SMC Networks 4101-28 User manual

Model 4101-28/5100-28
IR Gas Sensor Module
APPLICABILITY&EFFECTIVITY
This manual provides instructions for the following Sierra Monitor products:
Model Description
4101-28 IR Gas Sensor Module (4-20 mA output)
5100-28 IR Gas Sensor Module (Sentry bus output)
The instructions are effective for the above models as of October 2002
Instruction Manual Part Number T12013
Rev. B1

Table of Contents
Table of Contents
1.0 Description ................................................................................................................................................................. 1
1.1 How It Works ......................................................................................................................................................... 1
1.2 Sensors Poisons and Inhibitors............................................................................................................................... 1
2.0 System Installation ........................................................................................................................................................ 2
2.1 Installation .............................................................................................................................................................. 2
2.1.1 Location of Sensors ................................................................................................................................. 2
2.1.2 Unpacking ................................................................................................................................................ 2
2.1.3 Mounting.................................................................................................................................................. 2
2.2 Wiring -- 4 - 20 mA version ................................................................................................................................... 2
2.2.1 Wiring ...................................................................................................................................................... 2
2.2.2 Jumper Location for Non-Isolated / Isolated Current Output .................................................................. 2
2.2.3 Initial LED Status - 4-20mAOperator ..................................................................................................... 2
2.2.4 Sensor Life ............................................................................................................................................... 3
2.2.5 Test Jacks ................................................................................................................................................. 3
2.3 Wiring and System Installation - Model 5000Application .................................................................................... 5
2.3.1 Wiring ...................................................................................................................................................... 5
3.0 Calibration ................................................................................................................................................................. 6
3.1 Overview ................................................................................................................................................................ 6
3.2 Local Calibration Procedure .................................................................................................................................. 6
3.3 Start Calibration ..................................................................................................................................................... 6
4.0 Specifications: ............................................................................................................................................................... 7
5.0 Limited Warranty .......................................................................................................................................................... 8

Model4101-28/5100-28IRGas SensorModule (7/03)
Page:
Instruction Manual
1.0 Description
The IR Gas Sensor Module utilizes Infrared technol-
ogy to monitor for combustible gases over the range
of 0-100% LEL. The IR Gas Sensor Module requires
minimal maintenance with a calibration check once a
year. Internal continuous self-diagnostics will auto-
matically indicate any fault or optics problems. The
IR Gas Sensor Module has both digital signal (5100-
28) and a 4-20 mAoutput signal (4101-28). The digi-
tal Sentry bus output signal interfaces directly to Si-
erra Monitor Sentry System. The 4-20 mAoutput sig-
nal can interface directly to the Sierra Monitor Model
4000 single controller or any standard industrial con-
troller.
Infrared technology has the benefits of:
• Reduced need for calibration and thus lower oper-
ating costs.
• Operates in high combustible gas and/or low oxy-
gen environment
• Works in environments where catalytic bead poi-
sons might exist
• Rapid recovery after exposure to high concentra-
tions of hydrocarbon gas (exceeding 100% LEL)
1.1 How It Works
Most combustible gases absorb infrared light energy
at defined wavelengths, providing an absorption sig-
nature for that gas. The principle of an infrared de-
tectorisbased upon theabsorption of theinfraredlight
at a specific wavelength as it passes through the gas.
Themoreof the absorbinggas that ispresent,the more
light is absorbed. The detector measures the energy
coming from an infrared light beam at a wavelength
that is absorbed by the combustible gas and compares
it to the energy transmitted by the same. The differ-
ence in energy received by the detector indicates the
level of combustible gas in the atmosphere.
1.2 Sensors Poisons and Inhibitors
The IR Gas Sensor Module is not affected by poisons
or inhibitors that may affect Catalytic bead sensors.
Fig. 1.0 Outline Dimensions
1
3.85”
4.85”
6.75”
4.50”
3.25”
4.35”
2.60”
12.05”
CURRENTO/P CHECK
Connect cu rrent prob es
to meter jacks and
read mA out put
+ Meter Jack
- Meter Jack
Cal/Reset
PowerStatus
Pull Here
CALIBRATION
- Ensu re clean ai r
- Hold reset 10 sec
until s olid green
- On fish’g red apply
50% span gas
- On solidgreen
removegas
Model 4101-28
Cal/Reset
Mag net
On Side
STATUS RE D
Slow- Gas
Fast-Cal or Fault
Solid- Overrange
C
o
m
b
u
s
t
i
b
le
G
a
s
C
o
n
tr
o
ll
e
r

