General Monitors S4000C Instruction Manual Download Page 52

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S4000C

1400155-BD

Replacement Cylinder, Butadiene @ 50% LEL

1400155-PR

Replacement Cylinder, Propane @ 50% LEL

Cylinder refills are available for Methane and Hydrogen only. Replacement cylinders must be
ordered for the other gases.

922-009

Pressure Regulator Gauge

1400152-1

Small Calibration Cup

1400154

Large Calibration Cup

925-026 Tubing

9.6.5 Intelligent

Transmitter (S4000C) Replacement Parts

31146-1

Control Board Electronics

31151-1

Output Board Electronics

31156-1

Display Board Electronics

31170-1

Enclosure Cover Assembly with Window

31195-2

Enclosure Base Assembly

30060-1 Calibration

Magnet

925-5007

Cover Assy. O-Ring

9.6.6 Recommended Spare Parts for One (1) Year

30060-1

Extra Calibration Magnet (Qty. 1)

Summary of Contents for S4000C

Page 1: ... this document may be used and disseminated only for the purposes and to the extent specifically authorized in writing by General Monitors Instruction Manual 0307 General Monitors reserves the right to change published specifications and designs without prior notice MANS4000C Part No MANS4000C Revision G 03 07 ...

Page 2: ...S4000C ii This page intentionally left blank ...

Page 3: ...inal Block TB1 Sensor Connections 7 3 5 2 Terminal Block TB2 Power and Signal Connections 7 3 5 3 DC Power and Ground Connections 8 3 5 4 Analog Signal Connections 9 3 5 5 Terminal Block TB3 Relay Connections 10 3 5 6 European Union EU Approved Applications 11 3 5 7 Cable Termination in the Non Hazardous Area 11 3 6 Maintaining the X P Integrity 12 4 0 OPERATION 13 4 1 Start Up Checklist 13 4 2 St...

Page 4: ...24 6 1 7 F8 Failure to Complete Setup 24 6 1 8 F9 Gas Check Period Exceeded 24 6 1 9 F10 Switch Error 24 7 0 CUSTOMER SUPPORT 25 T 7 1 General Monitors Offices 25 8 1 Baud Rate 26 8 2 Data Format 26 8 3 MODBUS Read Status Protocol Query Response 26 8 3 1 MODBUS Read Query Message 26 8 3 2 MODBUS Read Response Message 26 8 4 MODBUS Write Command Protocol Query Response 27 8 4 1 MODBUS Write Query M...

Page 5: ...ress Errors 35 8 8 23 Number of Register Errors 35 8 8 24 RXD CRC Hi Errors 35 8 8 25 RXD CRC Low Errors 35 8 8 26 Clear Comm Errors 35 9 0 APPENDIX 36 9 1 Warranty 36 9 2 Principle of Operation 36 9 3 Specifications 37 9 3 1 System Specifications 37 9 3 2 Mechanical Specifications 37 9 3 3 Electrical Specifications 37 9 3 4 Environmental Specifications 38 9 4 Approvals 39 9 6 Spare Parts and Acce...

Page 6: ... Outline and Mounting Dimensions 6 Figure 6 Spring Type Terminal Block Operation 8 Figure 7 Screw Type Terminal Block Operation 8 Figure 8 Wire Strip Length 8 Figure 9 Relay Protection for DC and AC Loads 11 Figure 10 Relay Reset 14 Figure 11 User Menu Structure 15 Figure 12 Calibration Check 18 Figure 13 Automatic Calibration Mode 19 Figure 14 Calibration In Progress Mode 19 Figure 15 Calibration...

Page 7: ...7 Fault Relay Connections 10 Table 8 GM Locations 25 Table 9 Data Format 26 Table 10 Exception Codes 28 Table 11 Command Register Locations 29 Table 12 Command Register Locations Cont 30 Table 13 Com1 Baud Rate 33 Table 14 Com1 Data Format 33 Table 15 Com2 Baud Rate 33 Table 16 Com2 Data Format 34 Table 17 24VDC Cable Lengths 38 Table 18 Analog Output Cable Lengths 38 Table 19 Sensor Cable Lengths...

