General Monitors TS4000H User manual

The information and technical data disclosed in
this document may be used and disseminated
only for the purposes and to the extent
specifically authorized in writing by General
Monitors.
Instruction Manual 02-17
General Monitors reserves the right to change
published specifications and designs without
prior notice.
MANTS4000H
Part No. MANTS4000H
Revision P/02-17
Model TS4000H
Intelligent Sensor for
Toxic Gas Detection

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TS4000H
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Table of Contents
TABLE OF FIGURES.................................................................................................................VII
TABLE OF TABLES..................................................................................................................VIII
ABOUT THIS MANUAL ...............................................................................................................1
Format Conventions................................................................................................................................1
Notes, Cautions, and Warnings .................................................................................................1
Menu Formats ............................................................................................................................1
Modbus Register Formats..........................................................................................................1
Other Sources of Help.............................................................................................................................1
Contacting Customer Support....................................................................................................1
1.0 BEFORE INSTALLATION......................................................................................................2
1.1 System Integrity Verification ......................................................................................................2
1.2 Commissioning Safety Systems ................................................................................................2
1.3 Notes and Warnings...................................................................................................................2
1.4 Glossary of Terms......................................................................................................................3
2.0 PRODUCT OVERVIEW..........................................................................................................6
2.1 General Description ...................................................................................................................6
2.2 Features and Benefits................................................................................................................6
2.3 Applications................................................................................................................................7
2.4 Base Unit....................................................................................................................................7
2.5 Interface Module ........................................................................................................................8
2.6 Electrochemical Cell.................................................................................................................10
3.0 INSTALLATION....................................................................................................................11
3.1 Unpacking the Equipment........................................................................................................11
3.2 Preparing for the Installation ....................................................................................................11
3.2.1 Required Tools............................................................................................................12
3.2.2 Detection Location Guidelines ....................................................................................12
3.3 Installation Overview................................................................................................................13
3.3.1 Intrinsic Safety Barrier.................................................................................................14
3.3.2 Electrochemical Cell Maintenance..............................................................................14
3.4 Mounting Instructions...............................................................................................................14
3.4.1 Mounting Dimensions..................................................................................................15
3.4.2 Mounting – Local Configuration ..................................................................................16
3.4.3 Mounting – Remote Configuration with External Junction Box...................................17
3.5 Wiring Connections..................................................................................................................18
3.5.1 Wiring Safety Notices..................................................................................................20
3.5.2 Base Unit Wiring .........................................................................................................21
3.5.3 Connecting to the Power Supply DC Ground .............................................................22
3.5.4 Connecting Control Room Devices to the TB1 Block .................................................23
3.5.5 Connecting to the +24 VDC Power Supply.................................................................24
3.5.6 Connecting Alarm Relay Devices to the TB3 Block....................................................25
3.6 Applying Power and Starting Operation...................................................................................26

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3.6.1 Start-up Readiness Checklist......................................................................................26
3.6.2 Start-up Process .........................................................................................................27
3.7 Maintaining Explosion Proof Integrity.......................................................................................27
4.0 OPERATION.........................................................................................................................29
4.1 Start-up Checklist.....................................................................................................................29
4.2 User Menu Structure................................................................................................................29
4.3 User Menu Display...................................................................................................................31
4.4 Start-up ....................................................................................................................................32
4.5 Using the Selection Magnet .....................................................................................................33
4.6 Selectable Options...................................................................................................................34
4.6.1 Sensor Range .............................................................................................................34
4.6.2 Warning Relay Settings ..............................................................................................35
4.6.3 Alarm Relay Settings...................................................................................................36
4.6.4 Modbus Channel 1 Settings........................................................................................38
4.6.5 Modbus Channel 2 Settings........................................................................................39
4.6.6 HART/Modbus SELECT .............................................................................................40
4.7 Relay Reset..............................................................................................................................41
4.8 Gas Check Mode .....................................................................................................................42
4.8.1 Gas Check Procedure.................................................................................................42
4.9 Calibration Mode......................................................................................................................43
4.9.1 Calibration Procedure .................................................................................................43
4.10 Remaining Sensor Life.............................................................................................................45
4.10.1 Initializing the Remaining Sensor Life.........................................................................45
4.11 Calibration Equipment – Portable Purge Calibrator.................................................................45
5.0 MODBUS INTERFACE ........................................................................................................47
5.1 Introduction ..............................................................................................................................47
5.2 Baud Rate ................................................................................................................................47
5.3 Data Format .............................................................................................................................47
5.4 Function Codes Supported ......................................................................................................47
5.5 Modbus Read Status Protocol (Query / Response).................................................................48
5.6 Modbus Write Command Protocol (Query / Response) ..........................................................49
5.7 Exception Responses and Exception Codes...........................................................................50
5.7.1 Exception Response ...................................................................................................50
5.7.2 Exception Code...........................................................................................................51
5.8 Command Register Locations..................................................................................................52
5.9 Command Register Details ......................................................................................................59
5.9.1 Analog (0x0000)..........................................................................................................59
5.9.2 Mode (0x0001)............................................................................................................59
5.9.3 Status / Error (0x0002)................................................................................................60
5.9.4 Sensor Raw Data (0x0003).........................................................................................61
5.9.5 Unit Type (0x0004)......................................................................................................61
5.9.6 Software Revision (0x0005)........................................................................................61
5.9.7 Sensor Temperature Output (0x0006)........................................................................61
5.9.8 Display Registers (0x0007 & 0x0008).........................................................................61
5.9.9 HART Configuration (0x000C) ....................................................................................61
5.9.10 Alarm Relay Settings (0x000D)...................................................................................62
5.9.11 Warn Relay Settings (0x000E)....................................................................................62
5.9.12 MOD1 Address (0x000F) ............................................................................................63
5.9.13 MOD1 Baud Rate (0x0010) ........................................................................................63

