Sierra Monitor Corporation 5100-04-IT Instruction manual

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Sierra Monitor Corporation 5100-04-IT Instruction manual | Manualzz

MODEL 4501-XX

2-Wire Series

TOXIC GAS SENSOR MODULE

APPLICABILITY & EFFECTIVITY

Effective for all Model 4501-XX Modules manufactured after September 1, 2006.

4501-04 FM Pending

4501-05 FM Approved

4501-06 FM Pending

Instruction Manual Part Number T13022

Rev. A

Model 4501-XX Toxic Gas Sensor Module

FM PERFORMANCE APPROVAL

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

Model 4501-05 Hydrogen Sulfide Gas Sensor Module

Sensor Module

Model 4501-05

Calibration Equipment

Model 1250-01

Model 1260-05

Model 1260-45

Model 5358-01

Notes:

Sensor Module - Hydrogen Sulfide

Gas Sensor Calibration Kit, Type A

Hydrogen Sulfide in N2, 25 ppm Gas Cylinder

Hydrogen Sulfide in N2, 10 ppm Gas Cylinder

Calibration Adapter

1) Apparatus must be installed in accordance with National Electrical Code.

* FM Approvals, a subsidiary of FM Global

 Project# 3028099

Model 4501-XX Toxic Gas Sensor Module

TABLE OF CONTENTS

1.1 GENERAL........................................................................................................................................................1

1.2 MOUNTING

1.3 THEORY

CONFIGURATION......................................................................................................................1

OF OPERATION..............................................................................................................................1

1.4 MECHANICAL .................................................................................................................................................2

1.4.1 ENCLOSURE ...........................................................................................................................................2

1.4.2 TRANSMITTER ELECTRONICS .............................................................................................................2

1.4.3 SENSOR ASSEMBLY ..............................................................................................................................2

1.5 INTERCONNECT WIRING..............................................................................................................................2

2.1 INTRODUCTION .............................................................................................................................................4

2.2 GAS SENSOR MODULES - GENERAL.........................................................................................................4

2.3 WIRING............................................................................................................................................................4

2.4 CALIBRATION FREQUENCY .........................................................................................................................4

3.1 OVERVIEW......................................................................................................................................................5

3.2 WIRING............................................................................................................................................................5

INSTALLATION...............................................................................................................................5

3.4 TRANSMITTER

3.5 START-UP

INSTALLATION ....................................................................................................................5

& OPERATION .............................................................................................................................5

4. INSTALLATION ...............................................................................................................................................6

MODULE LOCATIONS ...................................................................................................................6

4.2 WIRING............................................................................................................................................................6

INSTALLATION........................................................................................................................6

4.4 TRANSMITTER

5. OPERATION....................................................................................................................................................8

5.1 INTRODUCTION .............................................................................................................................................8

ENTRY KEYPAD ..................................................................................................................................8

5.3 MAIN MENU ....................................................................................................................................................9

5.4 MAINTENANCE SUB-MENU ........................................................................................................................10

5.5 DIAGNOSTICS SUB-MENU..........................................................................................................................11

5.5.1 Notes ......................................................................................................................................................12

6. CALIBRATION...............................................................................................................................................13

6.1 CALIBRATION FREQUENCY .......................................................................................................................13

6.2 CALIBRATION PREPARATION....................................................................................................................13

6.2.1 CALIBRATION

CALIBRATION PROCEDURE..................................................................................................................................13

7. SERVICE .......................................................................................................................................................15

MODULE

REPLACEMENT ....................................................................................................................15

7.3 TRANSMITTER

7.4 SENSOR

INSTALLATION INSPECTION .................................................................................................................................16

Contents

Model 4501-XX Toxic Gas Sensor Module

MODULE INSTALLATION .....................................................................................................16

7.4.4 MOISTURE AND RAINSHIELDS..............................................................................................17

7.4.5 STANDARD VOLTAGES .......................................................................................................................17

