Model 4501-XX 2-Wire Series Toxic Gas Sensor Module

Transcription

1 odel 4501-XX 2-Wire Series Toxic Gas Sensor odule APPLICABILITY & FFCTIVITY ffective for all odel 4501-XX odules manufactured after July (F Approved) anual # T13022 Document Revision: C1

2 Driver Version: 1.00 Document Revision: 0

3 odel 4501-XX Toxic Gas Sensor odule 2017 Sierra onitor Corporation. All rights reserved. anual Number: T13022 This manual contains intellectual property that was developed by Sierra onitor Corporation and is protected by the copyright laws of the United States, international copyright treaties, and all other applicable national laws. This manual contains information regarding technology that is protected under one or more issued or pending United States and foreign patents. Sierra onitor and Sentry IT are trademarks of Sierra onitor Corporation. All other trademarks are the property of their respective owners. This manual is licensed to users of Sierra onitor products and may be copied, in whole or in part. The offices of Sierra onitor are located at: Sierra onitor Corporation 1991 Tarob Court ilpitas, CA USA Customer Service: Telephone: (408) Fax: (408) Toll-Free: (800) mail: Website: Contact Information

4 F PRFORANC APPROVAL odel 4501-XX Toxic Gas Sensor odule ONLY TH FOLLOWING ITS, FUNCTIONS AND OPTIONS AR F* APPROVD Sensor odule odel Hydrogen Sulfide Gas Sensor odule odel Calibration quipment odel odel odel odel Sensor odule - Hydrogen Sulfide Gas Sensor Calibration Kit, Type A Hydrogen Sulfide in N2, 25 ppm Gas Cylinder Hydrogen Sulfide in N2, 10 ppm Gas Cylinder Calibration Adapter Notes: 1) Apparatus must be installed in accordance with National lectrical Code. 2) F Comments *F Approvals, a subsidiary of F Global Project# Table of Contents

5 odel 4501-XX Toxic Gas Sensor odule TABL OF CONTNTS TABL OF CONTNTS...5 LIST OF FIGURS PRODUCT DSCRIPTION General ounting Configuration Theory of Operation echanical nclosure Transmitter lectronics Sensor Assembly Interconnected Wiring Power Requirements CAUTIONS AND WARNINGS Introduction Gas Sensor odules General Wiring Calibration Frequency QUICK START Overview Wiring odule Installation Transmitter Installation Start-Up & Operation Zero Stabilization INSTALLATION Sensor odule Locations Wiring nclosure Installation Transmitter and Sensor Installation OPRATION Introduction Data ntry Keypad ain enu Setup Sub-enu aintenance Sub-enu CALIBRATION Calibration Frequency Calibration Preparation Calibration Gas Delivery ethods Sensor xposure to Gas Calibration Sub-enu APPNDIX A. SRVIC Appendix A.1. Sensor odule Configuration Appendix A.2. nclosure Replacement Appendix A.3. Transmitter Replacement Appendix A.4. Sensor Replacement Appendix A.5. Installation Inspection Appendix A.5.1. Controller Installation Appendix A.5.2. Cabling Installation Appendix A.5.3. Sensor odule Installation Appendix A.5.4. oisture Traps And Rainshields List of Figures

6 odel 4501-XX Toxic Gas Sensor odule Appendix A.5.5. Standard Voltages Appendix A.6. Inspection and Troubleshooting Guide Appendix A.6.1. odule Does Not Respond to Gas Appendix A.6.2. The odule Displays Starting for ore Than 1 Hour Appendix A.6.3. The odule Does Not Display The Correct PP Appendix A.6.4. The Display Shows F OR NO SNSOR Appendix A.6.5. The Display Shows C APPNDIX B. SPCIFICATIONS APPNDIX C. ODL NUBRS & PARTS LIST APPNDIX D. LIITD WARRNTY APPNDIX & GAS SNSOR ODUL APPNDIX F. US F APPROVAL APPNDIX F: CANADIAN F APPROVAL APPNDIX G. ATX CRTIFICAT APPNDIX H. PIP OUNTING FOR 4501-XX ALUINU Table of Contents

7 odel 4501-XX Toxic Gas Sensor odule LIST OF FIGURS Figure 1: odel 4501-XX Hydrogen Sulfide Gas Sensor odule ounting Options...9 Figure 2: odel S1/S2/A2 Toxic Gas Sensor Stainless Steel/Aluminum nclosure, Dimensions Figure 3: odel A1 Toxic Gas Sensor Cast Aluminum nclosure, Dimensions Figure 4: Specific Gravities Figure 5: Typical ounting Options Figure 6: 4-20 ma Connection Figure 7: Connector Locations Figure 8: Face Plate with Operator Keypad Figure 9: aster enu Figure 10: Operation Display Values Figure 11: Set-Up Configuration Figure 12: aintenance Sub-enu Figure 13: odel Calibration Adapter Figure 14: Calibration Sub-enu Figure 15: odule Components Figure 16: lectrolyte Replacement Figure 17: Sensor Assembly xploded View Figure 18: odel A1 and odel A Figure 19: odel S1 and odel S Figure 20: odel 4501-XX-A1 Aluminum nclosure Pipe ount Figure 21: Pipe ount Bracket for 4501-XX-A1 Aluminum nclosure List of Figures

8 odel 4501-XX Toxic Gas Sensor odule 1 PRODUCT DSCRIPTION 1.1 General The odel 4501-XX Toxic Gas Sensor odule is a 2-wire transmitter with 4-20 ma output and it offers a broad array of features including: 2-wire loop powered 180 day calibration interval Selectable ranges (if appropriate for gas type) Non-intrusive one-person calibration Integral LCD 2-line, 20-character display Stainless steel enclosure and sensor housing 4-20 ma output Long sensor life Rotatable faceplate enables multidirectional conduit installation. The 4501-XX is designed and approved for installation and operation in hazardous locations. embers of the 4501-XX Two-Wire Toxic Gas family include: Oxygen Gas Sensor odule Carbon onoxide Gas Sensor odule Hydrogen Sulfide Gas Sensor odule Chlorine Dioxide Gas Sensor odule Chlorine Dioxide Gas Sensor odule Sulfur Dioxide Gas Sensor odule Nitrogen Dioxide Gas Sensor odule Ammonia Gas Sensor odule Hydrogen Fluoride Gas Sensor odule 1.2 ounting Configuration Various module mounting configurations can be implemented without special fixtures. Where applicable, these options are factory configured prior to shipment. ounting configuration can be selected by the installer or field technician and are fully described in this manual. Sensor must always be oriented downward. Page 8 of 42

