RC System SENSMART 2000 User manual

SenSmart 3000 User's Manual
Document: UM-1003 Revision Level B
2
INSTRUCTION
MANUAL
R.C. SYSTEMS CO. INC.
MODEL SENSMART 3000/2000 SENSOR TRANSMITTER
(Built with our Proven St-48 Transmitter)
PH. 409-986-9800 FAX [phone]
8621 Hwy. 6 Hitchcock, TX 77563
Website: http://www.rcsystemsco.com
Warning: Read & understand contents of this manual prior
to operation. Failure to do so could result in serious injury or death.
Users are responsible for correct translations of this manual into
their native language.

SenSmart 3000 User's Manual
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SECTION 1 –SAFETY INFORMATION......................................................................................... 1
1.1Safety Information –Read Before Installation & Applying Power ......................... 1
1.2 Contacting R. C. Systems Co. Inc.............................................................................. 1
SECTION 2 –INSTALLATION INSTRUCTIONS........................................................................... 1
2.1 Introduction.................................................................................................................. 1
2.2 Ratings and Certifications.......................................................................................... 3
2.2.1 SenSmart 3000 ATEX Certified Model................................................................ 3
2.3 Sensor Location .......................................................................................................... 3
2.4 Mounting the Enclosure.............................................................................................. 4
2.5 System Design Specifications ................................................................................... 5
2.6 Field Wiring Installation.............................................................................................. 6
2.7 SenSmart 2000 2-Wire Intrinsically Safe & Explosion Proof Installations ............ 6
2.7a Installation Drawing # 11-0100............................................................................ 8
2.8 3-Wire 4-20mA Mode Installation............................................................................... 9
2.9 Alarms / RS-485 Modbus 10-0234 Option Installation ........................................... 10
2.10 Isolated 4-20mA Output 10-0250 Option................................................................. 11
2.11 Sensor Installation (with Smart / Simple Sensor Definition)................................. 11
2.12 “Sensor Type” and SenSmart 3000 Signal Conditioning...................................... 12
SECTION 3 –INITIAL START-UP................................................................................................ 13
3.1 “Transmitter Configuration” Menu .......................................................................... 13
3.1.1 Single / Dual Gas Monitor Configuration......................................................... 14
3.1.2 Output Zero / Output Span Trims (Factory Preset, Technicians only!):....... 14
3.1.3 Model Name............................................................................................................ 14
3.1.4 Real Time Clock ........................................................................................................... 14
3.1.5 Backlight....................................................................................................................... 14
3.2 Initial Bridge Sensor Monitor Start-Up.................................................................... 15
3.2.1 Initial Bridge Sensor Monitor “Sensor Volts” Check ..................................... 15
3.2.2 Initial Bridge Sensor Monitor “Balance” Check.............................................. 15
3.2.3 Initial Bridge Sensor Monitor “Span” Check................................................... 15
3.3 Initial Toxic / Oxygen Sensor Monitor Start-Up...................................................... 15
3.3.1 Initial Toxic / Oxygen Sensor Monitor “Span” Check .................................... 15
SECTION 4 –OPERATING INSTRUCTIONS.............................................................................. 16
4.1 Routine Sensor Calibrations.................................................................................... 16
4.2 ALARM OPERATION ................................................................................................. 18
4.2.1 ALARM 3 –UNDERSTANDING FAULT / LEVEL OPERATION........................ 18
SECTION 5 –SETUP MENU CONFIGURATION ........................................................................ 18
5.1 Menus Database Configuration ............................................................................... 18
5.2 Configuration Using the Magnetic Wand:............................................................... 19
5.3 System Configuration Menus: ................................................................................. 20
Measurement Name........................................................................................................ 20
Eunits............................................................................................................................... 20
Zero.................................................................................................................................. 20
Span................................................................................................................................. 20
Decimal Points................................................................................................................ 20
Cal Span Value................................................................................................................ 20
Readout Deadband......................................................................................................... 20
Track Negative................................................................................................................ 20
Temp Compensation...................................................................................................... 21
Backup Config. ............................................................................................................... 21
Restore Config................................................................................................................ 21
Upload Sensor Data ....................................................................................................... 21
Cal Marker ....................................................................................................................... 21

