RC Systems SenSmart 4000 User manual

8621 Hwy 6
Hitchcock, TX 77563
409-986-9800
www.rcsystemsco.com
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Universal Gas Detector Series
Operations Manual

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Table of Contents
Table of Figures ................................................................................................................................. I
Chapter 1 Safety Information.......................................................................................................1
1.1 Safety Information –Read Before Installation and Applying Power ............................................................1
1.2 Contacting RC Systems Inc. ..........................................................................................................................1
Chapter 2 General Description .....................................................................................................2
Chapter 3 Installation Instructions ...............................................................................................3
3.1 Selecting a Location .....................................................................................................................................3
3.2 Mounting the Enclosure ...............................................................................................................................4
3.3 Power and Analog Outputs Wiring...............................................................................................................4
3.3.1 SenSmart 4000 ...................................................................................................................... 5
3.3.2 SenSmart 5000 and SenSmart 8000X ................................................................................... 5
3.4 Option Board Wiring ....................................................................................................................................6
3.4.1 SenSmart 5000 RS 485 Option Board.................................................................................... 6
3.4.2 SenSmart 5000 Relay Option ................................................................................................ 7
3.5 Remote Sensor Installation ..........................................................................................................................8
3.5.1 SenSmart 5000 Remote Sensor ............................................................................................ 8
3.5.2 SenSmart 8000X Remote Sensor .......................................................................................... 9
3.6 Sensor Installation and Replacement .........................................................................................................10
3.7 Smart Sensors.............................................................................................................................................10
Chapter 4 General Operating Instructions ..................................................................................11
4.1 Introduction................................................................................................................................................11
4.2 General Setup for SenSmart 4000 and SenSmart 5000 ..............................................................................11

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4.3 Wireless Network Setup for SenSmart 8000 and SenSmart 8000X ............................................................12
4.4 Normal Operation ......................................................................................................................................12
4.5 Fault Condition ...........................................................................................................................................12
4.6 Alarm Conditions ........................................................................................................................................13
4.6.1 SenSmart 4000 .................................................................................................................... 13
4.6.2 SenSmart 5000 .................................................................................................................... 13
Chapter 5 Calibration Procedure ................................................................................................14
5.1 Preparation ................................................................................................................................................14
5.2 Routine Calibration Procedure ...................................................................................................................16
5.3 Bump Test Procedure .................................................................................................................................17
Chapter 6 Maintenance Procedure.............................................................................................18
6.1 Regular Maintenance.................................................................................................................................18
6.2 Sensor Replacement ...................................................................................................................................18
Appendix 1 Gas Detector Specifications ........................................................................................19
Appendix 2 Sensor Specifications .................................................................................................22
Appendix 3 Modbus Table and Operations ...................................................................................24
Appendix 4 Menu Navigation .......................................................................................................25
Appendix 5 Antenna Selection......................................................................................................30
Antenna Transmission Range..................................................................................................................................30
Antenna Selection and Location ..............................................................................................................................30
Water-proofing Antenna Connections ....................................................................................................................31
Dipole and Collinear Antennas ................................................................................................................................31
Yagi Antennas..........................................................................................................................................................32
Mounting Near other Antennas ..............................................................................................................................32

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Coax Cables .............................................................................................................................................................32
Surge Protection and Grounding .............................................................................................................................33
Antenna Grounding .................................................................................................................................................33
Connections to other Equipment.............................................................................................................................34
Appendix 6 Ordering Information.................................................................................................35
Appendix 7 Frequently Asked Questions.......................................................................................36
Appendix 8 Channel States...........................................................................................................38
Appendix 9 Drawings ...................................................................................................................39

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Table of Figures
Figure 1 Mounting Dimensions..................................................................................................................... 4
Figure 2 SenSmart 4000 Wiring .................................................................................................................... 5
Figure 3 SenSmart 5000 Wiring .................................................................................................................... 5
Figure 4 SenSmart 5000 Modbus Option Wiring .......................................................................................... 6
Figure 5 SenSmart 5000 Relay Option Wiring............................................................................................... 7
Figure 6 Remote Sensor Option.................................................................................................................... 8
Figure 7 Stainless Steel Sensor Head .......................................................................................................... 10
Figure 8 Universal Gas Detector Data Display Screens............................................................................... 12
Figure 9 Calibration Diagram ...................................................................................................................... 15
Figure 10 Calibration Menu Flowchart .......................................................................................................16
Figure 11 Gas Detector Specifications Table .............................................................................................. 19
Figure 12 Water-proofing Antenna Connections........................................................................................ 31