9 odel 4501-XX Toxic Gas Sensor odule 1.3 Theory of Operation lectrochemical sensors are fuel cell-like devices consisting of an anode, cathode and electrolyte. The components of the cell are selected so a subject gas, allowed to diffuse into the cell, will cause a chemical reaction and generate a current. The cells are diffusion limited so the rate the gas enters the cell is solely dependent on the gas concentration. The current generated is proportional to the rate of consumption of the subject gas in the cell. Sierra onitor electrochemical sensors provide improved reliability by allowing the gas to diffuse into the sensor through a capillary port, rather than diffusing through membranes. The result is an extremely stable sensor with very low temperature and pressure coefficients and the capability to monitor gas as ppm. 1.4 echanical The sensor module is comprised of the following three primary components: nclosure xplosion proof, rain-tight aluminum or stainless steel electrical (Figure 2 & Figure 3) housing with three ¾ FNPT conduit hubs. The enclosure cover has a viewing window. The 3 conduit hubs combined with the rotatable faceplate enable the user to mount the module in a variety of configurations (Figure 1). Figure 1: odel 4501-XX Hydrogen Sulfide Gas Sensor odule ounting Options NOT: odule installation must be such that it is mounted vertically with sensor pointing downward. Page 9 of 42

10 odel 4501-XX Toxic Gas Sensor odule Figure 2: odel S1/S2/A2 Toxic Gas Sensor Stainless Steel/Aluminum nclosure, Dimensions Figure 3: odel A1 Toxic Gas Sensor Cast Aluminum nclosure, Dimensions Page 10 of 42

11 odel 4501-XX Toxic Gas Sensor odule Transmitter lectronics lectronic Assembly consisting of one printed circuit board assembly mounted under a cover plate. Wiring connections for power and signal interface are located on the back side of the display Sensor Assembly The sensor assembly includes a stainless steel, explosion proof, housing containing the gas sensor and a wiring harness for connection to the transmitter. The sensor assembly threads into one hub of the enclosure. The exposed end of the sensor assembly is threaded to allow connection of a rain-shield or calibration gas delivery fitting. 1.5 Interconnected Wiring Not supplied with the sensor module, but necessary to the installation and operation is the two conductor wiring shielded which connects the module to its power source and controller. Before this wiring is installed it is important to read and understand the control system installation instructions to determine wiring requirements and alternatives. 1.6 Power Requirements The 4501-XX module operates on DC power between 14 VDC and 30 VDC. The DC power must be supplied by the loop controller. Page 11 of 42

12 odel 4501-XX Toxic Gas Sensor odule 2 CAUTIONS AND WARNINGS 2.1 Introduction Although the 4501-XX Gas Sensor odule is designed and constructed for installation and operation in industrial applications including hostile environments, caution should be taken to insure that the installation is made in compliance with this instruction manual and that certain procedures and conditions are avoided. This chapter discusses the necessary cautions. Read the entire chapter prior to installation of the equipment. 2.2 Gas Sensor odules General Avoid installing sensor modules where they will be unnecessarily exposed to wind, dust, water (i.e. direct hose down), shock, or vibration. Observe temperature range limitations. Sensors may be adversely affected by prolonged exposure to certain materials. Loss of sensitivity or corrosion, may be gradual if such materials are present in low concentrations. These materials include: Halides (compounds containing chlorine, fluorine, bromine, iodine), acid vapors, caustic liquids or mists. Care has been taken by the manufacturer to ship modules in protective packaging to avoid contamination prior to installation. It is recommended that the modules remain protected during installation and that the covering be removed immediately prior to system start up. During normal use the O2, CO, H2S, SO2, and NO2 sensors are protected from dirt and oil contamination by a sintered metal cover. If this cover becomes clogged, the response of the sensor will be reduced. Protect the sensor from contamination by careful placement, or by use of rain shields and dust shields. Sensor modules must not be painted. Paint may contain compounds which will contaminate the sensor. Paint will cause clogging of the sintered metal cover and will cause difficulties during attachment of the calibration head or other maintenance activity. It is recommended that the module be tagged DO NOT PAINT. 2.3 Wiring The manufacturer recommends that extra caution be taken where the installation is near any sources of electromagnetic or radio frequency interference. Precautions include: Avoid running sensor module cable close to high power cables, radio transmission lines, or cables subject to pulses of high current. Avoid running cables near large electric motors or generators. Analog devices require shielded cable. In conduit installations and cable applications the shield should be connected to instrument ground. All splices must be via either a termination hardware system or soldered. Improperly spliced cable can result in corrosion, resistance changes and system errors. NOT: Installation and wiring must be in accordance with the National lectrical Code. Voltage AC conductors are not to be run in the same conduit as voltage DC conductors. 2.4 Calibration Frequency The 4501-XX calibration frequency is six months (180 days). However, prudent gas detector maintenance practices normally suggest a simple recalibration following incidences of exposure to high levels of gas that would lead to alarm activation within any system utilizing the output of the gas sensor module. Page 12 of 42

