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GDS C64 PROTECTOR Operation & Maintenance Manual

Display & alarm controller
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Operation & Maintenance Manual
MODEL C64
PROTECTOR
Display & Alarm
Controller
Firmware V2.0 & above
Warning: Read & understand contents of this manual prior to operation.
Failure to do so could result in serious injury or death.
GDS Corp.
2513 Hwy 646 Santa Fe, Texas 77510
Ph (409) 927-2980
Fax (409) 927-4180
info@gdscorp.com
www.gdscorp.com

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Summary of Contents for GDS C64 PROTECTOR

  • Page 1 Firmware V2.0 & above Warning: Read & understand contents of this manual prior to operation. Failure to do so could result in serious injury or death. GDS Corp. 2513 Hwy 646 Santa Fe, Texas 77510 Ph (409) 927-2980 Fax (409) 927-4180 info@gdscorp.com...
  • Page 2 Update Section 2, 3, 6 and add Revision History page © 2013 GDS Corp All Rights Reserved Specifications and features subject to change without notice. For more information contact GDS Corp at (409) 927-2980 or email us at info@gdscorp.com GDS Corp. 2513 Hwy 646 Santa Fe, Texas 77510...

  • Page 3: Table Of Contents

    SECTION 1 GENERAL DESCRIPTION ............. 2 IMPORTANT SAFETY ISSUES ................. 1 GENERAL DESCRIPTION................. 2 DATA DISPLAY SCREENS ................3 1.3.1 MAIN DATA SCREEN 1.3.2 24 HOUR TREND SCREEN 1.3.3 BAR GRAPHS SCREEN 1.3.4 COMBINATION SCREEN 1.3.5 ZONE SCREEN SPECIFICATIONS ..................... 9 1.4.1 DC POWER SUPPLY REQUIREMENTS 1.4.1.1...
  • Page 4 2.4.3 FAULT ALARM MENU 2.4.4 DATA FROM MENU TO SET INPUT SOURCE 2.4.4.1 SOURCE 2.4.4.2 MIN RAW & MAX RAW 2.4.4.3 FILTER SAMPLE COUNT 2.4.4.4 LOCAL CAL 2.4.4.5 MARKER MENU 2.4.4.6 REMOTE ID 2.4.4.7 ALIAS 2.4.4.8 INTERFACE 2.4.4.9 SLAVE BYTE ORDER 2.4.5 LINEARIZE 2.4.6...
  • Page 5 2.6.2 LOCK CODE 2.6.3 MODBUS LOCK CODE SYSTEM MENU ....................43 2.7.1 VERSION 2.7.2 CONFIGURE 2.7.2.1 NAME 2.7.2.2 CONTRAST 2.7.2.3 DATE & TIME 2.7.2.4 ENABLE CHANNEL COUNT 2.7.2.5 DISPLAY ALARM 2.7.2.6 WARMUP & CAL PURGE TIME 2.7.2.7 ZONE SCREEN ENABLED 2.7.2.8 BLOCK NEGATIVE 2.7.2.9...
  • Page 6 MODBUS TCP ....................71 MODBUS SLAVE WRITES ................71 MODBUS SLAVE REGISTER LOCATION ............71 5.3.1 COILS 5.3.2 DISCRETE INPUTS 5.3.3 INPUT REGISTERS 5.3.4 HOLDING REGISTERS 5.3.5 STANDARD RELAY 1 5.3.6 STANDARD RELAY 2 5.3.7 STANDARD RELAY 3 5.3.8 DISCRETE RELAYS 5.3.9 HORN/PIEZO 5.3.10 CHANNEL CONFIGURATION...
  • Page 7 8.5.4 PROGRAMMABLE RELAYS 8.5.5 SYSTEM CONFIGURATION 8.5.6 CONFIGURATION UPLOAD/DOWNLOAD SECTION 9 TROUBLESHOOTING ............... 120 CHANNEL ERRORS..................120 9.1.1 COMM ERROR 9.1.2 CONFIG ERROR 9.1.3 I/O ERROR RESET TO FACTORY DEFAULTS ............... 121 SECTION 10 NETWORK CONNECTION ............122 10.1 DIRECT CONNECTION WITH CROSSOVER CABLE OR HUB/SWITCH ..122 10.2 CONNECTING THE ST-72 TO AN EXISTING LAN ........
  • Page 8 C64 Controller Users Manual Revision 2.0a 1.1 SAFETY RECOMMENDATIONS The following symbols are used in this manual to alert the user of important instrument operating issues: This symbol is intended to alert the user to the presence of important operating and maintenance (servicing) instructions. This symbol is intended to alert the user to the presence of dangerous voltage within the instrument enclosure that may be sufficient magnitude to constitute a risk of electric shock.