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Chapter 1 Safety Information
1.1 Safety Information –Read Before Installation and Applying Power
The following symbols are used in this manual to alert the user of important instrument operating
issues:
This symbol is intended to alert the user to the presence of important operating and
maintenance (servicing) instructions.
This symbol is intended to alert the user to the presence of dangerous voltage within the
instrument enclosure that may be sufficient magnitude to constitute a risk of electric
shock.
WARNINGS:
WARNING- EXPLOSION HAZARD -DO NOT REPLACE FUSE UNLESS POWER HAS BEEN SWITCHED
OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS.
WARNING- EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN
SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS.
Use a properly rated CERTIFIED AC power (mains) cable installed as per local or national codes
A certified AC power (mains) disconnect or circuit breaker should be mounted near the
controller and installed following applicable local and national codes. If a switch is used instead
of a circuit breaker, a properly rate CERTIFIED fuse or current limiter is required to be installed
as per local or national codes. Markings for positions of the switch or breaker should state (I)
for on and (O) for off.
Clean only with a damp cloth without solvents.
Equipment not used as prescribed within this manual may impair overall safety.
1.2 Contacting RC Systems Inc.
To contact RC Systems Inc., call, fax, email or write:
409–986-9800 FAX [phone] Email: [e-mail]
8621 Hwy. 6 Hitchcock, TX 77563
Or visit us on the Web at www.rcsystemsco.com
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SenSmart 8000 and 8000X
SenSmart 5000
SenSmart 4000
Chapter 2 General Description
The Universal Transmitter Series consists of a
common processor board connected to various
combinations of input output options. The
models are based on wireless vs wired
communications; and powering as follows:
SenSmart 4000 –Low-power, 4-20mA loop
powered gas detector for toxic and oxygen
detection. Includes a 4-20mA output.
SenSmart 5000 –10-30VDC powered gas
detector for toxic, oxygen, combustible, VOC and
CO2 detection. This model adds a color backlit
LCD display, and has Modbus and/or 4-20mA
communications and relays available.
SenSmart 8000 –Battery powered wireless gas
detector for toxic, oxygen, combustible and CO2
detection. Available in either 900MHz or 2.4GHz
models.
SenSmart 8000X –10-30VDC powered wireless
gas detector for toxic, oxygen, combustible and
CO2 detection. This model adds a color backlit
LCD display.
All models use RC Systems latest Smart Sensor
technology, providing smarter gas detection
with simplified solutions.

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Chapter 3 Installation Instructions
3.1 Selecting a 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 detector mounted 12 to 18 inches (30 to 45 cm) above the
potential gas leak, and heavier than air gases should be this
distance below the potential gas leak.
The Universal Series of gas detectors are designed for
rugged service in the field. However, sensors should always
be protected from environmental damage from water,
snow, shock, vibration and dirt.

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3.2 Mounting the Enclosure
Install the detector to a wall or bracket using the predrilled mounting flanges with I.D. 0.25
on 5 inch centers (Figure 1). If conduit is rigid and able to support the weight of the
universal detector, the mounting bolts may be omitted.
After you have determined the appropriate location for your gas detector, it is important to securely
mount the gas detector using the predrilled mounting flanges on the enclosure. Dimensions for the
mounting holes can be found for both the aluminum and poly enclosures in Figure 3-1.
Figure 1 Mounting Dimensions
3.3 Power and Analog Outputs Wiring
WARNING: Qualified personnel should perform the installation according to applicable
electrical codes, regulations and safety standards. Ensure correct cabling and sealing
fitting practices are implemented. Do not aim the sensor pointing upward.
Modular design simplifies the installation of the universal gas detectors. A top display assembly is
mounted with captive thumbscrews, and is easily removed to access field-wiring terminals. Option