INSPECTION AND TROUBLESHOOTING GUIDE .................................................................................................17

7.4.6 IF MODULE DOES NOT DISPLAY THE CORRECT PPM GAS ...........................................................17

7.4.7 If the module does not display the correct PPM.....................................................................................17

7.4.8 If the display shows ‘NO SENSOR’ – Sensor Failing.............................................................................17

7.4.9 If the display shows “C” – calibration mode ...........................................................................................17

7.4.10 If the display shows “ T ” – DOWNSCALE INDICATOR.......................................................................17

7.4.11 If the display shows “HIGH” – UPSCALE INDICATOR..........................................................................17

8. APPENDICES................................................................................................................................................18

APPENDIX A: SPECIFICATIONS ............................................................................................................................18

APPENDIX B: MODEL NUMBERS & PARTS LIST .................................................................................................20

APPENDIX C: LIMITED WARRANTY......................................................................................................................21

Contents

Model 4501-XX Toxic Gas Sensor Module

1. PRODUCT DESCRIPTION

1.1 GENERAL

The Model 4501-XX Toxic Gas Sensor Module is a 2-wire transmitter with 4-20 mA output and it offers a broad array of features including:

2-wire loop powered

180 day calibration interval

Selectable ranges

Non-intrusive one-person calibration

Integral LCD 2-line, 20-character display

Stainless steel enclosure and sensor housing

4-20 mA output

Long sensor life

Rotatable faceplate enables multi-directional installation attitudes.

The 4501-XX is designed and approved for installation and operation in hazardous locations.

Members of the 4501-XX Two-Wire Toxic Gas family include:

▪ 4501-04 Carbon Monoxide Gas Sensor Module

▪ 4501-05 Hydrogen Sulfide Gas Sensor Module

▪ 4501-06 Chlorine Gas Sensor Module

1.2 MOUNTING CONFIGURATION

Various module mounting configurations can be implemented without special fixtures. Where applicable, these options are factory configured prior to shipment. Mounting configuration can be selected by the installer or field technician and are fully described in this manual.

1.3 THEORY OF OPERATION

Electrochemical sensors are fuel cell-like devices consisting of an anode, cathode, and electrolyte. The components of the cell are selected so a subject gas, allowed to diffuse into the cell, will cause a chemical reaction and generate a current. The cells are diffusion limited so the rate the gas enters the cell is solely dependent on the gas concentration. The current generated is proportional to the rate of consumption of the subject gas in the cell.

Sierra Monitor electrochemical sensors provide improved reliability by allowing the gas to diffuse into the sensor through a capillary port, rather than diffusing through membranes. The result is an extremely stable sensor with very low temperature and pressure coefficients and the capability to monitor gas as ppm.

Page: 1

Model 4501-XX Toxic Gas Sensor Module

1.4 MECHANICAL

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

1.4.1 ENCLOSURE

Explosion proof, rain-tight stainless steel electrical housing with three ¾” FNPT conduit hubs. The enclosure cover has a viewing window. The 3 conduit hubs combined with the rotatable faceplate enable the user to mount the module in a variety of configurations. See Figure 1-2 for details.

1.4.2 TRANSMITTER ELECTRONICS

Electronic Assembly consisting of one printed circuit board assembly mounted under a cover plate. Wiring connections for power and signal interface are located on the back side of the display.

1.4.3 SENSOR ASSEMBLY

The sensor assembly includes a stainless steel, explosion proof, housing containing the gas sensor and a wiring harness for connection to the transmitter. The sensor assembly threads into one hub of the enclosure. The exposed end of the sensor assembly is threaded to allow connection of a rain-shield or calibration gas delivery fitting.

1.5 INTERCONNECT WIRING

Not supplied with the sensor module, but necessary to the installation and operation is the two conductor wiring which connects the module to its power source and controller. Before this wiring is installed it is important to read and understand the control system installation instructions to determine wiring requirements and alternatives.