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5.9.14 MOD1 Data Format (0x0011) .....................................................................................63
5.9.15 MOD2 Address (0x0012) ............................................................................................64
5.9.16 MOD2 Baud Rate (0x0013) ........................................................................................64
5.9.17 MOD2 Data Format (0x0014) .....................................................................................64
5.9.18 Reset Relays (0x0016) ...............................................................................................64
5.9.19 Sensor Life (0x0017)...................................................................................................64
5.9.20 Sensor Scale (0x0018) ...............................................................................................65
5.9.21 Sensor Type (0x0019) ................................................................................................65
5.9.22 MOD1 Total Receive Errors (0x0020).........................................................................66
5.9.23 MOD1 Total Data Errors (0x0021)..............................................................................66
5.9.24 MOD1 Function Code Errors (0x0022) .......................................................................66
5.9.25 MOD1 Starting Address Errors (0x0023)....................................................................66
5.9.26 MOD1 CRC High Byte Errors (0x0025) ......................................................................66
5.9.27 MOD1 CRC Low Byte Errors (0x0026).......................................................................66
5.9.28 MOD1 Hardware Overrun Errors (0x0027).................................................................66
5.9.29 MOD1 Hardware Framing Errors (0x0028).................................................................66
5.9.30 MOD1 Hardware Parity Errors (0x0029).....................................................................66
5.9.31 MOD1 Hardware Total Receive Errors (0x002A) .......................................................67
5.9.32 MOD1 Hardware Clear Errors (0x002C).....................................................................67
5.9.33 MOD1 Clear Communication Errors (0x002D) ...........................................................67
5.9.34 Clear Interface Module Communication Errors (0x002E)...........................................67
5.9.35 MOD2 Total Receive Errors (0x0043).........................................................................67
5.9.36 MOD2 Total Data Errors (0x0044)..............................................................................67
5.9.37 MOD2 Function Code Errors (0x0045) .......................................................................67
5.9.38 MOD2 Starting Address Errors (0x0046)....................................................................67
5.9.39 MOD2 CRC High Byte Errors (0x0048) ......................................................................68
5.9.40 MOD2 CRC Low Byte Errors (0x0049).......................................................................68
5.9.41 MOD2 Hardware Overrun Errors (0x004A) ................................................................68
5.9.42 MOD2 Hardware Framing Errors (0x004B) ................................................................68
5.9.43 MOD2 Hardware Parity Errors (0x004C) ....................................................................68
5.9.44 MOD2 Hardware Total Receive Errors (0x004D) .......................................................68
5.9.45 MOD2 Hardware Clear Error (0x004E).......................................................................68
5.9.46 MOD2 Clear Communication Errors (0x004F)............................................................68
5.10 TS4000H Run Time Meter and Real Time Clock (Time/Date) ................................................68
5.11 Conversion between Run Time Meter and Time/Date Clock...................................................69
5.12 Event Logging ..........................................................................................................................69
5.12.1 Fault Event..................................................................................................................70
5.12.2 Warning Event.............................................................................................................71
5.12.3 Alarm Event.................................................................................................................72
5.12.4 Maintenance Event .....................................................................................................73
5.12.5 Calibration Event.........................................................................................................73
6.0 MAINTENANCE ...................................................................................................................75
6.1 General Maintenance...............................................................................................................75
6.2 Storage.....................................................................................................................................75
7.0 TROUBLESHOOTING .........................................................................................................76
7.1 Fault Codes and Remedies .....................................................................................................76
8.0 CUSTOMER SUPPORT.......................................................................................................78

