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SMC Networks IT Series Instruction Manual

Combustible gas sensor module
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MODEL 5100-02-IT
IT Series
COMBUSTIBLE GAS SENSOR MODULE
Version 2.00a
APPLICABILITY & EFFECTIVITY
Effective for all Model 5100-02-IT Modules manufactured after February 15, 2008.
Instruction Manual Part Number T12019
Rev. B1

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  • Page 1 MODEL 5100-02-IT IT Series COMBUSTIBLE GAS SENSOR MODULE Version 2.00a APPLICABILITY & EFFECTIVITY Effective for all Model 5100-02-IT Modules manufactured after February 15, 2008. Instruction Manual Part Number T12019 Rev. B1...
  • Page 2 Model 5100-02-IT Combustible Gas Sensor Module FM APPROVAL ONLY THE FOLLOWING ITEMS, FUNCTIONS AND OPTIONS ARE FM* APPROVED Model 5100-02-IT Combustible Gas Sensor Module Sensor Module Model 5100-02-IT Combustible Gas Sensor Module Model 5100-02-IT-SS Combustible Gas Sensor Module, 316SS Calibration Equipment Model 1200-26 Calibration Gas Delivery System Model 1290-02...

  • Page 3: Table Of Contents

    Model 5100-02-IT Combustible Gas Sensor Module TABLE OF CONTENTS PRODUCT DESCRIPTION ..........................3 GENERAL................................3 PRODUCT CONFIGURATION........................3 THEORY OF OPERATION ..........................3 MODES OF OPERATION..........................3 1.4.1 SENTRY INTERFACE..........................3 1.4.2 MODBUS OPERATION..........................5 1.4.3 ANALOG OPERATION ..........................5 1.4.4 AUXILIARY RELAY OPERATION (Appendix E)..................5 1.4.5 ENHANCED CONNECTION (Appendix F) ....................5 1.4.6 AUXILIARY RS-485 MULTIDROP (Appendix G)..................5 1.4.7...
  • Page 4 Model 5100-02-IT Combustible Gas Sensor Module ENCLOSURE REPLACEMENT ........................23 TRANSMITTER REPLACEMENT .........................24 SENSOR REPLACEMENT..........................24 INSTALLATION INSPECTION ........................24 CONTROLLER INSTALLATION ......................24 CABLING INSTALLATION ........................24 SENSOR MODULE INSTALLATION .....................24 MOISTURE TRAPS AND RAINSHIELDS....................25 STANDARD VOLTAGES ........................25 INSPECTION AND TROUBLESHOOTING GUIDE ................25 IF MODULE DOES NOT RESPOND TO GAS ..................25 IF THE MODULE DOES NOT COME OUT OF WARM UP..............25 If the module does not display the correct %LEL...................25 If the display shows ‘NO SENSR’...

  • Page 5: Product Description

    Model 5100-02-IT Combustible Gas Sensor Module 1. PRODUCT DESCRIPTION 1.1 GENERAL The Model 5100-02-IT Catalytic Bead Combustible Gas Sensor Module is a member of the Sentry Information Technology family of gas ”IT” sensor transmitter modules. modules offer a broad array of features including: •...
  • Page 6 Model 5100-02-IT Combustible Gas Sensor Module Figure 1-1 Model 5100-02-IT Combustible Gas Sensor Module Stainless Steel – Dimensions Figure 1-2 Model 5100-02-IT Combustible Gas Sensor Module Aluminum – Dimensions Page: 4...

  • Page 7: Modbus Operation

    Model 5100-02-IT Combustible Gas Sensor Module 1.4.2 MODBUS OPERATION gas sensor modules have a Modbus RTU RS-485 serial interface to allow direct connection to any standard PLC or DCS. The Module Address Switch (section 3.5) allows the user to select Modbus addresses 1 thru 15.

  • Page 8: Interconnect Wiring

    Model 5100-02-IT Combustible Gas Sensor Module 1.6 INTERCONNECT WIRING Not supplied with the sensor module, but necessary to the installation and operation is the multi conductor wiring which connects the module to its power source and controller. Before this wiring is installed it is important to read and understand the control system installation instructions to determine wiring requirements and alternatives.

  • Page 9: Cautions & Warnings

    Model 5100-02-IT Combustible Gas Sensor Module 2. CAUTIONS & WARNINGS 2.1 INTRODUCTION Although 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.