1.6 POWER REQUIREMENTS

The 4501-XX module operates on DC power between 14 VDC and 30 VDC. The DC power must be supplied by the loop controller.

Page: 2

Model 4501-XX Toxic Gas Sensor Module

Figure 1-1

Model 4501-05 Hydrogen Sulfide Gas Sensor Module– Dimensions

Figure 1-2

Model 4501-05 Hydrogen Sulfide Gas Sensor Module– Orientation Options

Page: 3

Model 4501-XX Toxic Gas Sensor Module

2. CAUTIONS & WARNINGS

2.1 INTRODUCTION

Although the 4501-XX Gas Sensor Module is 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 GAS SENSOR MODULES - GENERAL

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

Sensors may be adversely affected by prolonged exposure to certain materials. Loss of sensitivity, or corrosion, may be gradual if such materials are present in low concentrations. These materials include:

Halides (compounds containing chlorine, fluorine, bromine, iodine), acid vapors, caustic liquids or mists.

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

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

• Analog devices require shielded cable.

• In conduit installations and cable applications the shield should be connected to instrument ground.

• All splices must be via either a termination hardware system or soldered. Improperly spliced cable can result in corrosion, resistance changes and system errors.

NOTE

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

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

2.4 CALIBRATION FREQUENCY

The 4501-XX calibration frequency is six months (180 days). However, prudent gas detector maintenance practices normally suggest a simple recalibration following incidences of exposure to high levels of H would lead to alarm activation within any system utilizing the output of the 4501-05.

2

S that

Page: 4

Model 4501-XX Toxic Gas Sensor Module

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

Provide two conductor shielded wiring from the power supply/control device to the sensor module location.

Use wire that is 16 AWG or larger.

3.3 MODULE INSTALLATION

The 4501-XX can be mounted in a variety of configurations supported by the conduit. See figure 1-2 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.

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 14-30 VDC. Each time the sensor module is powered up it will perform a warm-up for approximately 2.5 minutes (148 seconds). During this time the display will read “Warm. 148” and count down. The loop output will be held at 4 mA.

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 and depends on the selected range. For instance, when the range of 0 to 50 PPM has been selected, a current of 4 mA corresponds to 0 PPM and a current of 20 mA corresponds to 50 PPM.

3.6 ZERO STABILIZATION

All electrochemical sensors require at least 30 minutes on power prior to calibration. This allows the electrode potentials to equilibrate, resulting in a stable zero signal level.

Page: 5

Model 4501-XX Toxic Gas Sensor Module

4. INSTALLATION

4.1 SENSOR MODULE LOCATIONS

The gas sensor module utilizes a diffusion type sensor which should be located close to either the expected source or destination of the gas hazard. If the gas is heavier than air, the sensor module should be installed within 24 inches of the ground or floor. If it is lighter than air, move it above 6’.

After optimum locations are determined based on the above recommendations, consideration should be given to placing the sensor modules in locations which are accessible for calibration service. Slight adjustments to the location of the sensor module may have little impact on effectiveness but major effect on accessibility.

• Modules should be placed in areas accessible for calibration.

• The cover should face out from the wall for easy access.

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

(condensation) from accumulating in the electronics enclosure.

4.2 WIRING

• Wire should be 16 AWG minimum at a maximum distance is 5,000 feet. Install conduit as required by local code or construction specifications.

• See figure 4-1 for typical 2 terminal and 4 terminal connections.

Figure 4-1

4-20 mA Connection

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.

Prior to installation and wiring:

Page: 6

Model 4501-XX Toxic Gas Sensor Module

1. Remove the transmitter from the module housing by:

• Unscrew the two captive panel screws on the faceplate.

• Lift the transmitter out of the enclosure.

• Unplug the sensor cable from transmitter connector J1.

• Remove the sensor assembly from the enclosure hub.

