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Gasguard Controller User Manual

1. Page 69 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 ZONE 5 DEFAULT ZONE 6 DEFAULT PARAMETER PARAMETER STATUS OFF STATUS ON TAG ZONE 5 TAG ZONE 6 CH1 LF NOT IN CH1 LF NOT IN CH1 A1 NOT IN CH1A1 NOT IN CH1 A2 NOT IN CH1A2 NOT IN CH1 A3 NOT IN CH1 A3 NOT IN CH1 HF NOT IN CH1 HF NOT IN CH2 LF NOT IN CH2 LF NOT IN CH2 M NOT IN CH2 A1 NOT IN CH2 A2 NOT IN CH2 A2 NOT IN CH2 A3 NOT IN CH2 A3 NOT IN CH2 HF NOT IN CH2 HF NOT IN CH3 LF NOT IN CH3 LF NOT IN CH3 NOT IN CH3 A1 NOT IN CH3 A2 NOT IN CH3 A2 NOT IN CH3 A3 NOT IN CH3 A3 NOT IN CH3 HF NOT IN CH3 HF NOT IN CH4 LF NOT IN CH4 LF NOT IN CH4 A1 NOT IN CH4 A1 NOT IN A2 NOT IN CH4 A2 NOT IN NOT IN NOT IN CH4 HF NOT IN CH4 HF NOT IN VOTING 1 VOTING 1 Page 70 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 RELAY INFORMATION RELAY 1 DEFAULT RELAY 2 DEFAULT PARAMETER PARAMETER RELAY 3 DEFAULT RELAY 4 DEFAULT PARAMETER PARAMETER Page 71 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 OUTPUT INFORMATION OUTPUT 1 DEFAULT OUTPUT 2 DEFAULT PARAMETER PARAMETER OUTPUT 3 D
2. CHANNEL 3 DEFAULT PARAMETER INPUT TYPE 4 20mA STATUS ON GAS NAME CO DEGPT 50 00 ppm FS 50 00 ppm UNIT ppm TAG CHAN 3 LF 02 00mA LF DIR FALLING LF LATCH NO 10 00 ppm A1 DIR RISING A1 LATCH YES A2 20 00 ppm A2 DIR RISING A2 LATCH YES A3 30 00 ppm A3 DIR RISING A3 LATCH NO HF 23 00mA HF DIR RISING HF LATCH NO ALMDLY 1000mS A1 HYST 596 A2 HYST 5 A3 HYST 5 67 CHANNEL 4 DEFAULT PARAMETER INPUT TYPE 4 20mA STATUS ON GAS NAME CO2 DECPT 5 00 v v FS 5 00 viv UNIT viv TAG CHAN 4 02 00mA LF DIR FALLING LF LATCH NO A1 1 00 v v A1 DIR RISING A1 LATCH NO A2 1 50 viv A2 DIR RISING A2 LATCH NO A3 2 00 v v A3 DIR RISING A3 LATCH NO HF 23 00mA HF DIR RISING HF LATCH NO ALMDLY 1000mS A1 HYST 596 A2 HYST 596 A3 HYST 596 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 ZONE INFORMATION ZONE 1 DEFAULT PARAMETER STATUS ON TAG ZONE 1 CH1 LF NOT IN CH1 A1 IN CH1 2 NOT IN CH1 A3 NOT IN CH1 HF NOT IN CH2 LF NOT IN CH2 A1 NOT IN CH2 A2 NOT IN CH2 A3 NOT IN CH2 HF NOT IN CH3 LF NOT IN CH3 A1 NOT IN CH3 A2 NOT IN CH3 A3 NOT IN
3. AMPCONTROL Channel 2 Gas CH4 Range 5 viv Verified mA V Engineering Value Sensor Input Type 4 20mA L Apply minimum range to channel zero if necessary s 4 0mA 0 00 0 02 0 02 Channel Delay 1s Delay L Apply maximum to channel adjust span if required L 20 0mA 5 00 4 95 5 05 Programmed Test Values r Relays Setpoint Engineering Value V Action iMAC 1 2 3 4 Operation Low Fault 2mA 2 0mA Falling Latching Fault LED L amp Programmed Values 1 98 2 02 L L UO IL IL Verified on Test Alarm 1 1 0096 7 2mA Rising Non Latching Alarm LED U L Programmed Values 7 13 7 27 L UO L L ILI ILI ID Verified on Test Alarm 2 1 5096 8 8mA Rising Non Latching Alarm LED L ILU CI Programmed Values 8 71 8 89 L m U L LU ILI ILI ID Verified on Test Alarm 3 2 00 10 4mA Rising Latching Alarm LED L X IL amp Programmed Values 10 3 10 5 L L UO ID G IL Verified on Test High Fault 22mA 22mA Rising Latching Fault LED L x amp Programmed Values 21 8 222 L L UO ID IL IL Verified on Test Page 56 GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 7502 AMPCONTHROL Channel 3 Gas CH4 Range 5 viv Verified mA V Engineering Value Sensor Input Type 4 20MA L Apply mini
4. 2 H E CONFIGURATION ZN2 K CHANGE RLY ZONEJ 8 ce lt gt 9 RY zoNE gt CONFIGURATION ZN3 5 RELAY 1 CONFIG V CHANGE RLY ZONEJ 5 ZNA a SES 5 2 x K CHANGE RLY ZONEJ S Wem 7 Gu V CHANGE RLY ZONEJ gt CHANGEPWRUP E 3 r MODE O OUTPUT 1 OUTPUT 1 CONFIG CONFIGURATION STATUS CHANGE STATUS B a 9 s 5 a K 9 ENTER TAG MAMER L amp CONFIGURATION E TAG a5 s i 25 MEM MSN A K CHANGE TYPE L CONFIGURATION OP TYPE mt z OUTPUT 1 CONFIG k CH1 E a Ree OUTPUT 1 CONFIG a j CH2 amp 8 OUTPUT 1 CONFIG k 9 3 cance op cna 5 CH3 pee e CH4 K CHANGE OP CH J gt s CONFIGURATION CFG VERSION CHANGESLAVEADD MODBUS ADDR 2 MODBUS ADDR E 2 CHANGE BAUD RATE o gt BAUD RATE BAUD RATE E D o c X CHANGEPARITY gt E PARITY PARITY M SYSTEM L c X SYSTEM CONFIG S DLY S DLY CHANGE E SYSTEM E Se K ENTER TAG NAME G gt CHANGE PASS
5. INOZ lt gt 114100 9 INOZ lt gt S INOZ lt gt 118100 r INOZ lt gt 1041070 INOZ ANdLNO Z INOZ lt gt 1 41 INOZ gt INYA 38 S3NCZ SAV TI3S INVHOVIG 32018 IWNOILONNA H3TIOHLNOO 93NOZ TWNOIS lt IVN IS Z lt gt LNdLNO 9 INOZ TVN9IS L WAV IV lt WNOIS WHY TV 114 MOT lt TWNOIS 114 lt S3NOZ TWNOIS lt WNOIS Z WAVY lt gt O LNdLNO S INOZ TVN9IS L WHV IV 7 WHY TV 114 lt gt TWNOIS WHVTV 114 lt gt 3 WHVTV lt WNOIS Z lt gt LNdLNO p INOZ L WHVIV lt WNOIS WAV TV 114 lt gt TWNOIS 114 lt 3NOZ WNOIS E WHVTV lt 7IVNSIS 2 WV TV lt gt 114100 INOZ TVN9IS WAV IV TWNOIS WHY TV 174 lt WNOIS WAV TY 114 lt 3 WNOIS lt TIVNSIS Z lt gt Z INOZ TVN9IS lt WNOIS WHY TV 1714 lt WNOIS WHVTV 114 H9IH lt V3NOZ 7VNOIS WV TV O WNOIS 2 lt lt gt 108110 L INOZ TWNOIS L WHV TV lt WAV TV 113 O TWNOIS 114 H9IH lt Wav Tv 113 1 4 E gt TWNOIS SACH E gt TWNOIS Z WHY ZO GE gt
6. GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 7502 AMPCONTROL Channel 1 Gas CH4 Range 5 viv Verified mA V Engineering Value Sensor Input Type 4 20MA L Apply minimum range to channel zero if necessary L 4mA 0 00 0 02 0 02 Channel Delay 1s Delay L Apply maximum to channel adjust span if required UO 20 5 00 4 95 5 05 Programmed Test Values r Relays Setpoint Engineering Value V Action iMAC 1 2 3 4 Operation Low Fault 2mA 2 0mA Falling Latching Fault LED amp Programmed Values 1 98 2 02 U L L L LU ILI ILI ID Verified on Test Alarm 1 1 0096 7 2mA Rising Non Latching Alarm LED L Programmed Values 7 13 7 27 U L L L ILI ID Verified on Test Alarm 2 1 5096 8 8mA Rising Non Latching Alarm LED O O IL IL Programmed Values 8 71 8 89 L L UO ID IL IL Verified on Test Alarm 3 2 0096 10 4mA Rising Latching Alarm LED L X L amp Programmed Values 10 3 10 5 L L UO ID IL IL Verified on Test High Fault 22mA 22mA Rising Latching Fault LED L x D Programmed Values 21 8 222 L L L L ILI ILI ID Verified on Test Page 55 GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 7502
7. HF NOT IN CH4 LF NOT IN CH4 A1 NOT IN CH4 A2 NOT IN CH4 A3 NOT IN CH4 HF NOT IN VOTING 1 ZONE 2 DEFAULT PARAMETER STATUS ON TAG ZONE 2 CH1 LF NOT IN CH1 A1 NOT IN CH1 A2 IN CH1 A3 NOT IN CH1 HF NOT IN CH2 LF NOT IN CH2 A1 NOT IN CH2 A2 NOT IN CH2 A3 NOT IN CH2 HF NOT IN CH3 LF NOT IN CH3 A1 NOT IN CH3 A2 NOT IN CH3 A3 NOT IN CH3 HF NOT IN CH4 LF NOT IN CH4 A1 NOT IN CH4 A2 NOT IN CH4 A3 NOT IN CH4 HF NOT IN VOTING 68 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 ZONE 3 DEFAULT PARAMETER STATUS ON TAG ZONE 3 CH1 LF NOT IN CH1 A1 NOT IN CH1 A2 NOT IN CH1 A3 IN CH1 HF NOT IN CH2 LF NOT IN 2 1 NOT IN CH2 A2 NOT IN CH2 A3 NOT IN CH2 HF NOT IN CH3 LF NOT IN CH3 A1 NOT IN CH3 2 NOT IN CH3 A3 NOT IN CH3 HF NOT IN CH4 LF NOT IN CH4 A1 NOT IN A2 NOT IN NOT IN CH4 HF NOT IN VOTING 1 ZONE 4 DEFAULT PARAMETER STATUS ON TAG ZONE 4 CH1 LF NOT IN CH1 A1 NOT IN CH1A2 NOT IN CH1 A3 NOT IN CH1 HF NOT IN CH2 LF NOT IN CH2 A1 IN CH2 A2 NOT IN CH2 A3 NOT IN CH2 HF NOT IN CH3 LF NOT IN CH3 A1 NOT IN CH3 A2 NOT IN CH3 A3 NOT IN CH3 HF NOT IN CH4 LF NOT IN CH4 A1 NOT IN 2 NOT IN NOT IN CH4 HF NOT IN VOTING 1
8. r O9NITW3SNSIS 3097 HOLY C OS 2 r OSNTN39NSIH INTIVA 3svdiWoo WNOIS THLO o i l 10738 roj F kes views d m aog TANNVHO 17907 ET 93 YISN TOULNOD TVN9IS ANY SNTWA 38VdWO9 LW 5 SALON 1 age HOLY EE Eet Ginen FONOTIOSNHO oumueuen Unani asn pet INTA e DO env mue ZETA KH INWA 38vdIN00 Wal gt LAdNI sn SONIL13S We OL aweu 9V1 N 53 78079 aen SYD I TI SLNN afr NA TWLISIG TYNDIS T3NNYHO S30V1d 1701030 SNITVOS T3NNYHO INANI DOTVNV TINNVH2 330 T3NNYHO WOCH 39018 T3NNVHO UO Ca 49 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 TWNOIS THO HLYd TVN IS lt 3NOZ OL 1V90 1 SUV 93 5 TOH LNOO TVN9IS ANY NOILVH OIJNOO SALON 33O NO 3NOZ T TVNOIS INAINO 3NOZ UNI YISN lt SWHYTV 3HVdWOO lt 5 WHY TY TV 3 40 TWA LONI 4380 SNILOA Zoning Functional Block Diagram A4 1 WV mg PHO 1 PHO 1 L PHO 1 1
9. GASGUARD Programmable Intrinsically Safe Controller INSTALLATION OPERATION amp MAINTENANCE MANUAL Revision 2 Issued 04 10 2011 CRN 7502 Ampcontrol User Manual Part No 120875 Designed and Manufactured in Australia by Ampcontrol CSM Pty Limited ih AMPCONTR AMPCONTROL AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 Safety and other Warnings WARNING Identifies important safety messages contained within this manual These messages highlight potential risks the occurrence of which may result in serious injury or death to personnel When you see this symbol pay close attention to the message that follows understand its meaning and ensure other operators are made aware of the risk CAUTION Identifies important technical information contained within this manual Information of this type provides instruction or guidance that will help ensure safe installation A operation and maintenance of the Controller This information must be understood and applied in order to reduce the possibility of injury to personnel Correct application of these instructions will also reduce the possibility of damage to the Controller and or other connected equipment A Supplementary information not directly affecting safety or integrity of the equipment y 4 Information concerning possible impact on the environment along with ac
10. 30 4 6 7 S t Tad Nalfie 2 adve 30 4 6 8 Change Configuration e D 30 4 6 9 Change Fault Clear Setting 90 A Calibration Menu tate SE 30 4 7 1 To Enter the Calibration 30 4 7 2 Channel 1 Zero oa el RR Re ade 31 4 7 9 Channel 4 Span Calibration pao t E 31 4 14 10 Volt Supply Voltage clipei t tte 31 4 75 16 Volt Supply Voltage a uet Seca 31 4 7 6 Output 4 Zero GCallDFatiOFis hcl ee ont 31 4 7 7 Q tp t 1 Span Calibration ai e R eh EE 31 Controller LR E 32 5 1 Ensuring 92 5 14 Ensuring that the Controller will properly perform the required functions 32 5 1 5 Ensuring that connected devices are compatible with the controller s entity parameters 32 5 2 Mounting the Controler tse Sut 33 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 5 2 1 IP rating and Physical OL CMI aas est Se ae teased ect raso seen a e ea ie 33 9 2 2 Ease Of ACCESS asc an os D POR RT 33 5 3 Connecting to he CODITOIGE ste Eeler
11. 6 CALIBRATION VIEW amp MODIFY DO YOU WANT TO ENTER DO YOU WANT TO ENTER CHANNEL 1 CHANNEL 1 CALIB CONTINUE PASSWORD 1 CONTINUE PASSWORD 2 CALIBRATION 4 CHANNEL 2 CALIB CALIBRATION 4mA CHANNEL 3 CALIB CALIBRATION 4mA gt 4 CALIBRATION 14 SUPPLY VOLT SUPPLY CALIB 10V OUTPUT 1 OUTPUT 1 CALIB CALIBRATION 4mA gt CALIBRATION 4mA OUTPUT3 OUTPUT 3 CALIB CALIBRATION 4mA 62 CHECK FOR CORRECT HW SETTINGS SAVE SETTING AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 B4 Configuration Flowchart 7 VIEW amp MODIFY 7 CONFIGURATION TO MENU OPTION 18 SYSTEM CONFIGURATION ENTER PASSWORD 1 CONTINUE L1 CONFIGURATION CHANNEL 2 2 gt CONFIGURATION CONFIGURATION 2 ASPER CHANNEL1 CHANNEL 4 CONFIGURATION To CONFIGURATION To enter and change the To ZONE 1 CONFIGURATION parameter press up and down arrow next page Page 63 INPUT TYPE lt gt CHAN
12. JOM F 0001 OO 0 818 senjeA ejqissog enieA 181110 ejdsiq y jeuuey 1005 pJOM OO 2 senjeA ejqissog euo Kejdsig jeuueu 6666 0 Parowe ulod ym ked 6666 0 Parowa juod Tee yum Kejdsi 6666 0 ui Ke dsi snes y 9107 Deen JON pesn OM Dest ION pesn ION 95 JON EUION 50 5 JON POM Jeuueu G POM g uuelv jne4wo g uue y Jeuueu jeuueu Z jeuueyy z jeuueu z jeuueu z jeuueu z jeuueu z z jeuueu 4000 cooo oo0 pooo 6000 9000 7000 000 6000 000 000 ecloo lo0bh 00 GOOD 900 40 0 POM lnpoN CH US 5 Page 45 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 D 0001 00 0 918 senjeA ejqssod enjeA 1811101 ejdsiq y jeuueu 000L 00L 1888 ejqssod jeuuo Aejdsi jeuueu 0001 00 L 918 senjeA ejqssod ewo Aejdsi jeuueu 0001 O04 OL ag senjeA ejqissod enjeA euo ejdsiq jeuueu 11104 ui ejdsi puenBses Jed uo pe ejdsip se anjer julodjas e p jeuueu 1 jurod jewi9eq ui Aejdsiq 1 jo uoo psenBsesy Jad uo pakejdsip se anjen julodjas Z jeuueu 1
13. 1 PowerLED illuminates 2 All LEDs illuminate and display indicates SELF TEST IN PROGRESS lal 3 After 4 seconds display indicates DELAY in the display window for each enabled channel Alarm and Fault LEDs extinguish RL1 RL2 and RL4 LEDs illuminate 4 Delay expires and display indicates channel readings relays have been set to LATCHED power up mode then all relay LEDs will remain illuminated once the start up delay expires An alarm reset is required to clear the states of relays that start up in latched mode a The self test phase of the Controller checks the integrity of the system configurations and memory read write integrity If the memory check fails the Controller will pulse all LEDs on and off and toggle the state of all four relays on a 1 second on 1 second off cycle If this occurs contact Ampcontrol b The Controller start up delay delays the action of processing channel input signals thereby allowing connected equipment to establish stable working conditions after power up During this time the Controller s alarm relays are held in an alarm state Page 35 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 622 Checking Controller Functionality Once the configuration setting has been made the overall Controller functionality must be verified across all of its expected operating conditions This will typically consist of driving each active Controller input cha
14. 2 Usethe A key to scroll through the numbers 3 Usethe V key to move the cursor across to the next digit 4 To save use the gt key 5 escape use the lt key 4 2 13 Set Alarm Hysteresis To modify A1 HYST press gt to enter Use the A key to scroll through the percentages Use the V key to move the cursor across to the next digit To save use the gt key To escape use the lt key To set A2 and A3 Hysteresis levels recompleted steps 1 through 5 OF Xx Bes GD NOS I Page 25 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 4 9 Zone Configuration Menu To view and modify the Zone Configuration settings use the following procedure This procedure can be applied to the configuration of all six Zones and for all four Channels 1 2 4 3 1 Treo SS 4 9 2 DF gt 4 9 9 aT o 4 9 4 2 3 4 4 3 5 1 2 3 4 4 3 6 1 2 3 4 Once in the Configuration Main Menu scroll down using the V key to position 5 Zone Configuration Press gt to enter into sub menu Set Zone Status To Modify Status press the D gt key to enter Use the A key to toggle between ON and OFF To save use the gt key To escape use the lt key Set Zone Tag Name To modify press the gt key to enter Use the A key to scroll through the alpha numerals Use the V key to move the cursor across to the next digit To save use the gt
