Sierra Monitor Corporation 5100-03-IT Instruction Manual
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Sierra Monitor Corporation 5100-03-IT Instruction Manual

It series toxic gas sensor module
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MODEL 5100-XX-IT
IT Series
TOXIC GAS SENSOR MODULE
Version 3.00A
APPLICABILITY & EFFECTIVITY
Effective for all Model 5100-XX-IT Modules manufactured after December 1, 2011.
5100-03-IT
5100-04-IT
5100-05-IT FM Approved
5100-06-IT
5100-08-IT
5100-10-IT
5100-12-IT
5100-25-IT
5100-26-IT
Instruction Manual Part Number T12020
Rev. C

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Summary of Contents for Sierra Monitor Corporation 5100-03-IT

  • Page 1 MODEL 5100-XX-IT IT Series TOXIC GAS SENSOR MODULE Version 3.00A APPLICABILITY & EFFECTIVITY Effective for all Model 5100-XX-IT Modules manufactured after December 1, 2011. 5100-03-IT 5100-04-IT 5100-05-IT FM Approved 5100-06-IT 5100-08-IT 5100-10-IT 5100-12-IT 5100-25-IT 5100-26-IT Instruction Manual Part Number T12020...
  • Page 2 FM PERFORMANCE APPROVAL ONLY THE FOLLOWING ITEMS, FUNCTIONS AND OPTIONS ARE FM* APPROVED Model 5100-05-IT Hydrogen Sulfide Gas Sensor Module Sensor Module Model 5100-05-IT Calibration Equipment Model 1250-01 Model 1260-05 Model 1260-45 Model 5358-01 Notes: Apparatus must be installed in accordance with National Electrical Code. FM Comments *FM Approvals, a subsidiary of FM Global Project# 3034435...

  • Page 3: Table Of Contents

    PRODUCT DESCRIPTION ... 1 GENERAL ... 1 PRODUCT CONFIGURATION ... 1 THEORY OF OPERATION ... 2 MODES OF OPERATION ... 2 MECHANICAL ... 3 INTERCONNECT WIRING ... 3 POWER REQUIREMENTS ... 3 CAUTIONS & WARNINGS ... 6 INTRODUCTION ... 6 GAS SENSOR MODULES - GENERAL ...
  • Page 4 APPENDICES ... 29 APPENDIX A: SPECIFICATIONS... 29 APPENDIX B: MODEL NUMBERS & PARTS LIST ... 32 APPENDIX C: LIMITED WARRANTY ... 33 APPENDIX D: REMOTE SENSOR DRAWING ... 34 APPENDIX E: MODBUS MEMORY MAP ... 35 APPENDIX F: HART ... 36 APPENDIX G: MENU KEY FOR 5100-XX-IT GAS SENSOR MODULE ...

  • Page 5: Product Description

    ATEX Approval (5100-05-IT) The 5100-XX-IT is designed and approved for installation and operation in hazardous locations. Members of the 5100-XX-IT Series Toxic Gas family include: • 5100-03-IT Oxygen Gas Sensor Module • 5100-04-IT Carbon Monoxide Gas Sensor Module • 5100-05-IT Hydrogen Sulfide Gas Sensor Module •...

  • Page 6: Theory Of Operation

    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.

  • Page 7: Mechanical

    1.5 MECHANICAL The sensor module is comprised of the following three primary components: ENCLOSURE Standard on the 5100-XX-IT is an explosion-proof, rain-tight cast aluminum electrical housing (Figure 1-3) with three ¾” FNPT conduit hubs. The 5100-XX-IT-SS has a 316 Stainless Steel enclosure (Figure 1-2). Both enclosure covers have a viewing window.

  • Page 8: Figure 1 - 1: Model 5100-05-It-Al Toxic Gas Sensor Module Aluminum - Dimensions

    Model 5100-XX-IT Toxic Gas Sensor Module Figure 1 - 1: Model 5100-05-IT-AL Toxic Gas Sensor Module Aluminum – Dimensions (Valid for all except 5100-25/26-IT – See Appendix G) Figure 1 - 2: Model 5100-05-IT-SS Toxic Gas Sensor Module Stainless Steel – Dimensions (Valid for all except 5100-25/26-IT –...