Page 8: ... Terminal Connections The terminal blocks TB are located inside the housing and can be accessed by removing the cover A label on the inside of the housing cover provides details of all the terminal connections WARNING Do not connect 24VDC to TB1 Damage to the electronics or sensor may result It is recommended that a three wire red black white shielded cable be used for making power and output sign...

Page 9: ...ure 3 Screw Type Terminal Block Operation NOTE Power must remain disconnected until all other wiring connections have been made The maximum distance between the Model S4000C and the power supply is 3430 feet or 1040 meters each cable run should be as short as possible See Section 9 3 3 for cable length specifications Connect 24VDC to TB2 position 9 Connect the ground or common to TB2 position 8 Th...

Page 10: ...46 4872 Phone 1 949 581 4464 Fax 1 949 581 1151 Houston Texas Phone 1 281 855 6000 Fax 1 281 855 3290 Ireland Phone 353 91 751175 Fax 353 91 751317 Singapore Phone 65 6748 3488 Fax 65 6748 1911 United Arab Emirates Phone 971 4 8815751 Fax 971 4 8817927 United Kingdom Phone 44 1625 619583 Fax 44 1625 619098 ...

Page 11: ...ricity Special care must be taken when wiring the system to ensure that only the connection points are touched Toxic combustible and flammable gases and vapors are very dangerous Extreme caution should be used when these hazards are present 1 3 System Integrity Verification Commissioning Safety Systems Before power up verify wiring terminal connections and stability of mounting for all integral sa...

Page 12: ...cement of the suspect device s should be performed as necessary Maintenance intervals should be independently established through a documented procedure including a maintenance log maintained by plant personnel or third party testing services Periodic System Verification The following system verifications should be performed at least annually Verify wiring terminal connections and stability of mou...

Page 13: ...over A red LED above the digital display signifies an ALARM condition while a red LED below the digital display signifies a WARN condition Analog signal 4 20mA and optional Dual Redundant MODBUS communications and relays provide remote and or discrete indications of the sensor s operation The Model S4000C Intelligent Sensor is rated explosion proof for use in the following hazardous areas CSA FM C...

Page 14: ...as detector 2 Flat head screwdriver maximum 3 16 5 mm width for terminal block connections included with gas detector 3 Adjustable wrench for conduit or cable gland connections not included 3 3 Choosing Product Locations There are no standard rules for sensor placement since the optimum sensor location is different for each application The customer must evaluate conditions at the facility to make ...

Page 15: ...any such installation Sensors used in these areas usually require more frequent calibration checks than normal and typically have a shorter life In many such applications the standard two year warranty would not apply WARNING General Monitors discourages the painting of sensor assemblies If the sensor head is painted over the gas will not be able to diffuse into the sensor If the assembly cover is...

Page 16: ...proof integrity however conduit runs containing wires attached to the Model S4000C s relay contacts must be sealed Section 3 5 Information on Class I location seals can be found in the NEC Article 501 5 WARNING Acetic acid will cause damage to metal components metal hardware ceramic IC s etc If damage results from the use of a sealant that outgases acetic acid RTV silicone the warranty will be voi...

Page 17: ...rd by pressing it into place and tightening the two captive screws WARNING Do not connect 24VDC to TB1 Damage to the electronics may result 3 5 2 Terminal Block TB2 Power and Signal Connections TB2 contains the connections for Power Relay Reset Remote Calibration MODBUS and 0 20mA Output Signal The terminal connections are as follows TB2 position Function 1 0 20mA Output 2 CH1 MODBUS 3 CH1 MODBUS ...