15. Under normal operating conditions a measured value from a sensor connected to the Controller may be sat close to the value set as an alarm set point For example a slowly rising gas level may have just reached the set point threshold The measured value may briefly cross the set point threshold and then drop back below it again If no alarm delay has been set then an alarm relay may chatter on and off creating unreliable alarm signals to connected equipment To overcome this problem a hysteresis level may be set for each process alarm on each channel The hysteresis value can be set from 0 to 20 of the channel full scale setting 10 Alarm Response without hysteresis Alarm Threshold NO HYSTERESIS Relay Operation 10 Alarm Response with hysteresis Alarm Threshold set 5 a 6625295 Alarm reset level determined by Bee value Operation Figure 1 Effect of Setting Alarm Hysteresis Page 20 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 3 Menu Structure The Gasguard IS Programmable Controller has two levels of use 1 Main Menu user read only 2 View and Modify programmable password protected The first level which is read only enables the user to view all current settings and real time data without affecting the configuration of the controller The second level has the features
16. ENTER PASSWORD E CHECK FOR CORRECT HW SETTINGS CHANGECALPAss ENTER PASSWORD E FLT CLR Key YES 2 CLR KEY N 2 Page 65 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 B5 System Default Table CHANNEL INFORMATION CHANNEL 1 DEFAULT CHANNEL 2 DEFAULT PARAMETER PARAMETER INPUT TYPE 4 20mA INPUT TYPE 4 20mA STATUS ON STATUS ON GAS NAME CH4 GAS NAME 02 5 00 viv 25 00 v v FS 5 00 viv FS 25 00 viv UNIT vlv UNIT vlv TAG CHAN 1 TAG CHAN 2 LF 02 00mA UF 02 00mA LF DIR FALLING LF DIR FALLING LF LATCH NO LF LATCH NO 1 00 v v A1 19 5 vlv A1 DIR RISING A1 DIR FALLING A1 LATCH NO A1 LATCH NO A2 1 25 v v A2 22 0 viv A2 DIR RISING A2 DIR RISING A2 LATCH NO A2 LATCH NO A3 1 50 v v A3 25 0 9ovlv A3 DIR RISING A3 DIR RISING A3 LATCH NO A3 LATCH NO HF 23 00mA HF 23 00mA HF DIR RISING HF DIR RISING HF LATCH NO HF LATCH NO ALMDLY 1000mS ALMDLY 1000mS A1 HYST 5 1 HYST 5 A2 HYST 5 A2 HYST 596 A3 HYST 596 A3 HYST 596 Page 66 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502
17. TWNOIS gt 114 114 PHO WAV TV EHO Z WHY TV EHO L WV TV EHD 113 114 H2 T lVNOIS TVNOSISEHO gt IVN IS TANNVHD gt TWNOIS WHY V 174 H9IH lt gt 1fdNI p 13NNVHO T3NNVHO gt IWNOIS WI gt TWNOIS Z gt WNOIS L WHv1V WNOIS 114 gt WNOIS WaV1V 114 ANANI OK AfidNI TANNVHD 174 CHO ZHD WNOIS Z TANNVHD Z snw M95 tW gt IWNOIS Z Wee TWHVIVEHO _ VWSV1V ZHI E ENEE WV Ta MOTE TEE 1 4 gt TWNOIS 114 TNNYH9 G gt lt K 1ndNI Z 13NNYHO T3NNVHO ot lt gt WNOIS W3V 1V gt NEIE Z Z WAV TV CRT gt TWNOIS Wav WAV TV 114 LHI WHY TV 114 FH WNOIS THO TANNVHD lt gt WNOIS 114 lt gt TWNOIS 174 H9IH T3NNVH2 o AfidNI TANNVHD SLAdNI TANNVHO Page 48 GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 Input Channel Functional Block Diagram AMPCONTROL A3 OTT eum Let EWELL al Eu EL i
18. and offers access to the following seven levels Channel Information Zone Information Relay information Analogue Information Data Communication Information Calibration View and Modify 7 Configuration View and Modify OQ gr ar x Levels 1 to 5 are read only The user can operate the keypad as previously described to view all current settings Level 6 and 7 are view and modify and are password protected This level enables calibration and or configuration of all relevant settings inputs and outputs This is discussed in more detail in Section 4 Programming Page 21 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 3 3 Controller LED and Display Operation There are seven Status LED s located on the facia of the IS Controller Power LED Red Alarm LED Red Fault LED Red Relay Indication LEDs x 4 These LEDs do not indicate the presence of power to the relay coils An illuminated relay LED indicates that a relay has changed state from a non alarm state into an alarm state On power up the power LED will activate and the controller will enter its start up procedure This includes a 10 second long self test mode that carries out internal tests Input signal status and alarm states are checked during the start up sequence Once the start up procedure is completed the Display will show all current gas levels Alarm Fault and Relay LED s will reflect the state
19. gt ZONE 1 CONFIG ALMS CH2 A3 CHANGE ZN ALMS s S E t ZONE 1 CONFIG 5 Ee ALMS CH2 CHANGE ZN ALMSJ gt BEE ZONE 1 CONFIG c N CH3 LF CHANGE ZN ALMS b gt 2 CH3A1 4 y CHANGE ZN ALMS gt A e ZONE 1 CONFIG ALMS CH3 A2 CHANGE 2 ZONE 1 CONFIG C ALMS CH3 A3 CHANGE ZN ALMS ALMS CH3 CHANGE ZN ALMS Ch TE K V CHANGE ZN ALMS 9 4 CHANGE ZN ALMS L ZONE 1 CONFIG ALMS A2 CHANGE ZN ALMS gt ZONE 1 CONFIG C ALMS CHANGE ZN ALMS SS E HE CHANGE 5 gt ZONE T CONFIG VOTING K VOTING CHANGE E Page 64 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 Configuration Flowchart con t em STATUS K CHANGE STATUS B RELAY 2 RELAY 1 CONFIG CONFIGURATION RLY TYPE K T CHANGE RLY Wem DA 9 RELAY 3 RELAY 1 CONFIG CONFIGURATION lt gt 3 TAG K 9 ENTER TAG NAMEG L 2 E lt K CHANGE RLY ZONEJ gt CONFIGURATION EZ ZN1 M
20. press the key to access a second password entry screen Repeat the above steps to enter the password Press the gt to enter the Calibration Menu Jo om N gt To view and modify the Calibration settings use the following procedure There are eight Levels in the Calibration Menu These levels allow the programmer to calibrate the four channels three outputs and the supply voltage To perform a supply voltage calibration it will be necessary to connect a variable 10 16 Vdc power source Page 30 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 The following instructions 4 7 2 and 4 7 3 apply to all 4 Channels 4 7 2 DF wn gt 4 7 3 gt gt 4 7 4 eon ei 4 7 5 Ze oom gt Channel 1 Zero Calibration Press the key to enter into Channel 1 Calibration Connect a calibrated 4 mA 0 4V signal depending on input type to channel 1 contacts The displayed value should read around zero Press the key to save this calibration To escape use the lt key Channel 1 Span Calibration In Channel 1 Calibration hold the A key down for 5 seconds Connect a calibrated 20 mA 2 0V signal depending on input type to channel 1 contacts The displayed value should read a number above zero Press the D gt key to save this calibration To escape use the lt key 10 Volt Supply Voltage Calibration To modify Supply Voltage Calibration press the key to ent
21. 0003X Date of Issue 2007 05 29 Issue 0 Page20t3 Manufacturer Austech Instruments Unit 1 8 Ponderosa P arade Warriewood New South Wales 2102 Australia Manufacturing location s This certificate ts issued as verification that a sample s representative of production was assessed and tested and found to com ply wth the IE C Standard list below and that the manufacturer s quality system relating to the E x products covered by this certificate was assessed and found to comply with the IE CEx Quality system requirements This certificate is granted subject to the conditions as set out in IECEx Scheme Rules IE CEx 02 and Operational Docum ents as amended STANDARDS The electrical apparatus and any acceptable variationsto it specified in the schedule ofthis certificate and the identified documents was found to comply with the following standard s IEC 60079 0 2004 Electrical apparatus for explosive gas atmospheres P art 0 General requirements Edition 4 0 60079 11 2006 Explosive atmospheres P art 11 Equipment protection by intrinsic safety 7 Edition 5 This Certificate does not indicate compliance wth electrical safely and performance requirements other than those expressly included in the Standards lied above TEST amp ASSESSMEHT REPORTS A sampfe s of the equipment fisted has successtul met the examination and te st requirements as recorded in Test Report ALAT AE xXTRO 0006 00 Quality Assessment Repor
22. Pty Ltd makes no warranties as to the contents of this documentation and specifically disclaims any implied warranties or fitness for any particular purpose Ampcontrol further reserves the right to alter the specification of the system and or manual without obligation to notify any person or organisation of these changes Before You Begin WARNING To minimise the possibility of unsafe operation of this equipment the user must be competent via appropriate training in regards to international standards and safety requirements relating to its installation operation and maintenance Safety related Information contained within this manual is supplementary to such standards but must be equally understood and applied to both maximise safe use of this equipment and minimise risk to persons or other equipment We would like to take a moment to thank you for purchasing the Gasguard IS Controller Gasguard Controller Certification Information The Gasguard Controller is certified for use in underground hazardous area applications and carries the following certification and marking Type of Protection Exia Marking Ex ial Certificate No IECExITA07 0003X For conditions of safe use see the certificate of conformity at the end of this manual Ampcontrol Electronics Contact details Ampcontrol CSM Pty Ltd 7 Billbrooke Close Cameron Park NSW 2285 P 61 2 4903 4800 F 61 2 4903 4888 EMAIL electronic
23. Switch TopLayer 24 6554L V2 PCB Controller Display Switch BottomLayer V2 PCB ontroller Display Switch Bottom Overlay V2 PCB CONTROLLER DISPLAY V2A Sheet 2 of 2 24 6553L V2 PCB Controller Output TopLayer 24 6553L V2 PCB Controller Output BottomLayer 24 6553L V2 PCB Controller Output Bottom Overlay V2 PCB Sheet 2 75 6553L Sheet 3 75 6553L Sheet 4 V3 PCB V3 PCB 2007 01 31 2004 06 03 N Q o 5 0 x o c N 5 Loi a lt N An e N Leve l a 2007 04 04 BI B B B Bg B 8 04 05 27 Controller Output Top Overlay Controller CPU Top Overlay Controller CPU TopLayer lt 76 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 ATTACHMENT TO CERTIFICATE IECEx ITA 07 0003X Controller CPU BottomLayer Controller CPU Bottom Overlay Input Circuits Power supply Power supply GASGUARD CONTROLLER RELAY BOARD IEC VERSION Gasguard Controller Relay Board IEC Version Bottom Trace Gasguard Controller Relay Board IEC Version Top CONDITIONS Page 2 of 3 Drawing Rev Date Leve V3 PCB 24 6552L V3 PCB Sheet 2 Sheets 3 amp 4 Sheet 5 BT 24 6559L V1 7 03 16 TO 24 6559L V1 The following list of Special Conditions apply to this certificate 1 negligibl e L negligibl pH The combined total capacitance and either the combined
24. Zone 6 Voting Number 40083 Relay 1 Control Bit0 Mode 40084 Relay 2 Control 1 NE 0 ND 40085 Relay 3 Control 40086 Relay 4 Control Bit1 Bits N A Bit6 Hide 1 gt On 02 Off Bit7 Status 1 gt Off 0 On Bit8 Bit15 N A 40087 Relay 1 To Zone Map Zone 1 40088 Relay 2 To Zone Map Bit1 Zone 2 40089 Relay 3 To Zone Map Bit2 Zone 3 40090 Relay 4 To Zone Map Bit3 Zone 4 Bit4 Zone 5 Bits Zone 6 Bit6 Bit15 N A 1 Selected 0 gt Not Selected Page 43 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 40091 Output 1 Control Bit2 Function 40092 Output 2 Control 0 Follow 40093 Output 3 Control 1 Highest 2 Lowest Bit3 Bitb N A Bit6 Hide 1 gt On 0 gt Off Bit7 Status 1 gt Off 0 On Bit8 15 N A 40094 Output 1 To Channel Map BitO Channel 1 40095 Output 2 To Channel Map Bit1 Channel 2 40096 Output 3 To Channel Map Bit2 Channel 3 40096 Output 3 To Channel Map Bit3 Channel 4 Bit4 Bit5 N A 1 gt Selected 0 gt Not Selected Available Modbus function code is 0x03 Read Holding Registers Note If there is any other information needed it can be added to the Modbus Address map Page 44 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 10 2 Modbus Memory Map Part 2 JequinN 1395 O WI Y N 94 POM uoneoiunuluo G87 SY 20 10100 DUT
25. alarm can be reset by any person whether authorised or not It is up to the user to control access to and or permissions relating to the resetting of latched alarm conditions Note Alarm and relay states are NOT intentionally preserved during the time power is removed from the controller Alarm and relay states are re established once power is restored and the Controller has completed its self test The interpretation of a relay contact state during a power failure will depend on how it has been configured to operate 29 Configuring Relay Operation Each of the four relays within the Controller is a single pole change over type There are three connections associated with each relay namely C Normally Open NO and Normally Closed At any given time the Common terminal will be connected to either the NO or NC terminal depending on the relay configuration and the logic of the Zone Block driving it Relays can be configured to be Normally Energised NE or Normally de energised ND see below The context of NC and NO will change depending on whether a relay coil has been configured to be normally energised or normally de energised under non alarm conditions 2 9 1 Relay Start Up Conditions AN When the Controller powers up it enters a period of self test for a number of seconds Following this self test there may be a further start up delay if this has been c
26. is important to ensure that they comply with recognised A standards applicable to the application into which the controller is installed If no standards exist to specify the alarm thresholds they should be set based on a full understanding of the application by a Suitably authorised person or body e Alarm levels should be used the order of their nomenclature i e the first alarm level is A1 the second is A2 and the third is A3 e An alarm that sits higher in the naming order A1 2 A3 should be set to a higher trip threshold than one that sits below it Latching Alarms If an alarm state could be missed because there is likely to be nobody present to observe an event as it occurs a latching alarm should be set A latched alarm will remain active even when the event triggering it is no longer present If the Controller undergoes a power cycle following the triggering of a latched alarm the latched status will be re instated once the Controller has re booted Resetting Alarms A A latched alarm may be manually reset by the use of either the LEFT key held for 5 seconds only if the left key reset feature is enabled in the configuration settings or by the remote reset terminals The Controller configuration allows the left key reset feature to be enabled or disabled When disabled only authorised users who know the Controller system passwords are able to change this to an enabled status If the left key reset is enabled a latched