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8.1 General Monitors’ Offices.........................................................................................................78
9.0 APPENDIX............................................................................................................................79
9.1 Warranty...................................................................................................................................79
9.2 Conversion Matrix – Percent of Scale to Scaled Value ...........................................................80
9.3 Periodic Testing / Calibration of Field Devices ........................................................................83
9.4 Periodic System Verification ....................................................................................................83
9.5 Specifications ...........................................................................................................................84
9.5.1 Junction Boxes............................................................................................................88
9.5.2 Splash Guards ............................................................................................................89
9.5.3 Accessories.................................................................................................................89
9.5.4 Calibration Accessories ..............................................................................................90
9.6 Calibration Schedule................................................................................................................91
9.7 Parts and Accessories .............................................................................................................92
INDEX.........................................................................................................................................95

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Table of Figures
Figure 1: Base Unit................................................................................................................................................ 8
Figure 2: Interface Module..................................................................................................................................... 9
Figure 3: Electrochemical Cell Assembly ............................................................................................................ 10
Figure 4: Mounting Dimensions........................................................................................................................... 15
Figure 5: Local Configuration Diagram................................................................................................................ 16
Figure 6: Remote Configuration Diagram............................................................................................................ 17
Figure 7: Wiring Diagram – Local Configuration .................................................................................................. 19
Figure 8: Wiring Diagram – Remote Configuration ............................................................................................. 20
Figure 9: Terminal Block Connector Pin outs...................................................................................................... 21
Figure 10: Terminal Block Connector Detail........................................................................................................ 22
Figure 11: Relay Protection for DC and AC Loads.............................................................................................. 26
Figure 12: User Menu Structure .......................................................................................................................... 30
Figure 13: Selection Magnet................................................................................................................................ 33
Figure 14: Start-up Menu Sequence ................................................................................................................... 33
Figure 15: Selectable Options ............................................................................................................................. 34
Figure 16: Relay Reset........................................................................................................................................ 41
Figure 17: Gas Check.......................................................................................................................................... 42
Figure 18: Calibration Mode ................................................................................................................................ 43
Figure 19: 10252-1 Round Anodized Aluminum Junction Box............................................................................ 88
Figure 20: B13-020-1 European Aluminum Junction Box ................................................................................... 88
Figure 21: 45167-1 Splash Guard Used for CI2, CIO2, and NO2Gases.............................................................. 89
Figure 22: 70631-2 Splash Guard ....................................................................................................................... 89
Figure 23: 45170-1 Flow Block Assy................................................................................................................... 89
Figure 24: 45172-1 Calibration Plug Assy........................................................................................................... 90
Figure 25: 1400152-1 Calibration Cup for calibrating with splash guard ............................................................ 90

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TS4000H
Table of Tables
Table 1: Glossary of Terms ................................................................................................................................... 4
Table 2: Sample Industry Applications .................................................................................................................. 7
Table 3: Installation Overview ............................................................................................................................. 11
Table 4: Required Tools ...................................................................................................................................... 12
Table 5: Gas Combination Table......................................................................................................................... 13
Table 6: TS4000H to GM Display Device DC Ground Connections ................................................................... 23
Table 7: TS4000H Terminal Block TB1 Pinouts.................................................................................................. 23
Table 8: Connection to GM Display Device 4-20 mA Connections..................................................................... 23
Table 9: Connection to Control Room Modbus Devices ..................................................................................... 24
Table 10: Connections to Remote Calibration and Relay Reset Devices........................................................... 24
Table 11: TS4000H to GM Display Device +24 VDC Connections..................................................................... 25
Table 12: TB3 Relay Contacts Energized / De-Energized Settings .................................................................... 25
Table 13: Start-up Readiness Checklist .............................................................................................................. 26
Table 14: Start-up Checklist ................................................................................................................................ 29
Table 15: User Menu Display .............................................................................................................................. 31
Table 16: Sensor Flow Rates ............................................................................................................................... 46
Table 17: Selectable Data Formats..................................................................................................................... 47
Table 18: Modbus Read Register(s) Request ..................................................................................................... 48
Table 19: Modbus Read Register(s) Response .................................................................................................. 48
Table 20: Modbus Write Register Request ......................................................................................................... 49
Table 21: Modbus Write Register Response....................................................................................................... 49
Table 22: Exception Response............................................................................................................................ 50
Table 23: Exception Codes ................................................................................................................................. 51
Table 24: Selectable Data Formats..................................................................................................................... 52
Table 25: Base Unit Mode Bitmap....................................................................................................................... 59
Table 26: Mode Descriptions............................................................................................................................... 60
Table 27: Base Unit Status Error Bitmap............................................................................................................. 60
Table 28: Alarm Relay Settings........................................................................................................................... 62
Table 29: Warning Relay Settings....................................................................................................................... 63
Table 30: MOD1 Baud Rate ................................................................................................................................ 63
Table 31: Selectable Data Formats..................................................................................................................... 63
Table 32: MOD2 Baud Rate ................................................................................................................................ 64
Table 33: MOD2 Baud Rate ................................................................................................................................ 64
Table 34: Sensor Scale ....................................................................................................................................... 65
Table 35: Fault Codes ......................................................................................................................................... 76
Table 36: Fault Code Priorities ............................................................................................................................ 77
Table 37: GM Locations ...................................................................................................................................... 78
Table 38: Conversion Matrix – Percent of Scale to Scaled Value....................................................................... 82
Table 39: System Specifications ......................................................................................................................... 84
Table 40: Mechanical Specifications – Base Unit ............................................................................................... 85
Table 41: Mechanical Specifications – Interface Module .................................................................................... 85
Table 42: Cable Requirements............................................................................................................................. 85
Table 43: Electrical Specifications........................................................................................................................ 86
Table 44: Environmental Specifications .............................................................................................................. 87
Table 45: TS4000H Toxic Gas Sensor Accuracy Specifications ........................................................................ 87
Table 46: TS4000H Part Numbers ...................................................................................................................... 92
Table 47: Replacement Sensors ......................................................................................................................... 92
Table 48: Mounting Accessories ......................................................................................................................... 93
Table 49: TS4000H Calibration Accessories....................................................................................................... 93
Table 50: Calibration Kits (Cylinder, Regulator, and Tubing).............................................................................. 93
Table 51: Spare Cylinders ................................................................................................................................... 94