  • Page 9: Figure 1 - 3: Model 5100-Xx-It Toxic Gas Sensor Module - Mounting Options

    Model 5100-XX-IT Toxic Gas Sensor Module Figure 1 - 3: Model 5100-XX-IT Toxic Gas Sensor Module – Mounting Options NOTE Module installation must be such that it is mounted vertical with sensor pointing downward. Page: 5...

  • Page 10: Cautions & Warnings

    2.1 INTRODUCTION Although the 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.

  • Page 11: 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.

  • Page 12: Installation

    4.1 SENSOR MODULE LOCATIONS All modules are tagged to indicate the configuration including the sensor module number Identify all components during unpacking and install using the factory configuration. 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.

  • Page 13: Wiring

    4.2 WIRING 4.2.1 ANALOG 4-20 MA OPERATION (FIGURE 4-6) The 4-20 mA output for the 5100-XX-IT can be either 3-wire (ISA Type 3 Circuit) or standard 4-wire (ISA Type 4 Circuit) operation. If using 3-wire operation, use a minimum of 18 AWG, shielded, 3-conductor cable up to 2000’.

  • Page 14: Enclosure Installation

    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. modules Prior to installation and wiring: 1. Remove the transmitter from the module housing by: •...
  • Page 15 PCB Label RS 485 RS 485 PCB Label P4 Connections are only available when the optional Relays are included PCB Label LO ALM HI ALM TRBL * Trouble relay is fail safe so it is energized for normal operation, functions are labeled for normal operation. 8.

  • Page 16: Module Address Switch

    4.5 MODULE ADDRESS SWITCH For digital interface applications the module address switch (or Modbus node) Figure 4-2 must be set per Table 4-3: 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 Model 5100-XX-IT Toxic Gas Sensor Module OSITION DDRESS...

  • Page 17: Figure 4 - 3: Interface Board Connectors

    Model 5100-XX-IT Toxic Gas Sensor Module Figure 4 - 3: Interface Board Connectors Figure 4 - 4: RS-485: Termination, BIAS Jumper Page: 13...

  • Page 18: Figure 4 - 5: Ma Circuit Types

    Model 5100-XX-IT Toxic Gas Sensor Module TYPE 3 CIRCUIT (3 WIRE NON-ISOLATED) TYPE 3 CIRCUIT (3 WIRE NON-ISOLATED) Figure 4 - 5: mA Circuit Types Page: 14...

  • Page 19: Figure 4 - 6: 4-20 Ma Circuit Type Connections For 5100-Xx-It

    Model 5100-XX-IT Toxic Gas Sensor Module Figure 4 - 6: 4-20 mA Circuit Type Connections for 5100-XX-IT Page: 15...

  • Page 20: Figure 4 - 7: Writing Connections For Modbus And Sentry Interface

    Model 5100-XX-IT Toxic Gas Sensor Module 5100-XX-IT TO SENTRY (Dry contact only unpowered) 5100-XX-IT TO MODBUS DEVICE Figure 4 - 7: Wiring Connections for Modbus and Sentry Interface Page: 16...

  • Page 21: Figure 4 - 8: Wiring Connections For Remote Alarm Reset

    5100-XX-IT Remote Alarm Reset (Unsupervised) (Dry contact only unpowered) SWITCH IN SWITCH IN 5100-XX-IT Remote Alarm Reset (Supervised) 5100-05-IT REMOTE ALARM RESET (SUPERVISED) Figure 4 - 8: Wiring Connections for Remote Alarm Reset Page: 17 Model 5100-XX-IT Toxic Gas Sensor Module 4.7K OHM (CUSTOMER SUPPLIED)

  • Page 22: Operation

    5.1 INTRODUCTION The Gas Sensor Module utilizes a visual menu system operated by means of a magnet. A magnetic tool (5358-50) 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. 5.2 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.

  • Page 23: Main Menu

    5.3 MAIN MENU Function Display Mode Switch [M] Enter Switch [E] Switch [▲] Previous Menu Down Switch [▼] Next Menu 5100-XX First screen at power up: Model No. VXX-XX-- Second screen at power up: Version No. STARTING Third screen at start up: Starting Delay XXX PPM Normal condition - default display Mode...

