5100-02-IT and upon selecting the 4 mA output calibration then the [ ▲ ] or [ ▼ ] keys can be used to adjust the 4 mA reading on the amp meter until it reads 4 mA. Similar steps can then be performed for the 20 mA output. The CalibOut section allows the user to select the 4-20 mA output action desired during calibration. * indicates the current selected value. Available selections include:

Track – the 4-20mA value tracks the calibration gas exposed to the gas sensor module

 C2.5mA

– the 4-20mA value is held at 1.50mA during calibration

 C4.00mA

– the 4-20mA value is held at 4.0mA during calibration.

The Tbl Out menu enables the user to select the mA output value for the Trouble Alarm. Select

“T1.5mA” to choose the 1.5mA default valve. Or select “User mA” and use the [ ▲ ] or [ ▼ ] keys to select any valve between 0.5mA and 3.7mA.

•

RS-485 - Use the [ ▲ ] or [ ▼ ] keys to select Address or Baud rate menu and press [E]. Note that the

5100-02-IT has a rotary switch on the faceplate and it is used to select addresses 1-15. When connected to Sentry the user can select 1-8 and using Modbus RS-485 the user can select addresses 1-15. For Modbus addresses above 15, set the rotary switch to 0 and then use the

“Address” menu to select any address between 16 and 254. The Baud rate menu allows the user to select a baud rate of 38400, 19200, 9600, 4800 or 2400. * indicates current selection.

Page: 20


M E

S T

M E

S T

M E

S T

M E

S T

M E

S T

Key Function Display

--0%LELDefault Display

Description

M E

S T

M E

S T

M E

S T

M E

S T

M E

S T

M E

S T

M E

S T

M E

S T

Mode

Mode

Mode

Enter

Down

Down

Down

Down

ALMRSET:

CALIB:--

SETUP:---

Alarms

Relays

Gas

4-20mA

RS-485

Mode Function - Alarm Reset


Mode Function - Set Point Adjustments

S.P. Function - Alarm Adjust

S.P. Function - Relays Adjust

S.P. Function - Gas Type/Range Adjust

S.P. Function - 4-20 mA Adjust

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

High Alarm Set Point Adjustment Example

M E

S T

M E

S T

Enter

Enter

H.Alarm

HASP:60-

S.P. Function - High Alarm Adjust

Alarm Set Point: current = 60

M E

S T

M E

S T

Down (x5) HASP:55Alarm Set Point: new = 55

Enter ACK

Use S or T keys to adjust to new set point

Momentary Acknowledge of new Set Point

H.Alarm

S.P. Function - Alarm Adjust

Enter

Down

Enter

Down

Down

Relays Set Point Adjustment Example

H. Relay S.P. Function - Alarm Relay Adjust

L.Relay

Latch

Sentry

*Sentry

S.P. Function - Warning Relay Adjust

Use S or T keys to adjust to new relay action

(Latch, Sentry, NonLatc) * indicates current

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

Alarm Relay set to Sentry

Table 5 - 3 A: Set-Up Configuration

Reference

* A Below

* B Below

* C Page 22

* D Page 22

* E Page 22

*A

*B

Page: 21


M E

S T

M E

S T

M E

S T

M E

S T

M E

S T

M E

S T

M E

S T

M E

S T

M E

S T

M E

S T

Gas Factor Example

Enter GasFactr S.P. Function - Gas Factor Adjust

Enter

Enter

Factr100

ACK

Select [E] to select or S or T to adjust factor number and press [E]

Acknowledgement of new Gas Factor Value

*C

Enter Calib

4-20 mA Adjustment Example

S.P. Function - Calib Adjust

Enter Out: 4mA Use S or T keys to select 4 mA or 20mA

Enter 4mA Selects 4 mA

Enter

Mode

ACK

Calib

Momentary Acknowledge of new Set Point


Down

Enter

CalibOut

Track

S.P. Function - Output during Calibration Adjust

Use S or T keys to select Track, C2.5mA, C4.00mA

*D

M E

S T

M E

S T

M E

S T

M E

S T

M E

S T

M E

S T

M E

S T

Enter

Mode

Down

*Track

Calib

Tbl Out

Track = Output during calibration tracks the calibration gas,

C1.50mA = Output during calibration is 2.5mA, C4.00mA =

Output during calibration is 4.0mA

* = Current selection


S.P. Function - output during Trouble Alarm

Enter *T1.50mA

Current Valve 1.5mA for Trouble

Down User mA S.P. Function - User Selectable mA Valve

Enter *T1.50mA

Use S or T keys to select mA Valve between 0.5 and 0.7mA

Enter *T1.75mA

Selctd 1.75mA for volume during trouble

Address

RS-485 Adjustment Example

S.P. Function - RS-485 Address Adjust *E

M E

S T

M E

S T

M E

S T

M E

S T

M E

S T

M E

S T

Enter

Enter

Enter

Enter

Down

Enter

Addr:016

ACK

Address

Baud

*38400

Use S or T keys to enter new address

New address selected

S.P. Function - RS-485 Address Adjust

S.P. Function - RS-485 Baud Rate Adjust

Press [E] to select or [ S ] or [ T ] to select another

Table 5 - 3 B: Set-Up Configuration

Page: 22


5.4 MAINTENANCE FUNCTIONS

The maintenance menu allows the operator to verify module firmware version and configuration code. The maintenance menu operation is described in Table 5-4.