  • Page 10: Catalytic Bead Sensor Modules

    Model 5100-02-IT Combustible Gas Sensor Module 2.3.1 CATALYTIC BEAD SENSOR MODULES Model 5100-02-IT Gas Sensor Modules are FM performance approved for detection of Combustible gas (methane and hydrogen). The sensor is cross sensitive to the combustible gases indicated in Table 2-1. Risk management planning should take into consideration the potential for the presence of other gases in the monitored area.

  • Page 11: Installation

    Model 5100-02-IT Combustible Gas Sensor Module 3. INSTALLATION NOTE 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. 3.1 SENSOR MODULE LOCATIONS Select locations for each sensor module based on the following: •...

  • Page 12: Enclosure Installation

    Model 5100-02-IT Combustible Gas Sensor Module 3.3 ENCLOSURE INSTALLATION To protect the transmitter and sensor assembly they should be removed from the enclosure and preserved until final installation and wiring termination. Prior to installation and wiring. 1. Remove the transmitter from the module housing by: •...
  • Page 13 Model 5100-02-IT Combustible Gas Sensor Module 6. Carefully return the transmitter to the enclosure installing it over the two standoffs. Tighten the retaining screws into the standoffs. UNCTION UNCTION High Alarm Relay NC Power High Alarm Relay NO Signal High Alarm Relay COM Ground Low Alarm Relay NC Low Alarm Relay NO...

  • Page 14: Installation Configuration

    Model 5100-02-IT Combustible Gas Sensor Module 3.5 INSTALLATION CONFIGURATION Table 3-3 and Figures 3-1 through 3-4 provide location and installation details. OSITION DDRESS OSITION DDRESS Sensor 1 Sensor 09 Sensor 2 Sensor 10 Sensor 3 Sensor 11 Sensor 4 Sensor 12 Sensor 5 Sensor 13 Sensor 6...
  • Page 15 Model 5100-02-IT Combustible Gas Sensor Module Figure 3-3 4-20 mA Connection Page: 13...
  • Page 16 Model 5100-02-IT Combustible Gas Sensor Module Figure 3-4 Digital Interface Connections Figure 3-5 Remote Alarm Reset Page: 14...

  • Page 17: Introduction - Human-Machine Interface System

    Model 5100-02-IT Combustible Gas Sensor Module 4. INTRODUCTION – HUMAN-MACHINE INTERFACE SYSTEM 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.

  • Page 18: Main Menu

    Model 5100-02-IT Combustible Gas Sensor Module 4.2 MAIN MENU Table 4-1 describes the primary human-machine interface operation. Function Display Description Reference Mode Switch [M] Enter Switch [E] Switch [▲] Previous Menu Down Switch [▼] Next Menu 5100-02 First screen at power up-model 1.Xxa VX.Xxx Second screen at power up-version...

  • Page 19: Configure Set-Points

    Model 5100-02-IT Combustible Gas Sensor Module 4.3 CONFIGURE SET-POINTS 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). •...
  • Page 20 Model 5100-02-IT Combustible Gas Sensor Module Function Display Description Reference --0%LEL- Default Display Mode ALMRSET: Mode Function - Alarm Reset Mode CALIB:-- Mode Function - Calibrate Mode SETUP:--- Mode Function - Set Point Adjustments Enter Alarms S.P. Function - Alarm Adjust * A Below Down Relays...
  • Page 21 Model 5100-02-IT Combustible Gas Sensor Module Gas Factor Example Enter GasFactr S.P. Function - Gas Factor Adjust Select [E] to select or to adjust factor Enter Factr100 number and press [E] Enter Acknowledgement of new Gas Factor Value 4-20 mA Adjustment Example Enter Calib S.P.

  • Page 22: Maintenance Functions

    Model 5100-02-IT Combustible Gas Sensor Module 4.4 MAINTENANCE FUNCTIONS The maintenance menu allows the operator to monitor certain Sensor values, and select the required analog or digital communication interface. The maintenance menu operation is described in Table 4-4. Function Display Description Reference 0%LEL...

  • Page 23: Calibration

    Model 5100-02-IT Combustible Gas Sensor Module 5. CALIBRATION CALIBRATION FREQUENCY The manufacturer specifies that sensor modules 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.
  • Page 24 Model 5100-02-IT Combustible Gas Sensor Module Function Display Description Reference 0%LEL Default Display Mode ALMRSET: Mode Function - Alarms Reset Mode CALIB: Mode Function - Calibrate or Sub Routine A Enter CAL-0% Banner: Apply zero gas, enter <E> when done Operation: Confirm area clear of gas, or apply zero air to sensor.