Instruction Manual
Model4101-28/5100-28 IRGas SensorModule (7/03) Page:
2.0 System Installation
2.1 Installation
2.1.1 Location of Sensors
There are no absolute rules for determining the quan-
tity and location of gas detection heads to protect any
particular facility. Locate the sensors carefully in all
areas where gas escape may be expected and where it
is desirable to detect the presence of unwanted gas.
Use redundancy where enhanced protection or reli-
ability is required. Light gases such as methane tend
to rise while heavy gases such as propane tend to ac-
cumulate in low areas. Seek advice from experts who
know the characteristics of the gas being detected, air
movementpatternsand the facility.Use commonsense
and refer to various publications that discuss general
guidelines for your industry. See Application Data
SheetADS-001 for further information.
2.1.2 Unpacking
The housing and terminal board are a single assembly
to which the sensor is wired. The control module is a
separateplug-in assembly.Since all modern electronic
equipment can be damaged by static electricity dis-
charge it is important to take precautions. Discharge
static electricity from your body by touching a
grounded metal object before handling the module.
To gain access to the field terminal block remove the
module carefully from the housing by grasping the
centre “pull” knob and pull straight away. Field wir-
ing is connected to the terminal strip located in the
base of the housing.
2
2.1.3 Mounting
The housing should be oriented so that the sensor is
on the under-side of the housing. Use a conduit seal
and conduit loop or trap on the field wiring side to
preventwater or condensation from entering the hous-
ing through the conduit or its threaded connection.
2.2 Wiring -- 4-20 mAversion
2.2.1 Wiring
We recommend using shielded cable. See table be-
low. Refer to applicable wiring codes when installing
andwiring the 4101-28.After the field wiring has been
carefully connected as per Fig 2.1. CHECK THAT
THE CORRECT WIRES ARE CONNECTED TO
THECORRESPONDINGTERMINALSANDTHAT
VOLTAGE LEVELS DO NOT EXCEED THE
SPECIFICATIONS. When the wiring and voltages
have been verified, gently plug-in the control module.
Use gentle hand pressure to align and seat the module
then use firm hand pressure to fully seat the module.
Wire Gauge Maximum Length
16 AWG 2,000 ft.
14 AWG 3,500 ft.
12 AWG 6,000 ft.
10 AWG 9,000 ft.
Recommended Wire / Cable Gauge
Table 1
2.2.2 Jumper Location for Non-Isolated /
Isolated Current Output
The 4101-28 is capable of providing an isolated cur-
rent output. A jumper must be moved to select be-
tween isolated, or non-isolated current output on the
terminal board.
The analog output is precisely controlled by the inter-
nal micro-processor and digital-to-analog converter.
The standard 4 to 20ma signal is proportional to gas
concentration of 0 to 100% LEL. Additional stepped
levels below 4mA provide various diagnostic signals.
2.2.3 Initial LED Status - 4-20 mA
Operation
With power applied, check that the green POWER
LED is ON and the FAULT/ CAL LED is showing a
slow red flash during the first 90 seconds which will
then change to a short green flash every 2 seconds
(confidence blip). During the first 90 seconds the ana-
logoutputwill be at 3.0mA and then change to4.0mA.
Ifafter the 90 secondswarm-up the current isat 2.5mA
orany value other than 4.0mAthen the sensor requires
calibration and the calibration procedure must be ini-
tiated. Observation of the LED status signals and out-
put current levels aid the operator when calibrating
the sensor/transmitter as described below under
CALIBRATION.
Themoduleincludes an alphanumeric displaythat pro-
videsavariety of English languagecommands scrolled
across the display to supplement the LED sequences
and aid the operator. Please refer to the following list
and see Table of Responses