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

NOTE

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

4.4 TRANSMITTER AND SENSOR INSTALLATION

When all pre-wiring 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 loop wires (Loop + and Loop -) to transmitter connector P1, pins 1 and 2 (Figure 4-2)

3. Connect the sensor assembly cable to transmitter connector J1. (Figure 4.2)

4. Carefully return the transmitter to the enclosure installing it over the two standoffs. Finger tighten the retaining screws into the standoffs.

Loop Power

Sensor

Connector

Figure 4-2

Connector Locations

Page: 7

Model 4501-XX Toxic Gas Sensor Module

5. OPERATION

5.1 INTRODUCTION

The 4501-XX Toxic Gas Sensor Module 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 calibrate the sensor module, and for maintenance and diagnostic procedures.

The following adjustments can be made to the sensor module:

 Range adjustments (see section 5.4)

 4mA and 20mA calibration adjustments (see section 5.4)

 Span adjustment (see section 6.3.1)

5.2 DATA ENTRY KEYPAD

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 under the faceplate above and below the LCD and are labeled M , E , S and T as shown in

Figure 5-1.

• Key : MODE

• Key ENTER

• Key : UP (+)

• Key : DOWN (-)

Figure 5-1

Face Plate with Operator Keypad

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Model 4501-XX Toxic Gas Sensor Module

5.3 MAIN MENU

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

Mode

Down

Down

Down

4501-XX

XX.XXaA

Warm 148

XX.XXaA

H2S

XXX.PPM

H2S

CALIB:

H2S

MAINT:

H2S

DIAG:

H2S

Exit-?

Switch [M]

Switch [E]

Description

Switch [▲] Previous Menu

Switch [▼] Next Menu

First screen at power-up, Model and Version

Second screen at start-up, count down of Warm-up

Default Display (example 4501-05)

Mode Function: Calibration (example 4501-05)

Mode Function: Maintenance (example 4501-05)

Mode Function: Diagnostics (example 4501-05)

Exit Mode (example 4501-05)

Table 5-1

Master Menu

Table 5-2 defines the key operational displays on the operator interface.

Display

H2S

WARM XXX

SENSOR

FAIL

NO

SENSOR

Sensor failure

Description

Sensor not found or plugged in

Reference

Table 6-1

Table 5-3

Table 5-4

Warm-up at start-up (example 4501-05)

C.## PPM

XXX

DONE

Calibration Mode

Finished with step

Figure 5-2

Key Operational Display

Page: 9

Model 4501-XX Toxic Gas Sensor Module

M E

S T

M E

S T

M E

S T

5.4 MAINTENANCE SUB-MENU

Key Function Display

H2S

XX PPM

M E

S T

M E

S T

Mode

Down

H2S

CALIB:

H2S

MAINT:

M E

Enter Cal: 4mA

S T

M E

S T

Enter

Down

Enter

Enter

4mA

DONE

H2S

MAINT:

MAINT

CAL:20mA

Description

Default Display (example 4501-05)

Reference

Enter Calibration 4 mA Menu

Banner: Use [S] or [T] to change 4mA output, [E] when done

A multi-meter should be inserted into the current loop to measure the loop current between the power and the sensor module No gas is required for this step

Acknowledges 4mA calibration or Sub-Routine A

Enter Calibration 20 mA Menu

Banner: Use [S] or [T] to change 20mA output, [E] when done

A multi-meter should be inserted into the current loop to measure the loop current between the power and the sensor module No gas is required for this step

Acknowledges 20mA calibration or Sub-Routine A

M E

S T

M E

S T

M E

S T

M E

S T

Down

Down

Enter

Enter

20mA

DONE

H2S

MAINT:

MAINT:

4mA

MAINT:

20mA

H2S

Range

M- Range

100 PPM

Range

DONE

Enter Range Menu

Enter Calibration Range Menu

Banner: Use [S] or [T] to change range, [E] when done

Acknowledge range selection

CAL: XmA

ERROR!

