5100 02 IT - Manual

MODEL 5100-02-IT
IT Series
COMBUSTIBLE GAS SENSOR MODULE
Version 3.00A
APPLICABILITY & EFFECTIVITY
Effective for all Model 5100-02-IT Modules manufactured after December 1, 2011.
Instruction Manual Part Number T12019

Rev. E
Model 5100-02-IT Combustible Gas Sensor Module
FM APPROVAL
ONLY THE FOLLOWING ITEMS, FUNCTIONS AND OPTIONS ARE FM* APPROVED
Sensor Module
Calibration Equipment
Model 1200-26 Calibration Gas Delivery System
Model 1290-02 Combustible Gas Cylinder
Model 5358-01 Calibration Head, Standard
Model 5360-00 Calibration Gas Delivery Fitting
Model 1260-02 Combustible 50% LEL Gas Cylinder
Model 1260-42 Cylinder H2 50% LEL Type A
Model 1250-01 Gas Sensor Calibrator Kit, Type A
Model 1256-01 Regulator Type A Calibrator
Model 5394-51 Remote Sensor Option – 5100-02-IT
Notes:
1) FM Approval applies only to conventional (one cable run per sensor module)
or multiplexed (multiple sensor modules per cable) installations. Apparatus
must be installed in accordance with National Electrical Code.
2) FM Comments
*FM Approvals, a subsidiary of FM Global
 Project# 3021050
TABLE OF CONTENTS
1. PRODUCT DESCRIPTION ................................................................................................................................. 3

1.1 GENERAL ........................................................................................................................................................ 3
1.2 PRODUCT CONFIGURATION ........................................................................................................................ 3
1.3 THEORY OF OPERATION .............................................................................................................................. 3
1.4 MODES OF OPERATION ................................................................................................................................ 3
1.5 MECHANICAL ................................................................................................................................................. 4
1.6 INTERCONNECT WIRING .............................................................................................................................. 5
1.7 POWER REQUIREMENTS ............................................................................................................................. 5
2. CAUTIONS & WARNINGS ................................................................................................................................. 7
2.1 INTRODUCTION ............................................................................................................................................. 7
2.2 IT MODULES - GENERAL .............................................................................................................................. 7
2.3 WIRING ........................................................................................................................................................... 7
3. QUICK START .................................................................................................................................................... 9
3.1 OVERVIEW ..................................................................................................................................................... 9
3.2 WIRING ........................................................................................................................................................... 9
3.3 MODULE INSTALLATION ............................................................................................................................... 9
3.4 TRANSMITTER INSTALLATION..................................................................................................................... 9
3.5 START-UP & OPERATION ............................................................................................................................. 9
4. INSTALLATION ................................................................................................................................................ 10
4.1 SENSOR MODULE LOCATIONS ................................................................................................................. 10
4.2 WIRING (FIGURE 4-2 REFERS TO ANALOG, MODBUS AND SENTRY OPERATION)................................................. 10
4.3 ENCLOSURE INSTALLATION ...................................................................................................................... 11
4.4 TRANSMITTER AND SENSOR INSTALLATION .......................................................................................... 12
4.5 MODULE ADDRESS SWITCH ...................................................................................................................... 13
5. OPERATION ..................................................................................................................................................... 18
5.1 DATA ENTRY KEY PAD ................................................................................................................................ 18
5.2 MAIN MENU ................................................................................................................................................... 19
5.3 SET-UP .......................................................................................................................................................... 20
5.4 MAINTENANCE FUNCTIONS ....................................................................................................................... 23
6. CALIBRATION .................................................................................................................................................. 24
6.1 CALIBRATION FREQUENCY........................................................................................................................ 24
6.2 CALIBRATION PREPARATION .................................................................................................................... 24
6.3 CALIBRATION GAS DELIVERY METHODS ................................................................................................. 24
6.4 CALIBRATION PROCEDURE ....................................................................................................................... 24
6.5 SENSOR EXPOSURE TO GAS ..................................................................................................................... 24
6.6 CALIBRATION SUB-MENU ........................................................................................................................... 25
7. SERVICE ........................................................................................................................................................... 26
7.1 MODULE SUB ASSEMBLY ........................................................................................................................... 26
7.2 ENCLOSURE REPLACEMENT ..................................................................................................................... 26
7.3 TRANSMITTER REPLACEMENT ................................................................................................................. 27
7.4 SENSOR REPLACEMENT ............................................................................................................................ 27
7.5 INSTALLATION INSPECTION ...................................................................................................................... 27
Page: 1
8. APPENDICES ................................................................................................................................................... 29
8.1 APPENDIX A: SPECIFICATIONS .................................................................................................................. 29
8.2 APPENDIX B: MODEL NUMBERS, PARTS LIST & PARAMETERS ............................................................. 30
8.3 APPENDIX C: LIMITED WARRANTY ............................................................................................................ 31
8.4 APPENDIX D: REMOTE SENSOR OPTION ................................................................................................. 32
8.5 APPENDIX E: HART ...................................................................................................................................... 34
8.6 APPENDIX F: MODBUS MEMORY MAP....................................................................................................... 42
8.7 APPENDIX G: COMBUSTIBLE GAS SCALING FACTORS .......................................................................... 43
8.8 APPENDIX H: FM APPROVAL ..................................................................................................................... 44
8.9 APPENDIX I: SIL-2 APPROVAL CERTIFICATE ............................................................................................ 46
LIST OF FIGURES
FIGURE 1 - 1: MODEL 5100-02-IT COMBUSTIBLE SENSOR – MOUNTING OPTIONS .....................................5
FIGURE 1 - 2: MODEL 5100-02-IT-S1 (AND S2) COMBUSTIBLE SENSOR – 316SS DIMENSIONS ..................6
FIGURE 1 - 3: MODEL 5100-02-IT-A1 (AND A2) COMBUSTIBLE SENSOR –ALUMINUM DIMENSIONS ..........6
FIGURE 4 - 1: TYPICAL MOUNTING OPTIONS ..................................................................................................10
FIGURE 4 - 2: TRANSMITTER FACE PLATE ......................................................................................................14
FIGURE 4 - 3: 4-20 MA CIRCUITS TYPES 5100-02-IT ........................................................................................14
FIGURE 4 - 4: 4-20 MA CIRCUITS TYPES 5100-02-IT – CONNECTIONS .........................................................15
FIGURE 4 - 6: REMOTE ALARM RESET .............................................................................................................16
FIGURE 4 - 5: DIGITAL INTERFACE CONNECTIONS ........................................................................................16
FIGURE 4 - 7: TERMINATION DRAWING ...........................................................................................................17
FIGURE 5 - 1: FACE PLATE WITH DATA ENTRY KEY PAD ..............................................................................18
FIGURE 6 - 1: MODEL 5358-01 CALIBRATION ADAPTER .................................................................................24
FIGURE 7 - 1: MODULE COMPONENTS .............................................................................................................26
FIGURE 8 - 1: REMOTE SENSOR OPTION ........................................................................................................32
FIGURE 8 - 2: HART .............................................................................................................................................34
FIGURE 8 - 3: 4-20 MA CIRCUITS TYPES 5100-02-IT – CONNECTIONS - HART ............................................35
LIST OF TABLES
TABLE 4 - 1: MINIMUM WIRE GAUGES ..............................................................................................................12
TABLE 4 - 2: SENSOR MODULE EXTERNAL INTERFACES ..............................................................................13
TABLE 4 - 3: SENSOR MODULE ADDRESS SWITCH POSITIONS ...................................................................13
TABLE 5 - 1: MASTER MENU ...............................................................................................................................19
TABLE 5 - 2: OPERATION DISPLAY VALUES .....................................................................................................19
TABLE 5 - 3: SET-UP CONFIGURATION .............................................................................................................21
TABLE 5 - 4: MAINTENANCE MENU ...................................................................................................................23
TABLE 6 - 1: CALIBRATION .................................................................................................................................25
TABLE 8 - 1: MODBUS MEMORY MAP................................................................................................................42
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1. PRODUCT DESCRIPTION
1.1 GENERAL
The Model 5100-02-IT Catalytic Bead Combustible Gas Sensor Module is a member of the Sentry
Information Technology ”IT” family of gas sensor transmitter modules. IT modules offer a broad array of
features including:
• Integral Alphanumeric display
• 180 day calibration frequency
• SIL-2 Certified
• FM Approved for performance and hazardous locations
• 4-20 mA output
• Modbus® RTU interface
• SMC Sentry interface
• 316 Stainless steel enclosure option
• Remote alarm reset
• Optional Alarm Relays
• Remote sensor option
IT modules are designed, and approved for installation and operation in hazardous locations.
1.2 PRODUCT CONFIGURATION
Various module configuration options are available. Where applicable, these options are factory configured
prior to shipment.
1.3 THEORY OF OPERATION
Catalytic bead gas sensors detect gas by comparing the resistance of two heated elements. One element is
catalytic to enhance the burning of combustible gases, the other element is passive. Electronic circuits are
used to compare the change in the catalytic bead resistance relative to the passive bead. The relative change
is calibrated to determine the concentration of the gas of interest.
1.4 MODES OF OPERATION
1.4.1 SENTRY INTERFACE