13 odel 4501-XX Toxic Gas Sensor odule 3 QUICK START 3.1 Overview The gas sensor module has been supplied factory calibrated and ready for immediate installation and operation. An installer familiar with installation and operation of gas detection products can use this section to begin immediate use of the module. 3.2 Wiring Provide two conductor twisted shielded wiring from the power supply/control device to the sensor module location. Use wire that is 18 AWG or larger. 3.3 odule Installation The 4501-XX can be mounted in a variety of configurations supported by the conduit. See Figure 2 to determine which configuration is best for your specific application. The default configuration enables the modules to be put in line with other modules with the sensor element below the transmitter. To change the configuration simply remove the transmitter and rotate to the appropriate configuration and remount the standoffs and transmitter. The module is designed to be installed on a ¾ conduit. Three important warnings: The installation must meet any hazardous environment codes for electrical equipment. The sensor module enclosure mounting must be spaced far enough from any vertical surface to allow removal and replacement of the sensor assembly which is threaded into one ¾ conduit entry. Sensor housing must be oriented vertically pointing downward. 3.4 Transmitter Installation To install the transmitter printed circuit assembly into the housing, carefully turn the faceplate so that the printing is in the correct horizontal position for the mounting configuration and slide the assembly over the two stand-offs in the enclosure. Hand tighten the two captive panel thumb screws into the stand-offs. Replace the enclosure cover prior to providing power to the transmitter. NOT: For transmitters installed in classified hazardous areas, replace the threaded cover prior to providing power. 3.5 Start-Up & Operation To begin operation of the sensor module activate the instrument loop with VDC. ach time the sensor module is powered up it will perform a warm-up for approximately 1.0 minutes (60 seconds). During this time the display will read Starting. The loop output will be held at 4 ma. NOT: If the sensor is uncalibrated, the startup display will state UNCALIB instead of STARTING. NOT: The , , and require 300 seconds warm-up period. After the warm-up period has expired, the display will indicate the gas concentration. Also, the instrument loop will be released to output current in the range of 4 to 20 ma. The actual current is linear with the gas concentration and depends on the selected range. For instance, when the range of 0 to 50 PP has been selected, a current of 4 ma corresponds to 0 PP and a current of 20 ma corresponds to 50 PP. 3.6 Zero Stabilization All electrochemical sensors require at least 30 minutes on power prior to calibration. This allows the electrode potentials to equilibrate, resulting in a stable zero signal level. Page 13 of 42

14 odel 4501-XX Toxic Gas Sensor odule 4 INSTALLATION 4.1 Sensor odule Locations The gas sensor module utilizes a diffusion type sensor which should be located close to either the expected source or destination of the gas hazard. If the gas is heavier than air, the sensor module should be installed within 24 inches of the ground or floor. If it is lighter than air, move it above 6. After optimum locations are determined based on the above recommendations, consideration should be given to placing the sensor modules in locations which are accessible for calibration service. Slight adjustments to the location of the sensor module may have little impact on effectiveness but major effect on accessibility. odel Gas Specific Gravity N/A Air CO H2S Cl ClO SO NO NH HF 1.86 Figure 4: Specific Gravities odules should be placed in areas accessible for calibration. The cover should face out from the wall for easy access. Sensors should be pointed down and the conduit should include an inverse trap to reduce moisture (condensation) from accumulating in the electronics enclosure. Figure 5: Typical ounting Options Page 14 of 42

15 odel 4501-XX Toxic Gas Sensor odule 4.2 Wiring Wire should be 18 AWG minimum at a maximum distance is 5,000 feet. Install conduit as required by local code or construction specifications. See Figure 6 for typical 2 terminal and 4 terminal connections. Figure 6: 4-20 ma Connection 4.3 nclosure Installation To protect the transmitter and sensor assembly they should be removed from the enclosure and preserved until final installation and wiring termination. Prior to installation and wiring: 1. Remove the transmitter from the module housing. a. Unscrew the two captive panel screws on the faceplate. b. Lift the transmitter out of the enclosure. c. Unplug the sensor cable from transmitter connector J1. d. Remove the sensor assembly from the enclosure hub. 2. Install the module enclosure onto the end of the supply conduit and/or bolt into position as required. NOT: When enclosure earth grounding is required for the installation a grounding lug is located in the base of the enclosure. Install the earth ground under the green ground screw. Page 15 of 42

16 odel 4501-XX Toxic Gas Sensor odule 4.4 Transmitter and Sensor Installation When all pre-wiring is complete: 1. Install sensor assembly in the open hub on the module enclosure. The sensor assembly thread must be fully seated into the hub and tightened to maintain explosion proof assembly. 2. Connect the sensor assembly cable to transmitter connector J1. (Figure 7) 3. Connect the loop wires (Loop + and Loop -) to transmitter connector P ma + and (Figure 7). NOT: Conductor P1 is removable. 4. Carefully return the transmitter to the enclosure installing it over the two standoffs. Finger tighten the retaining screws into the standoffs. Loop Power Sensor Connector Figure 7: Connector Locations Page 16 of 42

17 odel 4501-XX Toxic Gas Sensor odule 5 OPRATION 5.1 Introduction The 4501-XX Toxic Gas Sensor odule utilizes a visual menu system operated by means of a magnet with the cover in place. A magnet stick is supplied for this purpose. Access the menu system to calibrate the sensor module, and for maintenance and diagnostic procedures. The following adjustments can be made to the sensor module: Range adjustments (Section 5.4) 4mA and 20mA calibration adjustments (Section 5.4) Span adjustment (Section 6.3) 5.2 Data ntry Keypad The module menu system is operated by means of directing the magnet stick toward each of four independent hall-effect magnetic switches. ach switch functions as if it is a manually activated panel key. The keys are located under the faceplate above and below the LCD and are labeled,, and as shown in Figure 8. Figure 8: Face Plate with Operator Keypad Page 17 of 42