  • Page 24: Set-Up

    [▲] 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 up to the following values: Model 5100-03-IT 5100-04-IT 5100-05-IT 5100-06-IT...

  • Page 25: Table 5 - 3: Set-Up Configuration

    Track – the 4-20mA value tracks the calibration gas exposed to the gas sensor module C2.50mA – the 4-20mA value is held at 2.50mA during calibration C4.00mA – the 4-20mA value is held at 4.0mA during calibration. • RS-485 - Use the [▲] or [▼] keys to select Address or Baud rate menu and press [E]. Note that the 5100-XX-IT has a rotary switch on the faceplate and it is used to select addresses 1-15.
  • Page 26 Gas Range Adjustment Example Enter Range S.P. Function - Range Adjust Select [E] to select or Enter *100 PPM press [E] Down 10 PPM Press [E] if selecting 0-10 PPM range Down USER Press [E] if selecting User adjustable range Select [E] to select or Enter 100 PPM...

  • Page 27: Maintenance Sub-Menu

    5.5 MAINTENANCE SUB-MENU The maintenance menu enables the operator to view sensor and software versions. Sierra Monitor technical support has access to other values as needed. The maintenance menu operation is described in Table 5-4. Function Display XXXPPM Mode ALMRSET: Mode CALIB:-- Mode...

  • Page 28: Calibration Frequency

    6.4 SENSOR EXPOSURE TO GAS Calibration gas must be delivered to the sensor using the flow rate and duration listed in below: Model Calibration Gas 5100-03-IT 5100-04-IT Carbon Monoxide 5100-05-IT Hydrogen Sulfide 5100-06-IT...

  • Page 29: Calibration Sub-Menu

    Zero gas setting acknowledged Banner: Select span, enter <E> to calibrate sensor Banner: (5100-03-IT) Specify Cal gas <E> when done Banner: Apply span gas, then enter <E> to calibrate gas sensor Operation: Apply calbration gas. Operation: As gas is applied the reading will increase - wait 3...

  • Page 30: Service

    7.1 SENSOR MODULE CONFIGURATION The gas sensor module is comprised of the following sub-assemblies (Figure 7-1): 5100-XX-IT SPL21810 SPL21823 SPL21824 XXXXXXX 5200-XX-IT 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.

  • Page 31: Transmitter Replacement

    7.3 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.

  • Page 32: Inspection And Troubleshooting Guide

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

  • Page 33: Appendices

    8.1 APPENDIX A: SPECIFICATIONS Sensor: Type: Standard Optional Range(1) Max Range 5-25% Vol 0-25% Vol 5100-03-IT O 0-500 PPM 1200 PPM 5100-04-IT CO 0-100 PPM 100 PPM 5100-05-IT H S (5) 0-10.0 PPM 10.0 PPM 5100-06-IT Cl 0-3.0 PPM 3.0 PPM...
  • Page 34 FM Standards 3600, 3615, 3810 UL Standard 508A II 2 G Ex d IIB+H2 T6 Gb Ta = -20 C to +50 5100-05-IT FM Approval Performance and Safety Approval (Appendix I) 5100-03-IT 10 feet 5100-04-IT 15 feet 5100-05-IT 15 feet...
  • Page 35 Cross Sensitivity Data: 5100-04-IT Carbon Monoxide Conc. 15 PPM 5 PPM 35 PPM 5 PPM 100 PPM 100 PPM 10 PPM 5 PPM 5100-05-IT Hydrogen Sulfide Conc. 400 PPM 20 PPM 50 PPM 10 PPM 10 PPM 400 PPM 400 PPM 20 PPM 5100-06-IT Chlorine Conc.

  • Page 36: Appendix B: Model Numbers & Parts List

    Sensor, for 5100-06-IT / 5100-08-IT Sensor, for 5100-10-IT Sensor, for 5100-12-IT Sensor Assembly, Aluminum, for 5100-03-IT - Oxygen Sensor Assembly, Aluminum, for 5100-04-IT - CO Sensor Assembly, Aluminum, for 5100-05-IT - H Sensor Assembly, Aluminum, for 5100-06-IT / 5100-08-IT - Cl Sensor Assembly, Aluminum, for 5100-10-IT - SO Sensor Assembly, Aluminum, for 5100-12-IT –...