27. jurod jeuuroeq Kejdsiq io UO psenBses Jad uo peKejdsip se anjen julodjas wey p jeuueu parowa jurod euer lo nu penses Jad uo pefe dsip se anjer jurodjes jeuueu jurod Kejdsiq psenBses Jad uo pefejdsip se anjer julodjas Z e jeuueu parowa juod euer ui Ke dsir lo nu psenBsesy ed uo peKe dsip se anjer julodjas jeuuey 1 jurod jeuuroeq Ap io uo psenBses Jad uo pefejdsip se anjen julodjas Z jauuey peAouje1 11104 ui ejdsi io Duo puenBses Jed uo pe ejdsip se en eA julodjas Z wey Z jeuueu 1 jurod jeuuroe ui ejdsiq ao uo psenBsed ad uo pe ejdsip se anjer julodjas Z jeuueu juod ui lo Duo p1enDsec Jad uo pakejdsip se julodjas e jauuey 1 juod jewioaq pien6seo uo pefe dsip se enjeA juredies Z jeuueu juiod ui e dsi puenDsec Jed uo pe ejdsip se uodas wey jeuueuo ON ON sseJppy e e s snapojA ajuon SSeJppv WIS uonduose D us ui 6 5 46 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 Appendix A Connection Diagram 4 20mA
28. key To escape use the lt key Set Zone 1 to Channel 1 Low Fault Alarm To modify CH1 LF press the key to enter Use the A key to toggle between IN and NOT IN To save use the gt key To escape use the lt key Set Zone 1 to Channel 1 Alarm 1 To modify CH1 A1 press the gt key to enter Use the key to toggle between IN and NOT IN To save use the key To escape use the lt key Set Zone 1 to Channel 1 Alarm 2 To modify CH1 A2 press the key to enter Use the A key to toggle between IN and NOT IN To save use the key To escape use the lt key Set Zone 1 to Channel 1 Alarm 3 To modify CH1 A3 press the gt key to enter Use the A key to toggle between IN and NOT IN To save use the key To escape use the lt key Page 26 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 4 3 7 Set Zone 1 to Channel 1 High Fault Alarm To modify CH1 HF press the gt key to enter Use the A key to toggle between IN and NOT IN To save use the key To escape use the lt key Boc mol A 4 3 8 Set Voting Configuration Refer to section 2 6 4 before setting voting functions To modify Voting Value press the gt key to enter Use the A key to toggle between values 1 and 20 To save use the key To escape use the lt key Boc ow gt 44 Relay Configuration Menu To view and modify individual Relay Configuration settings use the following procedure 1 Oncein the
29. of the first plus the ability to view and modify the calibration and configuration of the Gasguard Controller The default screen is the Monitoring screen This allows the user to view the actual monitored gas levels and will display alarms if activated view current settings the user must operate the keypad 3 1 Key Pad Functions in Main Menu The facia of the Gasguard IS Controller has a two line 16 character Liquid Crystal Display LCD Status LED s and a tactile keypad The layout of the display structure is graphically illustrated in Section 5 of this manual Flowcharts Navigation of the menu is performed by pressing the arrow keys on the keypad The display level is changed with the Up and Down arrow keys and the display position is changed with the Left and Right arrow keys UP Key Button DOWN Key Button LEFT Key Button RIGHT Key Button The Up arrow key and Down arrow key enable the user to scroll through the menu The Right arrow key allows the user to view more detailed information about channels zones relays alarms and outputs The Left arrow key allows the user to escape from the present screen The Alarm Reset function is carried out by holding the Left arrow key for 5 seconds Any alarm that is below the preset threshold will be reset only if the left button reset is enabled in the configuration settings 3 2 Main Menu The main menu is available from the Monitoring Screen Default Screen
30. of the input channel signals alarm states according to how the Controller has been configured There are 3 Alarms and 2 Faults Alarm A1 Alarm2 A2 Alarm3 lowFault LF High Fault 3 3 1 Inthe event of an Alarm in non latched mode The alarm LED activates The current gas level and alarm type ALM1 ALM2 or ALM3 toggle on the display The relevant relay and LED activates and remains ON If the gas level is no longer in an alarm region the Alarm and relay LEDs tums OFF The gas level only is displayed 3 3 2 Inthe event of an alarm in latched mode The alarm LED activates The current gas level and alarm type ALM1 ALM2 or ALM3 toggle on the display The relevant relay and LED activate and remain ON The current gas level and the latched alarm type ALM1 ALM2 or ALM3 toggle on the display The relevant relay and LED is activated and stays ON If the gas level is below a latched alarm level but still above another alarm point the latched alarm can be reset by holding the lt key down for 5 seconds or activating the remote reset button The display will now indicate the next lowest alarm that is active Other active alarms will not be reset OR Ifthe gas level has dropped into the region below all alarm setpoints but the latched alarm has not been reset the alarm LED and the latched relay LED remain ON The current gas level and highest alarm type ALM1 ALM2 or ALM3 toggle on the display The ala
31. specified per unit length It is therefore important to take into account the cable length used in an installation in respect to the total value of these parameters In addition to their electrical properties cables must afford physical protection against being damaged by impact or abrasion This applies particularly to cables that are external to a wall cabinet that houses the Controller Cables may be both electrically screened against noise interference as well as sheathed in a strong wire jacket to prevent crushing Such cables would generally also be sheathed in a material that is resistant to abrasion and attack from chemicals such as fuels 5 3 3 Cable Termination When connecting cables to the Controller it is not sufficient to simply strip and twist a cable s inner conductor and insert into the Controller terminal Stripped and twisted conductors must not be used and especially ones tinned with solder Solder exhibits a behaviour known as cold creep and in effect would flatten under the pressure of the Controller s terminal screw Once this happens the connection is likely to become loose and unreliable All connections to the Controller must be made via appropriate cable crimp connectors The Controllers terminals can take a cable crimp of up to 2 5mm diameter 5 34 Cable Marking When making connections to the Controller individual conductors should be marked with a cable marker or tag so that correct connections can be made acro
32. total inductance or the inductance to resistance L R ratio of the circuits connected to the Gasguard Controller Model 72 6501 terminals 1 to 32 must not exceed those specified in the Certificate for the power supply that power the system Page 77 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 7502 a ATTACHMENT TO CERTIFICATE IECEx ITA 07 0003X Page 3 of 3 The apparatus is considered as having the following output parameters Terminals 24 to 28 Terminals 29 to 32 Terminals 33 to 46 The capacitance and either the inductance or the inductance to resistance L R ratio of the circuits connected to the Gasguard Controller Model 72 6501 terminals 33 to 46 must not exceed those specified in the Certificate for the power supply that power the system Note The above load parameters apply where a The external circuit contains no combined lumped inductance Li and capacitance Ci greater than 196 of the above values or b The inductance and capacitance are distributed as in a cable or The external circuit contains only lumped inductance or only lumped capacitance in combination with a cable In all other situations e g the external circuit contains combined lumped inductance and capacitance up to 5096 of each of the inductance and capacitance values is allowed The Gasguard Controller Model 72 6501 is to be housed in an enclosure suitable for Group that offers an ingress protection of not less tha
33. 1 Set point A1 Value as displayed with 40022 Channel 1 Set point A2 decimal point removed 40023 Channel 1 Set point A3 40024 Channel 2 Set point A1 40025 Channel 2 Set point A2 40026 Channel 2 Set point A3 40027 Channel 3 Set point A1 40028 Channel 3 Set point A2 40029 Channel 3 Set point A3 40030 Channel 4 Set point A1 40031 Channel 4 Set point A2 40032 Channel 4 Set point A3 40033 Channel 1 Display Format Value Possible Values are 40034 Channel 2 Display Format Value 1 40035 Channel 3 Display Format Value 10 40036 Channel 4 Display Format Value 100 1000 40037 Channel 1 Display Full Scale Value as displayed with 40038 Channel 2 Display Full Scale decimal point removed 40039 Channel 3 Display Full Scale Value Range 0 9999 40040 Channel 4 Display Full Scale 40041 Channel 1 Alarm Direction Du LF A1 40042 Channel 2 Alarm Direction Bit2 A2 Bit3 40043 Channel 3 Alarm Direction Bit4 HF Bit5 Bit15 N A 40044 Channel 4 Alarm Direction 1 2 Raising 0 Falling 40045 Channel 1 Alarm Latch Du LF 40046 Channel 2 Alarm Latch Bit1 A1 40047 Channel 3 Alarm Latch Bit2 A2 40048 Channel 4 Alarm Latch Bit3 A3 Bit4 HF Bit5 Bit15 N A 1 gt Latch On 0 gt Latch Off Page 42 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 40049 Chann
34. 13 PHO 1 L13 PHO 1 Z Wav EHO lt 1 LNO NI L EHO 1 114 MOT LNO NIWYW1V 114 1 1 Wav LION L Wavv 114 1 114 114 CHO O 1 114 HO LH9 lt 1 Z WYYTY HO 1 1 L Wav TW 174 O 1 W3V1V 114 WaV1V 114 1 L74 HOIH S INVHOVIO 45018 IWNOILONNA 3NOZ S1 dNI WYYTY p THNNVHO S1 dNI TINNVHO S1 dNI THINNVHO SLAdNI 13 50 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 Relay Functional Block Diagram A5 SANG AV T38 TVN9IS 1819 4 O HLVd IWNOIS lt AV133 OL 1V201 SUV S3 18 VI vA YISN 1081402 TVN9IS SALON 3N NO 119110 9 3N0Z 1 9 3NOZ LAdLNO 3N0Z 1 3NOZ 119110 p 3N0Z ONT 3NOZ 1 41 0 3 2 LAOINI 3N0Z LAdLNO 3N0Z LAOINI 3NOZ LAdLNO 3N0Z LAOINI 3NOZ QN 3N 130 NO WV VIO x90 18 IVNOLLONA3 AV e Page 51 Loop Resistance Ohms NEEE AM
35. 9 2011 CRN 7502 4 6 6 Set Name 1 To modify TN1 press the gt key to enter Use the A key to scroll through the alpha numerals Use the V key to move the cursor across to the next digit To save use the gt key To escape use the lt key N gt 4 67 Set Tag Name 2 To modify TN2 press the gt key to enter Use the A key to scroll through the alpha numerals Use the V key to move the cursor across to the next digit To save use the gt key To escape use the lt key DF O P gt 4 6 8 Change Configuration Password 1 modify Change Pass press the D gt key to enter 2 Use the A key to scroll through the numbers 3 To save use the D gt key 4 To escape use the lt key 4 6 9 Change Fault Clear Setting 6 1 To modify Change FLT CLR press the gt key to enter 2 Use the A key to toggle between Enabled and Disabled 3 To save use the gt key 4 To escape use the lt key 4 7 Calibration Menu 4 751 ToEnter the Calibration Menu From the Monitoring Screen press the A key twice to scroll up to level 6 Calibration View and Modify Press the key to enter into the Do you want to Continue screen If YES press the D gt key to gain access if NO press use the lt key to escape On the Enter Password screen use the A key to scroll through the numbers Then use the V key to move the cursor to the next digit Once the password has been entered
36. C terminal as marked on the terminal label When an alarm state exists that is configured to drive an ND relay power is switched to the coil and the contacts change state The Common relay terminal will now be connected to the NO terminal The changing state of the contact signals an alarm condition If the Controller is operating with no active alarm conditions all relays set to ND will be unpowered and inactive If during this condition power is removed from the Controller there will be no change of state of any of the relay contacts Relays set to ND cannot signal a fault condition due to power loss Although the state of the relay contacts is preserved i e not changed under non powered conditions this is not an intentional state preservation rather it is just an outcome of having normally inactive unpowered relays 2 99 3 Normally Energised Relays If it is required to signal a fault due to power loss relays should be configured to Normally Energised NE operation Relays set to NE will have power applied to their coils during the normal non alarm state Under these conditions the Common relay terminal will be connected to the NO terminal as marked on the terminal label For NE configured relays the function of the contacts as marked on the terminal label is reversed i e NO becomes NC and vice versa When an alarm state exists that is co
37. Configuration Menu scroll down using the V key to position 11 Relay Configuration 2 Press gt to enter into sub menu 44 1 Set Relay Status To modify Status press the D gt key to enter Use the A key to toggle between ON and OFF To save use the gt key To escape use the lt key Boc m c 4 4 2 SetRelay Type To modify RLY TYPE press the gt key to enter Use the A key to toggle between ND NE To save use the key To escape use the lt key e O mm gt 44 3 SetTag Name To modify TAG press the D gt key to enter Use the A key to scroll through the alpha numerals Use the V key to move the cursor across to the next digit To save use the gt key To escape use the lt key DF oa gt 4 44 Set Relay 1 to Zone 1 To modify ZN1 press the key to enter Use the A key to toggle between IN and NOT IN To save use the gt key To escape use the lt key e Ga gt Page 27 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 4 4 5 Set Relay Start Up Mode To modify PwrUpMode press the gt key to enter Use the A key to toggle between LIVE and LATCHED To save use the gt key To escape use the lt key 5 4 5 Output Configuration Menu To view and modify the Output Configuration settings use the following procedure This procedure can be applied to the configuration of all three outputs Note Outputs are always 4 20mA even i
38. EFAULT PARAMETER SYSTEM CONFIGURATION SYSTEM DEFAULT CONFIGURATION PARAMETER Page 72 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 Appendix C Approvals IECEx Certificate of Conformity IEC INTERNATIONAL ELECTROTECHNICAL COMMISSION IEC Certification Scheme for Explosive Atmospheres for rules and details ofthe IECEx Scheme vist vwwiecex com Certificate No IECEx ITA 07 0003X issue No Cerificate history Status Current Date of issue 2007 05 29 Page 1 of 3 Applicant AmpcContro Pty Ltd 250 Macquarie Road Warners Bay New South Wales 2202 Australia Electrical Apparatus Gasguard Controller 72 6501 Optional accesso Type of Protection Ex ia Marking Ex ial IECEx ITA 07 0003X Approved for issue on behalf of the IECEX David Gray Certification Body Postion Certification Authority Signature for printed version Date 1 This certificate and schedule may only be reproduced in full 2 This certificate isnot transferable and remains the property ofthe issuing body 3 The Status and authenticity of this certificate may be vented by visiting the Of cial x Website Certificate issued by International Testing and Certification Servic es Pty Ltd 4 6 Second Street Bowden SA 5007 Australia Page 73 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 IECEx Certificate of Conformity Certificate IECE xIT A 07