Page 18: ...ing Type Terminal Block Operation Figure 7 Screw Type Terminal Block Operation Figure 8 Wire Strip Length NOTE Up to 12 AWG wire can be used if it is carefully stripped on a Screw Type terminal Figure 6 3 5 3 DC Power and Ground Connections The customer must provide primary DC power unless one of the following General Monitors Modules is being used with the Model S4000C DC130 Dual Channel Readout ...

Page 19: ...lay devices see Table 2 and Table 3 FROM TO Model S4000C Model DC110 Model DC130 Model TA102A TB2 8 COM Rear COMMON Rear Pin 3 or 6 COM Rear Pin 30d or 30z Table 2 Ground or Common Connections FROM TO Model S4000C Model DC110 Model DC130 Model TA102A TB2 9 24 VDC Rear CH 1 8 24V Rear Pin 4 or 7 DC OUT Rear Pin 28d or 28z Table 3 Power Connections 3 5 4 Analog Signal Connections The Model S4000C In...

Page 20: ...y Open NO and the Normally Closed NC contact TB3 position Relay Contact De Energized Relay Contact Energized 1 Normally Closed Normally Open 2 Common Common 3 Normally Open Normally Closed Table 5 Alarm Relay Connections TB3 position Relay Contact De Energized Relay Contact Energized 4 Normally Closed Normally Open 5 Common Common 6 Normally Open Normally Closed Table 6 Warn Relay Connections TB3 ...

Page 21: ...ed to an instrument earth in the safe area The power supply OV return must be connected to an instrument earth in the safe area The interconnecting cables should be segregated from power and other noisy cables Avoid proximity to cables associated with radio transmitters welders switch mode power supplies inverters battery chargers ignition systems generators switch gear arc lights and other high f...

Page 22: ...debris before replacing the cover This can be verified by tightening the cover bolts to a torque setting of 50 inch pounds or by using a feeler gauge to ensure the gap between the cover and the housing is less than 0015 inch 038 mm There are four entry holes one each on the left and right sides and two on the bottom of the Model S4000C housing These holes are dedicated for the sensor the reset swi...

Page 23: ...Upon first power up the sensor may take up to fifteen minutes to stabilize At the initial application of power the unit will test all of the LED segments by displaying 88 8 The software revision letter will then be displayed for a few seconds The unit will then enter a fifty second Start Up mode During this period the display will read SU The unit will then enter Operational Mode and the current g...

Page 24: ...4 User Selectable Options The Model S4000C Intelligent Sensor includes many selectable options to provide the user with the most flexible combustible gas detector possible These options include Adjustable Calibration Level Warn and Alarm Relay Set Points and Configuration and MODBUS Communications Settings These allow the unit to operate with a wide variety of PLC and DCS Systems The following sec...

Page 25: ...Rate DataFormat Address Fi Y N Figure 11 User Menu Structure NOTE Co represents Calibration Output When Co is enabled and calibration is successful the analog output goes from 1 5 mA to 3 2 mA for 5 seconds settling at the desired value of 4mA 4 4 2 Calibration Level To adjust the calibration level of the Model S4000C apply the magnet to the GM Logo on the cover of the unit until SE is displayed t...

Page 26: ...ply and remove the magnet to return to the next level of the Setup menu When Fi is displayed again apply and remove the magnet to return to normal operation The default Warning relay settings are non latching de energized 30 LEL set point NOTE The Warn relay set point cannot be set higher than the Alarm Relay set point or higher than 60 LEL 4 4 4 Alarm Relay Settings To adjust the Alarm Relay Sett...

Page 27: ...emove the magnet to return to normal operation Default settings for Channel 1 are address 1 19 2k baud 8 N 1 NOTE The address can be adjusted from 1 247 Channel 1 and Channel 2 addresses may be the same 4 4 6 MODBUS Channel 2 Settings To change the MODBUS Channel 2 Settings of the Model S4000C apply the magnet to the GM Logo on the cover of the unit until SE is displayed then remove the magnet Thi...