  • Page 25: Service

    Model 5100-02-IT Combustible Gas Sensor Module 6. SERVICE SENSOR MODULE CONFIGURATION The gas sensor module is comprised of the following sub-assemblies (Figure 6-1): 5100-02-IT Gas Sensor Module SPL21810 Alluminum Enclosure (SPL32178 316SS Enclosure) SPL21813 Transmitter Assembly 5200-02 Sensor Assembly 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.

  • Page 26: Transmitter Replacement

    Model 5100-02-IT Combustible Gas Sensor Module TRANSMITTER REPLACEMENT The transmitter assembly should be replaced when it is determined that it is unreliable, noisy or cannot be calibrated. This may occur due to age, corrosion or failed components. To replace the transmitter assembly: a.

  • Page 27: Moisture Traps And Rainshields

    Model 5100-02-IT Combustible Gas Sensor Module • Wiring terminations clean and correct. 6.5.4 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 28: Appendices

    Model 5100-02-IT Combustible Gas Sensor Module 7. APPENDICES 7.1 APPENDIX A: SPECIFICATIONS Specifications: Sensor: Type: Catalytic Bead Range: 0-100% LEL Combustible Repeatability: +/-1% LEL Response time: < 12 sec to 60% full scale Accuracy: +/- 1% for 0-50% LEL range +/- 2% for 51-100% LEL range Sensor Life: Typically >3 years...

  • Page 29: Appendix B: Model Numbers & Parts List

    Model 5100-02-IT Combustible Gas Sensor Module 7.2 APPENDIX B: MODEL NUMBERS & PARTS LIST Sensor Module 5100-02-IT-AL Sensor Module, Combustible, Aluminum housing 5100-02-IT-SS Sensor Module, Combustible, 316SS housing Options 5311-00 Rainshield 5394-51 Remote Sensor/Display Option 5394-61 Auxiliary Connection Assembly 5394-62 Auxiliary Relay Assembly Calibration Items 1200-26...

  • Page 30: Appendix C: Limited Warranty

    Model 5100-02-IT Combustible Gas Sensor Module 7.3 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 31: Appendix D: Remote Sensor/Display Drawing 5394-50

    Model 5100-02-IT Combustible Gas Sensor Module 7.4 APPENDIX D: REMOTE SENSOR DRAWING 5394-50 Page: 29...

  • Page 32: Appendix E: Auxiliary Relay Assembly 5394-62

    Model 5100-02-IT Combustible Gas Sensor Module 7.5 APPENDIX E: AUXILIARY RELAY ASSEMBLY 5394-62 Page: 30...

  • Page 33: Appendix F: Auxiliary Connection Assembly 5394-61

    Model 5100-02-IT Combustible Gas Sensor Module 7.6 APPENDIX F: AUXILIARY CONNECTION ASSEMBLY 5394-61 Page: 31...

  • Page 34: Appendix G: Auxiliary Rs-485 Multidrop Assembly 5394-64

    Model 5100-02-IT Combustible Gas Sensor Module 7.7 APPENDIX G: AUXILIARY RS-485 MULTIDROP ASSEMBLY 5394-64 Page: 32...
  • Page 35 Model 5100-02-IT Combustible Gas Sensor Module Page: 33...

  • Page 36: Appendix H: Modbus Memory Map

    Model 5100-02-IT Combustible Gas Sensor Module 7.8 APPENDIX H: MODBUS MEMORY MAP Read Register Table Register Description Comments 40001 Concentration Gas Concentration multiplied by 100 40002 Temperature Temperature in degrees Celsius scalled by a factor of 100 40003 High Alarm Relay Boolean indicating the High Alarm Status, 0 No Alarm, 1 High Alarm 40004 Low Alarm Relay...

  • Page 37: Appendix I: Combustible Gas Scaling Factors

    Model 5100-02-IT Combustible Gas Sensor Module 7.9 APPENDIX I: 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: METHANE METHANE FACTOR...

  • Page 38: Appendix J: Menu Key For 5100-02-It Gas Sensor Module

    Model 5100-02-IT Combustible Gas Sensor Module 7.10 APPENDIX J: Menu Key for 5100-02-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 39 Model 5100-02-IT Combustible Gas Sensor Module 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: |- GasFactr: |- 4-20mA: |- RS-485...
  • Page 40 Model 5100-02-IT Combustible Gas Sensor Module |----▼ 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 E t o accept) |- Out: 20mA ▼...
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