39. GE INPUT TYPE A gt STATUS CHANGE STATUS B 6 diu CHANGE GAS CHANNEL 1 CONFIG DECPT CHANGE DEC POINT D gt CHANNEL 1 CONFIG FS CHANNEL 1 CONFIG FS CHANGE E m CHANGE UNITS F gt m ENTER TAG NAME G LF CHANGE E eo 7 9 eC CHANNEL 1 LF DIR ONFIG CHANNEL 1 CONFIG K 3 CHANGE ALM LATCH H gt CHANNELICONFIG Al CHANGE E SM 3 CHANGE ALARM gt A1 LATCH CHANGE ALM LATCH H gt CHANGEL 1 CONFIG A2 CHANNEL 1 CONFIG A2 CHANGE E gt e CHANNEL 1 CONFIG A2 DIR gt CHANGE ALARM DIR h A2 LATCH CHANGE ALM LATCH H gt A3 CHANNEL 1 CONFIG A3 DIR CHANGE ALARM DIR CHANGEL 1 CONFIG A3 LATCH KC CHANGE ALM LATCH H s gt CHANNEL 1 CONFIG HF CHANNEL 1 CONFIG HF CHANGE E HF LATCH CHANGE ALM LATCH B CHANGEL 1 OH ONFIG lt CHANNEL 1 CONFIG A3 HYST ALMDLY ALMDLY CHANGE E CHANGEL 1 CONFIG CHANNEL 1 CONFIG A1 HYST 1 HYST CHANGE E s y CHANNEL CONFIG A2 HYST A2 HYST CHANGE E Bx m C
40. HANNEL 1 CONFIG HYST CHANGE E CHECK FOR CORRECT HW SETTINGS SAVE SETTING AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 Configuration Flowchart con t FROM CHANEL 4 CONFIGURATION previous page ZONE 1 CONFIGURATION ZONE 2 CONFIGURATION 3 CONFIGURATION gt 4 CONFIGURATION S gt ZONE 6 gt CONFIGURATION To RELAY 1 CONFIGURATION next page AS PER ZONE 1 To CONFIGURATION For enter and change the parameter press up and down arrow ZONE 1 CONFIG K STATUS CHANGESTATUS B Lo K h ENTER TAG NAMEG 9 CH1 LF CHANGE 5 aO CH1A1 K O CHANGE ZN ALMSJ ZONE 1 CONFIG 1 2 K CHANGE ZN ALMS gt ZONE 1 CONFIG UTHA ALMS 1 CHANGE 2 ur K sx CHANGE ZN ALMS Po aqui CHANGE ZN ALMS gt CH2 LF e z CH2 A1 K Y CHANGE ZN ALMS E hh ZONE 1 CONFIG 2 A2 Y CHANGE ZN ALMS
41. N 7502 Appendix B System Flow Chart B1 Flow Chart Legend Page 60 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 B2 Main Menu Flowchart MONITOR SCREEN C MODEL C 3 SUPPLY e TAG SOFTWARE 5 M VOLTAGE E HARDWARE INFORMATION CHANNEL ALARM LEVEL 1 e ALARM LEVEL 2 eo ALARM LEVEL 3 2 LOW FAULT 2 HIGH FAULT 2 ALARMS CHANNEL2 AS PER CHANNEL 1 AS CHANNEL3 K gt CHANNEL 1 1 AS PER CHANNEL A lt CHANNEL x INFORMATION VOTING 3 RELAY RELAY1 RELAY1TO gt RELAY 1 TYPE REFER TO FOLLOWING PAGE INFORMATION T T rayi AS PER T rewi REAYA Ao PER ANALOG INPUT OUTPUT INFORMATION T f au AS PER B OUTPUT 1 OUTPUT 3 INFORMATION lt gt ADDRESS BaUDRATE EZ rm ER REFER VIEW amp MODIFY FOLLOWING PAGE Page 61 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 B3 Calibration Flowchart
42. OUTPUT 5485 RELAYS A _ COMMS op oP2 ops PORT RL2 RL3 RL4 SEN gt En gt D gt gt O O w eiu a o w w w O O 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 e OX OR ON Os a O O OF Og OS C ON OD e C 5 O w ON ve Sig ve Sig ve Sig ve Sig POWER IN REM CH1 CH2 CH3 CH4 RESET SENSOR INPUTS System Functional Block Diagrams Key to Symbols d LOGICAL AND LOGICAL OR gt LOGICAL INVERSION gt LOGICAL EXLUSIVE OR Page 47 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 A2 Top Level Functional Block Diagram 1109 109 109 1109 CZE gt BAC p AV T3H 9 INOZ lt 1 41 0 S 3NOZ lt 118170 p INOZ lt gt 1 41 0 INOZ lt INOZ lt gt 1 41 0 INOZ lt gt V AVT3H Wmd gt INYA AN 9 INOZ lt gt S INOZ 1 41 p INOZ lt INOZ 118170 2 3NOZ lt Afid1fO INOZ lt gt meet lt gt INYO Av 9 INOZ lt gt 1 41 0 S INOZ lt gt 1 41 r INOZ lt gt INOZ lt 1 41 0 Z INOZ lt gt
43. Oa 41 10 14 Memory Type 4 5 dett ddl est en tds lea era sd tr el dle Pe ten 42 10 2 MG 45 Appendix A Connection DIOE BTE accio ah n iu as 47 Appendix 47 Appendix A Output Current Followers Performance Graphie 52 Appendix A Sample Test FOFTISa y u 53 Append B System Flow m Pede sort e eco mo Lp 60 Appendix B Default Settings Table REP Go polvere Goa 65 Appendix Tore qo EE T3 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 1 Receiving and Storage 1 1 Receiving All possible precautions are taken to protect the Gasguard controller against damage or losses during shipment however before accepting delivery check all items against the packing list or Bill of Lading If there are shortages or evidence of physical damage notify Ampcontrol immediately Notify Ampcontrol within 7 days maximum in case of shortages or discrepancies according to the packing list This action will help ensure a speedy resolution to any perceived problems Keep a record of all claims and correspondence Photographs are recommended Where practicable do not remove protective covers prior to installation unless there are indications of damage Boxes opened for inspection and inventory should be carefully repacked to ensure protection of the contents or el
44. PCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 A6 Current Follower Outputs Performance Graph Gasguard Controller Current Follower Maximum signal loop resistance vs power supply voltage 600 550 500 450 400 350 300 250 200 150 H HHH m 100 12 oo wo o e w 5 S m Supply Voltage V Page 52 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 A7 Sample Commissioning Test Form The sample test form shows a set of values for a typical system In a practical application these values will depend on the specific controller type and how the configuration has been set Page 53 AMPCONTROL GAS STATION TEST REPORT GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 Customer P O No Job No Type Date Controller Serial Number Labels fitted Control wiring checked Unit powered up successfully With 110V applied battery charge LED on UPS only Check 12V supply CH1 CH2 CH3 CH4 Check 12 15V to output terminal strip SIM Module is communicating with iMAC if fitted Relay Configuration Relay 1 Normally De energised L Verified Relay 2 Normally De energised L Verified Relay 3 Normally Energised L Verified Relay 4 Normally Energised L Verified Page 54
45. RN 7502 Set Gas Name The controller has 6 pre set gas types CH4 CO H2S AV and DP If another gas type is required the operator can select the User Function to input the desired gas type 1 65 5 a C 7 424 To modify Gas Name press gt key to enter Use the A key to scroll through the Gas names To save use the gt key or To input another Gas name scroll to User by pressing the A key Use the gt key to enter into User Enter the desired name by pressing A key to scroll through the alpha numerals Press the V key to move the cursor across to the next segment Once the desired Gas name has been entered use the gt key to save To escape use the lt key Set Decimal Point Required to set correct gas reading 1 2 3 4 4 2 5 To modify Dec Pt press D gt key to enter Use the A key to move the decimal point to the required position To save use the gt key To escape use the lt key Set Full Scale Required to set correct gas reading 1 eu d SS 4 2 6 To modify FS press gt to enter Use the A key to scroll through the numbers Use the V key to move the cursor across to the required alpha numeral setting To save use the key To escape use the lt key Set Units of Measure Required to set correct gas reading 1 2 3 4 4 2 7 To modify Units press D gt to enter Use the A key to scroll through the Units T
46. There are five available alarm set points per channel giving a total of 20 alarm signals The available alarms cover high fault low fault and three process level alarms Each channel s alarm group is independent of other channels The high and low fault alarms are active for process signals that rise above or drop below the baseline zero The high and low alarm threshold points are set in terms of input milliamps The high fault and low fault alarms are named HF and LF respectively in the menu system The process level alarms named A2 and A3 are configurable based on the units set for that channel Each alarm may be set to trip based on an input signal s position relative to the set point i e input above set point or input below set point Note Alarms that activate above or below a user set threshold are often referred to as rising or falling alarms For the Gasguard controller alarms become active only when an input crosses the set threshold An alarm is not activated by sensing a change in signal direction or by a rate of change of input signal level The following alarm parameters may be set by the user LF alarm level in mA 0 to 99 99 e HF alarm level in mA 0 to 99 99 e 1 alarm level in process units pos neg value 0 to value scaled by decimal place setting e A2alarm level in process units pos neg value 0 to value scaled by decimal place setting e A3alarm level in process un
47. as four relay outputs mappable to alarm set point from any channel 2 5 5 Each ofthe four relays can be set to e Latch This feature be used to preserve a record of a relay s state in the event of a power failure or to record an alarm event where there may be no one to respond to it at the time it occurs e normally energised or normally de energised Page 10 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 The Controller has six alarm zones that allow grouping of input channel set points and output relays 2 5 6 Each zone may be configured to Include a specific or multiple set point s from a specific input channel Include multiple set points from multiple input channels Include from zero to four of the output relays 2 5 7 Analogue Outputs The Controller has three 4 20 mA current repeater outputs to drive remote displays or PLC SCADA Systems The analogue outputs may be set to one of the following modes e Follow a particular channel e Follow the highest reading from a number of selected channels e Follow the lowest reading from a number of selected channels A During the start up delay time when power is applied to the Controller the follower outputs are active and will pass on whatever input signal current is present via assigned channels The Controller is DIN rail compatible and has been approved to be intrinsically safe for use in a Zone 0 hazardous area T
48. ble parts and is not provided with any user adjustments 7 3 Disposal of System Parts f The electronic equipment discussed in this manual must not be treated as general waste By A ensuring that this product is disposed of correctly you will be helping to prevent potentially negative consequences for the environment and human health which could otherwise be bd caused by incorrect waste handling of this product 8 Equipment List 105232 Four Channel IS Controller 105231 Two Channel IS Controller 120875 Gasguard User Manual Page 38 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 9 Specifications Voltage 10 to 16 5 VDC Nominal 12 V IS Supply Input Channels Four channels 4 20 mA or 0 4 2 V Set during manufacture For 4 20mA input type input resistance is 100 Ohms between channel input and channel Relay Outputs Four IS Relay Outputs Can be configured Normally Energised NE Normally De energised ND Latched L Non Latched NL Contacts 1 C O Rated 2 A 30 Vdc Resistive Relay contacts are considered as isolated intrinsically safe circuits See certificate of conformance for details Repeat outputs Three 4 20 mA programmable outputs Applies to both 4 20mA and 0 4 2 0V input controller types Maximum 300 Ohm load with 12V dc supply See performance graph in Appendix A A6 Set points 3 programmable set points per channel Hyste
49. ded relay The vote count does not allow for specific set points to be included in the number that must be active Any set point from any channel will be considered in the comparison For example if 12 set points are included and the vote count is setto 5 any 5 of the 12 set points will potentially activate an included relay 2 6 5 Zone Active Status A Zone Block may be set to be inactive irrespective of included set points and relays A Zone block that is set to OFF will not allow its included relay to be activated via the included input set points A relay included in a Zone Block that is set to OFF may still be activated if it is included in another Zone Block that is set to ON Example Settings for a Zone Block Refer to Section 4 for nomenclature relating to Controller settings Alarm Set Point inclusion is made in the Zone configuration menu Relay inclusion is set via the Relay configuration menu Page 12 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 Example 1 Assume set points and relay inclusions not shown to be set as NOT IN RELAY 1 Status ON Zn1 IN Allocate Relay 1 to Zone Block 1 ZONE 1 Status Ch1 LF IN include Chan 1 Low Fault set point Voting 1 only a single set point needs to be active to activate the relay For the above settings Relay 1 will become active when there is a Low Fault on channel 1 Example 2 Inclusion of multip
50. e 33 5 3 1 Entity Parameters cei o de ep 33 5 3 2 of Cable nyina acm itta 94 5 3 3 Cable Termination Datur n redd orato de Cot eO 34 5 3 4 E 94 5 3 5 Cable Restat u ted qapa sa 34 6 Gontroller En DE 35 6 1 Completing a Controller Test Form Common Header Information e 35 6 2 Running through Controller Commissioning acri 35 6 2 1 First power p Checks xot rir tre Pe E PT RT Re Hte 35 6 2 2 Checking Controller Functionality sese 36 7 Service Maintenance amp Dispnosza tte teta tetti ttr 37 7 1 Equipment Servico o Pre Aaaama 37 7 1 1 Visual Only IBSBECDOHS SU EE 37 7 12 Detailed Inspections sss tnter nnne netten 37 7 2 Equipment Maintenance teet neos bl teda Peri 38 Disposal or System Pals Rotes dS tome fette tue Lus 38 8 EqQuiIpMent Ee te eth ene 38 92 SD6GCIfICaliOriS etti 39 10 Data Communication Specification sse 40 10 1 Modbus Memory Map Part T rar dee eege 40 MEI I uv E 40 101 2 Memory Type ueber e 40 a otis a
51. e range 4 20mA and as such may represent a variety of actual process scaling To set the relationship between 4 20mA input and the process scaling the channel full scale value may be set Settings are per digit with up to four digits available The displayed value of this setting will depend on the decimal place setting The maximum value that may be set is to be 9999 999 99 9 9 99 depending on decimal point position Units The process displayed readings can be given units of measurement indicator There are ten pre set unit types available for selection namely vN percent volume per volume e ppm parts per million LEL Lower Explosive Limit percent V volts e mV millivolts e rpm revolutions per minute e Hz cycles per second e kHz thousands of cycles per second e m s meters per second Tag A channel may be given an identification name that provides meaningful representation of its purpose function within a system The tag input is entered as a 9 character name consisting of the following characters e Symbols blank e Numeric 0 9 e Alpha AZ uppercase only Page 16 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 The following information should be understood to ensure that the Controller reliably signals alarm states at appropriate levels Failure to observe correct settings may result in system alarm failure 2 8 Setting Alarm Set Points