Page 28: ...y the magnet to the GM Logo on the housing cover and the unit will enter Calibration Mode Gas Check Mode can be aborted if gas has not been applied to the sensor Simply reapply the magnet to the GM Logo on the cover and the unit will return to normal operation NOTE The test gas concentration must be at least 10 full scale before the unit will complete the gas check sequence If the Model S4000C is ...

Page 29: ... enter Calibration Mode place the magnet over the GM Logo on the cover of the unit Figure 4 and hold it there until AC Figure 13 appears on the display about ten seconds The display will flash the remaining sensor life Section 4 6 4 for about ten seconds while the unit acquires the zero reading Ensure that the sensor is seeing clean air during this time Figure 13 Automatic Calibration Mode Apply t...

Page 30: ...o be 5 Volume Calibration is at 50 LEL or 2 5 Volume WARNING General Monitors recommends calibrating the Model S4000C with 50 LEL of the gas being detected This provides the most accurate calibration since the Model S4000C is optimized for this concentration The accuracy of the calibration may be reduced by using a different calibration level and this inaccuracy will increase as the calibration le...

Page 31: ... system containing a non explosive gas concentration The lecture bottle is filled with a standard 50 LEL mixture of gas air Using a known gas air mixture reduces the likelihood of error in field calibration The hose and cup adapter included allow for quick calibrations and gas checks Pre mixed calibration gases at approximately 50 LEL are available in lecture bottles at 1200 psi 8 3 MPa maximum pr...

Page 32: ...xecutive component approval No 1051U for use as a jointing compound on flameproof electrical enclosures This is available from General Monitors The neoprene rubber gasket if it is found dry should also be lubricated with Type P80 lubricant available from General Monitors P N 610 010 5 2 Storage The Model S4000C Combustible Gas Detector should be stored in a clean dry area and within the temperatur...

Page 33: ...icroprocessor as follows 6 1 1 F2 Failed to Complete Calibration This Fault will occur if the unit is placed in the calibration mode and no gas has been applied within six minutes or if gas has been left on for more than six minutes ACTION Remove gas if present Apply the magnet to the GM Logo on the cover to clear the fault Attempt to calibrate 6 1 2 F3 EEPROM Checksum Error This fault indicates t...

Page 34: ...curs if the unit is left in setup mode for more than 6 minutes ACTION Exit setup mode Enter setup mode again if it is necessary to change any user selectable options 6 1 8 F9 Gas Check Period Exceeded If the Model S4000C is left in the gas check mode for more than six minutes without a Test Gas being applied or if test gas is left on the gas check mode for more than 6 minutes this fault will occur...

Page 35: ...ther Close Lyme Green Business Park Macclesfield Cheshire United Kingdom SK11 0LR Phone 44 1625 619 583 Fax 44 1625 619 098 Email info generalmonitors co uk IRELAND Ballybrit Business Park Galway Republic of Ireland Phone 353 91 751175 Fax 353 91 751317 Email info gmil ie SINGAPORE No 2 Kallang Pudding Rd 09 16 Mactech Building Singapore 349307 Phone 65 6 748 3488 Fax 65 6 748 1911 Email genmon gm...

Page 36: ...03 Read Holding Registers 3rd Starting Address Hi 00 Not Used by S4000C 4th Starting Address Lo 00 FF Hex S4000C Commands 5th No of Registers Hi 00 Not Used by S4000C 6th No of Registers Lo 01 No of 16 Bit Registers 7th CRC Lo 00 FF Hex CRC Lo Byte 8th CRC Hi 00 FF Hex CRC Hi Byte NOTE Address 0 is reserved for broadcast mode and will not be supported at this time NOTE Start Address can be a maxim...

Page 37: ...and Data 6th Preset Data Lo 00 FF Hex S4000C Lo Byte Command Data 7th CRC Lo 00 FF Hex CRC Lo Byte 8th CRC Hi 00 FF Hex CRC Hi Byte 8 5 Function Codes Supported Function Code 03 Read Holding Registers will be used to read status from the slave unit Function Code 06 Preset Single Register will be used to write a command to the slave unit 8 6 Exception Responses and Exception Codes 8 6 1 Exception R...