Reference Key Function Display

0%LEL Default Display

M E

S T

M E

S T

M E

S T

M E

S T

M E

S T

Mode

Mode

Mode

Mode

Enter

ALMRSET: Mode Function - Alarm Reset

CALIB:

MAINT:

Mode Function - Calibration

Mode Function - Maintenance

Description

SETUP: Mode Function - Set Point Adjustments

V2.00aA Module Version

Table 5 - 4: Maintenance Menu

Page: 23


6. CALIBRATION

6.1 CALIBRATION FREQUENCY

The 5100-02-IT has been calibrated in the factory prior to shipment. It is recommended that the user check calibration before placing in service. The Combustible sensor module must be calibrated every 6 months.

Periodic functional tests are advisable for critical applications and hostile environments.

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

6.2 CALIBRATION PREPARATION

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

N OTE

If an error is made during any stage of the calibration process, hold the magnet stick at the key

M for 10 seconds. A scrolling display will indicate “Calibration aborted” and the sensor module will exit the calibration activity and return to normal operating mode. The calibration

procedure can then be restarted

Calibration must be performed only when the area is known to be clear of combustible gas. If necessary, use a portable instrument to confirm that there is no background combustible gas.

For compliance with Factory Mutual (FM) Apparatus, the Sierra Monitor Model 1200-26, 1250-01, 1256-01,

1260 -02 are the only FM Approved calibration gas delivery device. Use Model 5358-01 Calibration Adapter or Model 5360-00 Gas Delivery Fitting.

6.3 CALIBRATION GAS DELIVERY METHODS

Calibration gas is can be delivered to the sensors via the following delivery devices:

Model 5358-01: Calibration Adapter - use with portable calibrators. See 6-1.

Model 5360-00: Calibration Gas Delivery fitting - permanently installed fitting which allows tubing to be run to a convenient delivery location

6.4 CALIBRATION PROCEDURE

Table 6-1 shows the step by step process of the calibration procedure.

The procedures requires that the menu “keys” be activated using the magnet stick.

Each key press steps through the process of setting the zero value for clean air and then setting the span value.

At each of these steps, apply calibration gas of the value corresponding to the setting accepted on the sensor module display.

Figure 6 - 1: Model

5358-01 Calibration

Adapter

6.5 SENSOR EXPOSURE TO GAS

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

Model Gas

5100-02-IT Methane

Flow

300 cc/min

Period

Until Stable – 3 minute minimum

NOTE:

Following calibration, the combustible module counts down for 300 seconds. During this time the module is updating its internal memory and it is very important that its power not be interrupted

Page: 24


6.6 CALIBRATION SUB-MENU

M E

S T

M E

S T

M E

S T

M E

S T

M E

S T

Key Function Display


M E

S T

M E

S T

M E

S T

M E

S T

Mode

Mode

Enter

Enter

ALMRSET:

CALIB:--

CAL-0%--

ACK

Description

Mode Function - Alarm Reset


Banner: Apply zero gas, enter <E> when done

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

Zero gas setting acknowledged

50%-SPAN Banner: Select span, enter <E> when done

M E

S T

Enter CAL-50% Banner: Apply 50% gas, then enter <E> to calibrate gas sensor

M E

S T

Enter

C 0%LEL

Operation: Apply calbration gas.

C50%LEL

CAL-OK

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

Calibration Passed - now remove gas

WAIT-300

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

Sub-Routines

50%-SPAN Banner: Select span, enter <E> when done

Down 25%-SPAN

Operation: Change Span Gas Value to 25%

Down Adj-SPAN

Operation: User adjustable value

Enter 50%-SPAN

Operation: Ready for user adjustment

Up (x5) 55%-SPAN

Enter CAL-55%

Operation: User adjustment to new value 55%

Banner: Apply 55% gas, then enter <E> to calibrate gas sensor

M E

S T

M E

S T

Enter

Mode

C 0%LEL

Operation: Apply calbration gas.

CAL-FAIL

WAIT-300

(Any)

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

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

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

Banner: Calibration Aborted


Reference

Sub A

Sub B

Sub A

Sub B

Sub C

Table 6 - 1: Calibration

Page: 25


7. SERVICE

7.1 MODULE SUB ASSEMBLY

Figure 7 - 1: Module Components

NOTE

Area must be determined to be non-hazardous before opening enclosure.

7.2 ENCLOSURE REPLACEMENT

The enclosure should be replaced if the cover threads or conduit threads have been damaged, or if the enclosure has been damaged sufficiently that it no longer meets the required NEMA classification.

To replace the enclosure follow the transmitter and sensor assembly removal instructions, remove the damaged enclosure from its conduit, install a new enclosure and continue the transmitter and sensor assembly replacement instructions.