52. ed UO 20 0 5 00 4 95 5 05 Programmed Test Values r Relays Setpoint Engineering Value V Action iMAC 1 2 3 4 Operation Low Fault 2mA 2 0mA Falling Latching Fault LED amp Programmed Values 1 98 2 02 L L L L UO ID G IL Verified on Test Alarm 1 1 0096 7 2mA Rising Non Latching Alarm LED O O L L Programmed Values 7 13 7 27 L L U L LU ILI ILI ID Verified on Test Alarm 2 1 5096 8 8mA Rising Non Latching Alarm LED U 1 ILU K IL Programmed Values 8 71 8 89 L UO L m LU ILI ILI ID Verified on Test Alarm 3 2 00 10 4mA Rising Latching Alarm LED L Dd IL L amp J Programmed Values 10 3 10 5 L L m L UO ID IL IL Verified on Test High Fault 22mA 22mA Rising Latching Fault LED L X L amp Programmed Values 21 8 22 2 L L UO ID IL IL Verified on Test Page 58 GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 7502 AMPCONTHROL Output Configuration Output 1 Output 2 Output 3 Status OFF L Verified OFF L_ Verified ON L Verified Tag IDA VALUE L Verified Output Type HIGHEST L Verified Channel 1 IN L Verified Channel 2 IN L Verified Channel 3 OUT L Verified Channel 4 OUT L Verified Tested By Date Page 59 GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CR
53. el 1 Alarm 3 10005 Channel 1 High Fault 10006 Channel 1 Spare 10007 Channel 1 Spare 10008 Channel 1 Spare 10009 Channel 2 Low Fault 10010 Channel 2 Alarm 1 10011 Channel 2 Alarm 2 10012 Channel 2 Alarm 3 10013 Channel 2 High Fault 10014 Channel 2 Spare 10015 Channel 2 Spare 10016 Channel 2 Spare 10017 Channel 3 Low Fault 10018 Channel 3 Alarm 1 10019 Channel 3 Alarm 2 10020 Channel 2 Alarm 3 1 gt Fault Alarm State 10021 Channel 3 High Fault 0 Normal 10022 Channel 3 Spare 10023 Channel 3 Spare 10024 Channel 3 Spare 10025 Channel 4 Low Fault 10026 Channel 4 Alarm 1 10027 Channel 4 Alarm 2 10028 Channel 4 Alarm 3 10029 Channel 4 High Fault 10030 Channel 4 Spare 10031 Channel 4 Spare 10032 Channel 4 Spare 10033 Zone 1 Status 1 gt Zone Active 10034 Zone 2 Status 0 Zone Normal 10035 Zone 3 Status 10036 Zone 4 Status 10037 Zone 5 Status 10038 Zone 6 Status Available Modbus function code is 0x02 Read Input Status Page 40 AMPCONTROL 10 1 3 Memory Type 3 GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 Modbus Address Description Data Format 30001 Channel 1 Analogue Input Normalize Values 30002 Channel 2 Analogue Input 4mA gt 4000 30003 Channel 3 Analogue Input 20mA gt 20000 90004 Channel 4 Analogue Input 30005 Channel 1 Analogue Input Value as displayed with 30006 Channel 2 Analogue Input decimal point r
54. el 1 Alarm Delay Value in mSec 40050 Channel 2 Alarm Delay Value Range 40051 Channel 3 Alarm Delay 0 9999 40052 Channel 4 Alarm Delay 40053 Channel 1 Control Du D N A 40054 Channel 2 Control Bit6 Hide 40055 Channel 3 Control 1 gt On 02 Off 40056 Channel 4 Control Bit7 Status 1 gt Off 0 On Bit8 Bit15 N A 40057 Channel 1 Gas Name Value Range 40058 Channel 2 Gas Name 12CH4 40059 Channel 3 Gas Name 2 CO 40060 Channel 4 Gas Name 3 02 4 H2S 5 AV Air Velocity 6 DP Diff Pressure 255 User 40061 Zone 1 Control Du Bits N A 40062 Zone 2 Control Hide 40063 Zone 3 Control 1 gt On 02 Off 40064 Zone 4 Control Bit7 Status 40065 Zone 5 Control 1 gt Off 0 gt On 40066 Zone 6 Control Bit8 Bitl5 N A 40067 Zone 1 To Ch1 Ch2 Alarms Dm Ch 1 LF 40068 Zone 1 To Ch3 Ch4 Alarms Bit1 Ch 1 A1 40069 Zone 2 To Ch1 Ch2 Alarms Bit2 Ch1 A2 40070 Zone 2 To Ch3 Ch4 Alarms Bit3 Ch1 A3 40071 Zone 3 To Ch1 Ch2 Alarms Bit4 Ch1 HF 40072 Zone 3 To Ch3 Ch4 Alarms Bit5 Bit N A 40073 Zone 4 To Ch1 Ch2 Alarms Bit Ch2 LF 40074 Zone 4 To Ch3 Ch4 Alarms Bit9 Ch 2 A1 40075 Zone 5 To Ch1 Ch2 Alarms 40076 Zone 5 Ch3 Ch4 Alarms E 40075 Zone 6 To Ch1 Ch2 Alarms r It 40076 Zone 6 To Ch3 Ch4 Alarms 1 gt Selected 0 Not Selected 40077 Zone 1 Voting Number Value Range 40078 Zone 2 Voting Number 1 20 40079 Zone 3 Voting Number 40080 Zone 4 Voting Number 40081 Zone 5 Voting Number 40082
55. elay blocks The basic Controller operation is best understood by becoming familiar with the workings of the Zone Block Zone Blocks are essentially the core of the Controllers input to output logic functionality All six Zone Blocks may be configured to share the same alarm set point signals and relays Each configured and enabled Zone Block will be simultaneously operational creating relay events based on alarm set point status included relays and vote count Page 11 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 2 6 2 Adding Input Alarm set points to a Zone Block Refer to Zone Functional Diagram in appendix A A Zone Block groups together alarm set point signals and maps them to selected relays A Zone Block input can be any or all of the alarm set point signals from any all input channel a max total of 20 set points A set point can be configured to be included or not included in a Zone Block s input Included alarm set point signals are effectively OR ed together such that any active set point may potentially operate a relay Note set point even if active is ignored if it is not included in a Zone Block input 263 Adding Relays to Zone Blocks Refer to Relay Functional Diagram in appendix A Any or all of the four relays may be included in a Zone Block s output Including a relay into a Zone Block output maps it to the selected alarm set points at the Zone Block s input A relay ma
56. emoved 30007 Channel 3 Analogue Input 30008 Channel 4 Analogue Input 30009 Channel 1 Display Format Value Possible Values are 1 10 100 1000 30010 Channel 2 Display Format Value Same as for Channel 1 30011 Channel 3 Display Format Value Same as for Channel 1 30012 Channel 4 Display Format Value Same as for Channel 1 30013 Supply Voltage Register Voltage in millivolts Example 11058 11 058 11 058V Available Modbus function code is 0x04 Read Input Registers Page 41 AMPCONTROL 10 1 4 Memory Type 4 GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 Modbus Address Description Data Format 40001 Channel 1 Set point LF Normalize Values 40002 Channel 1 Set point A1 4mA gt 4000 40003 Channel 1 Set point A2 20mA 20000 40004 Channel 1 Set point A3 40005 Channel 2 Set point HF 40006 Channel 2 Set point LF 40007 Channel 2 Set point A1 Normalize Values 40008 Channel 2 Set point A2 4mA gt 4000 40009 Channel 2 Set point A3 20mA 20000 40010 Channel 2 Set point HF 40011 Channel 3 Set point LF 40012 Channel 3 Set point A1 40013 Channel 3 Set point A2 40014 Channel 3 Set point A3 40015 Channel 3 Set point HF 40016 Channel 4 Set point LF 40017 Channel 4 Set point A1 40018 Channel 4 Set point A2 40019 Channel 4 Set point A3 40020 Channel 4 Set point HF 40021 Channel
57. er Select 10 Volts from the 10 16 Volt variable power supply connected across the power contacts Press the key to save the calibration at 10 Volts To escape use the lt key 16 Volt Supply Voltage Calibration In Supply Voltage Calibration hold the A key down for 5 seconds Select 16 Volts from the 10 16 Volt variable power supply connected across the power contacts Press the gt key to save the calibration at 16 Volts To escape use the lt key The following instructions 4 7 6 and 4 7 7 apply to all 3 outputs 4 7 6 4 7 7 Output 1 Zero Calibration To modify Output 1 Calibration press the gt key to enter Connect a calibrated multi meter set to mA across output 1 contacts The multi meter should read 4 mA if it does not use the A key to increase the signal or the V key to decrease the signal Once the signal is reading 4 mA press the gt key to save the calibration To escape use the lt key Output 1 Span Calibration In Output 1 Calibration hold the A key for 5 seconds With the multi meter still connected the reading should be 20 mA if not use the A key to increase the signal or the V key to decrease the signal Once the signal is reading 20 mA press the gt key to save the calibration To escape use the lt key Page 31 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 5 Controller Installation 5 1 Ensuring Safe Installation The Controller req
58. ers Each of the four input channels may be configured to match the characteristics of the equipment connected to it Note In all cases the input signal type is fixed during manufacture to either Current input This input will normally operate over the range 4 20mA Fault levels lie outside this range e Voltage input This input will normally operate over the range 0 4 2V Fault levels lie outside this range A channel may be set to operate according to the following Channel Activity A channel may be set to be active or non active Inactive channels provide no process signals or alarm outputs to functions further downstream e Anon active channel is displayed as OFF e An active channel is displayed as ON Gas Name A channel may be identified by selection of one of six standard types or a user specified type namely CH4 methane carbon monoxide e 02 oxygen e H2S hydrogen sulphide Air Velocity DP Differential Pressure e User 7 character name may be input Page 15 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 Decimal Point Each Input channel may have its display reading configured to correctly indicate the process value The available settings for decimal places are nnnn e g 2500 e nnn e g 250 e e g 25 0 e e g 2 50 Full Scale Reading Input process signals to the controller are typically in th
59. escape use the lt key Bone 4 5 7 Set Output to Channel 4 To modify CH4 press the gt key to enter Use the A key toggle between IN and NOT IN To save use the gt key To escape use the lt key ONS 4 6 System Configuration Menu 1 in the Configuration Main Menu scroll down using V key to position 18 System Configuration 2 Press gt key to enter into sub menu 4 6 1 Configuration Version This level is read only and displays the Configuration Version set at manufacturing 4 6 2 Modbus Address To modify Modbus Addr press the gt key to enter Use the A key to increment the address from 1 to 32 To save use the gt key To escape use the lt key eO N 4 6 3 Set Baud Rate To modify Baud Rate press the D gt key to enter Use the A key to toggle between 2400 4800 9600 and 19 2k To save use the gt key To escape use the lt key 2 En 4 6 4 Set Parity To modify Parity press the gt key to enter Use the A key to toggle between ODD EVEN and NONE To save use the gt key To escape use the lt key gt N c 4 6 5 Set Start Up Delay To modify S DLY sec press the gt key to enter Use the A key to scroll through the numbers Use the V key to move cursor across to the next digit To save use the gt key To escape use the lt key ar N gt Page 29 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 0
60. ettings 2 e Measure the relay contacts with a continuity meter are the appropriate contacts in the correct state per the configuration settings Measure the current follower outputs are the outputs correct per the configuration settings e Increase the input signal and continue the same checks as above as the signal passes through each configured alarm trip points e Check for correct operation of any configured alarm delays e Check that latched alarms remain when the input is reduced below the alarm trigger point e Ensure that when powered down and back up again the latched alarm states are re instated e Ensure that following an alarm reset from the front panel if this is enabled in the controller configuration all alarms clear and relays reset to non alarm state input signal set below all alarm set points e Ensure that following an alarm reset from the remote reset input all alarms clear and relays reset to non alarm state input signal set below all alarm set points e Check that any digital communications to other devices is working correctly check Modbus settings and operation When all Controller operations have been checked and verified as working the test record should be signed off and stored in a secure place for future reference Page 36 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 7 Service Maintenance Disposal 7 1 Equipment Service The Controller require
61. f the inputs are 0 4 2 0V types 1 in the Configuration Main Menu scroll down using V key to position 15 Output Configuration 2 Press key to enter into sub menu 4 5 1 Set Output Status To modify Status press the key to enter Use the A key to toggle between ON and OFF To save use the gt key To escape use the lt key Boo UNS e 4 5 2 SetOutput Tag Name To modify Output press the D gt key to enter Use the key to scroll through the alpha numerals Use the V key to move cursor across to the next digit To save use the gt key To escape use the lt key DF gt 4 5 3 Set Output Type To modify Type press the D gt key to enter Use the A key to toggle between FOLLOW HIGHEST and LOWEST To save use the gt key To escape use the lt key m 4 5 4 Set Output to Channel 1 To modify CH1 press the key to enter Use the key toggle between IN and NOT IN To save use the gt key To escape use the lt key T ouo O 4 5 5 Set Output to Channel 2 To modify CH2 press the D gt key to enter Use the key toggle between IN and NOT IN To save use the gt key To escape use the lt key fece Page 28 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 4 5 6 Set Output to Channel 3 To modify CH3 press the key to enter Use the A key toggle between IN and NOT IN To save use the gt key To
62. f this Manual for details Input channels may be supplied to operate with a 4 20mA current input signal or a 0 4 2 0V voltage input signal This configuration is fixed by the manufacturer and is not user modifiable Each input channel is independent of the others and can be configured on a per channel basis allowing flexible system configuration 2 5 2 Input channels are user configurable and may be e Set to be ON or OFF e Given a name to represent its function Selected to display one of a number of gas types e Configured to display one of a number of measurement units e Configured to display from none to two decimal places e Scaled to a user defined maximum value ranging from zero 9999 Each input channel has three programmable set points which can be set to trip based on the signal input level 2 5 3 Each set point may be e Setto operate at a specific channel input level e Set to operate with hysteresis Set to operate in a particular direction rising signal or falling signal e Operate immediately or after a user configured delay Set to latch an alarm indication or auto reset In addition to the input based set points there are two fault set points These set points are referred to as High Fault and Low Fault 2 5 4 High and Low Fault set points may be e Set to operate at a specific channel input level e Set to operate on a rising or falling input signal The controller h