All IT gas sensor modules can be installed on Sierra Monitor Sentry Model 5000 controllers. Catalytic bead
modules communicate as a combustible gas sensor module (Type 2 communication) and are automatically
detected by the Sentry controller. When it is installed in a Sentry system the IT module must have a unique
address which can be established by setting an address between 1 and 8 on the rotary switch accessible
from the cover plate as illustrated in Figure 4-1. Figure 4-4 in this manual provides the wiring terminations
for connections to the Sentry controller.
When the module is operated in conjunction with a Sentry controller, the alarm relay setup (See section 4.3)
should be set to “Sentry”, allowing the Sentry controller to manage alarm relay action rather than the
5100-02-IT Gas Sensor Module.
An available option, applicable only to Sentry installations, is a connector card which allows daisy chain
installation using the Sentry multiplex capability. Use of the connector card reduces costs by avoiding the
requirement for wiring junction boxes. The connector card has two sets of connections, allowing for a
continuous run to the next module
® Registered trademark of Schneider Electric.
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1.4.2 MODBUS OPERATION

An RS-485 Modbus RTU serial interface allows direct connection to standard PLCs and DCSs. The Module
Address Switch (section 4.5) allows the user to select up to 15 different Modbus addresses. Also, up to 254
different Modbus Addresses are available via menu selection. Figure 4-5 in this manual provides the wiring
terminations for Modbus connections.
1.4.3 ANALOG OPERATION
The analog 4-20 mA interface allows direct connection to standard controller and distributed system. The
module is an active current source.
The standard configuration is set up for a 3-wire non-isolated connection. An optional 4-wire isolated
connection is also available and can be enabled by changing JP1 and JP2.
1.4.4 REMOTE SENSOR (APPENDIX E)
The Remote Sensor option enables the remote mounting of the sensor up to 50’ from the transmitter.
1.4.5 HART CONNECTION (APPENDIX F)
A HART interface option is available. Refer to Appendix F for information.
1.4.6 OPTIONAL INTEGRAL RELAYS
The optional relays are integral to the gas sensor module and are rated as SPDT, 250VAC, 5 Amps for the
High Alarm and Low Alarm relays and SPDT, 250VAC, 0.25 Amp for the Trouble relay.
* HART option, alarm relays are all SPDT, 250VAC, 2 Amp
If the gas sensor module is provided with the optional relays, it will include Terminal P4 on the interface
board (Figure 4-3). Relay output connections are on P4.
1.4.7 REMOTE ALARM RESET
An input is available for connection of remote alarm reset/acknowledge. Figure 4-6 provides the wiring
termination for connecting the remote alarm reset. This only resets local alarms, not Sentry alarms.
1.5 MECHANICAL
The sensor module of comprised of the following three primary components:
⧫ ENCLOSURE
Standard on the 5100-02-IT is an explosion-proof, rain-tight cast aluminum electrical housing (Figure 1-2)
with three ¾” FNPT conduit hubs. The 5100-02-IT-SS has a 316 Stainless Steel enclosure (Figure 1-3).
Both enclosure covers have a viewing window. The design of the enclosure allows 3-way mounting choices
as shown in figure 1-1.
⧫ TRANSMITTER ELECTRONICS
Electronic Assembly consisting of one printed circuit board assembly mounted under a cover plate, plugged
into one field termination board. Connectors for wiring for power, signal interface and alarm relays are
located on the bottom of the termination board.
⧫ SENSOR ASSEMBLY
The sensor assembly includes an 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.
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1.6 INTERCONNECT WIRING

Not supplied with the sensor module, but necessary to the installation and operation is the multi 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 alternatives
requirements and alternatives.
1.7 POWER REQUIREMENTS
IT modules operate on DC power between 10 VDC and 30 VDC. Regulated DC power must be supplied from
a separate source, or from an approved Sentry or IT controller.
Figure 1 - 1: Model 5100-02-IT Combustible Sensor – Mounting Options
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Figure 1 - 2: Model 5100-02-IT-S1 (and S2) Combustible Sensor – 316SS Enclosures, Dimensions
Figure 1 - 3: Model 5100-02-IT-A1 (and A2) Combustible Sensor – Cast Aluminum Enclosures, Dimensions
Page: 6
2. CAUTIONS & WARNINGS
2.1 INTRODUCTION
Although IT Transmitter Modules are 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 IT MODULES - GENERAL
Avoid installing sensor modules where they will be unnecessarily exposed to wind, dust, water (esp. 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:
silicones, sulfides, Halides (compounds containing chlorine, fluorine, bromine, iodine), acid vapors, caustic
liquids or mists.
Care has been taken by the manufacturer to ship your 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 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.
• When shielding is used, it is recommended that shields be grounded at the controller and nowhere else.
• All splices must be via either a termination hardware system or soldered. Improperly spliced cable can
result in corrosion, resistance changes and system errors. The use of wire nuts and crimp-on
connectors is unacceptable.
NOTE
Installation and wiring must be in accordance with the National Electrical Code.
AC Voltage conductors are not to be run in the same conduit as DC voltage
conductors.
2.3.1 CATALYTIC BEAD SENSOR MODULES

Model 5100-02-IT Gas Sensor Modules are FM performance approved for detection of Combustible gas
(methane and hydrogen). The sensor is cross sensitive to the combustible gases indicated in Table 2-1.
Risk management planning should take into consideration the potential for the presence of other gases in
the monitored area.
Page: 7
Note that the 5100-02-IT has a gas factor scaling feature in which a calibration standard of Methane or
Propane may be used in conjunction with scaling factors to cause alarm function in %LEL scale of another
gas. See Appendix G.
Acetaldehyde 2,3-Dimethylpentane Methyl Chloride

Acetic Acid 2,3-Dimethylpropane Methylcyclohexane
Acetic Anhydride Dimethylsulphide Methylenedichloride
Acetone 1,4-Dioxane Methylethylether
Acetylene Epichlorohydrin Methylethylketone
Alkyl Alcohol Ethane Methyl Formate
Ammonia Ethyl Acetate Methylmercaptan
n-Amyl Alcohol Ethyl Alcohol Methylpropionate
Aniline Ethylamine Methyl n-propylketone
Benzene Ethyl Benzene Napthalene
Biphenyl Ethyl Bromide Nitromethane
1,3-Butadiene Ethyl Chloride n-Nonane
n-Butane Ethylcyclopentane n-Octane
iso-Butane Ethylene n-Pentane
Butene-1 Ethylenedichloride i-Pentane
cis-Butene-2 Ethyleneoxide Propane
trans-Butene-2 Diethyl Ether n-Propyl Alcohol
n-Butyl Alcohol Dimethoxyethane n-Propylamine
iso-Butyl Alcohol Dimethyl Ether n-Propylchloride
tert-Butyl-Alcohol Dimethylformamide Propylene
n-Butyl Benzene Ethyl Formate Propyleneoxide
iso-Butyl Benzene Ethylmercaptan iso-Propylether
n-Butyric Acid n-Heptane Propyne
Carbon Disulfide n-Hexane Toluene
Carbon Monoxide Hydrazine Triethylamine
Carbon Oxysulphide Hydrogencyanide Trimethylamine
Chlorobenzene Hydrogen Vinylethylether
Cyanogen Hydrogen Sulfide o-Xylene
Cyclohexane Methane m-Xylene
Cyclopropane Methyl Actetate p-Xylene
n-Decane Methyl Alcohol JP-4 (Jet Fuel)
Diethylamine Methylamine
Dimethylamine Methyl Bromide
Table 2 - 1: Combustible gases detected by Model 5100-02-IT Combustible Gas Sensor Module
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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
See section 4.2 to determine if 3-wire or 4-wire operation is necessary.
Provide twisted shielded wiring from the power supply/control device to the sensor module location. Use
stranded wire that is 18 AWG or larger.
3.3 MODULE INSTALLATION
The sensor module can be mounted in a variety of configurations supported by the conduit. See figure 1-1 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.
• Sensor housing must be oriented vertically pointing downward.
• If module is installed outdoors it is recommended that it be sheltered from direct sunlight.
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 10-30 VDC. Each time the sensor
module is powered up it will perform a warm-up for approximately 5-10 minutes. During this time the display
will read “Starting”. The loop output will be held at 4 mA.
NOTE: If the sensor is uncalibrated, the startup display will state “START” instead of “STARTING”
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.
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4. INSTALLATION
NOTE
All IT modules are factory pre-configured and calibrated.
All modules are tagged to indicate the configuration including the sensor module number
Identify all components during unpacking and install using the factory configuration.
4.1 SENSOR MODULE LOCATIONS

