MODEL 4501-XX
2-Wire Series
TOXIC GAS SENSOR MODULE
APPLICABILITY & EFFECTIVITY
Effective for all Model 4501-XX Modules manufactured after September 1, 2006.
4501-04 FM Pending
4501-05 FM Approved
4501-06 FM Pending
Instruction Manual Part Number T13022
Rev. A
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Model 4501-XX Toxic Gas Sensor Module
TABLE OF CONTENTS
SENSOR ASSEMBLY..............................................................................................................................2
CAUTIONS & WARNINGS..............................................................................................................................4
GAS SENSOR MODULES - GENERAL.........................................................................................................4
CALIBRATION FREQUENCY.........................................................................................................................4
CALIBRATION...............................................................................................................................................13
CALIBRATION FREQUENCY.......................................................................................................................13
CALIBRATION PREPARATION....................................................................................................................13
6.2.2 SENSOR EXPOSURE TO GAS.............................................................................................................13
CALIBRATION GAS DELIVERY METHODS.........................................................................................13
TRANSMITTER REPLACEMENT.................................................................................................................16
INSTALLATION INSPECTION.................................................................................................................................16
Contents
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Model 4501-XX Toxic Gas Sensor Module
CABLING INSTALLATION.....................................................................................................................16
INSPECTION AND TROUBLESHOOTING GUIDE.................................................................................................17
IF MODULE DOES NOT DISPLAY THE CORRECT PPM GAS...........................................................17
7.4.10 If the display shows “ T ” – DOWNSCALE INDICATOR.......................................................................17
7.4.11 If the display shows “HIGH” – UPSCALE INDICATOR..........................................................................17
APPENDIX A: SPECIFICATIONS............................................................................................................................18
APPENDIX B: MODEL NUMBERS & PARTS LIST.................................................................................................20
APPENDIX C: LIMITED WARRANTY......................................................................................................................21
Contents
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Model 4501-XX Toxic Gas Sensor Module
1. PRODUCT DESCRIPTION
1.1 GENERAL
The Model 4501-XX Toxic Gas Sensor Module 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
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 multi-directional installation
attitudes.
The 4501-XX is designed and approved for installation and
operation in hazardous locations.
Members of the 4501-XX Two-Wire Toxic Gas family include:
▪
▪
▪
4501-04 Carbon Monoxide Gas Sensor Module
4501-05 Hydrogen Sulfide Gas Sensor Module
4501-06 Chlorine Gas Sensor Module
1.2 MOUNTING CONFIGURATION
Various module mounting configurations can be implemented without special fixtures. Where applicable,
these options are factory configured prior to shipment. Mounting configuration can be selected by the installer
or field technician and are fully described in this manual.
1.3 THEORY OF OPERATION
Electrochemical 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 Monitor 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.
Page: 1
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Model 4501-XX Toxic Gas Sensor Module
1.4 MECHANICAL
The sensor module is comprised of the following three primary components:
1.4.1 ENCLOSURE
Explosion proof, rain-tight stainless steel electrical 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. See Figure 1-2 for details.
1.4.2 TRANSMITTER ELECTRONICS
Electronic 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.
1.4.3 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 INTERCONNECT WIRING
Not supplied with the sensor module, but necessary to the installation and operation is the two conductor
wiring 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: 2
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Model 4501-XX Toxic Gas Sensor Module
Figure 1-1
Model 4501-05 Hydrogen Sulfide Gas Sensor Module– Dimensions
Figure 1-2
Model 4501-05 Hydrogen Sulfide Gas Sensor Module– Orientation Options
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Model 4501-XX Toxic Gas Sensor Module
2. CAUTIONS & WARNINGS
2.1 INTRODUCTION
Although the 4501-XX Gas Sensor Module 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 MODULES - 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 sensor is 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.
NOTE
Installation and wiring must be in accordance with the National Electrical 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 H2S that
would lead to alarm activation within any system utilizing the output of the 4501-05.
Page: 4
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Model 4501-XX Toxic Gas Sensor Module
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 shielded wiring from the power supply/control device to the sensor module location.
Use wire that is 16 AWG or larger.
3.3 MODULE INSTALLATION
The 4501-XX can be mounted in a variety of configurations supported by the conduit. See figure 1-2 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. Two 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.