Page 38: ...ds that differentiate it from a normal response 8 6 2 Exception Code Exception Code Field In a normal response the S4000C returns data and status in the data field which was requested in the query from the master In an exception response the S4000C returns an exception code in the data field which describes the S4000C condition that caused the exception Below is a list of exception codes that are ...

Page 39: ...ormat Read or change settings for the Com1 Data Format Bit 0 7 R W 0011 40018 Com2 Addr Read or change settings for the Com2 Address Value 8 Bit R W 0012 40019 Com2 Baud Read or change settings for the Com2 Baud Rate Bit 0 7 R W 0013 40020 Com2 Data Format Read or change settings for the Com2 Data Format Bit 0 7 R W 0014 40021 Cal Level Read or change settings for the calibration level Value 8 Bit...

Page 40: ...s to 0 21 7mA 8 8 2 Mode A read returns the present mode of the S4000C A write command changes the mode to the requested mode Exception Returns an Exception Code 01 illegal function if an illegal write is requested A calibrate command returns an Exception Code 01 Acknowledge 05 The operation will take a long time to complete Function Bit Position Access Calibration Complete 7 MSB Read Spanning 6 R...

Page 41: ...returns a 6 byte message containing the analog 2 bytes Mode 1 byte Status Error 2 bytes and Sensor Life 1 byte in that order For the format of each byte refer to the appropriate individual commands 8 8 7 Alarm Settings A read returns the present Alarm settings of the S4000C A write command changes the settings to the requested values The set points are programmable in 5 FS steps NOTE The maximum a...

Page 42: ...eans it is Non Latching A 1 in the 8th bit position means the output is normally energized a 0 means it is normally De Energized The Warn set point cannot be set above the Alarm set point Factory default is 30 FS non latching de energized Exception Returns an Exception Code 01 Illegal Function if an illegal write is requested Byte Function Bit Position Access High Not Used 15 MSB Read Not Used 14 ...

Page 43: ...1 8 N 1 0 Read Write 8 Even 1 8 E 1 1 Read Write 8 Odd 1 8 O 1 2 Read Write 8 None 2 8 N 2 3 Read Write Table 14 Com1 Data Format Exception If the data format is not in range an illegal data value 03 is returned 8 8 12 Com2 Address A read command returns the current address for Com2 A write command changes the address to the requested values Valid addresses are 1 247 decimal Factory default is 2 E...

Page 44: ...ded the current gas level is below the alarm set point On the S4000C it will also reset the latching over range function provided the gas level is below 100 LEL 8 8 17 Sensor Life A read returns the current estimate of remaining sensor life in percentage 8 8 18 HazardWatch Co Calibration Output A read to this register will return the status of the HazardWatch Option 0x01 enables this option 0x00 d...

Page 45: ...n 8 8 23 Number of Register Errors A read indicates the Number of Register Errors that occurred in the slave device The maximum count is 255 and then the counter will rollover to zero and begin counting again 8 8 24 RXD CRC Hi Errors A read indicates the number of RXD CRC Hi Byte Errors that occurred in the slave device The maximum count is 255 and then the counter will rollover to zero and begin ...

Page 46: ...tors for damages including but not limited to consequential damages arising out of or in connection with the performance of the product 9 2 Principle of Operation Many gases and vapors are combustible General Monitors uses a low temperature catalytic bead to detect the presence of combustible gases and vapors The catalytic bead converts the combustible materials to heat A change in heat is then co...

Page 47: ... 2 5 kg Mounting Holes 5 0 inches 127mm center to center 9 3 3 Electrical Specifications Input Power 24 VDC nominal 20 to 36 VDC 250mA max Power Consumption Start up 280mA Normal Operation 160mA Relay Ratings 8A 250 VAC 8A 30 VDC resistive max Optional 3x SPDT Warning Alarm Fault Analog Signal 0 20mA 650 ohms max load Malfunction 0mA Calibration 1 5mA Gas Check 1 5mA Setup mode 1 5mA Startup 4mA 0...