63. he Controller must be powered from an Intrinsically Safe power supply with a maximum output of 16 5V The Controller is designed to operate with a minimum supply voltage of 12V dc A two line Liquid Crystal Display LCD combined with a keypad provides an intuitive user interface providing easy access and rapid adjustment to all controller settings CAUTION The user is responsible for maintaining the Ex ia Intrinsic Safety rating by complying with A the List of Special Conditions outlined in the certificate Appendix C Approvals 2 6 Understanding Gasguard Controller Functionality The Controller s operation can be modified via changes to its configuration settings Configuration changes must therefore be carried out with an understanding of the Controller s functional specifications its limitations and the effect that configuration changes may have on the system into which it is installed Refer to the Controller functional diagrams in Appendix A of this manual These diagrams show level block diagram showing connectivity of each Controller section e Input Channel block showing signal path and user configurable settings e Zone block showing alarm routing and user configurable settings e Relay block showing trigger sources and user configurable settings 2 6 1 Controller Layout With reference to the top level block diagram the controller is arranged as four input blocks six zone blocks and four r
64. its pos neg value 0 to value scaled by decimal place setting LF alarm direction Falling Rising e HF alarm direction Falling Rising Alalarm direction Falling Rising e A2alarm direction Falling Rising e A3alarm direction Falling Rising LF alarm latching mode mask bit Latch YES non latch NO e HF alarm latching mode mask bit Latch YES non latch NO e 1 alarm latching mode mask bit Latch YES non latch NO e A2alarm latching mode mask bit Latch YES non latch NO e A3alarm latching mode mask bit Latch YES non latch NO e Alarm Delay in mS 0 to 9999 Sets time delay from process input matching set threshold to alarm signal becoming active Operates on any all 5 channel alarms and is not configurable per individual alarm Within each channel an alarm threshold cannot be set that exceeds the full scale for that channel The controller scales all set point values according to the full scale setting For example a channel with a full scale reading initially set to 1000 and set point configured to 500 the set point is 50 of the scale value If the channel full scale value is now changed to 2000 the Controller will automatically rescale the trip point to 1000 This maintains the trip point at the same proportion of full scale 5096 in this example Page 17 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 When setting alarm set point thresholds it
65. ld lead to a dangerously installed system 5 3 1 Entity Parameters When connecting the Controller to other equipment it is important that the specified parameters that apply to each Controller terminal are known and understood It is also important to know and understand these parameters in relation to connected equipment and cables These parameters are given on the equipment s certificate of compliance and set the maximum limits beyond which the equipment is no longer safe to use within its hazardous area certification These specified limits known as entity parameters inform and restrict quantities such as voltages currents capacitance and inductance in relation to the terminals that will be used to connect to other equipment Inputs will have maximum allowable voltages and currents that may be applied to them along with maximum values of capacitance and inductance that appear at these terminals resulting from internal circuitry Typical input parameters would be Ui Maximum voltage that can be applied to an input terminal li Maximum current that can be supplied to an input terminal Ci Li Maximum capacitance inductance that appears at an input terminal Output terminals will have maximum values of voltages and currents available from them specified under worst case conditions Outputs also carry limitations regarding the maximum capacitance and inductance that they can connect to whilst maintaining safe operation Output terminal
66. le set points across multiple channels vote set points Assume set points and relay inclusions not shown to be set as NOT IN RELAY 1 Status Zn1 IN Allocate Relay 1 to Zone Block 1 ZONE 1 Status Chi A1 include Chan 1 A1 set point Ch2 A1 include Chan 2 A1 set point Ch4 include Chan 4 A3 set point Voting 3 Relay 1 will become active when Ch1 A1 is active AND CH2 A1 is active AND Ch4 A3 is active Example 3 Inclusion of multiple set points across multiple channels vote 1 Assume set points and relay inclusions not shown to be set as NOT IN RELAY 1 Status Zn1 IN Allocate Relay 1 to Zone Block 1 ZONE 1 Status ON Ch1 A1 IN include Chan 1 A1 set point Ch2 A1 include Chan 2 A1 set point Ch4 include Chan 4 A3 set point Voting 1 Relay 1 will become active when Ch1 A1 is active OR CH2 A1 is active OR Ch4 A3 is active Page 13 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 Example 4 Inclusion of a relay across two Zone Blocks Vote counts set to allow basic alarm logic decoding Assume set points and relay inclusions not shown to be set as NOT IN RELAY 1 Status ON Zn1 IN Allocate Relay 1 to Zone Block 1 Zn2 IN Also allocate Relay 1 to Zone Block 2 ZONE 1 Status Ch1 A1 IN include Chan 1 A1 set point Ch2 A1 include Chan 2 A1
67. ller showing any visible signs of damage must not be used Sensors and Power Supply connected to the Gasguard controller must comply with the requirement of I S configuration Cleaning the controller may create an electrostatic hazard Anti static cleaning media must be used 24 Conditions of Conformity Ex ia WARNING To comply with the Conditions of Certification ensure full serviceable life of the product and avoid nullifying the warranty it is essential to exercise great care with the installation use and storage of the System components Failure to comply with the Conditions of Certification Appendix C Approvals may seriously compromise the integrity of the system and or its components and the consequence could be fatal The user must ensure that the Conditions of Safe Use outlined in the certificate are met or the certificate and the IS rating will not be valid Page 9 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 2 5 Overview of the Gasguard Controller 2 5 1 Basic Description The Gasguard Programmable Intrinsically Safe controller Controller produced by Ampcontrol is designed to operate with a variety of hazardous area certified gas detectors Compatible detectors are presently supplied by Ampcontrol and other manufacturers The Controller is supplied with either two or four programmable input channels see Parts List in Section 8 o
68. ment that collectively form the means to minimise the risk of injury or death to personnel The selection installation commissioning and use of this protective device should only be undertaken following the application of a detailed risk assessment that is consistent with the methodology outlined in AS NZS ISO 31000 risk management Additionally identified risk control measures identified within the risk assessment additional to safety controls and or directions contained within the products operating manual must be validated as effective before use of the product in any capacity The Gasguard controller is NOT designed to be used as the sole means of ensuring safety to personnel or equipment The Gasguard controller does NOT have an associated Safe Failure Fraction SFF The Gasguard controller is NOT certified for use in Group hazardous area applications The Gasguard controller is NOT to be considered as a PLC since the device does not support full logic decoding of input alarm conditions and output relay actions The Gasguard controller is NOT water resistant and must be mounted within a suitably IP rated enclosure for use where the overall system is to be rated water resistant The Gasguard controller is NOT on site repairable and contains no user serviceable parts The Gasguard controller must NOT be modified in any way A controller that differs in any way from its as certified condition must not be used A Gasguard contro
69. mum range to channel zero if necessary U 4 0 0 00 0 02 0 02 Channel Delay 1s Delay E Apply maximum to channel adjust span if required al 20 0mA 5 00 4 95 5 05 Programmed Test Values p Relays Setpoint Engineering Value V Action iMAC 1 2 3 4 Operation Low Fault 2mA 2 0mA Falling Latching Fault LED amp Programmed Values 1 98 2 02 L L U L LU ILI ILI ID Verified on Test Alarm 1 1 0096 7 2mA Rising Non Latching Alarm LED U bd L Programmed Values 7 13 7 27 L UO L L ILI ILI ID Verified on Test Alarm 2 1 5096 8 8mA Rising Non Latching Alarm LED L O IL IL Programmed Values 8 71 8 89 L O L O L ILI IL Verified on Test Alarm 3 2 00 10 4mA Rising Latching Alarm LED L Dd IL D Programmed Values 10 3 10 5 L s m O O L ILI IL Verified on Test High Fault 22mA 22mA Rising Latching Fault LED x amp Programmed Values 21 8 22 2 UO m L L ILI ILI ID Verified on Test Page 57 GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 7502 AMPCONTROL Channel 4 Gas CH4 Range 5 viv Verified mA V Engineering Value Sensor Input Type 4 20mA L Apply minimum range to channel zero if necessary O 4 0 0 00 0 02 0 02 Channel Delay 1s Delay L Apply maximum to channel adjust span if requir
70. n IP54 in accordance with IEC 60529 Connections for programming purposes shall be effected in a non hazardous area only Page 78
71. n and maintenance of the equipment reference this manual in conjunction with information contained within any risk assessments conducted to identify risks and hazards 2 1 2 Safety Communication All safety instructions and design requirements within this manual must be communicated to all users These requirements are necessary to identify and control any foreseeable risk associated with this piece of equipment In the event of any damage or malfunction that results in the potential to harm the health or safety of any person the owner operator should notify the manufacturer immediately 2 2 Safe Use of Equipment This equipment has been manufactured in accordance with quality standard 00005 to ensure compliance to its certificate of conformity If there are any signs of modification or damage to this equipment it must not be used until it has been repaired and deemed fit for purpose by the equipments manufacturer or by an AS3800 accredited workshop The instructions within this manual must be implemented as an aid towards achieving safe operation 2 2 1 Intended Use of the Equipment The Gasguard Programmable Intrinsically Safe Controller is designed to operate with a variety of Group hazardous area certified gas detectors and offer versatility of sensor management and data acquisition The controller is used to connect to a system that is responsible for activating ventilation and or alarm systems to reduce the probability of potentially ha
72. ned in the certificate Appendix C Approvals Page 32 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 5 2 Mounting the Controller 5 2 1 IP rating and Physical Protection The Controller enclosure is not rated to provide either dust or water ingress protection To ensure that the Controller is not subjected to conditions that could cause dust or moisture to enter the enclosure it must be mounted inside a suitable IP rated wall mounted enclosure Although the Controller housing is made from tough ABS it will not provide protection against impact from heavy objects Damage to the enclosure and internal electronics could cause malfunction rendering the controller unsafe Mounting the Controller in a robust lockable enclosure will minimise the chance of physical damage 5 2 2 Ease of Access Mounting the Controller within an enclosure should be done in such a way as to allow full access to the connection terminals display and buttons Positioning of the Controller should also be such to allow easy removal of the unit for repair The Controller should also be clearly visible to allow inspections to be carried out without having to remove parts of the installation visual inspections 5 3 Connecting to the Controller Wiring of the controller and systems must be carried out with reference to standards appropriate for the application industry and or locale Failure to comply with standards cou
73. nfigured to drive an NE relay power is removed from the coil and the contacts change state The Common relay terminal will now be connected to the NC terminal as marked on the terminal label The changing state of the contact signals an alarm condition If the Controller is operating with no active alarm conditions all relays set to NE will be powered If during this condition power is removed from the Controller there will be a change of state of any of the relay contacts since the coils are no longer being supplied with power Relays set to NE are therefore able to signal a fault condition due to power loss 2 94 Alarm Set Point Delays Under some conditions it may be desirable to trigger a set point only if an alarm condition has existed greater than a certain period of time This allows transient conditions to occur without triggering an alarm event The Controller allows a delay to be set from 0 9999mS 9 999 seconds The delay is common to all 5 trip points within a channel but each channel may have a different delay When setting alarm set point delays it is important to ensure that the time set before a relay is triggered does not create a hazardous situation Delays must set based an understanding of their effect on the system into which the controller is fitted Page 19 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 2 9 5 Alarm Set Point Hysteresis
74. nnel from a zero input signal all the way up to and beyond the channel s full scale value During the time each channel is driven observations checks and measurements must be made of alarm points relays current repeater outputs and display values A record of Controller test results should be recorded on the test form A channel may be driven either by its connected sensor or by a device that simulates the signal from that sensor If the sensor itself is used then some means of stimulating it will be needed In the case of a gas detector this would be a cylinder of calibration gas For other sensor types such as pressure temperature flow and humidity it may be difficult to create the conditions required to drive the connected controller channel over the required range to allow proper testing It is more convenient to simulate the output of a sensor using a device such as a loop calibrator simulator This device signal simulator provides accurately adjustable levels of voltage or current that can be injected into the Controller s input channels Assuming a signal simulator is used to provide channel input signals a typical test sequence would be e Connect the signal simulator to the input channel to be tested Set the simulator to provide zero input signal OV or OmA Observe the display value for that channel is it reading correctly 2 Observe the alarm and Fault LEDs are they correctly illuminated for the given configuration s