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
•
If the transmitter is installed in a classified hazardous area, 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 14-30 VDC. Each time the sensor
module is powered up it will perform a warm-up for approximately 2.5 minutes (148 seconds). During this time
the display will read “Warm. 148” and count down. The loop output will be held at 4 mA.
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 PPM has been
selected, a current of 4 mA corresponds to 0 PPM and a current of 20 mA corresponds to 50 PPM.
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: 5
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Model 4501-XX Toxic Gas Sensor Module
4. INSTALLATION
4.1 SENSOR MODULE 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.
•
•
•
Modules 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.
4.2 WIRING
•
Wire should be 16 AWG minimum at a maximum distance is 5,000 feet. Install conduit as required by
local code or construction specifications.
•
See figure 4-1 for typical 2 terminal and 4 terminal connections.
Figure 4-1
4-20 mA Connection
4.3 ENCLOSURE 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:
Page: 6
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Model 4501-XX Toxic Gas Sensor Module
1. Remove the transmitter from the module housing by:
•
•
•
•
Unscrew the two captive panel screws on the faceplate.
Lift the transmitter out of the enclosure.
Unplug the sensor cable from transmitter connector J1.
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.
NOTE
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.
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 loop wires (Loop + and Loop -) to transmitter connector P1, pins 1 and 2 (Figure 4-2)
3. Connect the sensor assembly cable to transmitter connector J1. (Figure 4.2)
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 4-2
Connector Locations
Page: 7
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Model 4501-XX Toxic Gas Sensor Module
5. OPERATION
5.1 INTRODUCTION
The 4501-XX Toxic Gas Sensor Module utilizes a visual menu system operated by means of a magnet. A
magnet stick is supplied for this purpose. The menu system is used to calibrate the sensor module, and for
maintenance and diagnostic procedures.
The following adjustments can be made to the sensor module:
Range adjustments (see section 5.4)
4mA and 20mA calibration adjustments (see section 5.4)
Span adjustment (see section 6.3.1)
5.2 DATA ENTRY KEYPAD
The module menu system is operated by means of directing the magnet stick toward each of four independent
hall-effect magnetic switches. Each 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 M , E , S and T as shown in
Figure 5-1.
•
•
•
•
Key
Key
Key
Key
: MODE
ENTER
: UP (+)
: DOWN (-)
Figure 5-1
Face Plate with Operator Keypad
Page: 8
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Model 4501-XX Toxic Gas Sensor Module
5.3 MAIN MENU
Key Function
Display
Description
Reference
M
S T
E
Mode
Enter
Up
Switch [M]
M
S T
E
Switch [E]
M
S T
E
Switch [▲] Previous Menu
M
S T
E
Down
Switch [▼] Next Menu
4501-XX
XX.XXaA
Warm 148
XX.XXaA
First screen at power-up, Model and Version
Second screen at start-up, count down of Warm-up
Default Display (example 4501-05)
Mode Function: Calibration (example 4501-05)
Mode Function: Maintenance (example 4501-05)
Mode Function: Diagnostics (example 4501-05)
Exit Mode (example 4501-05)
H2S
XXX.PPM
H2S
M
S T
E
Mode
Down
Down
Down
Table 6-1
Table 5-3
Table 5-4
CALIB:
M
S T
E
H2S
MAINT:
H2S
DIAG:
H2S
Exit-?
M
S T
E
M
S T
E
Table 5-1
Master Menu
Table 5-2 defines the key operational displays on the operator interface.