Model4101-28/5100-28 IRGas SensorModule (7/03)
Page:
Instruction Manual
3
START DELAY: power up delay in progress
SWITCH ON: magnetic reed switch is activated
SENSOR FAULT: fault present, sensor or sensor wiring table
SETTING ZERO: calibration zero gas setting in progress
APPLY 50%: apply 50% of span calibration gas
SETTING SPAN:
span gas detected,
automatic span setting in
progress
GAS: remove calibration gas
FAIL CAL: calibration span setting failed
TIME-OUT: calibration failed, no gas detected in calibration
SENSOR FAIL: sensor or sensor connections failed
NEG DRIFT: excessive negative sensor drift
Table 2: Messages
2.2.4 Sensor Life
Sensor life of the module can be expected to exceed 5
years.
Sensor response may deteriorate very slowly over a pe-
riod of years, depending on exposure to environmental
factors. If calibration becomes impossible for any rea-
son, the analog output will lock at 2.5mA and the status
LED flashes red. Install a new 4101-28 module and re-
calibrate. The calibration function automatically adjusts
span amplifier gain across a broad range without any
need for manual adjustment of potentiometers or jump-
ers.
2.2.5 Test Jacks
The module is equipped with test jacks to facilitate con-
venient current loop measurements without opening the
external current loop. To make measurements use the
following procedure;
1. Attach the current meter leads to the test jacks lo-
cated on the face plate.
2. Apply test gas and take meter readings. Set external
controller to Bypass if necessary to avoid unwanted
alarm response.
3. Remove meter leads from test jacks.
CURRENT
OUPUT LED RED LED GREEN
(mA) STATUS STATUS
Start-up delay 3 Slow Flash Start Delay
Excess drift (>10%) 2.5 Blip/blink NEG DRIFT
Auto Zero set 3 Solid SETTING ZERO
Apply calibration
gas 3.3 Fast Flash Apply 50% LEL
Span is set, remove
gas 3.6 Solid REMOVE GAS
Return to normal
operation 3.6 Solid CAL COMPLETE
Normal 4 Blip/blink 0.00%
Gas Present 4.4 – 20.0 Blip/Blink 1.0% TO 99% LEL
CONDITION ALPHANUMERIC
Table 3: LED Status
Note: The 4101-28's to 20 mA current output must be con-
nected to a load device in order to facilitate the use of the
test jacks (ie. 100 Ohm resistor must be connected between
the 4 to 20 mA signal output and the common terminal if the
unit is being bench tested to field installation).

Instruction Manual
Model4101-28/5100-28 IRGas SensorModule (7/03) Page:
Figure 2.0: Wiring Connections & Settings
4

Model4101-28/5100-28 IRGas SensorModule (7/03)
Page:
Instruction Manual
5
eludoM snoitisoPhctiwS
#123
1NONONO
2FFONONO
3NOFFONO
4FFOFFONO
5NONOFFO
6FFONOFFO
7NOFFOFFO
8FFOFFOFFO
6. When the wiring , module number, and the voltage
have been verified, gently plug in the control module.
7. The display will show Start delay Model 5100-28
Sierra Monitor.
8.Verify Sentry recognizes the desired module.
9.Calibrate 5100-28 gas sensor module.
2.3 Wiring and System Installation - Model
5000 Application
Refer to Sentry Gas Monitoring System, Ver. 6.0 In-
struction Manual.
2.3.1 Wiring
Caution: To access the wiring connections on the
5100-28, you will need to remove the enclosure cover
and then remove the cover plate. To remove the cover
plate, pull gently using the knob in the center of the
board.
1. See Table 1 for wire gauge recommendations.
2. Connect P (1) from Sentry channel to the terminal
at the right hand side which is labelled 24VDC
(position #1).
3.Connect G (3) from Sentry channel to the terminal
at the right hand side which is labelled
COMMON(position #2).
4.Connect S (2) from Sentry channel to the terminal
atthe right hand sidewhich is label Sentry (position
# 5).
5.Set the dip switch on each module to indicate the
module number. Each of the modules connected to
one controller must have a different address.
Note: Switch position 4 is not used