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boards mount to the back of the display assembly, and power, input and output wires mount to the
power supply board.
3.3.1 SenSmart 4000
The SenSmart 4000 is powered through a non-polar 4-20mA loop connected to TB2. Connect the +10-
30VDC/4-20mA loop wires to TB2.1 and TB2.2 on the 2-wire 4-20mA Output Board (Figure 2).
TB2
1 2
TB2. - +10-30VDC/4-20mA
(non-polar)
TB2. - +10-30VDC/4-20mA
(non-polar)
1
2
Figure 2 SenSmart 4000 Wiring
3.3.2 SenSmart 5000 and SenSmart 8000X
The SenSmart 5000 and SenSmart 8000X are 10-30VDC powered, and have a dedicated 4-20mA output
terminal. Connect the 10-30VDC Positive wire to terminal TB2.1. Connect the 10-30VDC Negative
(Common) wire to terminal TB2.3. Connect the 4-20mA signal wire to terminal TB2.5 on the I/O Board
(not necessary for SenSmart 8000X wireless communication) (Figure 3).
TB2. - 10 to 30VDC
Positive (+)
TB2. - 10 to 30VDC
Common (-)
TB2. - 4-20mA Output
1
3
1
1
2
3
4
6
5
5
Figure 3 SenSmart 5000 Wiring

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3.4 Option Board Wiring
3.4.1 SenSmart 5000 RS 485 Option Board
The RS 485 Option (Figure 4) adds a single Modbus master port and a single Modbus slave port.
For the Modbus master port, connect your Modbus communication wires to terminals TB1.A and TB1.B,
and connect your shield wire to TB1.SHLD.
For the Modbus slave port, connect your Modbus communication wires to terminals TB2.A and TB2.B,
and connect your shield wire to TB2.SHLD. Note that there are two sets of terminals labeled TB2.A and
TB2.B. This allows you to connect multiple SenSmart 5000 gas detectors in series. Each SenSmart 5000
represents an RS-485 slave, and must have a unique Remote ID address (slave address). It is also
important to note that wiring should be daisy chained as opposed to a star pattern for reliable
operation. RC Systems recommends using shielded twisted pair cable such as Belden 3106A.
TB1 –RS485 Modbus Master Port
TB2 –RS485 Modbus Slave Port
TB2
A
B
S
A
B
S
A
B
TB1
Figure 4 SenSmart 5000 Modbus Option Wiring

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3.4.2 SenSmart 5000 Relay Option
The SenSmart 5000 Relay option (Figure 5) includes three programmable relays and a single
programmable RS 485 Modbus master or slave port. The relay labeled “FAILSAFE” is set up as a failsafe
Fault relay by default, but can be configured as a programmable relay in the Relay Settings menu. It is
possible to use only the relays, only Modbus or both.
The relay terminals are labeled NO (Normally Open), NC (Normally Closed) or C (Common, or pole).
These designators correspond to the shelf, or de-energized, state of the relays. When a relay is in
Failsafe mode, it is energized when the alarm condition is not met, and therefore its action is reverse of
the designators.
For the RS-485 Modbus master/slave port, connect your Modbus communication wires to terminals
TB1.A and TB1.B, and connect your shield wire to TB1.SHLD.
TB1 –RS485 Modbus Master/
Slave Port
TB2–Relay Terminals
TB2
A B S
TB1
RLY 1 RLY 2 FLT
Figure 5 SenSmart 5000 Relay Option Wiring

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3.5 Remote Sensor Installation
3.5.1 SenSmart 5000 Remote Sensor
Use of the Remote Sensor Option Board requires the SenSmart 5000 to be equipped with a RS 485
Option or Relay Option Board. The Remote Sensor Option Board communicates to the SenSmart 5000 by
utilizing one of the RS-485 communication ports located on the option board.
Connect 24VDC and ground wires to the 24V and GND terminals on TB1 or TB2 of the Remote Sensor
Option Board to supply the necessary 24V. Connect the A and B terminals of TB1 or TB2 of the Remote
Sensor Option Board to the A and B Master Port terminals of the Relay/RS-485 Option Board.
SenSmart 5000 with RS485
Modbus/Relay Option
Remote Sensor Option
Figure 6 Remote Sensor Option