18 odel 4501-XX Toxic Gas Sensor odule 5.3 ain enu Key Function Display Description Reference ode Switch [] nter Switch [] Up Switch [ ] Previous enu Down Switch [ ] Next enu CAL 180 First screen at power up: odel No. and days to calibration Version Second screen at power up: Version No. (e.g. V300aA) STARTING Third screen at start up, will remain for 60 seconds XXX PP Normal condition - default display ode CALIB: ode Function - Calibrate Figure 14 Down STUP: ode Function - Set up alarms, relays, etc Figure 11 Down AINT: ode Function - aintenance Figure 12 Down XIT-? xit ode Figure 9: aster enu The table below defines the key operational displays on the operator interface. Display - H2S STARTING SNSOR FAIL NO SNSOR C.## PP F.## PP XXX DON Description Warm-up at start-up (example from ) Sensor failure Sensor not found or plugged in Calibration ode Failure detected, sensor is attempting recovery Finished with step Figure 10: Operation Display Values Page 18 of 42

19 odel 4501-XX Toxic Gas Sensor odule 5.4 Setup Sub-enu The sensor module set-points menu is used to initially set-up the range and 4-20 ma calibration. Range: Once the Set-up menu is selected, press key [ ] twice and press [] to activate the Range Set-up menu. Use the [ ] or [ ] keys to select Range menu and press []. When Range is selected menu provides any choices of ranges available for the gas type selected. Use the [ ] or [ ] keys to select the desired range. If the User range is selected, use the [ ] or [ ] keys to adjust the high end of the range desired. See specifications below for optional ranges. Factory Range Set-up odel Range Other Available % 0-25% PP Variable PP Variable PP None PP None PP Variable PP None PP Variable PP None 4-20mA: Once the Set-up menu is selected, press key [ ] three times and press [] to activate the 4-20mA Set-up menu. Use the [ ] or [ ] keys to select Calib menu and press []. The Calib section of the menu allows the user to calibrate the 4 ma and 20 ma outputs. To calibrate the 4 ma and 20 ma outputs it is necessary to have an amp meter connected to the 4501-XX and upon selecting the 4 ma output calibration then the [ ] or [ ] keys can be used to adjust the 4 ma reading on the amp meter until it reads 4 ma. Similar steps can then be performed for the 20 ma output. Key Function Display Description Reference XX PP Default Display (example ) ode Down CALIB: STUP: Gas Range Adjustment xample nter Range S.P. Function - Range Adjust nter *100 PP Select [] to select or or to select another and press [] Down 10 PP Press [] if selecting 0-10 PP range Down USR Press [] if selecting user adjustable range nter 100 PP Select [] to select or or to select another and press [] 4-20 ma Adjustment xample Down 4-20mA S.P. Function 4-20 ma Calibrator nter Calib S.P. Function - Calib Adjust nter Out: 4mA Use or keys to select 4 ma or 20mA nter 4mA Selects 4 ma nter ACK omentary Acknowledge of new Set Point Figure 11: Set-Up Configuration Page 19 of 42

20 odel 4501-XX Toxic Gas Sensor odule 5.5 aintenance Sub-enu The maintenance menu enables the operator to view sensor and software versions. Sierra onitor technical support has access to other values as needed. The maintenance menu operation is described in the table below. Key Function Display Description Reference ode XXX PP Default Display (example ( ) ode CALIB Go to previous maintenance menu item ode ode STUP: AINT: nter VX.XX Version number of firmware nter CCC001 Configuration Version Figure 12: aintenance Sub-enu Page 20 of 42

21 odel 4501-XX Toxic Gas Sensor odule 6 CALIBRATION 6.1 Calibration Frequency The sensor module must be calibrated every 180 days at a minimum. Periodic functional tests are advisable for critical applications and hostile environments. The sensor module microprocessor software includes high-level self checking algorithms which provide continuous sensor diagnostic and self adjustment. 6.2 Calibration Preparation Calibration of the sensor is accomplished by simple menu based steps and application of span gas. NOT: If an error is made during any stage of the calibration process, hold the magnet stick at the [] for 10 seconds. A scrolling display will indicate calibration aborted and the sensor module will exit the calibration activity and return to normal operating mode. The calibration procedure can then be restarted. Calibration must be performed only when the area is known to be clear of the gas of interest. When in doubt, use a portable instrument to confirm that there is no background. For compliance with Factory utual (F) Approvals, the Sierra onitor odel , and are the F Approved calibration gas delivery devices. Use the odel Calibration Adapter delivery fitting. NOT: Refer to Appendix D for information on use of permeation tube for calibration. 6.3 Calibration Gas Delivery ethods Calibration gas can be delivered to the sensors via the odel : Calibration Adapter (Figure 13) - used with portable calibrators. CALIBRATION PROCDUR The Calibration enu is described in Section 6.5: The procedure requires that the menu keys be activated using the magnet stick. ach key press steps through the process of setting the zero value for clean air and then setting the span value. At each of these steps, apply calibration gas of the value corresponding to the setting accepted on the sensor module display. Sample Gas In Figure 13: odel Calibration Adapter Page 21 of 42

22 odel 4501-XX Toxic Gas Sensor odule 6.4 Sensor xposure to Gas Calibration gas must be delivered to the sensor using the flow rate and duration listed in below: odel Calibration Gas Flow Period Air 300 cc of Zero Air or exposure to Ambient Air (3 minutes) Carbon onoxide 300 cc/min Until Stable (minimum 3 minutes) Hydrogen Sulfide 300 cc/min Until Stable (minimum 3 minutes) Chlorine 300 cc/min Until Stable (minimum 3 minutes) * Chlorine 300 cc/min Until Stable (minimum 3 minutes) Sulfur Dioxide 300 cc/min Until Stable (minimum 3 minutes) Nitrogen Dioxide 300 cc/min Until Stable (minimum 3 minutes) Ammonia See Appendix D ** Chlorine 500 cc/min Until Stable (minimum 6 minutes) * Use 10 PP Cl2 to calibrate, equivalent reading = 3.0 PP ClO2 ** Use 5 PP Cl2 to calibrate equivalent reading = 8.0 PP HF 6.5 Calibration Sub-enu Key Function Display Description Reference XXXPP Default Display ode CALIB:-- ode Function - Calibrate nter CAL Zero Banner: Apply zero gas, enter <> when done Operation: Confirm area clear of gas, or apply zero air to sensor nter ACK Zero gas setting acknowledged 10PP-SP Banner: Select span, enter <> when done* Sub A nter CXXX PP Banner: Apply span gas, then enter <> to calibrate gas sensor Sub B CXXX PP Operation: Apply calibration gas CXXXPP Operation: As gas is applied the reading will increase - wait 3 minutes nter CAL-OK Calibration Passed - now remove gas WAIT-300 Operation: Five minute time out before sensor is returned to service. Sub-Routines 10PP-SP Banner: Select span, enter <> when done Sub A Down 25PP-SP Operation: Change Span Gas Value to 25PP Down Adj-SPAN Operation: User adjustable value nter 25PP-SP Operation: Ready for user adjustment nter C 25PP Banner: Apply 25PP gas, then enter <> to calibrate gas sensor Sub B C 25PP Operation: Apply calibration gas Operation: No calibration gas applied, or sensor did not respond nter CAL-FAIL correctly. WAIT-300 Operation: Five minute time out before sensor is returned to service. Operation: Hold magnet over ode Switch for ten seconds to abort ode (Any) calibration Banner: Calibration Aborted XXXPP Default Display Figure 14: Calibration Sub-enu Sub C Page 22 of 42