  • Page 37: Appendix C: Limited Warranty

    Model 5100-XX-IT Toxic Gas Sensor Module 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.

  • Page 38: Appendix D: Remote Sensor Drawing

    Model 5100-XX-IT Toxic Gas Sensor Module Figure 8 - 1: Remote Sensor Drawing 8.4 APPENDIX D: REMOTE SENSOR DRAWING NOTE Drawing using Stainless Steel enclosure available from Sierra Monitor. Page: 34...

  • Page 39: Appendix E: Modbus Memory Map

    8.5 APPENDIX E: MODBUS MEMORY MAP Address Register Name Read/Write 40001 Concentration 40002 Temperature 40003 Alarm Relay 40004 Warning Relay 40005 Warning Setpoint 40006 Alarm Setpoint 40007 CCC detail 40008 Software Revision U 40009 Software Revision L 40010 Modbus Map Revision 40011 Trouble Bits 40012...

  • Page 40: Appendix F: Hart

    Model 5100-XX-IT Toxic Gas Sensor Module 8.6 APPENDIX F: HART Figure 8 - 2: HART Page: 36...
  • Page 41 Model 5100-XX-IT Toxic Gas Sensor Module Figure 8 - 3: 4-20 mA Circuits Types 5100-XX-IT – Connections - HART Page: 37...
  • Page 42 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.
  • Page 43   Device Specific Commands Summary  Command  Number  130  Key Press  131  Set Alarm Level  132  Set Warning Level  133  Set Alarm Relay Action  134  Set Warning Relay Action  135  Reset Alarms  136  Abort Calibration  137  Set Calibration Gas Level  138  Apply ZERO Gas  139  Apply SPAN Gas  140  RESERVED  141  Force Gas Value  142  Reset Force Gas Value  143  Read MODBUS RTU Register  144  Set Transducer Serial Number  145  Set Calibration Mode output current  146  Set Trouble Mode output current  147  RESERVED  148 ...
  • Page 44 Command 132: Set Warning Level  Request Data Bytes:  Byte  0  Command Specific Response Data Bytes:  Byte  0    Command 133: Set Alarm Relay Action  Request Data Bytes:  Byte  0  Command Specific Response Data Bytes:  Byte  0    Command 134: Set Warning Relay Action  Request Data Bytes:  Byte  0  Command Specific Response Data Bytes:  Byte  0    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:      Command Specific Response Data Bytes:   None    Command 136: Abort Calibration  This command aborts the calibration procedure.  Request Data Bytes:      Command Specific Response Data Bytes:   None    Command 137: Set Calibration Gas Level ...
  • Page 45 This command will signal the module to accept the present sensor output to as the ZERO gas condition.  Request Data Bytes:      Command Specific Response Data Bytes:   None    Command 139: Apply SPAN Gas  This command will signal the module to accept the present sensor output to as the SPAN gas condition.  Request Data Bytes:      Command Specific Response Data Bytes:   None    Command 141: Force Gas Value  Request Data Bytes:  Byte  0  Command Specific Response Data Bytes:  Byte  0    Command 142: Reset Force Gas Value  This command will signal the module to set the Force Gas Value to 0.  Request Data Bytes:      Command Specific Response Data Bytes:   None    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      Command Specific Response Data Bytes:  Byte  0‐1 ...
  • Page 46 Request Data Bytes:  Byte  0‐1  Command Specific Response Data Bytes:  Byte  0‐1    Command 146: Set Trouble Mode output current  Request Data Bytes:  Byte  0‐1  Command Specific Response Data Bytes:  Byte  0‐1    Command 149: Set Gas Factor  Request Data Bytes:  Byte  0  Command Specific Response Data Bytes:  Byte  0                        Version 1.00 Created 13 July 2011 Model 5100-XX-IT Toxic Gas Sensor Module Format ...

  • Page 47: Appendix G: Menu Key For 5100-Xx-It Gas Sensor Module

    8.7 APPENDIX G: MENU KEY FOR 5100-XX-IT GAS SENSOR MODULE • Key M : MODE • Key E : ENTER • Key ▲ UP (+) • Key ▼ DOWN (-) MAIN MENU key to access each of the 4 main sections of the menu. Use the |- ALMRSET: |- CALIB:...