Page: 26


7.3 TRANSMITTER REPLACEMENT

The transmitter assembly should be replaced when it is determined that it is unreliable, noisy or cannot be calibrated. This situation may occur due to age, corrosion or failed components.

To replace the transmitter assembly: a. Confirm that system power has been removed. b. Remove the cover of the main enclosure. c. Unscrew the two thumb screws in the top of the cover plate, lift the assembly and rotate 90 o to relieve the wiring service loop. d. Unplug the sensor connector from the transmitter assembly. e. Plug connector into new transmitter (be sure to match numbers between connector and socket). f. Restore power and allow a minimum of 2 hours for stabilization before re-calibration.

7.4 SENSOR REPLACEMENT

The gas sensor needs replacement when:

The “CAL-FAIL” message appears after calibration.

The sensor output signal is noisy, causing erroneous gas level readings.

The “Sensor Failure” message displays.

To replace the sensor assembly: a. Confirm that system power has been removed. b. Remove the gas sensor module enclosure cover. c. Unscrew the two thumb screws in the top of the faceplate, lift the transmitter assembly and rotate 90 o relieve the wiring service loop.

to d. Unplug the sensor connector from the transmitter. e. Unscrew the old sensor assembly from the enclosure conduit hub. Remove the sensor assembly with its harness. f. Install new sensor assembly into conduit hub. g. Allow the new sensor to stabilize for a minimum of 2 hours and then calibrate using the procedure in

Section 6.

7.5 INSTALLATION INSPECTION

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

7.5.1.1 CONTROLLER INSTALLATION

• Controller installed in conformance to instruction manual recommendations.

• AC power is correctly grounded.

• Hot AC and relay connections have safety covers installed.

7.5.1.2 SENSOR MODULE INSTALLATION

• Module installation in conformance with this manual.

• Modules accessible for calibration.

• Wiring terminations clean and correct.

7.5.1.3 MOISTURE TRAPS AND RAINSHIELDS

• Conduit seals and drains installed to avoid moisture build up in electronics enclosure. Water accumulation in sensor module enclosures is a major cause of damage and system failures - take precautions to seal electrical conduits and provide moisture traps and drains to avoid water damage

• Rain-shields installed where applicable.

7.5.1.4 STANDARD VOLTAGES

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

7.5.2 INSPECTION AND TROUBLESHOOTING GUIDE

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

Page: 27


7.5.3 IF MODULE DOES NOT RESPOND TO GAS

1. Repeat calibration procedure.

2. Remove the gas and wait for the timer to completely count down.

3. Apply 50%LEL and verify that the sensor sees 50% LEL gas after calibration.

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

7.5.4 IF THE MODULE DISPLAYS “STARTING” FOR MORE THAN 1 HOUR

1. Make sure the sensor is placed in an ambient room temperature environment.

2. Power cycle the sensor.

3. Ensure that the sensor is not exposed to methane during warm-up.

7.5.4.1 IF THE MODULE DOES NOT DISPLAY THE CORRECT %LEL

1. Power cycle the unit.

2. Recalibrate the sensor.

7.5.4.2 IF THE DISPLAY SHOWS ‘F’ – SENSOR FAILURE OR SENSOR MISSING

1. Power down the unit.

2. Open the enclosure and unplug the sensor assembly from the transmitter board.

3. Plug the sensor back into the transmitter board carefully and ensure a secure fit.

4. Check all other connections.

5. Power up the unit.

7.5.4.3 IF THE MODULE SHOWS “***CALIBRATION REQUIRED***”

1. Calibrate the module.

7.5.4.4 IF THE DISPLAY SHOWS ‘H’ (OR L) THEN THE LOCAL HIGH OR LOW ALARM IS ACTIVE

7.5.4.5 IF THE DISPLAY SHOWS “M” – NOT CALIBRATED

1. Calibrate the module.

7.5.4.6 IF THE DISPLAY SHOWS “C” – CALIBRATION MODE

1. Complete calibration and exit to operating mode.

7.5.4.7 IF THE DISPLAY SHOWS “S” – SENTRY CONNECTION

1. Check connections with Sentry Controller

7.5.4.8 IF THE DISPLAY SHOWS “SENSOR FAIL”

1. The sensor assembly is defective, contact technical support

LED 1 = 1 Hz Heartbeat normal, 2 Hz Panic Error

2 = Computation process

3 = 1 Hz Heartbeat normal

4 = HART or Sentry comms activity

Page: 28


8. APPENDICES

8.1 APPENDIX A: SPECIFICATIONS

Sensor:

Type:

Range:

Repeatability:

Response time:

Accuracy:

Sensor Life:

Output:

Display:

Relays (Standard):

Relays (Option):

Signal Output:

0-100% LEL Combustible

LEL

< 12 sec to 60% full scale

+/- 1% for 0-50% LEL range

+/- 2% for 51-100% LEL range

Typically >3 years

Fixed and Scrolling LED

Trouble (SPDT Form C, 0.25 Amp@ 250VAC)

High Alarm, Low Alarm (5 Amp, 250VAC)