Display
Description
H2S
WARM XXX
Warm-up at start-up (example 4501-05)
SENSOR
FAIL
Sensor failure
NO
SENSOR
Sensor not found or plugged in
Calibration Mode
C.## PPM
XXX
DONE
Finished with step
Figure 5-2
Key Operational Display
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Model 4501-XX Toxic Gas Sensor Module
5.4 MAINTENANCE SUB-MENU
Reference
Key Function
Display
H2S
XX PPM
Description
Default Display (example 4501-05)
M
E
H2S
CALIB:
Mode
Down
S T
M
E
H2S
MAINT:
S T
M
E
Enter Calibration 4 mA Menu
Banner: Use [S] or [T] to change 4mA output, [E] when done
Enter
Cal: 4mA
S T
A multi-meter should be inserted into the current loop
to measure the loop current between the power and
the sensor module No gas is required for this step
M
E
4mA
DONE
Enter
Down
Acknowledges 4mA calibration
or Sub-Routine A
S T
M
E
H2S
MAINT:
S T
Enter Calibration 20 mA Menu
Banner: Use [S] or [T] to change 20mA output, [E] when
done
M
E
MAINT
CAL:20mA
Enter
S T
A multi-meter should be inserted into the current loop
to measure the loop current between the power and
the sensor module No gas is required for this step
M
E
20mA
DONE
Enter
Acknowledges 20mA calibration
or Sub-Routine A
S T
H2S
MAINT:
M
E
MAINT:
4mA
Down
Down
Enter
S T
M
E
MAINT:
20mA
S T
M
E
H2S
Range
Enter Range Menu
S T
M- Range
100 PPM
Enter Calibration Range Menu
Banner: Use [
S] or [T] to change range, [E] when done
M
E
Range
DONE
Enter
Acknowledge range selection
S T
Sub-Routine A
The expected range of the 4mA and 20mA is limited to factory
defined values. If the actual signal is outside of this
predefined range, an error is displayed indicating a hardware
or installation problem. Contact technical support.
CAL: XmA
ERROR!
Table 5-3
Maintenance Sub Menu
Page: 10
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Model 4501-XX Toxic Gas Sensor Module
5.5 DIAGNOSTICS SUB-MENU
Description
Key Function
Display
H2S
XXX PPM
Reference
M
E
T
E
Mode
Enter
Down
Down
Enter
Enter
Mode
Down
Enter
Mode
Down
Enter
Mode
Down
Enter
Mode
Down
Enter
Mode
Down
Enter
Default Display(example 4501-05)
S
M
S
M
S
M
S
M
S
M
S
M
S
M
S
M
S
M
S
M
S
M
S
M
S
M
S
M
S
M
S
M
S
M
S
M
S
M
S
M
S
H2S
CALIB
Go to previous maintenance menu item
T
E
T
E
H2S
MAINT:
H2S
DIAG:
T
E
T
E
DIAG:
RawSig
Enter diagnostics sub-menu
D-RawSig
XXXXmV
Voltage reading of the output of the sensor element
Return to diagnostic menu
T
E
T
E
DIAG:
RawSig
DIAG:
Ref
T
E
T
E
D-Ref
XXXXmV
Voltage reading of the output of the reference
DIAG:
Ref
T
E
T
E
DIAG:
Temp
TEMP
XXXC
Temperature of sensor use [S] or [T] to switch between Celsius and Fahrenheit
T
E
T
E
DIAG:
Temp
DIAG:
4-20 mA
T
E
T
E
D-4-20 mA
Normal
Enter 4-20 mA output sub-menu
Sub-Routine A
DIAG:
4-20mA
T
E
T
E
DIAG:
Version
D-Ver
VX.XX
Version number of firmware
T
E
T
E
DIAG:
Version
DIAG:
FactInit
T
E
T
Accept?
NO
Banner: Use [S] or [T] to change, [E] to accept
Sub-Routine B
N
Y
Sub-Routine A
D-4-20mA
Normal
M
S
M
S
M
S
M
S
E
T
E
D-4-20mA
3.6 mA
Down
Down
Down
Down
Press [E] to send 3.6 mA signal
Press [E] to send 4.0 mA signal
Press [E] to send 10.0 mA signal
Press [E] to send 20.0 mA signal
D-4-20mA
4.0 mA
T
E
T
E
D-4-20mA
10-.0 mA
D-4-20mA
20.0 mA
T
Sub-Routine B
M
S
M
S
E
T
E
Accept?
YES
Down
Enter
If accepting [T] to change to yes and [E] to accept
Sub-Routine C
N
Y
Accept?
YES
N
Y
T
FactInit
Done
Factory initialization completed
Sub-Routine C
If not accepting, [E] to accept NO
Factory initialization not done
M
S
E
T
Accept?