  • Page 9: General Description

    Revision 2.0a 1.2 GENERAL DESCRIPTION The GDS Corp C64 Protector sixty-four channel controller is designed to display and control alarm event switching for up to 64 sensor data points. It may also be set as a 16, 32 or 48 channel controller for applications needing fewer inputs. Three programmable...

  • Page 10: Data Display Screens

    C64 Controller Users Manual Revision 2.0a Figure2-1 1.3 DATA DISPLAY SCREENS The C64 Controller offers five distinct graphic displays for depicting the monitored data. These are Main Data, 24 Hour Trend, Bar Graphs, Zone and Combination Screens. Menu Pressing from any of these display screens will bring you to the Main Menu. Edit Pressing from the Main Data, 24 Hour Trend or Combination Screens will skip the...
  • Page 11 C64 Controller Users Manual Revision 2.0a Alarm feature in the Systems Configuration menu allows new alarms to always force the LCD to the Main Data screen. This is useful for applications requiring channels with new alarms to be displayed. While in the Main Data screen, use to highlight any cell and press Edit Next...

  • Page 12: Hour Trend Screen

    C64 Controller Users Manual Revision 2.0a 1.3.2 24 HOUR TREND SCREEN The C64 24 Hour Trend screen shown in Figure 2-3 displays a 24 hour trend of input data for the channel selected. Vertical tic marks are each hour and horizontal tic marks are each 10% of full scale.

  • Page 13: Bar Graphs Screen

    C64 Controller Users Manual Revision 2.0a 1.3.3 BAR GRAPHS SCREEN The C64 Bar Graphs screen shown in Figure 2-4 allows 16 channels to be viewed simultaneously. Both engineering units and bar graph values are indicated in real time. Lines across the bars indicate the alarm trip points making it easy to identify channels near alarm.

  • Page 14: Combination Screen

    C64 Controller Users Manual Revision 2.0a 1.3.4 COMBINATION SCREEN The C64 Combination screen shown in Figure 2-5 offers a view of a single channel but displays the data as a 30 minute trend, bar graph and large engineering units. The bar graph and the background color changes and flashes indicating alarm condition.

  • Page 15: Zone Screen

    C64 Controller Users Manual Revision 2.0a 1.3.5 ZONE SCREEN The C64 Zone screen displays the eight possible zones simultaneously. If an alarm condition occurs the user will be able to quickly see in what zone the situation is occurring. Each active zone is divided into alarm levels which are green until an alarm is present.

  • Page 16: Specifications

    C64 Controller Users Manual Revision 2.0a 1.4 SPECIFICATIONS 1.4.1 DC POWER SUPPLY REQUIREMENTS Standard C64 power requirements are 10-30VDC @ 12 watts applied to terminals 1 & 3(+) and 5 & 7(-) of TB4 on the standard I/O Board (see section 3.0).