Page 48: ... 20 1900 580 Table 19 Sensor Cable Lengths European Union EU Approved Applications PSU noise and ripple voltage 1 0Vpp max The customer supplied PSU must comply with IEC 61010 1 limiting current to 8A under Fault conditions in order to comply with CE Marking requirements 9 3 4 Environmental Specifications Operating Temperature Range CSA FM ATEX Electronics 40 F to 167 F 40 C to 75 C Standard Senso...

Page 49: ... 100 0 ml 0 8 1 1 Methane 5 0 16 0 75 0 ml 125 0 ml 1 0 1 3 Propane 2 1 44 1 31 5 ml 52 5 ml 0 8 1 0 Propylene Propene 2 0 42 1 30 0 ml 50 0 ml 0 8 1 0 Trimethylamine 2 0 59 1 30 0 ml 50 0 ml 0 6 0 8 Vinyl Chloride Chloroethylene 3 6 62 5 54 0 ml 90 0 ml 0 7 0 9 Injection volumes Cal Ratio Liquids LEL M W Density 50 lel 3L 50 lel 5L Methane Propane Acetaldehyde 4 0 44 1 0 8 136 ul 228 ul 0 7 0 9 A...

Page 50: ...hyl t Butyl Ether MTBE 1 5 88 2 0 7 109 ul 182 ul 0 6 0 8 Naphtha Petroleum Ether 1 1 86 2 0 6 96 ul 161 ul 0 6 0 8 Octane 1 0 114 2 0 7 99 ul 166 ul 0 5 0 6 Pentane 1 5 72 2 0 6 105 ul 176 ul 0 6 0 8 2 Propanol Isopropyl Alcohol 2 0 60 1 0 8 93 ul 156 ul 0 6 0 8 Propanol Propyl Alcohol 2 2 60 1 0 8 100 ul 168 ul 0 6 0 7 Propylacetate 1 7 102 1 1 0 106 ul 177 ul 0 5 0 7 Propylamine 2 0 59 1 0 7 10...

Page 51: ...387 4 Sensor Assembly Standard Hydrocarbon Super Poison Resistant 10164 1 Sensor Assembly Hydrogen Specific 11159 1L General Purpose SST Sintered Steel Arrestor 11159 2L General Purpose SST High Temp Sintered Steel Arrestor 10102 1 Dummy Sensor 9 6 2 Sensor Housing B13 020 or B13 021 Sensor Housing 9 6 3 Sensor Accessories 10460 2 Test Gas Applicator 10041 1 Duct Mounting Plate 10044 1 Dust Guard ...

Page 52: ...Gauge 1400152 1 Small Calibration Cup 1400154 Large Calibration Cup 925 026 Tubing 9 6 5 Intelligent Transmitter S4000C Replacement Parts 31146 1 Control Board Electronics 31151 1 Output Board Electronics 31156 1 Display Board Electronics 31170 1 Enclosure Cover Assembly with Window 31195 2 Enclosure Base Assembly 30060 1 Calibration Magnet 925 5007 Cover Assy O Ring 9 6 6 Recommended Spare Parts ...

Page 53: ...a Model S4000C system Model DC110 Eight Channel Readout Relay Display Module Model DC130 Dual Channel Readout Relay Display Module Factory Mutual Research Corporation has tested the Model S4000C according to the criteria listed under the FMRC Approval Standards for Combustible Gas Detectors Class Numbers 6310 6320 FMRC has tested the Model S4000C using the specifications listed in Section 9 2 This...

Page 54: ...tates shall dispose according to WEEE regulations For further General Monitors product WEEE disposal information please visit www generalmonitors com customer_support faq_general html All other countries or states please dispose of in accordance with existing federal state and local environmental control regulations 44 ...

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