Sub-Routine A

The expected range of the 4mA and 20mA is limited to factory defined values. If the actual signal is outside of this predefined range, an error is displayed indicating a hardware or installation problem. Contact technical support.

Table 5-3

Maintenance Sub Menu

Page: 10

Model 4501-XX Toxic Gas Sensor Module

M E

S T

M E

S T

M E

S T

M E

S T

5.5 DIAGNOSTICS SUB-MENU

S T

M E

S T

M E

S T

M E

S T

M E

S T

M E

S T

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

M E

S T

M E

S T

M E

S T

M E

Key

M E

S T

M E

S T

M E

Function

Mode

Enter

Down

Down

Enter

Enter

Mode

Down

Enter

Mode

Down

Enter

Mode

Down

Enter

Mode

Down

Enter

Mode

Down

Enter

DIAG:

RawSig

DIAG:

Ref

D-Ref

XXXXmV

DIAG:

Ref

DIAG:

Temp

TEMP

XXXC

DIAG:

Temp

DIAG:

4-20 mA

D-4-20 mA

Normal

DIAG:

4-20mA

DIAG:

Version

Display

H2S

XXX PPM

H2S

CALIB

H2S

MAINT:

H2S

DIAG:

DIAG:

RawSig

D-RawSig

XXXXmV

D-Ver

VX.XX

DIAG:

Version

DIAG:

FactInit

Accept?

N NO Y

Default Display(example 4501-05)

Go to previous maintenance menu item

Enter diagnostics sub-menu

Voltage reading of the output of the sensor element

Return to diagnostic menu

Voltage reading of the output of the reference

Temperature of sensor use [S] or [T] to switch between Celsius and Fahrenheit

Enter 4-20 mA output sub-menu

Version number of firmware

Description

Banner: Use [S] or [T] to change, [E] to accept

Sub-Routine A

Down

Down

Down

Down

D-4-20mA

Normal

D-4-20mA

3.6 mA

D-4-20mA

4.0 mA

D-4-20mA

10-.0 mA

D-4-20mA

20.0 mA

Press [E] to send 3.6 mA signal

Press [E] to send 4.0 mA signal

Press [E] to send 10.0 mA signal

Press [E] to send 20.0 mA signal

Sub-Routine B

M E

S T

M E

S T

Down

Enter

Accept?

N YES Y

Accept?

N YES Y

FactInit

Done

If accepting [T] to change to yes and [E] to accept

Factory initialization completed

Sub-Routine C

M E

S T

Enter

Accept?

N NO Y

FactInit

Aborted

If not accepting, [E] to accept NO

Factory initialization not done

Table 5-4

Diagnostics Sub Menu

Page: 11

Reference

Sub-Routine A

Sub-Routine B

Sub-Routine C

Sub-Routine C

Model 4501-XX Toxic Gas Sensor Module

5.5.1 NOTES

When selecting the output current requested, an acknowledge message will appear on the screen. Select

[E] to accept this message.

Whenever a message appears on the screen, select [E] to accept the message. No other action can be taken with messages.

Except for the FactInit Menu, the sub-menus in the diagnostics section only provide information and do not cause action.

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Model 4501-XX Toxic Gas Sensor Module

6. CALIBRATION

6.1 CALIBRATION FREQUENCY

The sensor module must be calibrated every 180 days. Periodic functional tests are advisable for critical applications and hostile environments.

The sensor module microprocessor software includes high-level self checking algorithms which provide continuous sensor diagnostic and self adjustment.

6.2 CALIBRATION PREPARATION

Calibration of the 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

[M] for 10 seconds. A scrolling display will indicate “Operate Mode” and the sensor module will exit the calibration activity and return to normal operating mode. The calibration procedure can then be restarted.

Calibration must be performed only when the area is known to be clear of Hydrogen Sulfide gas. When in doubt, use a portable instrument to confirm that there is no background Hydrogen Sulfide gas.