23 odel 4501-XX Toxic Gas Sensor odule * Oxygen Calibration: If area is known to be safe with adequate air flow, you may use the surrounding air as the calibration gas. If Oxygen levels are unknown, it is recommended to use a Zero Air gas standard. When calibrating an Oxygen module, there is no zero gas process in the calibration procedure. Only span adjustments can be made. Normal ambient Air = 20.9% Oxygen. Begin calibration procedure using the magnet on the ode key until CALIB is displayed. nter to begin procedure. Select cal gas value (20.9), nter to confirm. Apply span gas for 3 minutes or use surrounding air if acceptable. Select nter when done, and procedure is complete. NOT: The Analog output values to be transmitted during the calibration procedure are selected in the maintenance configuration. Normal 20.9% value provides 17.3 ma. Page 23 of 42

24 odel 4501-XX Toxic Gas Sensor odule Appendix A. Service Appendix A.1. Sensor odule Configuration The gas sensor module is comprised of the following sub-assemblies (Figure 15): 4501-XX SPL27077 Gas Sensor odule Stainless Steel nclosure (SPL for Aluminum nclosure) SP27071 Transmitter Assembly XXXXXXX Sensor Assembly (see Appendix B) XXXXXXX Sensor (see Appendix B) There are no field serviceable components below the sub assembly level. NOT: Area must be determined to be non-hazardous before opening enclosure. Appendix A.2. nclosure Replacement The enclosure should be replaced if the cover threads or conduit threads have been damaged, or if the enclosure has been damaged sufficiently that it no longer meets the required NA classification. To replace the enclosure, follow the transmitter and sensor assembly removal instructions, remove the damaged enclosure from its conduit, install a new enclosure and continue the transmitter and sensor assembly replacement instructions. Figure 15: odule Components Page 24 of 42

25 odel 4501-XX Toxic Gas Sensor odule Appendix A.3. Transmitter Replacement The transmitter assembly should be replaced when it is determined that it is unreliable, noisy or cannot be adjusted for calibration. This may occur due to age, corrosion or failed components. To replace the transmitter assembly: a. Remove the cover of the main enclosure. b. Unscrew the two thumb screws in the top of the cover plate, lift the assembly and rotate 90 o to relieve the wiring service loop. c. Remove the two wires from P1 terminals (Figure 7). d. Unplug the sensor connector from the transmitter. e. Reverse the preceding steps to install the new transmitter. f. Restore power and allow a minimum of 30 minutes for stabilization before re-calibration. Appendix A.4. Sensor Replacement NOT: Refer to Appendix D for information on sensor electrolyte replacement for The gas sensor which is located inside the sensor assembly housing can be replaced without replacement of the housing. The gas sensor needs replacement when: It is no longer possible to obtain correct Zero and Span values. The LOW SNS message appears after calibration. The sensor output signal is noisy, causing erroneous gas level readings. To replace the sensor: a. Confirm that system power has been removed. b. Remove the gas sensor module enclosure cover. c. Unscrew the two thumb screws in the top of the faceplate, lift the transmitter assembly and rotate 90 o to relieve the wiring service loop. d. Unplug the sensor connector from the transmitter. e. Unscrew the old sensor assembly from the enclosure conduit hub. Remove the sensor assembly with its harness. f. Unscrew sensor housing cover from the sensor. g. Carefully pull the old sensor straight up from the socket. h. Press the new sensor into the socket. i. Reverse the preceding steps to install the sensor assembly. j. Allow the new sensor to stabilize for a minimum of 30 minutes and then calibrate using the procedure in Section 6. Appendix A.5. Installation Inspection Prior to system start-up or trouble shooting, the entire system should be visually inspected. The following are guidelines for that inspection. Appendix A.5.1. Controller Installation Controller installed in conformance to manufacturer s instruction manual recommendations. Appendix A.5.2. Cabling Installation All splices are soldered or via terminal block. Cabling is away from sources of electrical noise or RFI where possible. Page 25 of 42