Sentry Digital Bus

3-wire non-isolated, or 4-wire isolated analog 4-20 mA (current source)

Serial RS-485 Modbus RTU

Input:

Remote Alarm Reset:

Electrical Data:

Power consumption:

Connection type:

Input voltage:

RFI/EMI Protection:

Normally open digital input

3 watts

3 wire

24 VDC nominal: 10-30VDC

EN50081-2, EN50082-2

Operating Range:

Ambient Temperature Range:

Relative Humidity:

Enclosure:

Material – Aluminum:

Material – Stainless Steel:

Dimensions:

(H x W x D)

Weight:

Housing:

-40 o to 176 o

F(-40 o

to 80 o

C)

0-99% (noncondensing)

Polyester powder-coated, sand-cast, copper-free aluminum

316 SS optional

7.2 x 4.9 x 4.8 inches Al, 7.5 x 5.0 x 4.4 inches SS

(18.3 x 12.4 x 12.2 cm) Al, (21.6 x 12.7 x 11.2 cm) SS

2.7 lb. (1.3 Kg) Al, 5.4 lb. (2.6 Kg) SS

Approvals:

Factory Mutual (FM)

Performance:

UL:

FM Standard 6310 Performance Approval for

Hazardous fixed-based Combustible Gas Detectors (ANSI/ISA – 12.13.01)

FM Standards 3100, 3600, 3615, 3810

UL Standard 508A

SIL-2 Certified by Lloyds Register (IEC 61508)

NFPA 72 Compliant if installed to NEC Code

Modbus:

Baud: 38400 (Adjustable 2400 to 38400 baud)

Parity: None

1 bits:

Control:

8

None

Memory map: Appendix H

Warranty:

Limited warranty:

Specifications subject to change without notice

2 years

Page: 29


8.2 APPENDIX B: MODEL NUMBERS, PARTS LIST & PARAMETERS

Sensor Module

Model Enclosure Relay/Connection Protection Remote

- A1 = AL ¾” NPT - 01 = No Relays - 01 = Standard - 0 = Standard - 0 = None

- A2 = AL M20 x 1.5 - 02 = Relays - 1 = Remote Sensor

- S1 = SS ¾” NPT - 05 = HART Option

- S2 = SS M20 x 1.5

Options

5311-00 Rainshield

5311-02 Rainshield with calibration port

Calibration Items

1250-01

1256-01

1260-00

1260-02

1260-42

5358-01

Gas Sensor Calibrator Kit

Regulator Type A Calibrator

Gas Cylinder – Air (Type A), 105 liters

Gas Cylinder – Methane 50% LEL, (type A), 105 liters

Gas Cylinder - Hydrogen, 50% LEL, (Type A), 105 liters

Calibration Adapter - Direct, Standard

5360-00 Remote Calibration Fitting

Spare Parts

SPL21813

5200-02-IT-AL

5200-02-IT-SS

Transmitter for 5100-02-IT

Sensor Assy for 5100-02-IT, AL

Sensor Assy for 5100-02-IT, SS

SPL21810

SPL21823

SPL21825

SPL21829

Enclosure, Transmitter, AL

Enclosure, Transmitter, SS

Termination Board no Relays

Termination Board with Relays

SPL21876 HART Termination Board

Factory Default Settings

Output = 3-wire 4-20mA source

Range = 0-100% LEL

Warning = 20% LEL

Alarm = 60% LEL

Calibration = 50% LEL Methane

Modbus = 2-wire Half Duplex at 38,400 BAUD

Page: 30


8.3 APPENDIX C: LIMITED WARRANTY

SIERRA MONITOR CORPORATION warrants its products to be free from defects in workmanship or material under normal use and service for two years after date of shipment. SMC will repair or replace without charge any equipment found to be defective during the warranty period. Final determination of the nature and responsibility for defective or damaged equipment will be made by SMC personnel.

All warranties hereunder are contingent upon proper use in the application for which the product was intended and do not cover products which have been modified or repaired without SMC approval or which have been subjected to accident, improper maintenance, installation or application, or on which original identification marks have been removed or altered. This Limited Warranty also will not apply to interconnecting cables or wires, consumables (ie. calibration gases, batteries, sensors), nor to any damage resulting from battery leakage.

In all cases SMC’s responsibility and liability under this warranty shall be limited to the cost of the equipment.

The purchaser must obtain shipping instructions for the prepaid return of any item under this warranty provision and compliance with such instruction shall be a condition of this warranty.

Except for the express warranty stated above, SMC disclaims all warranties with regard to the products sold hereunder including all implied warranties of merchantability and fitness and the express warranties stated herein are in lieu of all obligations or liabilities on the part of SMC for damages including, but not limited to, consequential damages arising out of/or in connection with the use or performance of the product.

Page: 31


8.4 APPENDIX D: REMOTE SENSOR OPTION

Figure 8 - 1: Remote Sensor Option

NOTE:

Drawing using Stainless Steel enclosure available from Sierra Monitor.