Select locations for each sensor modules based on the following:
• Modules should be placed close to the potential source of gas.
• Modules should be placed in areas accessible for calibration.
• Sensors should be pointed down and the conduit should include an inverse trap to reduce moisture
(condensation) from accumulating in the electronics enclosure.
• Remote calibration fitting (5360-00) should be used to facilitate calibration gas delivery. Run
polyurethane tubing (1/4” O.D. x 1/8” I.D.) from fitting to an accessible location.
Figure 4 - 1: Typical Mounting Options
NOTE
Module must always be installed vertically with sensor pointing down.
4.2 WIRING (Figure 4-2 refers to Analog, Modbus and Sentry operation)
4.2.1 ANALOG 4-20 MA OPERATION

For a 3-Wire non-isolated connection, set jumpers, located on the bottom of the transmitter board, to the
lower position as illustrated in Figure 4.4. Verify that both jumpers are in the position marked by 3-wire.
When using a 3-wire connection, a minimum of an 18 AWG, 3 conductor shielded cable must be used. A
cable shield must never be used as a conductor. Larger gauge wire is recommended with distances over
1000’. Connect wires as shown in figure 4-4.
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For a 4-Wire isolated connection, set jumpers, located on the bottom of the transmitter board, to the upper
position as illustrated in Figure 4.4. Verify that both jumpers are in the position marked by 4-wire. When
using a 4-wire connection, a minimum of 2 each of an 18 AWG, 2 conductor twisted/shielded pair cable
must be used. A cable shield must never be used as a conductor. Larger gauge wire is recommended with
distances over 1000’. Connect wires as shown in figure 4-4.
4.2.2 MODBUS OPERATION USING RS-485 CONNECTION
Use a minimum of 18 AWG, 2 conductor for DC power connection. No shield required. In addition use a
minimum of 24 AWG, low capacitance, shielded data cable for RS485 half duplex communication. The
installation may be planned in a manner which provides up to 32 sensor modules on a single home run.
TERMINATION RESISTOR JUMPERS:
Termination resistors are used in RS-485 wire runs to provide impedance matching. The IT series modules
use a 120 Ohm resistor for this function. The cable being used for this RS-485 connection must have a
minimum of 100 Ohm impedance with a maximum of 120 Ohms.
Installations where the cable length is under 100’, termination resistors may not be required. In installations
where the cable length is greater than 100’, it is recommended to place the termination jumpers on the first
device and last device on the RS-485 wire run. Termination jumpers must be removed from all other
modules connected between the first and last device. The first device in the RS-485 multiplexed bus is
usually a gas controller or PLC. Factory term resistor setting is “not enabled.”
BIAS JUMPERS: (BIAS A, BIAS B)
Bias resistors are used to force RS-485 receiver outputs to a known (fail-safe) state, when the bus is idle.
Bias jumpers are always installed in pairs as the bias must be placed on both the TX A and TX B lines.
Sierra Monitor’s IT series of combustible gas sensors automatically apply the bias jumpers, and are factory
installed so that the bias is always enabled.
4.2.3 SENTRY OPERATION USING SENTRY PSG CONNECTION
Use a minimum of 18 AWG, 3-conductor cable up to 2000’. The cable may or may not be shielded. We
recommend shielded cable in circumstances that there could be RF or EM interference present. Shield to
be terminated and grounded only at the Sentry controller. Shield must be cut and dressed at the module
end so that no part of it comes in contact with the conduit or ground.
NOTE:
Be sure to follow all local electric code and safety requirements when installing the 5100-02-IT Gas Sensor Module
4.2.4 GENERAL
Install conduit as required by local code or construction specifications. Provide for splice boxes where
multiple modules will be wired to a single run. Pull conductors of the correct gauge wire from the controller
to each splice box and from the respective splice box to each planned module location. See for proper wire
termination in the splice box. Twisted wire secured with wire nuts is not an acceptable splice.
NOTES
RFI Noise Suppressor must be added to power/ground as per Appendix D.
The drain wire of shielded cable must NOT be used as one of the conductors.
Installation and wiring must be in accordance with the National Electrical Code. Temperature
rating of cable wire must be at least 75oC. If cable runs through higher temperature
environments, it must be specified for that environment.
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.
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Number Maximum length of wire run (feet)

of
modules 500 1,000 2,000 3,000 5,000
1 18 18 16 16 14
2 18 18 14 12 xx
3 18 16 12 xx xx
4 16 14 12 xx xx
Table 4 - 1: Minimum Wire Gauges

Prior to installation and wiring.
1. Remove the transmitter from the module housing by:
• Unscrew the two captive panel screws in the face plate.
• Lift the transmitter out of the enclosure housing.
• Unplug the sensor cable from transmitter assembly connector J1.
• Remove the sensor assembly from the enclosure hub.
2. Install the module housing onto the end of the supply conduit and/or bolt into position as required.
NOTES
When housing earth grounding is required for the installation a grounding lug is located in
the base of the enclosure. Install the earth ground wire under the green lug.
4.4 TRANSMITTER AND SENSOR INSTALLATION

When all pre-wire 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 top transmitter board connector J1.
3. Align the headers between the top transmitter board and the lower termination board and push
together.
4. Turn rotary switch to correct sensor address if required.
5. Carefully return the transmitter to the enclosure installing it over the two stand-off’s. Tighten the
retaining screws into the stand-offs.
6. Cycle power to accept module address change.
P1 PCB Label Function

1 IN + Digital Input SW +
Switch
2 IN - Digital Input SW -
3 4-20 IN + 4-20 mA Input +
4 IN - 4-20 mA Input -
5 GND Ground
6 OUT + 4-20 mA Output
4-20
7 OUT - 4-20 mA Output

1 + RS 485 (+) (A)
2 - RS 485 (-) (B)
RS 485
3 S RS 485 shield (Isolated GND)
4 + RS 485 (+) (A)
5 - RS 485 (-) (B)
RS 485
6 S RS 485 shield (Isolated GND)
Page: 12
P3B PCB Label Function

1 P VDC Power
2 S Sentry Signal or Communication
3 G VDC Ground
P3A
4 P VDC Power
5 S Sentry Signal or Communication
6 G VDC Ground
P4 Connections are only available when the optional Relays are included

1 N/C Low Alarm Relay NC
2 COM Low Alarm Relay COM
WARN
3 N/O Low Alarm Relay NO
4 N/C High Alarm Relay NC
5 COM High Alarm Relay COM
ALARM
6 N/O High Alarm Relay NO
7 N/C Trouble Alarm Relay NC *
8 COM Trouble Alarm Relay COM*
TRBL
9 N/O Trouble Alarm Relay NO*
* Trouble relay is fail safe so it is energized for normal operation,
functions are labeled for normal operation.
Table 4 - 2: Sensor Module External Interfaces
7. Establish the module address according to section 4.5.
NOTES
The starting delay period normally takes approximately 3 minutes but under some
circumstances can take longer.
4.5 MODULE ADDRESS SWITCH

For digital interface applications the module address switch (or Modbus node) must be set per Table 4-2:
POSITION ADDRESS POSITION ADDRESS NOTE
For Sentry applications only sensor addresses 1-8 are

1 Sensor 1 9 Sensor 09
allowed. If using Modbus output sensor addresses 1-15
2 Sensor 2 A Sensor 10 are available. Position 0 allows the Modbus Address to be
set by software menu, in the range 16-254.
3 Sensor 3 B Sensor 11
4 Sensor 4 C Sensor 12
5 Sensor 5 D Sensor 13
6 Sensor 6 E Sensor 14
7 Sensor 7 F Sensor 15
8 Sensor 8 0 Software Menu
Table 4 - 3: Sensor Module Address Switch