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TX Sensor Life ................................................................................................................ 22
5.4 Alarm Settings:.......................................................................................................... 22
5.4.1 Relay Configuration (if equipped): ................................................................... 23
5.5 Sensor Information: .................................................................................................. 23
5.6 CLOCK/DELAY SETUP: ............................................................................................ 24
5.7 LCD Contrast Adj: ..................................................................................................... 25
5.8 HELP Screen:............................................................................................................. 25
5.9 Diagnostics:............................................................................................................... 25
5.10 RS-485 / MODBUS SETUP:....................................................................................... 25
5.10.1 MODBUS REGISTER AND FUNCTION CODE SUMMARY ............................ 26
5.11 SYSTEM SECURITY: ................................................................................................. 29
SECTION 6 –TECHNICIANS ONLY MENUS.............................................................................. 29
6.1 Introduction: .............................................................................................................. 29
6.2 Set Balance / Set Sensor Voltage (Technicians only!):......................................... 30
6.3 Set Gain to Unity (Technicians only!): .................................................................... 31
6.4 PreAmp Gain Adjust (Technicians only!): .............................................................. 31
6.5 Simple Sensor Input Type (Technicians only!):..................................................... 32
6.6 Zero Cal Value (Technicians only!): ........................................................................ 32
6.7 Raw Min / Max Counts (Technicians only!): ........................................................... 33
6.8 4-20mA Input Marker / Message (Technicians only!): ........................................... 33
SECTION 7 –SPECIAL ORDER CONFIGURATIONS................................................................ 33
7.1 ARCTIC Option .......................................................................................................... 33
7.1.1 ARCTIC Smart Sensor Temperature Setpoint Option .................................... 33
7.2 Special Order; 18VAC Primary Power Supply Option ........................................... 34
7.3 Special Order; 4-20mA Input to Bridge Channel.................................................... 35
7.3.1 4-20mA Input Marker / Message (Technicians only!): .................................... 36

SenSmart 3000 User's Manual
Document: UM-1003 Revision Level B
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SECTION 1 –SAFETY INFORMATION
1.1 Safety Information –Read Before Installation & Applying Power
IMPORTANT
Users should have a detailed understanding of SenSmart 3000 operating and maintenance
instructions. Use the SenSmart 3000 only as specified in this manual or detection of gases and
the resulting protection provided may be impaired. Read the following WARNINGS prior to use.
WARNINGS
Calibrate with known target gas at start-up and check on a regular schedule, at least
every 90 days. More frequent inspections are encouraged to spot problems such as dirt,
oil, paint, grease or other foreign materials on the sensor head.
Do not paint the sensor assembly or the Transmitter.
Do not use the SenSmart 3000 if its enclosure is damaged or cracked or has missing
components.
Make sure the cover, internal PCB’s and field wiring are securely in place before
operation.
Use only a sensor assembly compatible with the SenSmart 3000 and approved by R. C.
Systems Co. Inc. (See the section ____ for Replacement Parts.) *Not Available this
printing*
Periodically test for correct operation of the system’s alarm events by exposing the
monitor to a targeted gas concentration above the High Alarm setpoint.
Do not expose the SenSmart 3000 to electrical shock or continuous severe mechanical
shock.
Protect the SenSmart 3000 from dripping liquids and high power sprays.
Use only for applications described within this manual.
CAUTION: FOR SAFETY REASONS THIS EQUIPMENT MUST BE OPERATED AND
SERVICED BY QUALIFIED PERSONNEL ONLY. READ AND UNDERSTAND INSTRUCTION
MANUAL COMPLETELY BEFORE OPERATING OR SERVICING.
ATTENTION: POUR DES RAISONS DE SÉCURITÉ, CET ÉQUIPEMENT DOIT ÊTRE UTILISÉ,
ENTRETENU ET RÉPARÉ UNIQUEMENT PAR UN PERSONNEL QUALIFIÉ. ÉTUDIER LE
MANUE D’INSTRUCTIONS EN ENTIER AVANT D’UTILISER, D’ENTRETENIR OU DE
RÉPARER L’ÉQUIPEMENT.
1.2 Contacting R. C. Systems Co. Inc.
To contact R. C. Systems Co. Inc., call, fax, email or write:
409–986-9800 FAX [phone] Email: [email protected] 8621 Hwy. 6 Hitchcock, TX 77563
Or visit us on the World Wide Web: www.rcsystemsco.com
SECTION 2 –INSTALLATION INSTRUCTIONS
2.1 Introduction
Important: This manual describes both the 2-Wire (SenSmart 2000) and the 3-Wire (SenSmart
3000) 4-20mA versions of the ST-48 transmitter. SenSmart 2000 2-Wire versions are only
possible if the 10-0232 Display PCB IS THE ONLY PCB IN THE ENCLOSURE. If the 10-0233
I/O Power Supply is installed it is a 3-Wire version.
The SenSmart 3000 is a single or dual channel fixed-point monitor designed to provide
continuous monitoring of hazardous gases in the workplace. Monitored values are displayed in