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3.5.2 SenSmart 8000X Remote Sensor
The Remote Sensor Option Board communicates with the SenSmart 8000X via the Modbus master port
located on the SenSmart 8000X’s radio board.
Connect 24VDC and ground wires to the 24V and GND terminals on TB1 or TB2 of the Remote Sensor
Option Board to supply the necessary 24V. Connect the A and B terminals of TB1 or TB2 of the Remote
Sensor Option Board to the A and B Master Port terminals of the radio board of the SenSmart 8000X.
Place holder for radio board/remote sensor drawing

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3.6 Sensor Installation and Replacement
The Universal Gas Detector series of monitors utilize RC Systems’ Gen II Smart Sensors. These sensors
come factory installed, and provide our highest level of performance with increased accuracy and signal
to noise ratio. The 8-conductor Smart Sensor interface connector attaches to the J1 connector on the
base board, and the detector detects the type of sensor automatically. This makes it easier than ever to
switch from any of our electrochemical Smart Sensors to any of our bridge (infrared, catalytic bead and
PID) Smart Sensors without having to reconfigure wiring.
3.7 Smart Sensors
WARNING: Prior to performing sensor replacement ensure the area has been declassified.
To install a new sensor, simply remove the sensor head cap, remove the old sensor assembly and align
the alignment arrows on the new sensor assembly with the sensor head body and press the sensor
assembly toward the sensor head body until it has fully seated in the connector. The sensor board
should be flush with the edge of the sensor head body when fully seated. Reinstall the sensor head cap,
and follow the on-screen prompts to upload the sensor settings into the gas detector.
Important: Sensor assembly must be fully inserted into the sensor head body when
tightening the sensor head cap. Failure to do so could result in damage to the sensor and/or
the sensor head body.
Figure 7 Stainless Steel Sensor Head
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Chapter 4 General Operating Instructions
4.1 Introduction
Swiping a magnetic wand past the Edit key, from any of the Data Display screens, displays the Main
Menu. The Up and Down keys maneuver the selection bar up and down, and Edit selects the highlighted
item to enter the sub-menus. All items with a sub-menu are indicated by a right facing arrow at the end
of the line. To edit menu item values swipe the Edit key, and use the Up and Down keys to edit the
value. Once the desired value is entered, swipe the Edit key again to save the value. Swipe the Next key
to reverse out of a sub-menu.
Important: Some values require a Technician Sequence to be entered to change their
values. This is to prevent the operator from inadvertently changing the values. When
prompted to “Enter technician sequence:” simply swipe the Up key four times to unlock the
value for editing.
4.2 General Setup for SenSmart 4000 and SenSmart 5000
After ensuring proper installation perform the following steps:
1. Apply power to the gas detector
2. Verify the detector has begun startup.
Note: Once the detector is on the data screen, you may notice high or low values out of the full-scale
range. These values should quickly return to the zero gas value if no gas is present. No false alarms
should be indicated at this time as the zero gas value will be transmitted by the detector during the
user-defined warmup delay period (up to 5 minutes).
3. Using the magnetic interface, navigate the menus to ensure:
a) Alarm levels for Alarm 1, 2 and 3 are set to the desired value
Note: SenSmart 5000 series gas detectors have optional relays, which should also be set up at this time.
When no relays are installed, alarms are indicated only by the display color and/or alarm LEDs.
b) Time and date are set correctly
c) Engineering units are set to the desired value
d) Calibration span gas value is set to the value of the calibration gas that will be used to
perform initial calibration
e) Calibration marker is set to the desired value (this is the value the output will be held at
during calibration and the calibration purge delay)
4. After sensor has stabilized, perform routine sensor calibration in accordance with Chapter 5.
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4.3 Wireless Network Setup for SenSmart 8000 and SenSmart 8000X
The Universal Gas Detector series utilizes R.C. Systems’ WaveNet wireless technology to make setup
simplified with three easy steps.
1. Power on the SenSmart 8000/8000X (for the SenSmart 8000 hold a magnet over the Up key, for
the SenSmart 8000X apply 10-30VDC to the power terminals).
Note: Once the detector is on the data screen, you may notice high or low values out of the full-scale
range. These values should quickly return to the zero gas value if no gas is present. No false alarms
should be indicated at this time as the zero gas value will be transmitted by the detector during the
user-defined warmup delay period (up to 5 minutes).
2. Using the magnetic interface, navigate the menus to :
a. Ensure the Network ID matches the Network ID of the controller.
b. Set the RTU number to the desired number.
3. Verify proper operation by ensuring readings on gas detector and controller match.
4.4 Normal Operation
During normal operation the sensor data is displayed on one of three data display screens as shown
below. To cycle through the data display screens, use a magnet and swipe the Next key until the desired
screen is reached.
Figure 8 Universal Gas Detector Data Display Screens
4.5 Fault Condition
The Fault alarm is used to indicate a condition when there is a failure from the sensor or an out of range
state has been reached. It is recommended to set the fault alarm level to -10% of the span value. For
example if an H2S sensor is installed with a span value of 100, the fault should be set at -10, or if an
oxygen sensor is installed with a span value of 25, the fault setting should be -2.5.
If relays are installed, the Fault relay is always Failsafe. This is necessary for the relay to de-energize in
the event there is a loss of power, so that a Fault will be indicated.
If relays are not installed, a Fault condition will only be indicated by the display color changing to red
and/or the red Fault LED flashing.