Positions
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Figure 4 - 2: Transmitter Face Plate
Figure 4 - 3: 4-20 mA Circuits Types 5100-02-IT
Page: 14
(DEFAULT)
Figure 4 - 4: 4-20 mA Circuits Types 5100-02-IT – Connections
Page: 15
+
-
Figure 4 - 5: Digital Interface Connections
Figure 4 - 6: Remote Alarm Reset
Page: 16
Figure 4 - 7: Termination Drawing
Page: 17
5. OPERATION
The Combustible Gas Sensor 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 configure alarm set-points, calibrate the sensor
module, and for maintenance procedures and alarms acknowledge.
5.1 DATA ENTRY KEY PAD

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 above and below the faceplate display and are labeled M , E , ▲, and ▼as shown in Figure 5-1.
• Key M : MODE
• Key E : ENTER
• Key ▲: UP (+)
• Key ▼: DOWN (-)
Mode Enter
Up Down
Figure 5 - 1: Face Plate with Data Entry Key Pad
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5.2 MAIN MENU

Table 5-1 describes the primary human-machine interface operation.
Key Function Display Description Reference

M E
p q
Mode Switch [M]
M E
p q
Enter Switch [E]
M E
p q
Up Switch [▲] Previous Menu
M E
p q
Down Switch [▼] Next Menu
5100-02 First screen at power up-model

1.Xxa VX.Xxx Second screen at power up-version
Warm.XXX Third screen at start up-warm up
0%LEL Normal condition - default display

M E
p q
Mode ALMRSET: Mode Function -Alarms Acknowledge
Banner: Use <M> sw itch for different menu items. Select
SSSSSSSS
<E> to enter menu item.
0%LEL Default Display
M E
p q
Mode ALMRSET: Mode Function - Alarms Reset
M E
p q
Mode CALIB: Mode Function - Calibrate Table 6-1
M E
p q
Mode SETUP: Mode Function - Module Set-up Table 5-3
M E
p q
Mode MAINT: Mode Function - Maintenance Table 5-4
M E
p q
Mode EXIT-? Exit Mode
M E
p q
Enter 0%LEL Apply Selected Mode (Exit)
Table 5 - 1: Master Menu
Table 5-2 describes the operational display values of the human-machine interface system.
Display Description
STARTING Warm-up at start-up
##%LEL Concentration
L ##%LEL Low Alarm (Warning)
H ##%LEL High Alarm (Alarm)
HIGH >100% Full Scale
NO SENSR Sensor Failure
C ##%LEL Calibration Mode
ACK Acknowledged Function
Table 5-2 Display Values
Table 5 - 2: Operation
Operation Display Values
ID THE DISPLAY SHOWS “START” INSTEAD OF “STARTING, THE MODULE MUST BE CALIBRATED BEFORE USING IT.
Page: 19
5.3 SET-UP
The sensor module set-points menu is used to initially set-up the alarm set points, relay actions, gas type and
range, 4-20 mA action and RS-485/Sentry address and baud rates (See Menu Key in Appendix J). When in the
SETUP screen use the [▲] or [▼] keys to select submenu and use [E] to enter.
• Alarms: Use the [▲] or [▼] keys to select Low Alarm (Warning) or High Alarm (Alarm) menu. Key
[▲] will adjust the setpoint upwards and Key [▼] will adjust the value downwards. Once it reaches
the desired setpoint, Key [E] will accept it and ACK will appear. Set-points can be configured using
this menu to values between 0 and 60.
• Relays: Use the [▲] or [▼] keys to select Low Alarm (Warning) or High Alarm (Alarm) relay menu
and press [E]. Use the [▲] or [▼] keys to select the correct alarm relay action for the application,
Latch, Sentry or Non-Latch. Selecting “Sentry” enables the Sentry controller to make all alarm
action decisions. * indicates the current selection.
• Gas Factor: A calibration standard of Methane may be used in conjunction with scaling factors to
cause alarm function in %LEL scale of another gas. See Appendix I for a list of the scaling factors.
Note that if the 5100-02-IT is interfaced to a Sentry controller that the gas factor can be set in the
Sentry or the Gas Sensor Module but NOT IN BOTH. It is recommended that the gas factor be
adjusted in the Gas Sensor Module so that the display values on both the Gas Sensor Module and
the Sentry are matched. Note that gas factors are not applicable during calibration.
• 4-20mA: Use the [▲] or [▼] keys to select Calib, or CalibOut TblOut menu and press [E]. 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 5100-02-IT 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. The CalibOut section allows the user to select the 4-20 mA output action desired during
calibration. * indicates the current selected value. Available selections include:
▪ Track – the 4-20mA value tracks the calibration gas exposed to the gas sensor module
▪ C2.5mA – the 4-20mA value is held at 2.5mA during calibration
▪ C4.00mA – the 4-20mA value is held at 4.0mA during calibration.
The Tbl Out menu enables the user to select the mA output value for the Trouble Alarm. Select
“T1.5mA” to choose the 1.5mA default valve. Or select “User mA” and use the [▲] or [▼] keys to
select any valve between 0.5mA and 3.7mA.
• RS-485 - Use the [▲] or [▼] keys to select Address or Baud rate menu and press [E]. Note that the
5100-02-IT has a rotary switch on the faceplate and it is used to select addresses 1-15. When
connected to Sentry the user can select 1-8 and using Modbus RS-485 the user can select
addresses 1-15. For Modbus addresses above 15, set the rotary switch to 0 and then use the
“Address” menu to select any address between 16 and 254. The Baud rate menu allows the user to
select a baud rate of 38400, 19200, 9600, 4800 or 2400. * indicates current selection.
RS485 default parameters are: 38,400 baud, 8 bits, 1 stop bit, no parity
Page: 20

--0%LEL- Default Display
M E
p q
Mode ALMRSET: Mode Function - Alarm Reset
M E
p q
Mode CALIB:-- Mode Function - Calibrate
M E
p q
Mode SETUP:--- Mode Function - Set Point Adjustments
M E
p q
Enter Alarms S.P. Function - Alarm Adjust * A Below
M E
p q
Down Relays S.P. Function - Relays Adjust * B Below
M E
p q
Down Gas S.P. Function - Gas Type/Range Adjust * C Page 22
M E
p q
Down 4-20mA S.P. Function - 4-20 mA Adjust * D Page 22
M E
p q
Down RS-485 S.P. Function - RS-485/Sentry Output Adjust * E Page 22
High Alarm Set Point Adjustment Example
M E
p q
Enter H.Alarm S.P. Function - High Alarm Adjust *A
M E
p q
Enter HASP:60- Alarm Set Point: current = 60
Use p or q keys to adjust to new set point
M E
p q
Down (x5) HASP:55- Alarm Set Point: new = 55
M E
p q
Enter ACK Momentary Acknowledge of new Set Point
H.Alarm S.P. Function - Alarm Adjust
Relays Set Point Adjustment Example
M E
p q
Enter H. Relay S.P. Function - Alarm Relay Adjust *B
M E
p q
Down L.Relay S.P. Function - Warning Relay Adjust
M E Use p or q keys to adjust to new relay action
p q
Enter Latch
(Latch, Sentry, NonLatc) * indicates current
M E NOTE: Sentry indicates that Sentry controls relay
Down Sentry
p q action and not the IT Sensor Module
M E
p q
Down *Sentry Alarm Relay set to Sentry
Table 5 - 3 A: Set-Up Configuration
Page: 21
Gas Factor Example

M E
p q
Enter GasFactr S.P. Function - Gas Factor Adjust *C
M E Select [E] to select or p or q to adjust factor
p q
Enter Factr100
number and press [E]
M E
p q
Enter ACK Acknowledgement of new Gas Factor Value
4-20 mA Adjustment Example

M E
Enter Calib S.P. Function - Calib Adjust *D
p q
M E
p q
Enter Out: 4mA Use p or q keys to select 4 mA or 20mA
M E
p q
Enter 4mA Selects 4 mA
M E
p q
Enter ACK Momentary Acknowledge of new Set Point
M E
Mode Calib S.P. Function - Calib Adjust
p q
M E
p q
Down CalibOut S.P. Function - Output during Calibration Adjust
M E
p q
Enter Track Use p or q keys to select Track, C2.5mA, C4.00mA
Track = Output during calibration tracks the calibration gas,