Page: 32

8.5 APPENDIX E: HART


Figure 8 - 2: HART

Page: 33


Figure 8 - 3: 4-20 mA Circuits Types 5100-02-IT – Connections - HART

Page: 34


HART PROTOCOL MENU

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

If the HART interface board has been provided with the gas sensor module, then HART will operate via the 4-

20 mA interface automatically. While no specific handheld device is necessary for HART operation, the gas sensor module does comply with the HART standard so any handheld or PC-based HCF certified tool will work.

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

Common Practice Commands

The following Common Practice commands are implemented.

Byte Number Description Command

Number

38

48

N/A

0

48

48

48

48

48

1

2

3

4

5

Reset Configuration Changed Flag

Returns Module Status

Module State ‐ In Calibration (0x10),

(0x30 = cal passed)

(0x50 = cal failed)

Module State ‐ Trouble (0x08)

Module State ‐ Warming (0x04)

Module State ‐ RUN (ALARM) (0x02)

Module State ‐ RUN (0x01)

Returns Alarm Relay Status

0x01 = Alarm Relay ON

0x02 = Warning Relay ON

0x03 = Both Relays ON

Returns Trouble Status (non ‐ zero value indicates Trouble)

Returns maximum gas value

Returns gas value used during calibration

Returns IT ‐ Series Model Number

0x28 = 5100 ‐ IT ‐ 28

Device Specific Commands

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

modules.

A response code of 0 indicates SUCCESS.

This applies to all commands.

As per HART specification, all command responses will have a response code and status byte, plus any command specific data bytes as indicated in the

following tables.

Page: 35


Device Specific Commands Summary

Command

Number

130

131

132

133

134

135

136

137

138

139

140

141

142

143

144

Key Press

Set Alarm Level

Set Warning Level

Set Alarm Relay Action

Set Warning Relay Action

Reset Alarms

Abort Calibration

Set Calibration Gas Level

Apply

Apply SPAN Gas

RESERVED

Force

Reset

Read

Set

ZERO

Gas Value

Force

Gas

Gas

MODBUS

Transducer

Value

RTU Register

Serial

Description

Number

145

146

Set Calibration Mode output current

Set Trouble Mode output current

147

148

Command 130: Key Press

RESERVED

RESERVED

This command mimics the front plate key inputs.

Request Data Bytes:

Byte

0

Format

Unsigned ‐ 8 1=Enter

2=Down

4=Up

8=Menu

Description

Command Specific Response Data Bytes:

Byte

0

Format Description

Unsigned ‐ 8 Returns same value as passed

Command 131: Set Alarm Level

Request Data Bytes:

Byte

0


Unsigned ‐ 8 Alarm level, range 0 to 60.

Default is 60.


Byte

0


Unsigned ‐ 8 Returns new Alarm Level.

Page: 36


Command 132: Set Warning Level

Request Data Bytes:

Byte

0


Unsigned ‐ 8 Warning level, range 0 to 60.

Default is 20.


Byte

0


Unsigned ‐ 8 Returns new Warning Level.

Command 133: Set Alarm Relay Action

Request Data Bytes:

Byte

0


Unsigned ‐ 8 0=Latching (default)

2=Non ‐ Latching


Byte

0


Unsigned ‐ 8 Returns new Alarm Relay Action value

Command 134: Set Warning Relay Action

Request Data Bytes:

Byte

0


Unsigned ‐ 8 0=Latching

2=Non ‐ Latching (default)


Byte

0


Unsigned ‐ 8 Returns new Warning Relay Action value

Command 135: Reset Alarms

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

Request Data Bytes: None

Command Specific Response Data Bytes: None

Command 136: Abort Calibration

This command aborts the calibration procedure.



Page: 37


Command 137: Set Calibration Gas Level

Request Data Bytes:

Byte

0


Unsigned ‐ 8 Calibration Gas Level, range 0 to 100


Byte

0


Unsigned ‐ 8 Returns new Calibration Gas Level

Command 138: Apply ZERO Gas

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



Command 139: Apply SPAN Gas

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



Command 141: Force Gas Value

Request Data Bytes:

Byte

0


Unsigned ‐ 8 Sets the Force Gas Value, range 0 to 100


Byte

0


Unsigned ‐ 8 Returns new Force Gas Value

Command 142: Reset Force Gas Value

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



Command 143: Read MODBUS RTU Register

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

Request Data Bytes:

Byte

0 ‐ 1


Unsigned ‐ 16 Address of Requested Modbus Register

40001 = lowest address

65535 = highest address

Page: 38



Byte

0 ‐ 1


Unsigned ‐ 16 Returns contents of selected Modbus Register

Command 144: Set Transducer Serial Number

This command allows user to add a device specific serial number, if required.

This is different from the serial number assigned by the Manufacturer.