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their engineering units as well as graphically as a bar graphs or 30-minute trends (Figure 2.1).
Input types include Electrochemical toxic / oxygen sensors, catalytic bead combustible sensors,
MOS solid-state sensors, as well as various millivolts, volt and 4-20mA inputs. Sensors supplied
by the factory include an 8-wire Smart Sensor interface capable of configuration data uploads to
the SenSmart 3000. Traditional 3-wire Simple sensors, without the smart interface, are also
supported by the SenSmart 3000. Its advanced microcontroller electronics and superior graphic
LCD operator interface offers enhanced diagnostics and fault analysis not possible in competing
products. The SenSmart 3000 provides a standard 4-20 mA output signal for connection to
control systems or other alarm instrumentation. Available options include an Alarm Relay / RS-
485-Modbus board or an Isolated 4-20mA output. Non-volatile memory retains all configuration
data during power interruptions. The magnetic, non-intrusive calibration can be easily performed
by one person without opening the enclosure. A standard “real time clock & calendar” feature
allows data logging of calibrations and alarm events for recall to the LCD readout or over the
serial port.
A separate PC compatible USB Interface allows a Smart sensor to be loaded with configuration
variables via a PC and upload this data to the SenSmart 3000. This includes alarm set points,
range, target gas, calibration constants and other variables required to match the SenSmart 3000
to a specific application. For traditional Simple sensors, without the smart interface, the USB
interface allows direct SenSmart 3000 configuration from a PC or a six channel SenSmart 3000
Educator device.
Toxic and oxygen monitors are capable of 2-wire 4-20mA operation (section 2.7) when the alarms
/ Modbus option and LCD backlight are not required. Catalytic LEL sensors, or addition of the 10-
0234 Alarms / Modbus option, require the 10-0233 I/O Power Supply board providing 3-wire 4-
20mA operation (section 2.8).
Only periodic calibration checks are needed to assure dependable performance. Operator
interface is very intuitive with the LCD displaying data both graphically as bar-graphs / trends and
in engineering units (Figure 2-1). Additional features include:
No potentiometer or jumper settings required. All setup is with menus accessed via the LCD
/ magnetic keypad operator interface without opening the enclosure.
Field adjustable alarm levels may be high, low, fault, fail-safe, latching and acknowledgeable.
New alarms cause front LED’s to flash and become steady after acknowledge.
CAL MODE advises when to apply gas during calibrations
One half hour trend screen shows rate of change of gas exposures
Sensor life bar-graph updates after each SPAN calibration.
Modular design affords efficient installation and plug in sensors allow changing target gases
after installation
New smart sensors are recognized by the SenSmart 3000 and prompts users to either
upload new configuration data or continue with data from the previous smart sensor.
Sensors are industry proven for fast response and long life.