75. nt No GSB010 a copy of this form is located in appendix A Test forms for individual applications will contain aspects of the system that must be checked part of which will be the Controller 6 1 Completing a Controller Test Form Common Header Information The specifics of a test form will vary but recording the following information should be considered standard across all applications Job number related to the commissioning Customer Name Location of the controller site address and location on the site system type e g continuous miner etc Product Type Version of Controller also included Serial Number Name of person carrying out the commissioning Date References to site specific restrictions and applicable standards 6 2 Running through a Controller Commissioning Refer to the example test sheet in appendix A The actual setting that the controller must have will have been defined at either the system design phase or between the time of the Controller installation and the first power up commissioning phase Although shipped with a set of default values each individual application will requires adjustments to the configuration settings If configuration is to be carried out with the Controller in situ it may be beneficial to disconnect all relay connections and current follower connections to prevent unwanted system interactions 6 2 1 From first power up the following operations can be checked immediately
76. ntroller is being installed has been properly defined approved and designed Any system intended to mitigate the risk of injury needs to be properly designed and implemented Such a system must be the result of structured risk analysis with the outcomes used to define the system requirements These requirements in turn will guide the choice of instrumentation logic solvers and actuators needed to implement the system Understanding the needs of the system will ensure proper selection of equipment 5 14 Ensure that the Controller will properly perform the required functions within the system design It is important to understand how the Controller is intended to interact with other equipment within a System For safe and reliable use it is crucial that neither the Controller s logical operation nor its signalling be compromised by incompatibilities with connected equipment 5 1 5 Ensure that the intended devices to be connected to the Controller are compatible with the entity parameters as specified on the Controller s certificate of compliance conditions of safe use Check the terminal parameters of all devices intended to be connected to the Controller against the Controllers certificate of conformance If in doubt consult a competent authority or contact an Ampcontrol applications engineer CAUTION The user is responsible for maintaining the Ex ia Intrinsic Safety rating by complying with A the List of Special Conditions outli
77. o save use the gt key To escape use the lt key Set Tag Name Enables customer to assign a name to the controller for identification purposes 1 P ba To modify Tag press D gt to enter Use the A key to scroll through the alpha numerals Use the V key to move the cursor across to the next digit To save use the gt key To escape use the lt key Page 24 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 4 28 Setting Alarm or Fault Levels To set alarm or fault levels use the procedure for the Low High Fault Alarm following The same three steps can be carried out on all alarm faults by scrolling down the menu to the required area and inputting the correct information 4 29 Set Low High Fault Alarm Level To modify LF press gt to enter Use the key to scroll through the numbers Use the V key to move the cursor across to the next digit To save use the gt key To escape use the lt key EF wn gt 4 2 10 Set Low High Fault Alarm Direction To modify LF DIR press gt to enter Use the A key to toggle between Falling Rising To save use the gt key To escape use the lt key PONS 4 2 11 Set Low High Fault Alarm Latch 1 To modify LF Latch press to enter 2 Use the A key to toggle between YES and NO 3 save use the D gt key 4 To escape use the lt key 4 2 12 Set Alarm Delay 1 To modify ALM DLY press to enter
78. onfigured by the user During the self test and start up delay periods the relays are held in an alarm condition The state of each relay is set based on the user configuration for the relay operation A normally energised relay non alarm state will sit in the de energised state during the power up delay period A normally de energised relay non alarm state will sit in the energised state during the power up delay period This start up behaviour is not user configurable except for the length of the start up delay Once the delay period has expired the condition of the relays will depend upon how the relay start up mode has been defined in the Controller relay configuration Each relay may independently be set to one of two start up modes namely 1 LIVE and 2 LATCHED In Latched mode a relay will remain latched in the alarm state after the start up delay has expired To clear this latched condition a left key reset or a remote reset is required For relays set to LIVE mode the relays will assume operation according to the state of the input channel signals and alarm settings once the start up delay has expired Page 18 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 2 9 2 Normally De Energised Relays A relay set to be ND will under normal non alarm conditions have no power applied to its coil With no power applied to the coil the Common relay terminal will be connected to the N
79. resis adjustable 0 20 of channel scale 2 programmable fault set points per channel No hysteresis Alarm Reset Volt Free switch or relay contact input Front panel left key press and hold Selectable in configuration settings to be enabled or disabled Communications RS485 Modbus RTU Slave only LED Indication There are seven 7 Status LED s located on the facia Power LED Red Alarm LED Red Fault LED Red Four Relay state Indication LED s Red Dimensions mm Overall 75H x 100W x 1100 Page 39 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 10 Data Communication Specification Communication Port RS485 Protocol Standard Modbus Protocol RTU Mode Baud rate 2400 4800 9600 19200 bps Parity Even Odd None Data bits 8 Modbus Slave Address 1 32 10 1 Modbus Memory Map Part 1 10 1 1 Memory Type 0 Modbus Address Description Data Format 00001 Relay 1 Status 1 gt Relay is Active 00002 Relay 2 Status 0 gt Relay is Normal 00003 Relay 3 Status 00004 Relay 4 Status Available Modbus Function code is 0x01 Read Coil Status 10 1 2 Memory Type 1 Modbus Address Description Data Format 10001 Channel 1 Low Fault 1 gt Fault Alarm State 10002 Channel 1 Alarm 1 0 gt Normal 10003 Channel 1 Alarm 2 10004 Chann
80. rm can be reset by holding the lt key down for 5 seconds or by activating the remote reset button The alarm and relay LEDs turn off and the current gas level is displayed no alarm flashing 3 3 3 Inthe event of a Fault indication Once the source of the fault has been identified and celared proceed in the same way as for an alarm condition Page 22 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 4 Programming 4 1 Programming Overview All operating functions of the Gasguard System can be programmed through the keypad on the controller by entering into the Configuration Menu Note that some keys have more than one function 4 1 1 Key Pad Functions in Modify Menu using the A key in the modify menu the operator can scroll the alpha numerals or pre set values using the V key in the modify menu the operator can move the cursor across to the next digit using the gt key in the modify menu the operator can save the new settings using the lt key in the modify menu the operator can escape out of the modify zone and not save the new settings 4 1 2 enter the Configuration Menu From the Monitoring Screen press the A key to scroll up to level 7 Configuration View and Modify Menu Press the gt key to enter into the Do you want to continue screen If YES press the gt key to gain access if NO press the lt key to exit On the Enter Password
81. rmful situations The Gasguard Controller is specifically intended for Group mining applications 2 2 2 Changes to Equipment Changes in the design and modifications to the equipment are not permitted Unauthorised changes made to the Controller hardware or operating firmware will void the manufacturer s warranty and may compromise the conditions of certification the integrity of the system into which it is installed and other connected equipment 22 3 Equipment Knowledge Experience with or understanding of this equipment is essential for the safe installation and removal of the equipment If in doubt contact Ampcontrol Mechanical and or Electrical installation and maintenance of plant and equipment must only be carried out by appropriately trained qualified technical personnel Page 8 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 2 3 Operational Restrictions and Limitations The operational restrictions listed below must be understood before considering using the Gasguard controller within systems designed to ensure the safety of personnel Using the Controller in a manner that exceeds its electrical functional or physical specifications or in a way that is contrary to its operating restrictions may create risks to personnel and or equipment resulting in injury or death The Gasguard Controller is designed to operate as part of a Safety Instrumented System alongside other equip
82. rtus ee 4 9 6 Set Zone 1 to Channel 1 Alarm aS 4 3 7 Set Zone 1 to Channel 1 High Fault Alarm sees tenente ntes 4 3 8 Set Voting Configuration IER 44 Relay Configuration Menu Nos TL AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 4 4 1 Set Relay SIUS aote tia ona a 27 4 4 2 Set Relay EU 27 443 Set Tag halal 27 444 Set Relay E 27 445 Set Relay Start Up Mode 28 45 Output Configuration Menu Nos 28 4 5 1 Set Output Status EE 28 4 5 2 Set Output Tag Name let note ole tal Ee eege 28 4 5 3 Set st nieto ta ha in dO CUL 28 4 54 Set Output to Channel lu ette oer n blo ot nen Rn 28 4 5 5 Set Output to Channel cu 28 4 5 6 Set Output to Channel E 29 4 5 7 Set Qutp t to eelere 29 4 6 System Configuration Menu No 18 ssssssseseseseee NEEN 29 4 6 1 Configuration Versiofi p diet ed een nd die diua 29 4 6 2 lk elek 29 4 6 9 Sor Bald 29 4 6 4 M 29 4 6 5 Set Stait a 29 4 6 6 Set Tat M LU
83. s may also specify the level of capacitance and inductance that appears on them as a result of internal circuitry Typical output parameters would be Uo Maximum voltage available from a terminal under worst case conditions lo Maximum current available from a terminal under worst case conditions Co Lo Total capacitance inductance that can be safely connected to a terminal Capacitance is found in connecting cables and the inputs of other equipment When connecting equipment together the total values of all capacitances and inductances must be taken into account and must not exceed the values specified for that connection or system total For example if a gas detector s output terminal has 1nF of capacitance associated with it and can connect safely to a maximum capacitance of 10nF any equipment and cable that is to be connected to the gas detector must have a total capacitance of no more than 9nF Page 33 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 5 3 2 of Cable Cables that are used to connect the Controller to other parts of a system or other equipment must be adequately rated in terms of maximum voltages and current that it can handle safely Cable electrical resistance capacitance and inductance must also be taken into account in order to maintain compliance with equipment system entity parameters see previous section Cables will have resistance capacitance and inductance parameters
84. s no internal servicing during its normal operating lifetime A number of external system based checks should however be made on a regular basis These routine inspections must be carried out by suitably trained people with knowledge of the Controller and the systems into which it is fitted Routine inspections may take the form of either simple visual only checks or visual and hands on checks 7 4 1 Visual Only Inspections A basic visual inspection will focus on looking at the installation for signs of physical damage water or dust ingress as well as the condition of cables and labels This type of inspection may involve opening cabinets to gain access to the Controller and other equipment This level of inspection may also include cleaning display windows that have become obscured by dirt static cleaning materials Do not clean the Controller with any cleaning products that may 1 NOTE The Controller s enclosure and display window must only be cleaned using anti cause the build up of static charge Observations would typically be e Check that equipment enclosures cable trays conduits wall boxes etc are in good order with no physical damage e Check that sealed wall boxes are free from water and dust ingress internally Door seals are in good condition e Check that connected cables are free from cuts abrasions and obvious signs of damage Cable restraints are in good order and correctly fitted e Check that labels on eq
85. screen use the A key to scroll through the numbers Then use the V key to move the cursor to the next digit d ON gt Once the password has been entered press the gt key to access the Calibration Menu e password is factory set at 9990 This can be changed in Configuration Menu shown on page 18 of this manual 4 2 Channel Configuration Menu To view and modify the Channel Configuration settings use the following procedure This procedure applies to the configuration of all four channels 1 When Channel 1 Configuration Menu is displayed press the D gt key to enter the menu There are 23 levels under each channel 22 of them can be modified to suit the user s requirements By using the A or V keys the programmer can scroll through the menu By using the gt key the programmer can enter into the displayed menu or save the new settings d co Using the lt key will allow the programmer to escape out of the modify zone 421 Input Type The first level is read only and displays the Input Type which is set by the manufacture For example 4 20 mA or 0 4 2 0 V inputs 422 Set Input Status Enables Channels to be selected ON or OFF 1 To modify Status press the gt key to enter 2 Usethe A key to toggle between ON and OFF i e Channel ON or OFF 3 To save use the key 4 To escape use the lt key Page 23 AMPCONTROL 4 2 3 GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 C