26 odel 4501-XX Toxic Gas Sensor odule Appendix A.5.3. Sensor odule Installation odule installation in conformance with this manual. odules accessible for calibration. Wiring terminations clean and correct. Appendix A.5.4. oisture Traps And Rainshields Conduit seals and drains installed to avoid moisture build up in electronics enclosure. Water accumulation in sensor module enclosures is a major cause of damage and system failures - take precautions to seal electrical conduits and provide moisture traps and drains to avoid water damage. Rain-shields installed where applicable. Appendix A.5.5. Standard Voltages Loop voltage to be applied to the sensor module must be between 14 VDC and 30 VDC. Appendix A.6. Inspection and Troubleshooting Guide The inspection and troubleshooting guide can be used to step through the system start-up and to determine the corrective action if a fault occurs. Appendix A.6.1. odule Does Not Respond to Gas 1. Repeat calibration procedure. 2. Remove the gas and wait for the timer to completely count down. 3. Apply calibration gas and verify that the sensor sees calibration gas after calibration. 4. If the sensor still does not see gas, power cycle the unit and repeat calibration. Appendix A.6.2. The odule Displays Starting for ore Than 1 Hour 1. ake sure the sensor is place in an ambient room temperature environment. 2. Power cycle the sensor. 3. nsure that the sensor is not exposed to the gas of interest during warm-up. Appendix A.6.3. The odule Does Not Display The Correct PP 1. Power cycle the unit. 2. Recalibrate the sensor. Appendix A.6.4. The Display Shows F OR NO SNSOR 1. Power down the unit. 2. Open the enclosure and unplug the sensor assembly from the transmitter board. 3. Plug the sensor back into the transmitter board carefully and ensure a secure fit. 4. Check all wire connections. 5. Power up the unit. 6. If the system still shows F, apply magnet to key, then key. The module will start scrolling an error message. Please write that message down and contact Sierra onitor for assistance. Appendix A.6.5. The Display Shows C Complete calibration and exit to operating mode. Page 26 of 42

27 odel 4501-XX Toxic Gas Sensor odule Appendix B. Specifications Sensor Type lectrochemical ax Range (1) Zero Drift Repeatability Linearity Resolution Response Time (2) Sensor Life (3) O2 0-25% Vol. +/- 0.5 Vol. +/- 0.1 % +/- 0.1 % 0.2% Vol. <10 seconds 20 months CO PP +/- 1 PP +/- 1 PP +/- 1 PP 0.5 PP <25 seconds 2 years H2S PP +/- 0.5 PP +/- 1 PP +/- 1 PP 0.1 PP <44 seconds 2 years Cl PP +/- 0.5 PP +/- 0.5 PP +/- 0.5 PP 0.1 PP <60 seconds 2 years ClO2 0-3 PP +/- 0.5 PP +/- 0.5 PP +/- 0.5 PP 0.1 PP <60 seconds 2 years SO PP +/- 0.5 PP +/- 1 PP +/- 1 PP 0.5 PP <20 seconds 2 years NO PP +/- 0.5 PP +/- 0.5 PP +/- 0.5 PP 0.2 PP <35 seconds 2 years NH PP +/- 1.0 PP +/- 1.0 PP +/- 1.0 PP +/- 1 PP <30 seconds (4) HF 0-10 PP +/- 0.5 PP +/- 0.5 PP +/- 0.5 PP +/- 0.5 PP <90 seconds (4) (1) Optional ranges available (2) Response time to 90% full signal value for applied concentration (3) Sensor life typical for use at standard temperature and pressure with occasional exposure to gas of interest (4) Sensor electrolyte needs to be recharged every six months Output Display Signal Output Loop Resistance lectrical Data Power Consumption Connection Type Input Voltage RFI/I Protection LCD, 2-line, 16-characters 2-wire sensor powered analog 4-20 ma (Trouble: 3.6 ma) 800 ohm 0.2 watts 2 wire loop-powered 24 VDC nominal: VDC N , N Operating Range Ambient Temp ( F) Ambient Temp ( C) Relative Humidity O2-4 to 122 F -20 to 50 C 15 90% CO -4 to 122 F -20 to 50 C 15 90% H2S -4 to 122 F -20 to 50 C 15 90% Cl2-4 to 122 F -20 to 50 C 15 90% ClO2-4 to 122 F -20 to 50 C 15 90% SO2-4 to 122 F -20 to 50 C 15 90% NO2-4 to 122 F -20 to 50 C 15 90% NH3 +14 to 113 F -10 to 45 C 20 90% HF +14 to 113 F -10 to 45 C 20 90% xtended Range Operation Storage Temperature Sensor and 4-20 ma will continue to operate to -40 F (-40 C) but the LCD display will decay over time if exposed to temperatures below -4 F (-20 C) for significant time (not applicable to ) -4 to 122 F (-20 to 50 C) nclosure Dimensions 7.0 x 3.6 x 4.0 inches (H x W x D) (17.8 x 9.1 x 11.2 cm) Weight 2.2 lb. (1.0Kg) Al 4.6 lb. (2.1 Kg) SS aterial of Construction 316 Stainless Steel, Aluminum Housing NA 4X, NA 7 Page 27 of 42

28 lectrical Approvals Performance Approvals Factory utual (F) Hazardous Locations F Standards 3600, 3615, 3810 (All odels) Class 1 Div I, Groups B, C, D Class II, Div I, Groups, F, G NA 4X1 CSA Class I, Div I, Groups B, C, D Class II, Div I, Groups, F, G NA 4X UL UL Standard 508A ATX II 2 G x d IIB+H2 T6 Gb Ta = -20 C to +50 C odel 4501-XX Toxic Gas Sensor odule F Performance Approval Approval Standards: ISA , Part I-1998 and F 3600 ( only) Warranty Limited Warranty 2 years Specifications subject to change without notice Page 28 of 42

