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Normal 20.9% value provides 17.3 mA. Page: 25 Model 5100-XX-IT Toxic Gas Sensor Module 7. SERVICE 7.1 SENSOR MODULE CONFIGURATION The gas sensor module is comprised of the following sub-assemblies (Figure 7-1): 5100-XX-IT Gas Sensor Module (See Appendix B) SPL21810 Aluminum Enclosure SPL21823 316SS Enclosure SPL21824 Transmitter Assembly XXXXXXX Sensor Assembly (See Appendix B) 5200-XX-IT Sensor (See Appendix B) 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. Figure 7 - 1: Module Components Page: 26 Model 5100-XX-IT Toxic Gas Sensor Module 7.3 TRANSMITTER REPLACEMENT The transmitter assembly should be replaced when it is determined that it is unreliable, noisy or cannot be adjusted for calibration. This may occur due to age, corrosion or failed components. To replace the transmitter assembly: a. Remove the cover of the main enclosure. b. Unscrew the two thumb screws in the top of the cover plate, lift the assembly and rotate 90o to relieve the wiring service loop. c. Remove all wires from bond, marking them carefully so they can be correctly replaced. d. Unplug the sensor connector from the transmitter. e. Reverse the preceding steps to install the new transmitter. f. Restore power and allow a minimum of 30 minutes for stabilization before re-calibration. 7.4 SENSOR REPLACEMENT NOTE: Refer to Appendix H for information on sensor electrolyte replacement for 5100-25-IT and 5100-26-IT. The gas sensor which is located inside the sensor assembly housing can be replaced without replacement of the housing. The gas sensor needs replacement when: • 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: a. Confirm that system power has been removed. b. Remove the gas sensor module enclosure cover. c. Unscrew the two thumb screws in the top of the faceplate, lift the transmitter assembly and rotate 90o to relieve the wiring service loop. d. Unplug the sensor connector from the transmitter. e. Unscrew the old sensor assembly from the enclosure conduit hub. Remove the sensor assembly with its harness. f. Unscrew sensor housing cover from the sensor. g. Carefully pull the old sensor straight up from the socket. h. Press the new sensor into the socket. i. Reverse the preceding steps to install the sensor assembly. j. Allow the new sensor to stabilize for a minimum of 60 minutes 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 CONTROLLER INSTALLATION • Controller installed in conformance to instruction manual recommendations. • AC power is correctly grounded. • Hot AC and relay connections have safety covers installed. 7.5.2 CABLING INSTALLATION • All splices are soldered or via terminal block. • Cabling is away from sources of electrical noise or RFI where possible. 7.5.3 SENSOR MODULE INSTALLATION • Module installation in conformance with this manual. • Modules accessible for calibration. • Wiring terminations clean and correct. Page: 27 Model 5100-XX-IT Toxic Gas Sensor Module 7.5.4 MOISTURE TRAPS AND RAINSHIELDS • Conduit seals and drains installed to avoid moisture build up in electronics enclosure. Water accumulation in sensor module enclosures is a major cause of damage and system failures - take precautions to seal electrical conduits and provide moisture traps and drains to avoid water damage. • Rain-shields installed where applicable. 7.5.5 STANDARD VOLTAGES • Regulated DC voltage to be applied to the sensor module must be between 10 VDC and 30 VDC. 7.6 INSPECTION AND TROUBLESHOOTING GUIDE The inspection and troubleshooting guide can be used to step through the system start-up and to determine the corrective action if a fault occurs. 4.2.5 IF IR 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 calibration gas and verify that the sensor sees calibration gas after calibration. 4. If the sensor still does not see gas, power cycle the unit and repeat calibration. 4.2.6 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 gas of interest during warm-up. 4.2.7 IF THE MODULE DOES NOT DISPLAY THE CORRECT %PPM 1. Power cycle the unit. 2. Recalibrate the sensor. 4.2.8 I...

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