Instruction Manual
Model4101-28/5100-28 IRGas SensorModule (7/03) Page: 6
3.0 Calibration
3.1 Overview
All applications require an initial calibration upon
power up and before putting the modules into service.
This initial calibration is considered a local calibra-
tion, begun and completed at the module. In the Sen-
try applications, the initial local calibration is to be
followed up with a global calibration at the control-
ler. (See Chapter 5 in the Sentry manual, T121001).
In the 4-20mA applications a system calibration un-
dertake at the control device may be necessary.
During the local calibration, the module output is
clamped to prevent the control devices from interpret-
ing the calibration gas as an alarm even.
System response should be checked every 6-9 months
and the modules should be recalibrated as necessary
or at least every year.
3.2 Local Calibration Procedure
You will need the following items to
complete calibration:
• 1260-01: Cylinder ofAir if none concentration of
gas in background is greater than zero
• 1260-02: Cylinder of 50% LEL Methane balance
air or 1256-28: Cylinder of 50% LEL Propane bal-
ance air.
• 1256-04: 2LPM flow Regulator.
• 1255-02: Gas Calibration Tubing, PTFE or equal
1/4 OD
• 1250-04: Calibration Kit is a case for storage of 2
cylinders and contains the tubing and regulator
3.3 Start Calibration
1.Deliver air if necessary for 2 minutes at 2LPM.
Remove at step noted below.
2.Place and hold curved side of the magnet attached
to the module at the 10:00 position on the module
to commence calibration. The display will indicate
the "Switch is on" followed by "Setting Zero". The
status LEDs goes from slow pulsing green to steady
green.
3. Remove magnet.
4. Remove air.
5. The status LED will go green indicating span gas
may be applied.
6. Follow the prompts on the display;
7. Deliver calibration gas for 3 minutes at 2LPM.
8. Remove the gas after 3 minutes or when
prompted.
9. The status LED will go to green indication calibra-
tion was successful.
10. When the concentration of calibration gas falls to ap-
proximately 12% LEL the module will come out of the
calibration mode and be in normal operation.
11. The status LED will return to its normal pulse rate.
12. Perform a system calibration.
13. Follow chapter 5 in the Sentry manual or follow the own-
ers manual of the control device.

Model4101-28/5100-28 IRGas SensorModule (7/03)
Page:
Instruction Manual
7
4.0 Specifications:
Construction: 5100-28 Sentry Display Bus
Dimensions: 13.5 x 4.75 x 4.2 inches
(HxWxD) (34.3 x 12.1 x 10.7 cm)
Weight: 5 lb. (2.2 Kg)
Housing: Explosion proof,
Class 1, Div. I, Groups B,
C, D
Appovals CSA Class 1, DIN I,
Groups B, C, D NRTL/C
Warranty: 2 years
(Specifications subject to change without notice)
Sensor type:
Infrared
Performance
Range: 0-100% LEL methane or
propane (Other Hydrocarbons
on request)
Repeatability: +/-2% LEL
Linearit
y
:+/- 3% LEL
Zero Drift: < 1% per month
Response time: 30 sec to 90% Full Scale
Accuracy: + 3% LEL up to 50% LEL,
+ 5% LEL above 50% LEL
Sensor Life: Typically >5 years (for use at
standard temperature &
pressure)
Operating Range:
Ambient Temperature
Range: -40o to 167oF (-40o to 75oC)
Relative Humidity: 5-99%
Electrical Data:
Power consumption: 3.0 watts nominal, 5.0 watts
maximum
Loop type: 3 wire
Loop resistance: 800 Ohms @

Instruction Manual
Model4101-28/5100-28 IRGas SensorModule (7/03) Page:
5.0 Limited Warranty
SIERRAMONITOR 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. Final de-
termination of the nature and responsibility for defective or
damaged equipment will be made by SMC personnel.
All warranties hereunder are contingent upon proper use in
the application for which the product was intended and do
not cover products which have been modified or repaired
without SMC approval or which have been subjected to acci-
dent, improper maintenance, installation or application, or
on which original identification marks have been removed
or altered. This Limited Warranty also will not apply to in-
terconnecting cables or wires, consumables (ie. calibration
gases, batteries, sensors), nor to any damage resulting from
battery leakage.
In all cases SMC’s responsibility and liability under this war-
ranty shall be limited to the cost of the equipment. The pur-
chaser must obtain shipping instructions for the prepaid re-
turn of any item under this warranty provision and compli-
ance with such instruction shall be a condition of this war-
ranty.
Exceptfor the express warranty statedabove, SMC disclaims
all warranties with regard to the products sold hereunder in-
cluding all implied warranties of merchantability and fitness
and the express warranties stated herein are in lieu of all ob-
ligations or liabilities on the part of SMC for damages in-
cluding, but not limited to, consequential damages arising
out of/or in connection with the use or performance of the
product.
8