29 odel 4501-XX Toxic Gas Sensor odule Cross Sensitivity Data Carbon onoxide Gas Conc. Response H2S 15 PP ~38 PP SO2 5 PP ~3 PP NO 35 PP ~10 PP NO2 5 PP ~-3 PP H2 100 PP <60 PP C2H4 100 PP <100 PP HCN 10 PP ~5 PP HCl 5 PP 0 PP Hydrogen Sulfide Gas Conc. Response CO 400 PP <.1 PP SO2 20 PP <10 PP NO 50 PP <3 PP NO2 10 PP <-30 PP Cl2 10 PP <-25 PP H2 400 PP 1 PP C2H4 400 PP <0.1 PP NH3 20 PP <0.1 PP Chlorine Gas Conc. Response CO 300 PP 0 PP H2S 15 PP 0 to PP SO2 5 PP PP NO 35 PP 0 PP NO2 5 PP ~5 PP H2 100 PP 0 PP C2H4 100 PP 0 PP HCN 10 PP 0 PP HCl 5 PP 0 PP Chlorine Dioxide Gas Conc. Response Cl2 3.1 PP 10 PP Nitrogen Dioxide Gas Conc. Response CO 300 PP 0 PP H2S 15 PP -1.5 to 0 PP SO2 5 PP to 0 PP NO 35 PP 0 PP Cl2 1 PP ~1 PP H2 100 PP 0 PP HCN 10 PP 0 PP HCl 5 PP 0 PP C2H4 100 PP 0 PP Ammonia Gas Conc. Response CO 1000 PP 0 PP SO2 15 PP >40 PP NO 100 PP 0 PP NO2 60 PP 0 PP H2 4% 0 PP CH4 4% 0 PP HCN 10 PP 75 PP H2S 3 PP 75 PP Hydrogen Fluoride Gas Conc. Response Cl2 5 PP 8 PP HCl 5 PP 9 PP NH3 75 PP 0 PP SiH4 15 PP 0 PP CO 1000 PP 0 PP SO2 5 PP 9 PP NO 100 PP 0 PP NO2 15 PP 2 PP H2 4% 0 PP H2S 30 PP 0 PP Sulfur Dioxide Gas Conc. Response H2S 15 PP 0 PP NO 35 PP -7 to 0 PP NO2 5 PP -5 PP Cl2 5 PP -1.5 to 0 PP NO2 5 PP ~5 PP H2 100 PP 0 PP HCN 10 PP <5 PP HCl 5 PP 0 PP C2H4 100 PP 0 PP Page 29 of 42

30 odel 4501-XX Toxic Gas Sensor odule Appendix C. odel Numbers & Parts List Sensor odule Ordering Information: The following part number is essential in selection of the correct product. Please build up the desired part by inserting the code for each element into the appropriate space (i.e S1-0). odel Gas nclosure Sensor Protection = O2-10 = SO2 - A1 = AL ¾ NPT - 0 = Standard - 04 = CO - 12 = NO2 - A2 = AL 20x1.5-1 = Conformal - 05 = H2S - 25 = NH3 - S1 = SS ¾ NPT Sensor - 06 = Cl2-26 = HF - S2 = SS 20x = ClO2 Options Rainshield Rainshield with calibration port Calibration Items Gas Sensor Calibration Kit, Type A (CO, H2S, Air) Gas Sensor Calibration Kit, Type B (SO2, NO2) Gas Sensor Calibration Kit, Type C (Cl2) Gas Cylinder, Air, (Type A), 105 liters Gas Cylinder, CO 100 PP, (Type A) 57 liters Gas Cylinder, H2S in N2, 25 PP, (Type A) 57 liters Gas Cylinder, Cl2, 5 PP, (Type C) 104 liters Gas Cylinder, SO2, 50 PP, (Type B) 74 liters Gas Cylinder, NO2, 10 PP, (Type B) 74 liters Gas Cylinder, CO, 1000 PP, (Type A), 105 liters Calibrator Head Standard Regulator Type A Calibrator Regulator Type B Calibrator Regulator Type C Calibrator Calibration Adapter - Direct, Standard Calibration/Configuration agnetic Tool, 4501-XX Calibrator, Permeation Tube Permeation Tube, Ammonia, NH3 SPX27057 Kit, Sensor Recharge, for IT SPX27061 Kit, Sensor Recharge, for IT Spare Parts SP21834 Sensor Assy, Aluminum, SP21832 Sensor Assy, Aluminum, SP21830 Sensor Assy, Aluminum, SP21833 Sensor Assy, Aluminum, / SP21844 Sensor Assy, Aluminum, SP21845 Sensor Assy, Aluminum, SP21840 Sensor Assy, Plastic, SP21878 Sensor Assy, Plastic, SP27071 Transmitter for 4501-XX SP27082 Sensor Assy, 316SS, SP27083 Sensor Assy, 316SS, SP27074 Sensor Assy, 316SS, SP27084 Sensor Assy, 316SS, / SP27087 Sensor Assy, 316SS, SP27088 Sensor Assy, 316SS, SP33044 Sensor for SP33030 Sensor for SP33041 Sensor for SP33050 Sensor for & SP33052 Sensor for SP33054 Sensor for SPL27085 odule nclosure AL SPL27077 odule nclosure SS SP21834 Sensor Assy, Aluminum, SP21832 Sensor Assy, Aluminum, Page 30 of 42

31 odel 4501-XX Toxic Gas Sensor odule Appendix D. Limited Warrenty SIRRA ONITOR 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. SC will repair or replace without charge any equipment found to be defective during the warranty period. Final determination of the nature and responsibility for defective or damaged equipment will be made by SC 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 SC approval or which have been subjected to accident, improper maintenance, installation or application, or on which original identification marks have been removed or altered. This Limited Warranty also will not apply to interconnecting cables or wires, consumables (i.e. calibration gases, batteries, sensors), nor to any damage resulting from battery leakage. In all cases SC s responsibility and liability under this warranty shall be limited to the cost of the equipment. The purchaser must obtain shipping instructions for the prepaid return of any item under this warranty provision and compliance with such instruction shall be a condition of this warranty. xcept for the express warranty stated above, SC disclaims all warranties with regard to the products sold hereunder including all implied warranties of merchantability and fitness and the express warranties stated herein are in lieu of all obligations or liabilities on the part of SC for damages including, but not limited to, consequential damages arising out of/or in connection with the use or performance of the product. Page 31 of 42