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Figure 9 SenSmart 5000 Fault Screen
4.6 Alarm Conditions
4.6.1 SenSmart 4000
Alarm levels are user configured. When an alarm condition is met the alarm condition will be indicated
by the alarm LED flashing.
4.6.2 SenSmart 5000 and SenSmart 8000X
The SenSmart 5000 and SenSmart 8000X allow the user to select the color associated with a certain
alarm level. Options include yellow, orange, red, blue and purple. Alarm 1 is always set to yellow, and
the Fault alarm is always set to Red.
Figure 10 SenSmart 5000 and SenSmart 8000X Alarm Screens
When an alarm level is reached, the display will change to the user defined color and the alarm level will
flash on the display. If Latching is turned on, the alarm will stay enabled until the user acknowledges the
alarm, even if the alarm condition has cleared.

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Chapter 5 Calibration Procedure
5.1 Preparation
Calibration is the most important function for ensuring correct operation of the Universal Series of gas
detectors. The CAL MODE is designed to make calibration quick, easy and error free, and a successful
Zero and Span calibration requires only four keystrokes. The 4-20mA output transmits 3mA during the
calibration, and 4mA during calibration purge to prevent alarms. After 5 minutes of inactivity the gas
detector will exit calibration mode automatically.
RC Systems recommends performing calibrations
Immediately prior to placing a gas detector in service
Any time a new sensor is installed
Every six months for routine calibrations (more often if sensor is known to have been
exposed to gas for extended periods of time)
Periodic bump tests are recommended if detector has potentially been exposed to
incompatible gases to ensure correct operation
Follow these calibration guidelines to ensure proper operation of your RC Systems, Inc. gas
detector:
Calibration accuracy is only as good as the calibration gas accuracy. RC Systems
recommends calibration gases with National Institute of Standards and Technology (NIST)
traceable accuracy to increase the validity of the calibration.
Do not use gas cylinders beyond their expiration date.
Calibrate a new sensor before it is put in use.
Allow the sensor to stabilize before starting calibration.
Calibrate on a regular schedule. RC Systems recommends once every 6 months, depending
on use and sensor exposure to poisons and contaminants.
Calibrate only in a clean atmosphere, free of background gas.

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Figure 11 Calibration Diagram
Prior to beginning your calibration make sure you have the following items:
1. A cylinder of calibration gas with concentration equal to the SPAN GAS VALUE setting (RC
Systems typically recommends choosing a value at 50% of full scale.)
2. A cylinder of Zero Air (unless you are confident there is no target gas potentially present in
the area)
3. A flow regulator, a fixed flow of 0.5LPM is recommended for most applications, but some
instances may require a 1.0LPM fixed flow regulator.
4. A Calibration Cup or Calibration Adaptor
5. Sufficient length of flexible tubing to connect the regulator to the calibration adaptor