For compliance with Factory Mutual (FM) Approvals, the Sierra Monitor Model 1250-01, 1260 -05 and 1260-45 are the FM Approved calibration gas delivery devices. Use the Model 5358-01 Calibration Adapter delivery fitting.

6.2.1 CALIBRATION GAS DELIVERY METHODS

Calibration gas can be delivered to the sensors via the Model 5358-01:

Calibration Adapter (Figure 6-1) - used with portable calibrators.

CALIBRATION PROCEDURE

The Calibration Menu is described on Table 6-1:

The procedure 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.

6.2.2 SENSOR EXPOSURE TO GAS

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

Model Gas Flow Period

4501-04 Carbon Monoxide 300 cc/min Until Stable (minimum 3 minutes)

4501-05 Hydrogen Sulfide 300 cc/min Until Stable (minimum 3 minutes)

4501-06 Chlorine 300 cc/min Until Stable (minimum 3 minutes)

Page: 13

Sample Gas In

Figure 6-1

Model 5358-01

Calibration Adapter

Model 4501-XX Toxic Gas Sensor Module

6.3 DIAGNOSTICS SUB-MENU

Key

M E

S T

M E

S T

Function Display

Mode

H2S

CALIB:

Enter CAL 0 PPM

Description

Default Display (example 4501-05)

Banner: Apply zero gas, [E] when done

M E

S T

M E

S T

Enter

Enter

Cal0PPM

Wait.XXX

ZERO

DONE

XXPPM

H2S

WAIT-148

H2S

CAL-OK

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

There is a minimum time to calibrate at 0PPM. If [E] is hit prior to this time has elapsed, a countdown screen will appear.

Zero gas setting completed (Message will appear on the screen and after 3 seconds will go to the next menu - 25PPM Span)

Banner: [S] or [T] to change span value, [E] when done

Operation: 148 second time out before sensor is returned to service.

Banner: Remove gas from sensor

Sub-Routine A - Abort Calibration

M E

S T

Mode

CALIB

ABORTED

H2S

XXX PPM

Operation: Hold magnet over [M] for 10 seconds to abort calibration

Default Display

Sub-Routine B - Select Span

Reference or Sub-Routine A

Sub-Routine B

Sub-Routine C

25PPM SPAN Banner: [S] or [T] to change span value, [E] when done

M E

S T

M E

S T

Down

Enter

C##PPM

H2S

REMOVE GAS

H2S

CAL-OK

Banner: Apply xx-PPM gas, [E] when stable

Operation: Remove gas from sensor

Calibration successful

M E

S T

Enter

READ

MANUAL

H2S

CAL-FAIL

Sub-Routine C - Calibration Fail

Operation: Remove gas from sensor read manual, particularly section 6.3 and

7.6, to check calibration procedures.

Calibration Failed

Table 6-1

Calibration Sub-Menu

Should be stable after 3 minutes of gas exposure

If calibration failed, then

Sub-Routine C

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Model 4501-XX Toxic Gas Sensor Module

7. SERVICE

7.1 SENSOR MODULE CONFIGURATION

The gas sensor module is comprised of the following sub-assemblies (Figure 7-1):

4501-XX Gas Sensor Module

SPL27077 Enclosure

XXXXXXX

XXXXXXX

Sensor Assembly (see Appendix B)

Sensor (see Appendix B)

There are no field serviceable components below the sub assembly level.

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.