Request Data Bytes:

Description Byte

0 ‐ 2

Format

Unsigned ‐

24


Serial Number

Byte

0 ‐ 2


Unsigned ‐ 16 Returns new Serial Number

Command 145: Set Calibration Mode output current

Request Data Bytes:

Byte

0 ‐ 1


Unsigned ‐ 16 Current output required during calibration, in micro ‐ amperes


Byte

0 ‐ 1


Unsigned ‐ 16 Returns new Calibration current value

Command 146: Set Trouble Mode output current

Request Data Bytes:

Byte Format Description

0 ‐ 1 Unsigned ‐ 16 Current output required to indicate Trouble, in micro ‐ amperes


Byte

0 ‐ 1


Unsigned ‐ 16 Returns new Trouble current value

Version 1.00

Created 13 July 2011

Page: 39


8.6 APPENDIX F: MODBUS MEMORY MAP

40023

40032

40033

40034

40035

40036

40037

40038

40039

40040

40041

40024

40025

40026

40027

40028

40029

40030

40031

40042

40043

40044

40045

Address

40001

40002

40011

40012

40013

40014

40015

40016

40017

40018

40003

40004

40005

40006

40007

40008

40009

40010

40019

40020

40021

40022

Register Name

Concentration

Temperature

Alarm Relay

Warning Relay

Warning Setpoint

Alarm Setpoint

CCC detail

Software Revision U

Software Revision L

Modbus Map Revision

Trouble Bits

Trouble

Alarm Immediate

Warning Immediate

Serial Number U

Serial Number L

Run time U

Run time L

Gas (MAX) value

Model

Range

Units

Module Status

Gas Scale

Cal Concentration level

Calibration due, in days

Calibration Count

Display Gas Output

Gas (MIN) value

Alarm Time U

Alarm Time L

Warning Time U

Warning Time L

Trouble Time U

Trouble Time L

Max Gas Time U

Max Gas Time L

Min Gas Time U

Min Gas Time L

Rotary Switch

Restart Count

Alarm Relay Action Setup

Warning Relay Action Setup

4-20mA CalibOut Value

4-20mA TroubleOut Value

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R/W

R

R

RW

RW

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R/W

R/W

R/W

R/W

R

R

RW

RW

Read/Write

R

R

Description

Gas concentration multiplied by Gas Scale (e.g. 209 = 20.9%)

Temperature in degrees Celcius scaled by a factor of 10

Boolean indicating the Alarm relay status (0 = No Alarm, 1 - (High) Alarm).

Clearing bit will reset alarm.

Boolean indicating the Warning relay status (0 = No Alarm, 1 - Warning Alarm). Clearing bit will reset alarm.

Warning Alarm set point, used for activating Low Alarm multiplied by Gas Scale

Alarm set point, used for activating High Alarm multiplied by Gas Scale e.g. 0001, 0007, etc e.g. 201 denotes version 2.01

e.g. version aA is denoted by 0x6141 e.g. version 2 is denoted as v2 = 0x7602

0 = no trouble

1 for any trouble, 0 = no trouble

Like 40003, but never latched

Like 40004, but never latched

Serial Number - 24 bits

In seconds

In seconds

Gas concentration multiplied by Gas Scale

Always read as 51028

R

1 = %LEL, 2 = %VOL

A bit is defined for each of the following states:

(no bit set also means some sort of trouble)

Module State - In Calibration (0x50) = calibration failed

Module State - In Calibration (0x30) = calibration passed

Module State - In Calibration (0x10)

Module State - Trouble (0x08)

Module State - Warming (0x04)

Module State - RUN (ALARM) (0x02)

Module State - RUN (0x01)

Value like 1, 10 or 100

Gas concentration value used during calibration, multiplied by Gas Scale

Gets reset to 365 / 180 if cal successful, Less then 0 = calibration due

Counter increments if cal successful (0 = not calibrated)

Gas value seen on display (i.e. useful during calibration)

Minimum gas value multiplied by Gas Scale

In seconds

In seconds

In seconds

In seconds

In seconds

LS Byte = rotary switch; MS Byte = any soft / polling address assigned

Restart count

Alarm Relay Action Setup - Latch/Sentry/Non-latch

Warning Relay Action Setup - Latch/Sentry/Non-latch

U = denotes upper word

L = denotes lower word

Table 8 - 1: Modbus Memory Map

Page: 40


8.7 APPENDIX G: COMBUSTIBLE GAS SCALING FACTORS

For combustible gas monitoring, a calibration standard of Methane may be used in conjunction with scaling factors to cause Sentry concentration display and alarm function in %LEL scale of another gas as follows:

GAS

METHANE

FACTOR

Acetaldehyde 60

Acetic Acid 54

Acetic Anhydride 46

Acetone 52

Acetylene 57

Alkyl Alcohol 51

Ammonia 126 n-Amyl Alcohol 33

Aniline 39

Benzene 41

Biphenyl 25

1,3-Butadiene 56 n-Butane 58 iso-Butane 52

Butene-1 45 cis-Butene-2 48 trans-Butene-2 51 n-Butyl Alcohol 34 iso-Butyl Alcohol 53 tert-Butyl-Alcohol 74 n-Butyl Benzene iso-Butyl Benzene n-Butyric Acid