Enter
Sub-Routine C
N
NO
Y
FactInit
Aborted
Table 5-4
Diagnostics Sub Menu
Page: 11
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Model 4501-XX Toxic Gas Sensor Module
5.5.1 NOTES
When selecting the output current requested, an acknowledge message will appear on the screen. Select
[E] to accept this message.
Whenever a message appears on the screen, select [E] to accept the message. No other action can be
taken with messages.
Except for the FactInit Menu, the sub-menus in the diagnostics section only provide information and do not
cause action.
Page: 12
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Model 4501-XX Toxic Gas Sensor Module
6. CALIBRATION
6.1 CALIBRATION FREQUENCY
The sensor module must be calibrated every 180 days. 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.
NOTE
If an error is made during any stage of the calibration process, hold the magnet stick at the
[M] for 10 seconds. A scrolling display will indicate “Operate Mode” 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 Hydrogen Sulfide gas. When in
doubt, use a portable instrument to confirm that there is no background Hydrogen Sulfide gas.
For compliance with Factory Mutual (FM) Approvals, the Sierra Monitor Model 1250-01, 1260 -05 and 1260-45
are the FM Approved calibration gas delivery devices. Use the Model 5358-01 Calibration Adapter delivery
fitting.
6.2.1 CALIBRATION GAS DELIVERY METHODS
Calibration gas can be delivered to the sensors via the Model 5358-01:
Calibration Adapter (Figure 6-1) - used with portable calibrators.
CALIBRATION PROCEDURE
The Calibration Menu is described on Table 6-1:
The procedure requires that the menu “keys” be activated using the magnet stick.
Each 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.
6.2.2 SENSOR EXPOSURE TO GAS
Figure 6-1
Model 5358-01
Calibration Adapter
Calibration gas must be delivered to the sensor using the flow rate and
duration listed in below:
Model
Gas
Flow
Period
4501-04
4501-05
4501-06
Carbon Monoxide 300 cc/min
Hydrogen Sulfide 300 cc/min
Until Stable (minimum 3 minutes)
Until Stable (minimum 3 minutes)
Until Stable (minimum 3 minutes)
Chlorine
300 cc/min
Page: 13
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Model 4501-XX Toxic Gas Sensor Module
6.3 DIAGNOSTICS SUB-MENU
Key Function Display
Description
Reference
M
S T
E
H2S
CALIB:
Default Display (example 4501-05)
Mode
Enter
or Sub-Routine A
M
S T
E
CAL 0 PPM
Banner: Apply zero gas, [E] when done
Operation: Confirm area clear of gas, or apply zero air to sensor.
M
S T
E
Cal0PPM
Wait.XXX
There is a minimum time to calibrate at 0PPM. If [E] is hit prior to this time
has elapsed, a countdown screen will appear.
Enter
Zero gas setting completed (Message will appear on the screen and after 3
seconds will go to the next menu - 25PPM Span)
ZERO
DONE
Banner: [S] or [T] to change span value, [E] when done
Operation: 148 second time out before sensor is returned to service.
Banner: Remove gas from sensor
XXPPM
Sub-Routine B
Sub-Routine C
H2S
WAIT-148
M
S T
E
H2S
CAL-OK
Enter
Mode
Sub-Routine A - Abort Calibration
Operation: Hold magnet over [M] for 10 seconds to abort calibration
Default Display
M
S T
E
CALIB
ABORTED
H2S
XXX PPM
Sub-Routine B - Select Span
Banner: [S] or [T] to change span value, [E] when done
Banner: Apply xx-PPM gas, [E] when stable
Operation: Remove gas from sensor
25PPM SPAN
C##PPM
M
S T
E
Should be stable after 3
minutes of gas exposure
If calibration failed, then
Sub-Routine C
Down
Enter
M
S T
E
H2S
REMOVE GAS
H2S
CAL-OK
Calibration successful
Sub-Routine C - Calibration Fail
M
S T
E
READ
MANUAL
Operation: Remove gas from sensor read manual, particularly section 6.3 and
7.6, to check calibration procedures.