C2.5mA = Output during calibration is 2.5mA, C4.00mA =
Output during calibration is 4.0mA
M E
p q
Enter *Track * = Current selection
M E
Mode Calib S.P. Function - Calib Adjust
p q
M E
Down Tbl Out S.P. Function - output during Trouble Alarm
p q
M E
Enter *T1.50mA Current Valve 1.5mA for Trouble
p q
M E
Down User mA S.P. Function - User Selectable mA Valve
p q
M E Use p or q keys to select mA Valve between 0.5
Enter *T1.50mA
p q and 3.7mA
M E
Enter *T1.50mA Select 1.50mA for volume during trouble
p q
RS-485 Adjustment Example
M E
p q
Enter Address S.P. Function - RS-485 Address Adjust *E
M E
p q
Enter Addr:016 Use p or q keys to enter new address
M E
p q
Enter ACK New address selected
M E
p q
Enter Address S.P. Function - RS-485 Address Adjust
M E
p q
Down Baud S.P. Function - RS-485 Baud Rate Adjust
M E
Enter *38400 Press [E] to select or [p] or [q] to select another
p q
Table 5 - 3 B: Set-Up Configuration
Page: 22
5.4 MAINTENANCE FUNCTIONS

The maintenance menu allows the operator to verify module firmware version and configuration code. The
maintenance menu operation is described in Table 5-4.

M E
p q
M E
Mode CALIB: Mode Function - Calibration
p q
M E
Mode SETUP: Mode Function - Set Point Adjustments
p q
M E
Mode MAINT: Mode Function - Maintenance
p q
M E
Enter V2.00aA Module Version
p q
Table 5 - 4: Maintenance Menu
Page: 23
6. CALIBRATION
6.1 CALIBRATION FREQUENCY
The 5100-02-IT has been calibrated in the factory prior to shipment. It is recommended that the user check
calibration before placing in service. The Combustible sensor module must be calibrated every 6 months.
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. Users may elect to increase calibration periods based on
low drift experience during the first two calibration periods.
6.2 CALIBRATION PREPARATION
Calibration of the Combustible 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
key M 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 combustible gas. If necessary, use a
portable instrument to confirm that there is no background combustible gas.
For compliance with Factory Mutual (FM) Apparatus, the Sierra Monitor Model 1200-26, 1250-01, 1256-01,
1260 -02 are the only FM Approved calibration gas delivery device. Use Model 5358-01 Calibration Adapter or
Model 5360-00 Gas Delivery Fitting.
6.3 CALIBRATION GAS DELIVERY METHODS
Calibration gas is can be delivered to the sensors via the following delivery devices:
Model 5358-01: Calibration Adapter - use with portable calibrators. See 6-1.
Model 5360-00: Calibration Gas Delivery fitting - permanently installed fitting which
allows tubing to be run to a convenient delivery location
6.4 CALIBRATION PROCEDURE

Table 6-1 shows the step by step process of the calibration procedure.
The procedures 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 Figure 6 - 1: Model
accepted on the sensor module display. 5358-01 Calibration
6.5 SENSOR EXPOSURE TO GAS
Adapter
Calibration gas must be delivered to the sensor using the flow rate and duration listed in below:
Model Gas Flow Period
5100-02-IT Methane 300 cc/min Until Stable – 3 minute minimum
NOTE:
Following calibration, the combustible module counts down for 300 seconds. During this time the module is updating its
internal memory and it is very important that its power not be interrupted
Page: 24
6.6 CALIBRATION SUB-MENU

M E
p q
M E
p q
Mode CALIB:-- Mode Function - Calibrate
M E
p q
Enter CAL-0%-- Banner: Apply zero gas, enter <E> when done
Operation: Confirm area clear of gas, or apply zero air to
sensor.
M E
p q
Enter ACK Zero gas setting acknowledged
50%-SPAN Banner: Select span, enter <E> when done Sub A
M E
p q
Enter CAL-50% Banner: Apply 50% gas, then enter <E> to calibrate gas sensor Sub B
C 0%LEL Operation: Apply calbration gas.
Operation: As gas is applied the reading will increase - wait 3
C50%LEL minutes
M E
p q
Enter CAL-OK Calibration Passed - now remove gas
Operation: Five minute time out before sensor is returned to
WAIT-300 service.
Sub-Routines
50%-SPAN Banner: Select span, enter <E> when done Sub A
M E
p q
Down 25%-SPAN Operation: Change Span Gas Value to 25%
M E
p q
Down Adj-SPAN Operation: User adjustable value
M E
p q
Enter 50%-SPAN Operation: Ready for user adjustment
M E
p q
Up (x5) 55%-SPAN Operation: User adjustment to new value 55%
M E
p q
Enter CAL-55% Banner: Apply 55% gas, then enter <E> to calibrate gas sensor Sub B
C 0%LEL Operation: Apply calbration gas.
M E Operation: No calibration gas applied, or sensor did not respond
p q
Enter CAL-FAIL correctly.
Operation: Five minute time out before sensor is returned to
WAIT-300 service.
M E Operation: Hold magnet over Mode Switch for ten senconds to
p q
Mode (Any) abort calibration
Sub C
Banner: Calibration Aborted
Table 6 - 1: Calibration
Page: 25
7. SERVICE
7.1 MODULE SUB ASSEMBLY
Figure 7 - 1: Module Components
NOTE
Area must be determined to be non-hazardous before opening enclosure.
7.2 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.
Page: 26
7.3 TRANSMITTER REPLACEMENT

The transmitter assembly should be replaced when it is determined that it is unreliable, noisy or cannot be
calibrated. This situation may occur due to age, corrosion or failed components.
To replace the transmitter assembly:
a. Confirm that system power has been removed.
b. Remove the cover of the main enclosure.
c. Unscrew the two thumb screws in the top of the cover plate, lift the assembly and rotate 90o to relieve the
wiring service loop.
d. Unplug the sensor connector from the transmitter assembly.
e. Plug connector into new transmitter (be sure to match numbers between connector and socket).
f. Restore power and allow a minimum of 2 hours for stabilization before re-calibration.
7.4 SENSOR REPLACEMENT
The gas sensor needs replacement when:
⧫ The “CAL-FAIL” message appears after calibration.
⧫ The sensor output signal is noisy, causing erroneous gas level readings.
⧫ The “Sensor Failure” message displays.
To replace the sensor assembly:
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. Install new sensor assembly into conduit hub.
g. Allow the new sensor to stabilize for a minimum of 2 hours and then calibrate using the procedure in
Section 6.
7.5 INSTALLATION INSPECTION
Prior to system start-up or trouble shooting the entire system should be visually inspected. The following are
guidelines for that inspection:
7.5.1.1 CONTROLLER INSTALLATION
• Controller installed in conformance to instruction manual recommendations.
• AC power is correctly grounded.
• Hot AC and relay connections have safety covers installed.
7.5.1.2 SENSOR MODULE INSTALLATION
• Module installation in conformance with this manual.
• Modules accessible for calibration.
• Wiring terminations clean and correct.
7.5.1.3 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.
7.5.1.4 STANDARD VOLTAGES
• Regulated DC Voltage to be applied to the sensor module must be between 10 VDC and 30 VDC.
7.5.2 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.
Page: 27
7.5.3 IF MODULE DOES NOT RESPOND TO GAS