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NEXTUP/
EDITDOWN/CAL
TXD
RXD
RS485
ALM1 ALM2 FAIL
ALM RST
% O2De f .
Dual Channel Split Screen
(Dual Sensor Mode Only)
% L EL
17 . 8
0
A 1
A 2
NEXTUP/
EDITDOWN/CAL
TXD
RXD
RS485
ALM1 ALM2 FAIL
ALM RST
10 % L E L
Engrg. Units / 30-Minute Trend
NEXTUP/
EDITDOWN/CAL
TXD
RXD
RS485
ALM1 ALM2 FAIL
ALM RST
Me a s u r e me n t Na me
% L EL
10
Engrg. Units / Bar Graph
NEXT key
toggles
readout
NEXT key
toggles
readout
Figure 2-1: Data Displays
2.2 Ratings and Certifications
CSA certified for Division 1 & 2 hazardous area installations for explosion proof Class 1 Groups
B,C,D, and intrinsically safe (SenSmart 2000 2-wire loops only) Class 1 Groups A,B,C,D. Also
see sections 2.7, 2.7a & 2.8. Designed to meet CSA C22.2 No.152 for Combustibles Monitors
and ISA 92.0.01 Part 1 for Toxic Monitors.
2.2.1 SenSmart 3000 ATEX Certified Model
An ATEX certified SenSmart 3000 model (certificate # DNV-2007-OSL-ATEX-1845) is also
available by changing the SenSmart 3000 designation to ST-ATEX48. ATEX certified models
including sensors are supplied only with sensor head part # 10-2072 and are not available with
the 10-0247 sensor head or the 0010-1200 “Y” fitting. ATEX installations must be in compliance
with EN60079-14 or suitable National or international standard and all cable glands and closing
devices must carry a suitable ATEX marking.
The ATEX label is shown below:
2.3 Sensor Location
Factors such as air movement, gas density in relation to air, emission sources and environmental
variables affect correct sensor location. Air movement by fans, prevailing winds and convection
should be carefully evaluated to determine if a leak is more likely to raise gas levels in certain
areas within the facility. Vapor density of a gas determines if it will rise or fall in air when there
are no significant currents. Lighter than air gases should have the monitors mounted 12 –18
inches (30 –45 centimeters) above the potential gas leak and heavier than air gases should be
this distance below. Even though the SenSmart 3000 is designed for rugged service, sensors
should be protected from environmental damage from water, snow, shock, vibration and dirt.

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2.4 Mounting the Enclosure
The SenSmart 3000 standard enclosure is a cast aluminum explosion-proof (NEMA 7) enclosure
as shown in Figure 2-2. Figure 2-2a shows dimensions with the dual local sensor ‘Y’ included.
Figure 2-2: SenSmart 3000 Explosion-Proof Housing
Figure 2-2a: SenSmart 3000 Explosion-Proof Housing with Dual Sensor Head Adaptor
Modular design simplifies the installation of the SenSmart 3000 (Figure 2-3). A top Display
Assembly is mounted with captive thumbscrews and is easily removed to access field-wiring
terminals. An optional 10-0234 Alarms/Modbus board mounts piggyback to the back of the
Display Assembly. Wiring from toxic or oxygen sensors terminates at the 10-0232 Display
Assembly along with 2-wire 4-20mA signal wires. This Display Assembly is the only PC board
0010-1200 “Y” Fitting not available
on ATEX compliant model

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supplied with toxic / oxygen SenSmart 3000s not requiring relays, RS-485 Modbus or LCD
backlight. The optional bottom 10-0233 I/O Power Supply board generates voltages needed for
LCD backlight, relays, RS-485 Modbus and Bridge sensor and is required with any of these I/O
functions. The enclosure is equipped with two threaded 3/4 inch NPT conduit fitting outlet and
pre-drilled mounting flanges.
WARNING: Qualified personnel should perform the installation according to applicable electrical
codes, regulations and safety standards. Insure correct cabling and sealing fitting practices are
implemented. Do not aim the sensor pointing upward. Install the SenSmart 3000 to a wall or
bracket using the predrilled mounting flanges with I.D. 0.25 on 5.5 inch centers (Figure 2-2). If
conduit is rigid and able to support the weight of the SenSmart 3000, the mounting bolts may be
omitted.
CAUTION: The sensor should never be installed pointing upwards.
Figure 2-3: Outline Drawing
2.5 System Design Specifications
Supply Voltage:
10 to 30 volts
Power Consumption:
With a typical .5 watt Bridge Sensors (requires 10-0233 I/O Power Supply and 3-wire
operation): 100 mA @ nominal 24 VDC
Toxic/Oxygen Sensors without Relays / Modbus Option (2-wire 4-20mA operation): 25 mA
max @ nominal 24 VDC.
ATEX compliant model requires
10-2072 ATEX marked sensor head