32 odel 4501-XX Toxic Gas Sensor odule Appendix & Gas Sensor odule 1. Calibration of (follow instructions in Section 6) 2. Calibration of (see below) 3. quipment Required The following tools and equipment will be required for calibration: - Permeation Device Calibrator (odel ), with Ammonia Permeation Tube (odel ). - Calibration Adapter (odel ). 4. Permeation Device Calibrator Operation The calibrator is a portable device with a pump that operates from a 1.5 V alkaline size D battery. A fresh battery should allow 8 hours of continuous operation. The permeation device will probably be shipped separately, usually in a pipe with screw cap ends, one of which will be marked for opening. The permeation device should come fitted with a scrubber, but, as a precaution, open the pipe and remove the permeation device in a well ventilated area. a. Remove the scrubber from the permeation device and attach the device to the stainless steel Tee assembly inside the calibrator box. Tighten the connection with a wrench, with the device resting inside one of the openings in the rack. b. Close the door of the calibrator and turn on the pump switch. c. Set the flow rate for the desired ppm of ammonia. The desired flow rate for calibration of the odel is cc/min. and the concentration range should be set between the high alarm point and 100 ppm full scale. The carrier gas flow rate can be calculated from the formula: P = (CxF)/K Where P = the permeation rate in nanograms/min., and C = ppm of span gas, F = carrier gas flow rate in ml./min. and K = for ammonia. The permeation rate for the temperature read on the front of the calibrator can be obtained from permeation rate vs. temperature chart. d. Run the gas calibrator for 30 min. before attaching the output hose to the ammonia sensor. e. When the use of the calibrator is completed, do not turn off the pump unit until the permeation device has been removed from the Tee and the gas scrubber reattached. Failure to remove the permeation device when the pump has been turned off will contaminate the system with high amounts of the permeating gas and result in erroneous concentrations. The device, with scrubber, can be stored in the storage rack overnight, but should not stay in the gas calibrator for longer storage periods. 5. Calibration Procedure Follow procedures outlined in Section 6 Figure 16: lectrolyte Replacement Page 32 of 42

33 lectrolyte/embrane Replacement (Figure 17) odels and odel 4501-XX Toxic Gas Sensor odule The electrolyte needs to be replaced at least every six months, or if there is evidence of low sensor output. The membrane and O-Ring should be replaced at the same time that the electrolyte is replaced. 1. quipment Required - lectrolyte Recharge Kit (SPX27057 for odel NH3 and SPX27061 for odel HF) consisting of the electrolyte, package of 5 membranes, one (1) 0-Ring and alcohol wipes to clean the electrode. - Tweezers to aid in removing and replacing the membrane. 2. Preparation a. Transfer the necessary electrolyte into a plastic wash bottle. b. Confirm that system power has been removed. c. Remove the transmitter electronics board from the main housing and unplug the sensor harness from the transmitter electronics. d. Unscrew the sensor assembly from the bottom of the enclosure. e. Remove the assembly cover from the sensor assembly. CAUTION: Only remove the sensor cover from the assembly, DO NOT attempt to unscrew the sensor from the mounting assembly or you could damage the wiring. 3. lectrolyte Replacement (Figure 16) a. Invert the sensor assembly so that the membrane is upward. b. Insert the sensor assembly in a clamp, if available, and unscrew the box nut counterclockwise, and take out the hold-down ring, membrane and O-Ring. Then pour out the old electrolyte into a beaker for disposal. CAUTION: Avoid contact of the electrolyte with skin, eyes and clothing. In case of contact wash immediately - rubber gloves and safety glasses are recommended. c. Clean the electrode with the alcohol wipes included in the electrolyte replacement kit. All oxidation residue must be removed before re-assembly. When dirt is found inside the sensor assembly, wash the dirt off with electrolyte. d. Hold the sensor assembly with the sensing electrode up. Close the pressure compensation port with a tissue. Pour approximately 10cc of fresh electrolyte from the wash bottle into the sensor, and rinse the inside of the sensor. mpty the electrolyte into the beaker. e. Place the O-ring on top of the washer. Then transfer one drop of electrolyte from the plastic wash bottle to the exposed electrode surface. f. Place a new membrane into the hold-down ring and carefully place the plastic hold-down ring on top of the sensor body with the ring ears in the slots of the sensor body. Then fasten the sensor cover over the assembly. CAUTION: Never touch the membrane with your hands. Use rubber gloves or tweezers. g. Invert the sensor so that the membrane is down. If this is the first time that electrolyte has been replace, there should be a round ili Seal covering the pressure compensation screw. This ili-seal prevented loss of electrolyte during shipment. Remove and discard the round ili Seal and remove the screw to expose the electrolyte supply port. h. Transfer electrolyte from the plastic wash bottle into the electrolyte supply port (Figure 16) until the level is at the maximum level line on the side of the sensor body. i. Replace the pressure compensation screw into the electrolyte supply port. Page 33 of 42

34 j. Replace the sensor housing cover. k. Install the sensor assembly into the enclosure hub and tighten firmly. odel 4501-XX Toxic Gas Sensor odule l. Reconnect the sensor harness to the transmitter, carefully install the transmitter into the housing and restore system power. m. Recalibrate the transmitter following the instructions in Section 6. (WHIT) Figure 17: Sensor Assembly xploded View Page 34 of 42

35 odel 4501-XX Toxic Gas Sensor odule Figure 18: odel A1 and odel A1 Figure 19: odel S1 and odel S1 Page 35 of 42

36 odel 4501-XX Toxic Gas Sensor odule Appendix F. US F Approval Page 36 of 42

37 Page 37 of 42 odel 4501-XX Toxic Gas Sensor odule

38 odel 4501-XX Toxic Gas Sensor odule Appendix G. APPNDIX F. Canadian F Approval. Page 38 of 42

39 Page 39 of 42 odel 4501-XX Toxic Gas Sensor odule

40 Page 40 of 42 odel 4501-XX Toxic Gas Sensor odule

41 odel 4501-XX Toxic Gas Sensor odule Appendix H. ATX Certificate Page 41 of 42

42 odel 4501-XX Toxic Gas Sensor odule Appendix I. Pipe ounting for 4501-XX Aluminum Figure 20: odel 4501-XX-A1 Aluminum nclosure Pipe ount Figure 21: Pipe ount Bracket for 4501-XX-A1 Aluminum nclosure Page 42 of 42