1. Repeat calibration procedure.
2. Remove the gas and wait for the timer to completely count down.
3. Apply 50%LEL and verify that the sensor sees 50% LEL gas after calibration.
4. If the sensor still does not see gas, power cycle the unit and repeat calibration.
7.5.4 IF THE MODULE DISPLAYS “STARTING” FOR MORE THAN 1 HOUR
1. Make sure the sensor is placed in an ambient room temperature environment.
2. Power cycle the sensor.
3. Ensure that the sensor is not exposed to methane during warm-up.
7.5.4.1 IF THE MODULE DOES NOT DISPLAY THE CORRECT %LEL
1. Power cycle the unit.
2. Recalibrate the sensor.
7.5.4.2 IF THE DISPLAY SHOWS ‘F’ – SENSOR FAILURE OR SENSOR MISSING
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 other connections.
5. Power up the unit.
7.5.4.3 IF THE MODULE SHOWS “***CALIBRATION REQUIRED***”
1. Calibrate the module.
7.5.4.4 IF THE DISPLAY SHOWS ‘H’ (OR L) THEN THE LOCAL HIGH OR LOW ALARM IS ACTIVE
7.5.4.5 IF THE DISPLAY SHOWS “M” – NOT CALIBRATED
1. Calibrate the module.
7.5.4.6 IF THE DISPLAY SHOWS “C” – CALIBRATION MODE
1. Complete calibration and exit to operating mode.
7.5.4.7 IF THE DISPLAY SHOWS “S” – SENTRY CONNECTION
1. Check connections with Sentry Controller
7.5.4.8 IF THE DISPLAY SHOWS “SENSOR FAIL”
1. The sensor assembly is defective, contact technical support
7.5.5 DIAGNOSTIC LEDS
LED 1 = 1 Hz Heartbeat normal, 2 Hz Panic Error
2 = Computation process
3 = 1 Hz Heartbeat normal
4 = HART or Sentry comms activity
If the display shows “▼” Down Arrow: Sensor signal too low - Recalibrate
Page: 28
8. APPENDICES
8.1 APPENDIX A: SPECIFICATIONS
Sensor:
Type: Catalytic Bead
Range: 0-100% LEL Combustible
Repeatability: +/-1% LEL
Response time: < 12 sec to 60% full scale
Accuracy: +/- 1% for 0-50% LEL range
+/- 2% for 51-100% LEL range
Sensor Life: Typically >3 years
Output:
Display: Fixed and Scrolling LED
Relays Option: Trouble (SPDT Form C, 0.25 Amp@ 250VAC)
High Alarm, Low Alarm (5 Amp, 250VAC)
Signal Output: Sentry Digital Bus
Analog 4-20 mA
3-wire Non-Isolated
4-wire Isolated
Serial RS-485 Modbus RTU
HART
Input:
Remote Alarm Reset: Normally open digital input
Power:
Power consumption: 3 watts
Input voltage: 24 VDC nominal: 10-30VDC
RFI/EMI Protection: EN50081-2, EN50082-2
Operating Range:
Ambient Temperature Range: -40o to 176oF (-40o to 80oC)
Relative Humidity: 0-99% (noncondensing)
Enclosure:
Material – Aluminum: Polyester powder-coated, sand-cast, copper-free aluminum
Material – Stainless Steel: 316 SS optional
Dimensions (H x W x D): (A1 & A2) 6.9 x 5.7 x 3.9 in. (17.5 x 14.5 x 9.9 cm)
(S1 & S2) 7.5 x 5.0 x 4.4 in. (19 x 13 x 11 cm)
Weight: (A1 & A2) 3.4 lb. (1.5 Kg)
(S1 & S2) 7.2 lb. (3.3 Kg)
Housing: NEMA 4X/7
Hazardous Area Approval: Explosion proof, Class I, Div. 1,
Groups B, C, D Class I, Zone 1,
Group IIC, IP66, IP65, NEMA 4X
II2 GD, Ex d IIC T6 = -40oC to 85oC
Approvals:
Factory Mutual (FM)
Performance: FM Standard 6310 Performance Approval for
fixed-based Combustible Gas Detectors (ANSI/ISA – 12.13.01)
Hazardous Locations: FM Standards 3100, 3600, 3615, 3810
UL: UL Standard 508A, 2075 (Methane Tested)
SIL-2 Certified: Certified by Lloyds Register (IEC 61508)
ABS: Certificate of Compliance
CQST
Page: 29
Modbus:
Baud: 38400 (Adjustable 2400 to 38400 baud)
Parity: None
Stop bit: 1
Data bits: 8
Flow Control: None
Memory map: Appendix H
Warranty:
Limited warranty: 2 years
Specifications subject to change without notice
8.2 APPENDIX B: MODEL NUMBERS, PARTS LIST & PARAMETERS
Sensor Module
Model Enclosure Relay/Connection Protection Remote
5100-02-IT - XX - XX - XX -X -X
- A1 = AL ¾” NPT - 01 = No Relays - 00 = Standard - 0 = Standard - 0 = None
- A2 = AL M20 x 1.5 - 02 = Relays - 2 = Conformal - 1 = Remote
- S1 = SS ¾” NPT - 05 = HART Option Transmitter Sensor
- S2 = SS M20 x 1.5
Options
5311-00 Rainshield
5311-02 Rainshield with calibration port
Calibration Items
1250-01 Gas Sensor Calibrator Kit
1256-01 Regulator Type A Calibrator
1260-00 Gas Cylinder – Air (Type A), 105 liters
1260-02 Gas Cylinder – Methane 50% LEL, (type A), 105 liters
1260-42 Gas Cylinder - Hydrogen, 50% LEL, (Type A), 105 liters
5358-01 Calibration Adapter - Direct, Standard
5358-50 Calibration/Configuration Magnetic Tool
5360-00 Remote Calibration Fitting
Spare Parts
SPL21813 Transmitter for 5100-02-IT
5200-02-IT-AL Sensor Assy for 5100-02-IT, AL
5200-02-IT-SS Sensor Assy for 5100-02-IT, SS
SPL21810 Enclosure, Transmitter, AL
SPL21823 Enclosure, Transmitter, SS
SPL21825 Termination Board no Relays
SPL21829 Termination Board with Relays
SPL21876 HART Termination Board
Factory Default Settings
Output = 3-wire 4-20mA source
Range = 0-100% LEL
Warning = 20% LEL
Alarm = 60% LEL
Calibration = 50% LEL Methane
Modbus = 2-wire Half Duplex at 38,400 BAUD
Page: 30
8.3 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 (ie. 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.
Page: 31
8.4 APPENDIX D: REMOTE SENSOR OPTION Figure 8 - 1: Remote Sensor Option
NOTE:
Drawing using Stainless Steel enclosure available from Sierra Monitor.
Page: 32
Setting Up and Testing Model 5100-02-IT with Remote Sensor
1. Connect the remote module (p/n 5394-51) to Model 5100-02-IT.

2. Power up Model 5100-02-IT.
3. Connect the voltmeter from pin 4 to pin 3 of the connector (p/n 59201) (at the side connected to the sensor).
4. Verify the voltage from pin 4 to pin 3 is 2 volts. If not, go to maintenance menu:
• Hit M key 4 times to see Maint: display, then hit E key to enter Maintenance Menu
• Hit Up Arrow key 5 times
• Display shows V1 Diag
• Hit Enter key
• Hit Up Arrow key to see 2V Output display
5. Adjust the 2V Output (switch Up Arrow to increase, switch Down Arrow to decrease, and switch E key to
accept the change).
6. Repeat step 5 a few times to get 2 volts at pin 4 and pin 3 of the connector (2 volts is the bridge voltage of
the sensor).
7. Hit M key a few times to see EXIT display, then hit Enter.
8. Cycle the power.
9. Perform the calibration for Model 5100-02-IT.
Page: 33
8.5 APPENDIX E: HART Figure 8 - 2: HART
Page: 34
Figure 8 - 3: 4-20 mA Circuits Types 5100-02-IT – Connections - HART
Page: 35
HART PROTOCOL MENU
HART (Highway Addressable Remote Transducer) Protocol is the global standard for sending and receiving
digital information across analog wires between smart devices and control or monitoring system. HART is a bi-
directional communication protocol that provides data access between intelligent field instruments and host
systems. A host can be any software application from technician's hand-held device or laptop to a plant's
process control, asset management, safety or other system using any control platform. The HART protocol
used on this gas sensor module has been developed to comply fully with the HART specifications outlined by
the HART Communication Foundation (HCF).
If the HART interface board has been provided with the gas sensor module, then HART will operate via the 4-
20 mA interface automatically. While no specific handheld device is necessary for HART operation, the gas
sensor module does comply with the HART standard so any handheld or PC-based HCF certified tool will
work.
The information below provides the operator instructions on connecting HART and the HART Protocol Menu.
Common Practice Commands

The following Common Practice commands are implemented.
Command Byte Number Description

Number
38 N/A Reset Configuration Changed Flag
48 0 Returns Module Status
Module State - In Calibration (0x10),
(0x30 = cal passed)
(0x50 = cal failed)
Module State - Trouble (0x08)
Module State - Warming (0x04)
Module State - RUN (ALARM) (0x02)
Module State - RUN (0x01)
48 1 Returns Alarm Relay Status
0x01 = Alarm Relay ON
0x02 = Warning Relay ON
0x03 = Both Relays ON
48 2 Returns Trouble Status (non-zero value indicates Trouble)
48 3 Returns maximum gas value
48 4 Returns gas value used during calibration
48 5 Returns IT-Series Model Number
0x28 = 5100-IT-28
Device Specific Commands