  • Page 48: Setup Menu

    SETUP MENU Once in the SETUP menu use the ▲ or ▼ keys to access each of the 5 main sections of the SETUP menu. ▼ ▼ ▼ |- Alarms: |- Relays: |- Gas: SETUP: E – Alarms (Alarms Set-Point Adjustment) E –...
  • Page 49 |----▼ 4-20mA (Verifies 4mA or 20mA output and selects condition of output during calibration) ▼ -------or--------------- E Mode: ▼ -------or--------------- E Calib ▼ -------or--------------- E CalibOut (Adjust 4-20mA output during Calibration) ▼ -------or--------------- E TblOut (Adjust 4-20mA output during Trouble condition) |----▼...

  • Page 50: Appendix H: 5100-25-It & 5100-26-It Gas Sensor Module

    8.8 APPENDIX H: 5100-25-IT & 5100-26-IT GAS SENSOR MODULE 1. Calibration of 5100-26-IT (Follow Instructions in Section 6) 2. Calibration of 5100-25-IT (Follow Instructions in Section 6) 3. Equipment Required The following tools and equipment will be required for calibration: Permeation Device Calibrator (Model 9210-00), with Ammonia Permeation Tube (Model 9211-09).
  • Page 51 1. Equipment Required Electrolyte Recharge Kit (SPX27057 for Model 5100-25-IT and SPX27061 for Model 5100-26- IT) consisting of the electrolyte, package of 5 membranes, 5 0-Rings and alcohol wipes to clean the electrode. Tweezers to aid in removing and replacing the membrane 2.

  • Page 52: Figure 8 - 3: Sensor Assembly - Exploded View

    l. Reconnect the sensor harness to the transmitter, carefully install the transmitter into the housing and restore system power. m. Recalibrate the transmitter following the instructions in Section 6. Figure 8 - 5: Sensor Assembly – Exploded View Spare Parts SPX27057 Recharge Kit NH3 SPX27061...

  • Page 53: Figure 8 - 4: Model 5100-25-It-Al And Model 5100-26-It-Al

    Model 5100-XX-IT Toxic Gas Sensor Module Figure 8 - 6: Model 5100-25-IT-AL and Model 5100-26-IT-AL Figure 8 - 7: Model 5100-25-IT-SS and Model 5100-26-IT-SS Page: 49...

  • Page 54: Appendix I: 5100-05-It Fm Performance Approval

    Model 5100-XX-IT Toxic Gas Sensor Module 8.9 APPENDIX I: 5100-05-IT FM PERFORMANCE APPROVAL Page: 50...
  • Page 55 Model 5100-XX-IT Toxic Gas Sensor Module Page: 51...

  • Page 56: Appendix J: 5100-Xx-It Sil-2 Certificates

    Model 5100-XX-IT Toxic Gas Sensor Module 8.10 APPENDIX J: 5100-XX-IT SIL-2 CERTIFICATES Page: 52...
  • Page 57 Model 5100-XX-IT Toxic Gas Sensor Module Page: 53...
  • Page 58 Model 5100-XX-IT Toxic Gas Sensor Module Page: 54...

  • Page 59: Appendix K: 5100-05-It Atex Certificate

    Model 5100-XX-IT Toxic Gas Sensor Module 8.11 APPENDIX K: 5100-05-IT ATEX CERTIFICATE Figure 8 - 8: ATEX Page: 55...
  • Page 60 Model 5100-XX-IT Toxic Gas Sensor Module Page: 56...
  • Page 61 Model 5100-XX-IT Toxic Gas Sensor Module Page: 57...
  • Page 62 Model 5100-XX-IT Toxic Gas Sensor Module THIS PAGE INTENTIONALLY LEFT BLANK Page: 58...
  • Page 63 4-20 MA ... 1, 14, 20, 22 5100-25-IT ... 24, 47 ALARM ... 1, 2, 20 AMMONIA ... 1 ANALOG ... 2 ANALOG 4-20 ... 9 ATEX ... 1, 56 AUXILIARY INTEGRAL RELAY ... 1 CALIBRATION ... 8, 24, 33 CALIBRATION FREQUENCY ...

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