Enter
H2S
CAL-FAIL
Calibration Failed
Table 6-1
Calibration Sub-Menu
Page: 14
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Model 4501-XX Toxic Gas Sensor Module
7. SERVICE
7.1SENSOR MODULE CONFIGURATION
The gas sensor module is comprised of the following sub-assemblies (Figure 7-1):
4501-XX
Gas Sensor Module
SPL27077
SPM27071
XXXXXXX
XXXXXXX
Enclosure
Transmitter Assembly
Sensor Assembly (see Appendix B)
Sensor (see Appendix B)
There are no field serviceable components below the sub assembly level.
ENCLOSURE 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 NEMA 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 7-1
Module Components
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Model 4501-XX Toxic Gas Sensor Module
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 90o to relieve the
wiring service loop
c. Unplug the sensor connector from the transmitter
d. Remove the two wires from J1 terminals (see figure 4-2)
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
SENSOR REPLACEMENT
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 SENS” 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 90o 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.
INSTALLATION INSPECTION
Prior to system start-up or trouble shooting, the entire system should be visually inspected. The following are
guidelines for that inspection:
7.1.1 CONTROLLER INSTALLATION
•
Controller installed in conformance to manufacturer’s instruction manual recommendations.
7.1.2 CABLING INSTALLATION
•
•
All splices are soldered or via terminal block.
Cabling is away from sources of electrical noise or RFI where possible.
7.1.3 SENSOR MODULE INSTALLATION
•
•
Module installation in conformance with this manual.
Modules accessible for calibration.
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Model 4501-XX Toxic Gas Sensor Module
•
Wiring terminations clean and correct.
7.1.4 MOISTURE 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.
7.1.5 STANDARD VOLTAGES
•
Loop voltage to be applied to the sensor module must be between 14 VDC and 30 VDC.
7.2 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.
7.2.1 IF MODULE DOES NOT DISPLAY THE CORRECT PPM GAS
1. Repeat calibration procedure.
2. Remove the gas and wait for the timer to completely count down.
3. Apply Span Gas and verify that the sensor sees the correct value of the span gas after calibration.
4. If the sensor still does not respond to gas, power cycle the unit and repeat calibration.
7.2.2 IF THE MODULE DOES NOT DISPLAY THE CORRECT PPM
1. Power cycle the module.
2. Recalibrate the sensor.
7.2.3 IF THE DISPLAY SHOWS ‘NO SENSOR’ – SENSOR FAILING
1. Power down the unit
2. Open the enclosure and unplug the sensor from the transmitter board.
3. Plug the sensor back into the transmitter board carefully and ensure a secure fit.
4. Power up the unit.
7.2.4 IF THE DISPLAY SHOWS “C” – CALIBRATION MODE
1. Complete calibration or exit to operating mode.
7.2.5 IF THE DISPLAY SHOWS “ T ” – DOWNSCALE INDICATOR
1. The reaction of the sensor to gas may, for a short period of time, result in a downscale indicator being
shown on the display.
2. If this indicator remains for a longer period of time, the sensor may need re-calibration.
7.2.6 IF THE DISPLAY SHOWS “HIGH” – UPSCALE INDICATOR
1. The concentration of the gas is outside the calibrated range.
Page: 17
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Model 4501-XX Toxic Gas Sensor Module
8. APPENDICES
APPENDIX A: SPECIFICATIONS
Specifications:
Sensor:
4501-04
0-1200 PPM
+/- 1 PPM
+/- 1 PPM
+/- 1 PPM
0.5 PPM
4501-05
0-100 PPM
+/- 0.5 PPM
+/- 1 PPM
+/- 1 PPM
0.1 PPM
4501-06
0-10 PPM
+/- 0.5 PPM
+/- 0.5 PPM
+/- 0.5 PPM
0.1 PPM
Max. Range (1)
Zero Drift
Repeatability
Linearity
Resolution
Response Time (2)
Sensor Life (3)
<25 sec.
2 years
<30 sec.