The Device Specific commands are used for accessing the unique features of the 5100-IT Series of gas sensor
modules.
A response code of 0 indicates SUCCESS. This applies to all commands. As per HART specification, all command
responses will have a response code and status byte, plus any command specific data bytes as indicated in the
following tables.
Page: 36
Device Specific Commands Summary

Command Description
Number
130 Key Press
131 Set Alarm Level
132 Set Warning Level
133 Set Alarm Relay Action
134 Set Warning Relay Action
135 Reset Alarms
136 Abort Calibration
137 Set Calibration Gas Level
138 Apply ZERO Gas
139 Apply SPAN Gas
140 RESERVED
141 Force Gas Value
142 Reset Force Gas Value
143 Read MODBUS RTU Register
144 Set Transducer Serial Number
145 Set Calibration Mode output current
146 Set Trouble Mode output current
147 RESERVED
148 RESERVED
149 Set Gas Factor
150 Write MODBUS RTU Register
Command 130: Key Press

This command mimics the front plate key inputs.
Request Data Bytes:
Byte Format Description
0 Unsigned-8 1=Enter
2=Down
4=Up
8=Menu
Command Specific Response Data Bytes:
0 Unsigned-8 Returns same value as passed
Command 131: Set Alarm Level

Request Data Bytes:
0 Unsigned-8 Alarm level, range 0 to 60. Default is 60.
Page: 37

0 Unsigned-8 Returns new Alarm Level.
Command 132: Set Warning Level

Request Data Bytes:
0 Unsigned-8 Warning level, range 0 to 60. Default is 20.
0 Unsigned-8 Returns new Warning Level.
Command 133: Set Alarm Relay Action

Request Data Bytes:
0 Unsigned-8 0=Latching (default)
2=Non-Latching
0 Unsigned-8 Returns new Alarm Relay Action value
Command 134: Set Warning Relay Action

Request Data Bytes:
0 Unsigned-8 0=Latching
2=Non-Latching (default)
0 Unsigned-8 Returns new Warning Relay Action value
Command 135: Reset Alarms
This command will reset any alarm relays that have been latched, providing the alarm condition is no longer
present on the sensor.
Request Data Bytes: None
Command Specific Response Data Bytes: None
Command 136: Abort Calibration

This command aborts the calibration procedure.
Page: 38
Command 137: Set Calibration Gas Level

Request Data Bytes:
0 Unsigned-8 Calibration Gas Level, range 0 to 100
0 Unsigned-8 Returns new Calibration Gas Level
Command 138: Apply ZERO Gas

This command will signal the module to accept the present sensor output to as the ZERO gas condition.
Command 139: Apply SPAN Gas

This command will signal the module to accept the present sensor output to as the SPAN gas condition.
Command 141: Force Gas Value

Request Data Bytes:
0 Unsigned-8 Sets the Force Gas Value, range 0 to 100
0 Unsigned-8 Returns new Force Gas Value
Command 142: Reset Force Gas Value

This command will signal the module to set the Force Gas Value to 0.
Command 143: Read MODBUS RTU Register

This command allows the reading of sensor module data as defined in the MODBUS RTU register map.
Request Data Bytes:
0-1 Unsigned-16 Address of Requested Modbus Register
40001 = lowest address
65535 = highest address
Page: 39

0-1 Unsigned-16 Returns contents of selected Modbus Register
Command 144: Set Transducer Serial Number

This command allows user to add a device specific serial number, if required. This is different from the
serial number assigned by the Manufacturer.
Request Data Bytes:
0-2 Unsigned-24 Serial Number
0-2 Unsigned-16 Returns new Serial Number
Command 145: Set Calibration Mode output current

Request Data Bytes:
0-1 Unsigned-16 Current output required during calibration, in
micro-amperes
0-1 Unsigned-16 Returns new Calibration current value
Command 146: Set Trouble Mode output current

Request Data Bytes:
0-1 Unsigned-16 Current output required to indicate Trouble, in
micro-amperes

0-1 Unsigned-16 Returns new Trouble current value
Command 149: Set Gas Factor

Request Data Bytes
0 Unsigned-8 Sets the Gas Factor value, range 30 to 200
Page: 40
Command Specific Response Data Bytes

0 Unsigned-8 Returns new Gas Factor value
Command 150: Write MODBUS RTU Register

This command allows the writing of sensor module data as defined in the MODBUS RTU register map.
Request Data Bytes
0-1 Unsigned-16 Address of Designated Modbus Register
40001 = lowest address
65535 = highest address
2-3 Unsigned-16 Data for Designated Modbus Register
Command Specific Response Data Bytes
0-1 Unsigned-16 Returns MODBUS register value
Version 1.20 Updated 30 January 2012
Page: 41
8.6 APPENDIX F: MODBUS MEMORY MAP
Register Description Read/ Comments

Write
40001 Concentration R Gas concentration multiplied by Gas Scale (e.g. 209 = 20.9%)
40002 Temperature R Temperature in degrees Celcius scaled by a factor of 10
Boolean indicating the Alarm relay status (0 = No Alarm, 1 - (High) Alarm).
40003 Alarm Relay R/W Clearing bit will reset alarm.
40004 Warning Relay R/W Boolean indicating the Warning relay status (0 = No Alarm, 1 - Warning Alarm). Clearing bit will reset alarm.
40005 Warning Setpoint R/W Warning Alarm set point, used for activating Low Alarm multiplied by Gas Scale
40006 Alarm Setpoint R/W Alarm set point, used for activating High Alarm multiplied by Gas Scale
40007 CCC detail R e.g. 0001, 0007, etc
40008 Software Revision U R e.g. 201 denotes version 2.01
40009 Software Revision L R e.g. version aA is denoted by 0x6141
40010 Modbus Map Revision R e.g. version 2 is denoted as v2 = 0x7602
40011 Trouble Bits R 0 = no trouble
40012 Trouble R 1 for any trouble, 0 = no trouble
40013 Alarm Immediate R Like 40003, but never latched
40014 Warning Immediate R Like 40004, but never latched
40015 Serial Number U R Serial Number - 24 bits (presently set to Random ID)
40016 Serial Number L R
40017 Run time U R In seconds
40018 Run time L R In seconds
40019 Gas (MAX) value R Gas concentration multiplied by Gas Scale
40020 Model R Read as 51028 for IR, 51002 for Cat Bead, 51005 for TOXIC H2S etc.
40021 Range RW
40022 Units RW 1 = %LEL, 2 = %VOL
A bit is defined for each of the following states:
(no bit set also means some sort of trouble)
Module State - In Calibration (0x40) = cal failed
Module State - In Calibration (0x20) = cal passed
Module State - In Calibration (0x10)
40023 Module Status R
Module State - Trouble (0x08)
Module State - Warming (0x04)
Module State - RUN (ALARM) (0x02)
Module State - RUN (0x01)
40024 Gas Scale R Value like 1, 10 or 100

40025 Cal Concentration level R/W Gas concentration value used during calibration, multiplied by Gas Scale
40026 Calibration due, in days R Gets reset to 365 / 180 if cal successful, Less then 0 = calibration due
40027 Calibration Count R Counter increments if cal successful (0 = not calibrated)
40028 Display Gas Output R Gas value seen on display (i.e. useful during calibration)
40029 Gas (MIN) value R Minimum gas value multiplied by Gas Scale
40030 Alarm Time U R In seconds
40031 Alarm Time L R
40032 Warning Time U R In seconds
40033 Warning Time L R
40034 Trouble Time U R In seconds
40035 Trouble Time L R
40036 Max Gas Time U R In seconds
40037 Max Gas Time L R
40038 Min Gas Time U R In seconds
40039 Min Gas Time L R
40040 Rotary Switch R Module address (If value < 16, the value reflects position of rotary switch)
40041 Restart Count R Restart count
40042 Alarm Relay Action Setup RW Alarm Relay Action Setup - Latch/Sentry/Non-latch
40043 Warning Relay Action Setup RW Warning Relay Action Setup - Latch/Sentry/Non-latch
40044 4-20mA CalibOut Value R
40045 4-20mA TroubleOut Value R
40046 Gas Factor RW Applies only to -02
40047 Force Value RW
40048 Module Number RW
0 indicates command failed, 1 = passed, supported commands:
Lock keys = 101
Unlock keys = 102
Abort calibration = 103
Apply zero gas = 104
Apply span gas = 105
Ack alarms = 106
40049 Command Register RW
Reset sensor = 107
Clear mem = 108
Speed up startup = 109
Clear eeprom = 110
Table 8 - 1: Modbus Memory Map
Force address disp= 111
Clear address disp= 112
40050 Last command executed R Displays last executed command from register 40049
Page: 42
8.7 APPENDIX G: COMBUSTIBLE GAS SCALING FACTORS