Figure 7-1

Module Components

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Model 4501-XX Toxic Gas Sensor Module

TRANSMITTER REPLACEMENT

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

To replace the transmitter assembly: a. Remove the cover of the main enclosure b. Unscrew the two thumb screws in the top of the cover plate, lift the assembly and rotate 90 o wiring service loop

to relieve the c. Unplug the sensor connector from the transmitter d. Remove the two wires from J1 terminals (see figure 4-2) e. Reverse the preceding steps to install the new transmitter f. Restore power and allow a minimum of 30 minutes for stabilization before re-calibration

SENSOR REPLACEMENT

The gas sensor which is located inside the sensor assembly housing can be replaced without replacement of the housing. The gas sensor needs replacement when:

 It is no longer possible to obtain correct Zero and Span values

 The “LOW SENS” message appears after calibration

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

To replace the sensor: a. Confirm that system power has been removed b. Remove the gas sensor module enclosure cover, c. Unscrew the two thumb screws in the top of the faceplate, lift the transmitter assembly and rotate 90 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. Unscrew sensor housing cover from the sensor g. Carefully pull the old sensor straight up from the socket h. Press the new sensor into the socket. i. Reverse the preceding steps to install the sensor assembly. j. Allow the new sensor to stabilize for a minimum of 30 minutes and then calibrate using the procedure in

Section 6.

INSTALLATION INSPECTION

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

7.1.1 CONTROLLER INSTALLATION

• Controller installed in conformance to manufacturer’s instruction manual recommendations.

7.1.2 CABLING INSTALLATION

• All splices are soldered or via terminal block.

• Cabling is away from sources of electrical noise or RFI where possible.

7.1.3 SENSOR MODULE INSTALLATION

• Module installation in conformance with this manual.

• Modules accessible for calibration.

Page: 16

Model 4501-XX Toxic Gas Sensor Module

• Wiring terminations clean and correct.

7.1.4 MOISTURE TRAPS AND RAINSHIELDS

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

• Rain-shields installed where applicable.

7.1.5 STANDARD VOLTAGES

• Loop voltage to be applied to the sensor module must be between 14 VDC and 30 VDC.

7.2 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.

7.2.1 IF MODULE DOES NOT DISPLAY THE CORRECT PPM GAS

1. Repeat calibration procedure.

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

3. Apply Span Gas and verify that the sensor sees the correct value of the span gas after calibration.

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

7.2.2 IF THE MODULE DOES NOT DISPLAY THE CORRECT PPM

1. Power cycle the module.

2. Recalibrate the sensor.

7.2.3 IF THE DISPLAY SHOWS ‘NO SENSOR’ – SENSOR FAILING

1. Power down the unit

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

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

4. Power up the unit.

7.2.4 IF THE DISPLAY SHOWS “C” – CALIBRATION MODE

1. Complete calibration or exit to operating mode.

7.2.5 IF THE DISPLAY SHOWS “ T ” – DOWNSCALE INDICATOR

1. The reaction of the sensor to gas may, for a short period of time, result in a downscale indicator being shown on the display.

2. If this indicator remains for a longer period of time, the sensor may need re-calibration.

7.2.6 IF THE DISPLAY SHOWS “HIGH” – UPSCALE INDICATOR

1. The concentration of the gas is outside the calibrated range.

Page: 17

Model 4501-XX Toxic Gas Sensor Module

8. APPENDICES

APPENDIX A: SPECIFICATIONS

Specifications:

Sensor:

Max. Range (1)

Zero Drift

Repeatability

Linearity

Resolution

Response Time (2)

Sensor Life (3)

4501-04

0-1200 PPM

+/- 1 PPM

+/- 1 PPM

+/- 1 PPM

0.5 PPM

<25 sec.

2 years

4501-05

0-100 PPM

+/- 0.5 PPM

+/- 1 PPM

+/- 1 PPM

0.1 PPM

<30 sec.