2 years
<60 sec
2 years
(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
Output:
Display:
LCD, 2-line, 20-characters
Signal Output:
Loop Resistance
2-wire sensor powered analog 4-20 mA (Trouble: 3.6 mA)
800 ohm
Electrical Data:
Power consumption:
Connection type:
Input voltage:
<160 milliwatts
2 wire
24 VDC nominal: 14-30VDC, 2-wire loop powered
EN50081-2, EN50082-2
RFI/EMI Protection:
Operating Range:
4501-04 CO
-4 to 122 oF
-20 to 50 oC
5 – 99%
4501-05 H2S
-40 to 122 oF
-40 to 50 oC
5 – 99%
4501-06 Cl2
-4 to 122 oF
-20 to 50 oC
5 – 99%
Ambient Temp (oF)
Ambient Temp (oC)
Relative Humidity
o
o
Extended Range
Operation
Sensor and 4-20 mA will continue to operate to -40 F (-40 C) but the
o
LCD display will decay over time if exposed to temperatures below -4 (-
o
20 C) for significant time
o
o
o
o
Storage Temperature:
-4 to 122 F(-20 to 50 C)
Enclosure:
Dimensions:
Weight:
7.0 x 3.6 x 4.0 inches (H x W x D)
(17.8 x 9.1 x 11.2 cm)
4.4 lb. (2.0 Kg)
Material of Construction:
Enclosure:
316 Stainless Steel
NEMA 4X
Electrical Classification:
FM Approved:
Explosion proof, Class 1, Div. I, Groups B, C, D
Class 1, Zone 1, Group IIB+H2 IP66
Approvals:
FM Performance Approval:
(4501-05 only)
Approval Standards: ISA-92.0.01, Part I-1998 and FM 3600
Remote Sensor Option:
Distance Sensor to Transmitter:
4501-04
4501-05
4501-06
25 feet
25 feet
15 feet
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Model 4501-XX Toxic Gas Sensor Module
Warranty:
Limited warranty:
2 year specifications subject to change without notice
Model Number
4501-04-IT
Gas Type CO
H2S
5
CI2
0
H2
SO2
0
NO2
0
NO
6
HCI
0
HCN
C2H4
<50
0
CO
H2S
C12
100
<2
0
<20
<0.1
0
0
0
0
4501-05-IT
100
<-10
-20
100
<15
0
-15
105
0
0
4501-06-IT
0
0
0
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Model 4501-XX Toxic Gas Sensor Module
APPENDIX B: MODEL NUMBERS & PARTS LIST
Sensor Module
4501-04
4501-05
4501-06
Sensor Module 2-wire, CO
Sensor Module 2-wire, H2S
Sensor Module 2-wire, CI2
Options
5394-52
5311-00
Remote Sensor/Display Option
Rainshield
Calibration Items
1250-01
Gas Sensor Calibration Kit, Type A (CO, H2S)
Gas Sensor Calibration Kit, Type C (Cl2)
Gas Cylinder, Air, (Type A), 105 litres
Gas Cylinder, CO 100 PPM, (Type A) 57 litres
Gas Cylinder, H2S in N2, 25 PPM, (Type A) 57 litres
Gas Cylinder, Cl2, 5 PPM, (Type C) 104 litres
Gas Cylinder, CO, 1000 PPM, (Type A), 105 liters
Calibrator Head Standard
Regulator Type A Calibrator
Regulator Type C Calibrator
Calibration Adapter - Direct, Standard
Calibration/Configuration Magnetic Tool, 4501-XX
1250-03
1260-00
1260-04
1260-05
1260-06
1260-13
5360-00
1256-01
1265-03
5358-01
5358-51
Spare Parts
SPM21830
SPM21832
SPM21833
SPM27071
SPM27074
SPM27083
SPM27084
SPM33030
SPM33041
SPM33050
Sensor Assy, Aluminum, 4501-05/5100-05-IT
Sensor Assy, Aluminum, 4501-04/5100-04-IT
Sensor Assy, Aluminum, 4501-06/5100-06-IT
Transmitter for 4501-XX
Sensor Assy, 316SS, 4501-05/5100-05-IT
Sensor Assy, 316SS, 4501-04/5100-04-IT
Sensor Assy, 316SS, 4501-06/5100-06-IT
Sensor for 4501-04
Sensor for 4501-05
Sensor for 4501-06
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Model 4501-XX Toxic Gas Sensor Module
APPENDIX C: LIMITED WARRANTY
SIERRA MONITOR 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 determination 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 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 SMC’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.
Except for the express warranty stated above, SMC 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 SMC for damages including, but not limited to,
consequential damages arising out of/or in connection with the use or performance of the product.
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