For combustible gas monitoring, a calibration standard of Methane may be used in conjunction with scaling factors
to cause Sentry concentration display and alarm function in %LEL scale of another gas as follows:
METHANE METHANE
GAS GAS
FACTOR FACTOR
Acetaldehyde 60 Diethyl Ether 46
Acetic Acid 54 Dimethoxyethane 42
Acetic Anhydride 46 Dimethyl Ether 63
Acetone 52 Dimethylformamide 46
Acetylene 57 Ethyl Formate 44
Alkyl Alcohol 51 Ethylmercaptan 56
Ammonia 126 n-Heptane 39
n-Amyl Alcohol 33 n-Hexane 37
Aniline 39 Hydrazine 45
Benzene 41 Hydrogencyanide 48
Biphenyl 25 Hydrogen 77
1,3-Butadiene 56 Hydrogen Sulfide 41
n-Butane 58 Methane 100
iso-Butane 52 Methyl Actetate 50
Butene-1 45 Methyl Alcohol 86
cis-Butene-2 48 Methylamine 77
trans-Butene-2 51 Methyl Bromide 90
n-Butyl Alcohol 34 Methyl Chloride 102
iso-Butyl Alcohol 53 Methylcyclohexane 44
tert-Butyl-Alcohol 74 Methylenedichloride 93
n-Butyl Benzene 31 Methylethylether 44
iso-Butyl Benzene 32 Methylethylketone 41
n-Butyric Acid 38 Methyl Formate 67
Carbon Disulfide 18 Methylmercaptan 61
Carbon Monoxide 75 Methylpropionate 51
Carbon Oxysulphide 93 Methyl n-propylketone 40
Chlorobenzene 34 Napthalene 34
Cyanogen 89 Nitromethane 34
Cyclohexane 41 n-Nonane 31
Cyclopropane 62 n-Octane 37
n-Decane 33 n-Pentane 46
Diethylamine 49 i-Pentane 46
Dimethylamine 58 Propane 55
2,3-Dimethylpentane 40 n-Propyl Alcohol 47
2,3-Dimethylpropane 40 n-Propylamine 48
Dimethylsulphide 43 n-Propylchloride 50
1,4-Dioxane 45 Propylene 52
Epichlorohydrin 45 Propyleneoxide 46
Ethane 68 iso-Propylether 44
Ethyl Acetate 51 Propyne 42
Ethyl Alcohol 73 Toluene 40
Ethylamine 53 Triethylamine 40
Ethyl Benzene 36 Trimethylamine 48
Ethyl Bromide 91 Vinylethylether 42
Ethyl Chloride 57 o-Xylene 36
Ethylcyclopentane 40 m-Xylene 39
Ethylene 71 p-Xylene 39
Ethylenedichloride 66 JP-4 (Jet Fuel) 41
Ethyleneoxide 52
NOTES:
1. Scaling factors are not FMRC approved.
2. Base data source: EEV sensor specification catalog. (EEV claims some data is the result of specific
tests, other data is empirically derived).
Page: 43
8.8 APPENDIX H: FM APPROVAL
Page: 44
Page: 45
8.9 APPENDIX I: SIL-2 APPROVAL CERTIFICATE
Page: 46
INDEX
4-20 MA ........................................................ 3, 20, 22 MODULE ...............................................................7, 9

ALARMS ........................................................... 20, 44 MODULE ADDRESS SWITCH ...............................13
ANALOG ................................................................... 4 OPTIONS ................................................................30
CALIBRATION ............................................ 10, 24, 30 POWER REQUIREMENTS ......................................5
CALIBRATION FREQUENCY ............................ 3, 24 RELAYS ..............................................................4, 20
CALIBRATION GAS DELIVERY............................. 24 REMOTE ALARM .................................................3, 4
CALIBRATION PREPARATION ............................. 24 REMOTE SENSOR ........................................3, 4, 33
CALIBRATION PROCEDURE ................................ 24 REPLACEMENT ...............................................26, 27
COMBUSTIBLE GAS SENSOR ............................... 3 RS-485 ........................................................11, 20, 22
COMBUSTIBLE GASES DETECTED ...................... 8 SENSOR .......................................................4, 12, 27
DATA ENTRY KEY PAD......................................... 18 SENSOR EXPOSURE TO GAS .............................24
ENCLOSURE............................................ 3, 4, 11, 26 SENTRY..............................................................3, 11
ENHANCED CONNECTION .................................... 4 SERVICE ................................................................26
FM APPROVED .................................................. 3, 48 SET-UP .............................................................20, 46
GAS FACTOR ........................................................ 20 SIL-2....................................................................3, 50
GAS SCALING FACTORS ..................................... 43 SPARE PARTS .......................................................30
GAS TYPE .............................................................. 22 SPECIFICATIONS ..................................................29
HART ................................................ 4, 33, 34, 36, 42 START-UP ................................................................9
INSTALLATION ...................................... 9, 10, 12, 27 TRANSMITTER ....................................4, 7, 9, 12, 27
MAINTENANCE ...................................................... 23 TROUBLESHOOT ..................................................27
MENU KEY ............................................................. 44 WARRANTY ...........................................................31
MODBUS .................................................. 3, 4, 20, 42 WIRING ............................................................5, 7, 9
MODEL NUMBER................................................... 30
Page: 47

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MODEL 5100-02-IT

APPLICABILITY & EFFECTIVITY

Instruction Manual Part Number T12019

Model 5100-02-IT Combustible Gas Sensor Module

1. PRODUCT DESCRIPTION ................................................................................................................................. 3

1.4.1 SENTRY INTERFACE

1.4.2 MODBUS OPERATION

* HART option, alarm relays are all SPDT, 250VAC, 2 Amp

1.6 INTERCONNECT WIRING

Figure 1 - 1: Model 5100-02-IT Combustible Sensor – Mounting Options

2. CAUTIONS & WARNINGS

2.3.1 CATALYTIC BEAD SENSOR MODULES

Acetaldehyde 2,3-Dimethylpentane Methyl Chloride

4.1 SENSOR MODULE LOCATIONS

Figure 4 - 1: Typical Mounting Options

4.2.1 ANALOG 4-20 MA OPERATION

4.3 ENCLOSURE INSTALLATION

Number Maximum length of wire run (feet)

Table 4 - 1: Minimum Wire Gauges

4.4 TRANSMITTER AND SENSOR INSTALLATION

P1 PCB Label Function

P2 PCB Label Function

P3B PCB Label Function

P4 PCB Label Function

Table 4 - 2: Sensor Module External Interfaces

7. Establish the module address according to section 4.5.

4.5 MODULE ADDRESS SWITCH

POSITION ADDRESS POSITION ADDRESS NOTE

For Sentry applications only sensor addresses 1-8 are

8 Sensor 8 0 Software Menu

Table 4 - 3: Sensor Module Address Switch

Figure 4 - 2: Transmitter Face Plate

Figure 4 - 3: 4-20 mA Circuits Types 5100-02-IT

Figure 4 - 4: 4-20 mA Circuits Types 5100-02-IT – Connections

Figure 4 - 5: Digital Interface Connections

Figure 4 - 6: Remote Alarm Reset

Figure 4 - 7: Termination Drawing

5.1 DATA ENTRY KEY PAD

Figure 5 - 1: Face Plate with Data Entry Key Pad

5.2 MAIN MENU

Key Function Display Description Reference

5100-02 First screen at power up-model

Warm.XXX Third screen at start up-warm up

0%LEL Normal condition - default display

Table 5 - 1: Master Menu

Key Function Display Description Reference

Table 5 - 3 A: Set-Up Configuration

Gas Factor Example

4-20 mA Adjustment Example

Track = Output during calibration tracks the calibration gas,

Table 5 - 3 B: Set-Up Configuration

5.4 MAINTENANCE FUNCTIONS

Key Function Display Description Reference

Table 5 - 4: Maintenance Menu

6.1 CALIBRATION FREQUENCY

6.2 CALIBRATION PREPARATION

6.3 CALIBRATION GAS DELIVERY METHODS

6.4 CALIBRATION PROCEDURE

6.6 CALIBRATION SUB-MENU