2 years

4501-06

0-10 PPM

+/- 0.5 PPM

+/- 0.5 PPM

+/- 0.5 PPM

0.1 PPM

<60 sec

2 years

(1) Optional ranges available

(2) Response time to 90% full signal value for applied concentration

(3) Sensor life typical for use at standard temperature and pressure with occasional exposure to gas of interest

Output:

Display:

Signal Output:

Loop Resistance

LCD, 2-line, 20-characters

2-wire sensor powered analog 4-20 mA (Trouble: 3.6 mA)

800 ohm

Electrical Data:

Power consumption:

Connection type:

Input voltage:

RFI/EMI Protection:

<160 milliwatts

2 wire

24 VDC nominal: 14-30VDC, 2-wire loop powered

EN50081-2, EN50082-2

Operating Range:

Ambient Temp (

Ambient Temp ( o o

F)

C)

Relative Humidity

Extended Range

Operation

4501-04 CO

-4 to 122

-20 to 50 o o

F

C

5 – 99%

4501-05 H2S

-40 to 122 o F

-40 to 50 o C

5 – 99%

4501-06 Cl2

-4 to 122

-20 to 50 o o

F

C

5 – 99%

Sensor and 4-20 mA will continue to operate to -40oF (-40oC) but the

LCD

20o C) for significant time

Enclosure:

Dimensions:

Weight:

Material of Construction:

Enclosure:

7.0 x 3.6 x 4.0 inches (H x W x D)

(17.8 x 9.1 x 11.2 cm)

4.4 lb. (2.0 Kg)

316 Stainless Steel

4X

Electrical Classification:

FM Approved: Explosion proof, Class 1, Div. I, Groups B, C, D

Class 1, Zone 1, Group IIB+H2 IP66

Approvals:

FM Performance Approval: Approval Standards: ISA-92.0.01, Part I-1998 and FM 3600

Remote Sensor Option:

Page: 18

Model 4501-XX Toxic Gas Sensor Module

Warranty:

Limited warranty:

Model Number Gas Type CO H

2

S

4501-05-IT

4501-06-IT

H

2

S

C1

2

CI

2

2 year specifications subject to change without notice

H

2

SO

2

NO

2

NO HCI HCN C

2

H

4

Page: 19

Model 4501-XX Toxic Gas Sensor Module

APPENDIX B: MODEL NUMBERS & PARTS LIST

Sensor Module

4501-04

4501-05

4501-06

Options

Sensor Module 2-wire, CO

Sensor Module 2-wire, H2S

Sensor Module 2-wire, CI

2

5394-52 Remote Sensor/Display Option

5311-00 Rainshield

Calibration Items

1250-01

1250-03

1260-00

1260-04

1260-05

1260-06

1260-13

5360-00

1256-01

1265-03

Gas Sensor Calibration Kit, Type A (CO

Gas Sensor Calibration Kit, Type C (Cl

2

)

Gas Cylinder, Air, (Type A), 105 litres

,

H

2

S)

Gas Cylinder, CO 100 PPM, (Type A) 57 litres

Gas Cylinder, H

2

Gas Cylinder, Cl

2

S in N

2

, 25 PPM, (Type A) 57 litres

, 5 PPM, (Type C) 104 litres

Gas Cylinder, CO, 1000 PPM, (Type A), 105 liters

Calibrator Head Standard

Regulator Type A Calibrator

Regulator Type C Calibrator

5358-01 Calibration Adapter - Direct, Standard

Calibration/Configuration Magnetic Tool, 4501-XX

Spare Parts

SPM21830 Sensor Assy, Aluminum, 4501-05/5100-05-IT

SPM21832 Sensor Assy, Aluminum, 4501-04/5100-04-IT

SPM21833 Sensor Assy, Aluminum, 4501-06/5100-06-IT

SPM27071 Transmitter for 4501-XX

SPM27074 Sensor Assy, 316SS, 4501-05/5100-05-IT

SPM27083 Sensor Assy, 316SS, 4501-04/5100-04-IT

SPM27084 Sensor Assy, 316SS, 4501-06/5100-06-IT

SPM33030 Sensor for 4501-04

SPM33041 Sensor for 4501-05

SPM33050 Sensor for 4501-06

Page: 20

Model 4501-XX Toxic Gas Sensor Module

APPENDIX C: LIMITED WARRANTY

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

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

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

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

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

Page: 21

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