31

32

38

Carbon Disulfide

Carbon Monoxide

18

75

Carbon Oxysulphide 93

Chlorobenzene 34

Cyanogen 89

Cyclohexane 41

Cyclopropane 62 n-Decane 33

Diethylamine 49

Dimethylamine 58

2,3-Dimethylpentane 40

2,3-Dimethylpropane 40

Dimethylsulphide 43

1,4-Dioxane 45

Epichlorohydrin 45

Ethane 68

Ethyl Acetate

Ethyl Alcohol

51

73

Ethylamine 53

Ethyl Benzene 36

Ethyl Bromide

Ethyl Chloride

91

57

Ethylcyclopentane 40

Ethylene 71

Ethylenedichloride 66

Ethyleneoxide 52

GAS

Diethyl Ether

METHANE

FACTOR

46

Dimethoxyethane 42

Dimethyl Ether 63

Dimethylformamide 46

Ethyl Formate 44

Ethylmercaptan 56 n-Heptane 39 n-Hexane 37

Hydrazine 45

Hydrogencyanide 48

Hydrogen 77

Hydrogen Sulfide 41

Methane 100

Methyl Actetate

Methyl Alcohol

50

86

Methylamine 77

Methyl Bromide

Methyl Chloride

90

102

Methylcyclohexane 44

Methylenedichloride 93

Methylethylether 44

Methylethylketone 41

Methyl Formate 67

Methylmercaptan 61

Methylpropionate 51

Methyl n-propylketone 40

Napthalene 34

Nitromethane 34 n-Nonane 31 n-Octane 37 n-Pentane 46 i-Pentane 46

Propane 55 n-Propyl Alcohol 47 n-Propylamine 48 n-Propylchloride 50

Propylene 52

Propyleneoxide 46 iso-Propylether 44

Propyne 42

Toluene 40

Triethylamine 40

Trimethylamine 48

Vinylethylether 42 o-Xylene 36 m-Xylene 39 p-Xylene 39

JP-4 (Jet Fuel) 41

NOTES:

1. Scaling factors are not FMRC approved.

2. Base data source: EEV sensor specification catalog. (EEV claims some data is the result of specific tests, other data is empirically derived).

Page: 41


8.8 APPENDIX H: MENU KEY FOR 5100-02-IT GAS SENSOR MODULE

•

M : MODE

• Key :

ENTER

• Key UP (+)

• Key DOWN (-)

MAIN MENU

Use the M key to access each of the 4 main sections of the menu.

M M M M M

| | | | |

|- ALMRSET : |- : |- : |- EXIT?

ALARM RESET MENU

ALMRSET:

|

E – RESET (Resets current alarm)

CALIB MENU

CALIB :

|

E

– CAL-0% (Calibrate Zero)

|

E – Ack (Acknowledges Zero)

|

*50%-SPAN (Last span gas used – initially set at 50%)

| |

| ▲ 25%-SPAN

| ▲ 50%-SPAN (Select Span gas value from below)

| ▲ 75%-SPAN

| ▲ Adj-SPAN (To select an alternate span gas value)

| |

|

E

50%-SPAN

| |

| ▲ 51%-SPAN (Change span value to desired, once completed

E

starts calibration)

|

E C XX%LEL (Reading the value of the calibration gas being applied)

|

|- CAL-OK (if successful) or CAL-FAIL (if unsuccessful)

Page: 42


SETUP MENU

Once in the SETUP menu u se the

▲ or ▼ keys to access each of the 5 main sections of the SETUP menu.

▼ ▼ ▼ ▼ ▼

| | | | |

|-

Alarms

: |- : |-

4-20mA

: |-

SETUP:

|

E

– Alarms (Alarms Set-Point Adjustment)

| |

| E – H.Alarm (High Alarm Setup)

| |

|

E

--------------------------- OR--------------------------------------▼

| | |

| |- HASP: 60 (Current Hi Alarm set-point

| |

|- L. ALARM (Low Alarm Setup)

|

|

|

▲

E

or ▼ (To adjust to desired set-point)

| |

– Ack (Accepts set-point)

|

|

|

E

LASP:20 (Current Lo Alarm Set-point)

|

▲ or ▼ (To adjust to desired set-point)

|

E


|

|----

▼ Relays (Relay Set Point Adjustment)

| |

|

E

----------------------------- OR----------------------------------------▼ :

| |

| | - H. Relay (High Relay Setup)

| |

|

E

– Latch

| |

|

|- L. Relay (Low Relay Setup)

|

E

– Latch

|

|

▲ or ▼ (To adjust to desired condition)

|

(Selections are Latch, NonLatc, or Senty)

▲ or ▼ (To adjust to desired condition)

|

(* indicates current status, Sentry = Sentry controller controls alarm relay action)

|

|----

▼ Gas (Gas Factor Adjustment)

| |

| E – Gas Type (Type of Gas Setup)

| |

| E --------------------------- OR--------------------------------------▼

| | |

| |- *Methane (Current Gas Type)

| |

|- Range (Gas Range Adjustment)

|

| ▲ or ▼ (To adjust to select different type if available)