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Relays / RS-485 Modbus Option Board (requires 10-0233 I/O Power Supply and 3-wire
operation): 40 mA per relay (120 mA total with all 3 energized); RS-485 use adds 20mA
Memory:
Non-volatile E2 memory retains configuration values in the event of power outages.
Loop Resistance at nominal 24 VDC power:
650 ohms maximum in 2-wire mode
750 ohms maximum in 3-wire mode.
Relays (Optional):
Three configurable form C (SPDT) relays rated for 5 amp at 30 VDC or 240 ~VAC RESISTIVE.
Relay 1 and Relay 2 level alarms are configurable for HIGH or LOW trip, for normally energized
(Failsafe) or normally de-energized and for latching or non-latching.
Relay 3 is always normally energized for failsafe operation so loss of power to the SenSmart
3000 will be indicated as a “FAULT” condition.
CAUTION: Relays are rated for RESISTIVE loads. Inductive loads, such contactor coils or
motors may cause contact arcing, which emits RFI into the sensor signals. Use appropriate
snubbers and MOV’s across inductive loads and keep wiring away from signal wires.
2.6 Field Wiring Installation
4-20mA Transmission Range Info:
The distance 4-20 mA signals can travel is dependent upon several factors including the cable
gauge, DC power supply voltage level and impedance of the input of the receiving device.
Assuming a nominal 24 VDC power supply, maximum total loop resistance is 650 ohms in the 2-
wire mode.
Note: ST-71 Controllers have 4-20mA input resistance of 100 ohms.
2.7 SenSmart 2000 2-Wire Intrinsically Safe & Explosion Proof
Installations
SenSmart 2000s equipped with 10-0247 sensor heads are NRTL (Nationally Recognized Testing
Lab) certified as suitable for both intrinsically safe and explosion proof installations. SenSmart
2000s equipped with 10-0247IS sensor heads (XP flame arrestor is not installed to allow
monitoring of highly reactive gases such as chlorine) are NRTL certified as suitable for
intrinsically safe installations. All SenSmart 2000s are NRTL certified for explosion proof
installations as long as the sensor head is CSA certified as explosion proof. Follow instructions
on Installation Drawing # 11-0100 in section 2.7a for correct intrinsically safe installations.
Description:
The 2-wire current sinking transmitter is the easiest and most economical to install since there are
only two wires. All of the power needed comes from the current loop and wire sizes may be
smaller. However, only very low power applications are eligible for such transmitters. The
SenSmart 2000 Display assembly shown in Figure 2-4 consumes <2.5 mA of quiescent current.
Toxic and oxygen electrochemical sensors generate their own signals and therefore require no
additional current. If a 4-20mA output is all that is required for toxic / oxygen measurements (no
LCD backlight, alarms or RS-485) the SenSmart 2000 may be used in the 2-wire mode.
CAUTION: It is important to understand the receiver, or controller device must supply the loop
power in 2-wire 4-20mA modes. Be sure the receiver to be used supports this type of operation.
Instructions:
Unscrew the cover on the SenSmart 2000 explosion-proof enclosure. Loosen the 2 thumbscrews
holding the display assembly in place and remove it. A small sensor cable is attached with

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sufficient length to allow access to the back of the display assembly where 2 position TB1 is
located. Route the receiver wires through the conduit entry and connect to TB1. Steering diodes
in the SenSmart 2000 2-wire 4-20mA output automatically correct for polarity so positive and
negative are interchangeable. Reassemble the SenSmart 2000. Follow the procedures and
recommendations in the receiver manual to complete the installation. Be sure the SenSmart
2000 enclosure and conduit are properly grounded. Apply loop power by appropriately powering
the receiver device (DCS, PLC, Controller, etc) and the SenSmart 2000 should function. Proceed
to section-3.
Figure 2-4: 10-0232 Display / SenSmart 2000 2-Wire 4-20mA Assembly