86. se the parts should be packaged and stored in a safe place Examine all packing boxes wrappings and covers for items attached to them especially if the wrappings are to be discarded 1 2 Storage after Delivery Where equipment is not to be installed immediately proper storage is important to ensure protection of equipment and validity of warranty All equipment should be stored indoors protected from the elements in a cool dry area If storing on the ground ensure that the storage area is not an area where water will collect 1 3 Unpacking of Equipment The method of packing used will depend on the size and quantity of the equipment Take care when unpacking the Controller to avoid damaging its enclosure or display window The disposal of packaging materials replaced parts or components must comply with environmental restrictions without polluting the soil air or water Ensure that any timber and cardboard used as packaging is disposed of in a safe and environmentally responsible manner Where possible dispose of all waste products i e oils metals plastic and rubber products by using an approved recycling service centre ENVIRONMENTAL ALERT Page 7 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 2 General Safety STOP 2 1 Personnel Safety Warnings 2 4 1 Relevant Personnel Ensure all personnel directly responsible or involved with the installation operatio
87. set point Voting 2 ZONE 2 Status ON Ch3 A2 IN include Chan 3 A2 set point Voting 1 Relay 1 will become active when Ch1 A1 is active AND CH2 A1 is active OR Ch3 A2 is active Page 14 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 2 6 6 Zone Block Configuration Warnings The following points must be observed to ensure that the Controller can predictably signal an alarm A state via its relays Failure to observe these points and select appropriate settings may result in alarm indication failure e Do NOT set a Zone Block Vote Count to a value greater than the number of included alarms For example if a Vote Count of 3 is set but there are only 2 included set points the included relay will not become active even if both set points are active e Ensure that the vote count setting is such as to provide the desired logic in relation to active set points and relay operation see examples 2 and 3 above Ensure that a required relay is included in a Zone Block s setting Make sure that all relays included in a Zone Block are set to ON Make sure that the Zone Block being configured for use is set to ON Multiple Zone Blocks may be configured each sharing the same set point signals and relays It is important to ensure that the use of multiple Zone Blocks with possibly different settings does not create conflict in triggering relay events 2 7 Setting Input channel Paramet
88. sorders ampcontrolgroup com WEB www ampcontrolgroup com Page 2 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 Table of Contents Receiving and ee 7 1 4 C s oL 7 1 2 storage aller D elieby nto on n ae Nn toa qasa 7 13 Unpacking of e EE 7 General Safeta o p 8 2 1 Personnel Safety Warnings ee eai rto i te s eda i at unda tuetur Ed 8 2 1 1 Relevant Pers nnel M aaa haya 8 2 1 2 Safety a a a 8 22 Sale Use of EE 8 2 2 1 Intended Use of the Thren Ee ho A TER 8 2 22 Changes Te Equipment SS ue anc ecran 8 2 2 3 Equipment Knowledge seen tette nnne tnnt tenent 8 2 9 Operational Restrictions and Limitations l a eee eA EAR een can ene 9 2 4 Conditions f Conformity EX lesinn cue oni Ee ee 9 25 Overview of the Gasguard Gomtrollen 10 2 5 1 Basie De 10 2 5 2 Input channels are configurable 5 5 tree tr Seed 10 2 5 3 Set Elle 10 2 54 High and Low Fault set points secs doit pete SO RM 10 2 5 5 Possible relays SCUINOS s at DIM DEM 10 2 5 6 Zone EENS 11 2 5 7 Analog
89. ss an entire system Unmarked conductors are generally hard to have their function identified across the physical parts of a system This could lead to potentially dangerous system operation due to mis matched connections between equipment as well as obvious system malfunction 5 3 5 Cable Restraint All connected cables that run from the Controller to other equipment must be suitable restrained to prevent stress on the controller terminals If cables are allowed to freely hang and pull against a terminals fixing screw then eventually the connection could fail Such unrestrained connections could create the potential of system malfunction resulting in the creation of a hazardous risk situation Proper cable restraint will ensure that the potential risk of system failures due to cable breakages is minimised Page 34 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 6 Controller Commissioning Before being placed into service the controller must be commissioned in order to validate its installation The checking of any complete system that the Controller may be installed into is beyond the scope of this manual Such system wide checks must be carried out in accordance with relevant site standards and must include an instruction or reference to a procedure for commissioning the Controller For any system supplied that involves a controller there will be a commissioning test form An example of such is Ampcontrol docume
90. stig eee SC EE 4 1 Programming et tom des 4 1 1 Key Pad Functions Modify MIU a ice bts dan ee amanda 4 12 To enter the Configuration teta Deena 4 2 Channel Configuration Menu Nos 1 4 nennen tnnt tnnt 4 2 1 Input VDO snn ta iet eere eb 4 2 2 Set Input Status soot sanat isti ione Ritt o so baise isnt e D odor an td 4 2 3 Set Gas 4 24 SI ae dec CPP 4 2 5 Set Pull Scale o E Rr ot do VR 4 2 6 Sel Units or MOdsUfe tete oio gd Lotta k ee uuu edet 4 2 7 SOWEIT 4 2 8 Setting alarm OF fault neiges ect laedit tussis ein ipsus 4 29 Set Low High Fault Alarm Level sotto Rire ee RR essi ded 4210 Set Low High Fault Alarm Direction 4241 Set Low High Fault Alarm eite dete eodd 4 2 12 ek ter 4 3 Zone Configuration Menu Nos BIO 4 3 1 Set Zone epee Ur 4 9 2 Set Zone Tag M CUM UCM 4 9 9 Set Zone 1 to Channel 1 Low Fault Alarm sss tenete tentent 4 34 Set Zone 1 to Channel 1 Alarm EE 4 3 5 Set Zone 1 to Channel 1 2 a
91. t AU AT AJQ RO06 0002 00 Page 74 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 IECEx Certificate of Conformity Certificate No IE CEx ITA 07 0003X Date of Issue 2007 05 29 Issue 0 Page 3 3 Schedule EQUIPMENT Equpment and systems covered by this certificate are as fotows The Gasquard Controller model 72 5501 is designed to provide a visual waming ofthe status of alarms The alarm signals are provided by external signals The apparatus comprises of four printed wiring boards upon which are mounted electronic components including a liquid crystal display which are enclosed in a plastic enclosure fitted with terminal blocks for the connection of external circuits Refer to attachment for Manufactuer s Drawings List and Special Condtions CONDITIONS OF CERTIFICATION YES as shown belove Refer to Attachment for list of Special Conditions Page 75 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 ATTACHMENT TO CERTIFICATE IECEx ITA 07 0003X Page 1 of 3 Manufacturer s Documents FUSE INTRINSICALLY SAFE GENERAL ARRANGEMENT LABEL 1 23 CONTROLLER TERMINALS MANUFACTURING DETAILS LABEL GASGUARD CONTROLLER OUTPUT BOARD MANUFACTURING DETAILS LABEL OVERLAY CONTROLLER ARTWORK amp MANUFACTURING DETAILS CONTROLLER 4 CHANNEL GENERAL LAYOUT amp CONNECTION DIAGRAM Controller Display Switch Top Overlay 24 6554L V2 V2 PCB Controller Display
92. tions required to reduce environmental risk ENVIRONMENTAL ALERT Applying This User Manual The contents of this user manual relate to the full range of Gasguard Sensor Controllers across a number of system firmware revisions The following list covers the differences between Controller versions and the features described by this Manual For all Controller types loaded with system firmware V2 7 09 2011 and above all of the functional descriptions covered in this Manual are applicable For all Controller types fitted with system firmware prior to V2 7 09 2011 the following functional descriptions do NOT apply since these functions are not present within the Controller i Relay start up behaviour section 2 9 1 ii Relay start up latch function and configuration sections 2 9 1 and 4 4 5 iii Enabling Disabling of alarm reset via the left navigation key section 2 8 Resetting Alarms iv Supply voltage measurment value available within the Modbus register set section 10 1 3 address 30013 v Memory check failure notification section 6 2 1 Page 1 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 Copyright Notice No part of this publication may be reproduced transmitted or transcribed into any language by any means without the express written permission of Ampcontrol CSM Pty Ltd 7 Billbrooke Close Cameron Park NSW 2285 Australia Disclaimer Ampcontrol CSM
93. ue OUIDUIS s ape PM ont ae ree du ee s 11 26 Understanding Gasguard Controller Eupen Redon ced 11 2 6 1 it 11 2 6 2 Adding Input Alarm set points to a Zone Block 12 2 6 3 Adding Relays to Zone Blocks al tet rdg t teta t t 12 2 64 Zoe VONA m ka Qs he qan donated hu Re 12 2 6 5 EENHEETEN 12 2 6 6 Zone Block Configuration Warnings l l tart a 15 21 Setting Input channel Parameters a Did b dus s 15 28 Setting Alarm EE EC 1f 2 9 Configuring Relay all E 18 2 9 1 Relay Start UP a t apupa hace p acd 19 2 9 2 Normally De Energised Relays aie ou but ene 19 2 9 9 Normally Energised RelayS o oc cou distet toda dieit 19 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 2 9 4 Alarm Ste 2 9 5 Alarm Set Point Hy ler sis eti 2 1 Key Pad Functions in Main eR sok EE Re eee ear oe 3 3 Controller LED and Display Operation AE 3 3 1 In the event of ENEE EE 3 3 2 In the event of an alarm in latched mode E 3 3 3 In the event of a fault indication er n nn y
94. uipment wall boxes and cables are present and in good clean condition especially certification labels e Check that no modifications have been carried out to installed equipment 7 1 2 Hand On Detailed Inspections A more detailed inspection would include all of the elements of a visual inspection plus some checks that cover the integrity of connections fixtures and fittings In addition to basic visual observations more detailed integrity checks would involve e Verify that equipment housings wall boxes and other mechanical fixtures are secured tightly in place This includes the lids of terminal boxes tightness of cable glands integrity of wall box mountings security of equipment fixing to walls DIN rails etc e Verify all electrical connections are secure with no loose screw terminals or DIN rail terminals not fitted to rails etc Page 37 AMPCONTROL GASGUARD IS CONTROLLER Issue R2 Date 26 09 2011 CRN 7502 7 2 Equipment Maintenance WARNING The Gasguard Controller has no user serviceable parts All repairs must be carried out by Ampcontrol personnel only If a fault develops return the Controller to Ampcontrol for repair It is essential that no attempt be made to repair the Controller as any attempt to dismantle or repair the Controller can seriously compromise the safety of the unit and the consequence can be fatal The Ampcontrol Gasguard Controller does not have any customer servicea
95. uires to be installed into a system along with appropriate devices providing input signals sensors and output control indication fan controls beacons sirens SCADA systems etc Before the Controller can be installed there are a number of things that need to be considered and understood to prevent incorrect or unsafe operation of the Controller or the system into which it is installed Along with relevant competence and an understanding of the target application the following points should be considered 5 1 1 Ensure that the information provided in sections 2 3 and 2 4 is fully understood It is extremely important that the limitations of the controller are understood to prevent incorrect installation and use from creating a potentially dangerous risk If in doubt as to the nature of the limitations or their implication consult a competent authority such as a supervisor or Ampcontrol applications engineer 5 1 2 Ensure that the information in sections 2 6 to 2 9 is understood Specific attention should be paid to the highlighted notes regarding incorrect Controller settings It is extremely important that the functionality of the controller is understood to prevent incorrect configuration creating a potentially dangerous risk If in doubt as to the nature of the limitations or their implication consult a competent authority such as a supervisor or Ampcontrol applications engineer 5 1 3 Ensure that the application into which the Co
96. y be included in any one or all of the six Zone Blocks simultaneously Note f there are no relays selected in any of the six Zone Blocks then the Controller will not indicate alarm states via the relays A relay may be set to be ON or OFF If a relay is set to OFF it cannot be activated irrespective of other settings within the relay configuration menu or via any conditions set within a Zone Block Relays may be set to be on off in or out of a Zone Block via the relay configuration menu 2 64 Zone Voting The Zone Voting function allows the operator to select the number of active included set points that are required to activate an included relay In total there are up to 20 alarm set points that can be included in a Zone Block s input and accordingly the vote number can be set from 1 to 20 Note The vote count value is important since it controls the logical behaviour of the included relay If a vote count of 1 is set then the set point signals are effectively OR ed together and any included set point will potentially activate the included relay If the vote count is set equal to the number of included set points then the logic effectively becomes an AND function Under this condition a relay will only be activated when the number of active set points is equal to or greater than the vote count Single set points becoming active or multiple active set points below the vote count will not activate an inclu

Gasguard Controller User Manual

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