1
TS4000H
About This Manual
This manual provides instructions for installing, operating, and maintaining the General
Monitors (GM) TS4000H Toxic Gas Detector. The intended audience includes installation
personnel, field service technicians, Modbus programmers, and other technical staff involved in
installing and using a TS4000H.
Format Conventions
Several format conventions are used throughout this manual for Notes, Cautions, Warnings,
User Menus, and Modbus notations. These conventions are described below.
Notes, Cautions, and Warnings
NOTE: Notes provide supplementary detail such as exception conditions, alternate methods
for a task, time saving tips, and references to related information.
CAUTION: These notices describe precautions to prevent hazardous conditions that may
damage the equipment.
WARNING: These notices describe precautions to prevent hazardous conditions that may
cause injury to people working with the equipment.
Menu Formats
TS4000H User Menu keywords and LED digital display messages are shown in bold (example:
rSt).
Modbus Register Formats
Hexadecimal numbers are used in Modbus registers and are indicated by the addition of either
“0x” in front of a number or “h” after the number (example: 0x000E or 000Eh, respectively).
Other Sources of Help
General Monitors provides extensive documentation, white papers, and product literature for
the company’s complete line of safety products, many of which can be used in combination with
the TS4000H. Many of these documents are available online at the General Monitors website
at http://www.generalmonitors.com.
Contacting Customer Support
For additional product information not contained in this manual, please contact General
Monitors Customer Support. Refer to Section 8.0 for contact information.

2
TS4000H
1.0 Before Installation
1.1 System Integrity Verification
General Monitors’ mission is to benefit society by providing safety solutions through industry-
leading products, services, and systems that save lives and protect capital resources from the
dangers of hazardous flames, gases, and vapors.
General Monitors’ safety products should be handled carefully and installed, calibrated, and
maintained in accordance with the individual product instruction manuals. To ensure operation
at optimum performance, General Monitors recommends that prescribed maintenance
procedures be followed.
1.2 Commissioning Safety Systems
Before power-up, verify wiring, terminal connections, and stability of the mountings for all
essential safety equipment including, but not limited to:
Power supplies
Control modules
Field detection devices
Signaling / output devices
Accessories connected to field and signaling devices
After the initial power-up and any factory specified warm-up period of the safety system, verify
that all signal outputs, to and from the devices and modules, are within the manufacturer’s
specifications. Initial calibration, calibration checking, and testing should be performed
according to the manufacturers’ recommendations and instructions. Proper system operation
should be verified by performing a full, functional test of all component devices of the safety
system, ensuring that the proper alarm levels occur.
Fault / Malfunction circuit operations should be verified.
1.3 Notes and Warnings
WARNING: The TS4000H detects many extremely toxic gases. Exposure to such gases may
result in sickness or death.
WARNING: The TS4000H contains components that can be damaged by static electricity. In
order to avoid static electricity, special care must be taken when wiring the
system to ensure that only the connection points are touched.
WARNING: The TS4000H Base Unit is rated Explosion Proof (XP) and the Interface Module
Intrinsically Safe (IS) for use in hazardous locations.