E

*100%LEL (Current Full Range)

| | |

| E – Ack (Accepts Gas Type Change)

|

|

|

▲ or ▼ (To select between %LEL or %VOL, or if

|

E


Page: 43


|

|----

▼ 4-20mA (Verifies 4mA or 20mA output and selects condition of output during calibration)

| |

| ▼ -------or-------------- E Calib

| |

| |

| |

| |

| |

| |

|

|- Out: 4mA

|

▼ --or— E (To calibrate analog output 4mA, | ▲ or ▼ to adjust level,

| then t o accept)

| |

| |

| |

| |

| |

| |

|

|

|

|

|

|

| |

▼ --or--

E

(To calibrate analog output 20mA, | ▲ or ▼ to adjust level,

| then to accept)

|- 4mA

▼ --or— E (To calibrate analog input 4mA, | ▲ or ▼ to adjust level,

|

|- 20mA

then to accept)

| |

| |

▼ --or--

E

(To calibrate analog input 20mA, | ▲ or ▼ to adjust level,

then to accept)

| |

| ▼ -------or-------------- E CalibOut (Adjust 4-20mA output during Calibration)

| |

| |

| |

| |

|

|- Track: ( ▲ or ▼ (To adjust action/mA value during calibration

Track = mA value tracks Gas value

Hold = holds mA value existing prior to calibration

C1.50mA = 1.50 mA during calibration

C4.00 mA = 4.00 mA during calibration

User = Select Value

| |

| |

|----

▼ RS-485 (Select RS-485 address and baud rate)

| |

| | - Address

| |

| ▼ | -------or-------------- E Addr:016 (Use ( ▲ or ▼ and E to select module address – 016 to 254)

| |

| |- Baud ---------------

E

*38400 (Use | ▲ or ▼ and

E

to select baud rate, * = current selection)

MAINT MENU

MAINT:

:

|

E – V2.00bB (Software version installed on module)

|

E – CCC001 (Configuration number if only configured for Methane)

Page: 44

8.9 APPENDIX I: FM APPROVAL


Page: 45


Page: 46


8.10 APPENDIX J: SIL-2 APPROVAL CERTIFICATE

Page: 47


THIS PAGE INTENTIONALLY LEFT BLANK

Page: 48


4-20 MA ........................................................ 3, 20, 22

ALARMS ........................................................... 20, 44

ANALOG ............................................................. 4, 10

CALIBRATION ............................................ 10, 24, 32

CALIBRATION FREQUENCY ............................ 3, 24

CALIBRATION GAS DELIVERY ............................ 24

CALIBRATION PREPARATION ............................. 24

CALIBRATION PROCEDURE ................................ 24

COMBUSTIBLE GAS SENSOR ............................... 3

COMBUSTIBLE GASES DETECTED ...................... 8

DATA ENTRY KEY PAD ........................................ 18

ENCLOSURE ........................................... 3, 4, 11, 27

ENHANCED CONNECTION .................................... 4

FM APPROVED .................................................. 3, 47

GAS FACTOR ........................................................ 20

GAS SCALING FACTORS ..................................... 43

GAS TYPE .............................................................. 22

HART ...................................................... 4, 35, 37, 41

INSTALLATION ...................................... 9, 10, 12, 29

MAINTENANCE ...................................................... 23

MENU KEY ............................................................. 44

MODBUS .................................................. 3, 4, 20, 42

MODEL NUMBER .................................................. 32

INDEX

MODULE .............................................................. 7, 9

MODULE ADDRESS SWITCH .............................. 13

OPTIONS ............................................................... 32

POWER REQUIREMENTS ..................................... 5

RELAYS ............................................................. 4, 20

REMOTE ALARM ................................................ 3, 4

REMOTE SENSOR ....................................... 3, 4, 34

REPLACEMENT .............................................. 27, 29

RS-485 ....................................................... 11, 20, 22

SENSOR ...................................................... 4, 12, 29

SENSOR EXPOSURE TO GAS ............................ 24

SENTRY ............................................................ 3, 11

SERVICE ............................................................... 27

SET-UP ............................................................ 20, 45

SIL-2 .................................................................. 3, 49

SPARE PARTS ...................................................... 32

SPECIFICATIONS ................................................. 31

START-UP ............................................................... 9

TRANSMITTER ................................... 4, 7, 9, 12, 29

TROUBLESHOOT ................................................. 30

WARRANTY .......................................................... 33

WIRING ...................................................... 5, 7, 9, 10

Page: 49

Sierra Monitor Corporation IT Series Instruction Manual

MODEL 5100-02-IT

IT Series

COMBUSTIBLE GAS SENSOR MODULE

Version 3.00A

1. PRODUCT DESCRIPTION

2. CAUTIONS & WARNINGS

3. QUICK START

4. INSTALLATION

5. OPERATION

6. CALIBRATION

7. SERVICE

8. APPENDICES

Related manuals

Table of contents

Sierra Monitor Corporation IT Series Instruction Manual

MODEL 5100-02-IT

IT Series

COMBUSTIBLE GAS SENSOR MODULE

Version 3.00A

1. PRODUCT DESCRIPTION

2. CAUTIONS & WARNINGS

3. QUICK START

4. INSTALLATION

5. OPERATION

6. CALIBRATION

7. SERVICE

8. APPENDICES

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Table of contents