  • Page 17: Relays

    C64 Controller Users Manual Revision 2.0a 1.4.1.3 RELAYS The C64 comes standard with five Standard SPDT 5A relays, consisting of one dedicated HORN and one dedicated FAULT relay plus 3 programmable alarm relays. Programmable relays provide voting logic for ALARM 1, ALARM 2, and ALARM 3. Discrete relays and additional Programmable relays are optional.

  • Page 18: Approvals

    C64 Controller Users Manual Revision 2.0a 1.4.7 APPROVALS C22.2 No. 142-M1987 - Process Control Equipment CAN/CSA-C22.2 No.152-M1984 - Combustible Gas Detection Instruments ANSI/ISA-12.13.01-2000 - Performance Requirements for Combustible Gas Detectors CSA-C22.2 No. 213-M1987 - Non-Incendive Electrical Equipment for Use in Class I, Division 2 Hazardous Locations UL Std No.

  • Page 19: Main Menu Configuration

    C64 Controller Users Manual Revision 2.0a BASIC OPERATION SECTION 2 The C64 offers 5 graphic screens for viewing monitored data and several Set-Up menu screens for operator interface to configuration menus. The Main Data screen allows viewing of all active channels simultaneously. The Trend screen displays a 24 hour trend one channel at a time.
  • Page 20 C64 Controller Users Manual Revision 2.0a Figure 2-1...
  • Page 21 C64 Controller Users Manual Revision 2.0a Figure 2-2...
  • Page 22 C64 Controller Users Manual Revision 2.0a C h . A l a r m 1 S e t P o i n t L a t c h i n g T r i p H i g h D e l a y ( s e c ) Of f D e l a y...
  • Page 23 C64 Controller Users Manual Revision 2.0a Figure 2-4...
  • Page 24 C64 Controller Users Manual Revision 2.0a Figure 2-5...
  • Page 25 C64 Controller Users Manual Revision 2.0a Figure 2-6...
  • Page 26 C64 Controller Users Manual Revision 2.0a Figure 2-7...

  • Page 27: Changing Menu Variables Using The Keypad

    C64 Controller Users Manual Revision 2.0a 2.2 CHANGING MENU VARIABLES USING THE KEYPAD Upon entering a menu, a blue highlight bar controlled by indicates the selected variable. Some are simple YES/NO or ON/OFF entries toggled by pressing Edit . Others, such as Measurement Name and Eunits fields may have many ASCII character possibilities.
  • Page 28 C64 Controller Users Manual Revision 2.0a Figure 2-8...

  • Page 29: Standard Relay 1, 2, And 3

    C64 Controller Users Manual Revision 2.0a 2.3.1 STANDARD RELAY 1, 2, AND 3 Every C64 comes standard with three programmable relays that the user can individually program to suit their needs. This is achieved through the STANDARD RELAY menus accessed from the ALARM OUTPUTS menu. Only one Standard Relay menu screen is shown in Figure 2-9 because all the standard relay’s menus are identical.

  • Page 30: Zone 1-8

    C64 Controller Users Manual Revision 2.0a standard Fault relay is always failsafe and may be monitored separately to indicate loss of power conditions in many applications. 2.3.1.4 ZONE 1-8 Zones offer additional flexibility by controlling which channel zones trip this menu’s standard alarm relay.

  • Page 31: Acknowledge

    C64 Controller Users Manual Revision 2.0a may also be configured to not affect the Horn relay on a channel by channel basis (see section 2.4.2.5). 2.3.2.2 ACKNOWLEDGE Turning Acknowledge YES allows the Horn relay to be deactivated during alarm conditions by an Alarm Reset. This is useful if an audible device is being driven by the relay 2.3.2.3 FAILSAFE Failsafe controls relay activation for this relay.

  • Page 32: Programmable Relay

    C64 Controller Users Manual Revision 2.0a 2.3.4 PROGRAMMABLE RELAY The 10-0350 Programmable relay option board may be added if the user needs sixteen more programmable relays in addition to the three standard relays. These 16 relays are configured through the PROGRAMMABLE RELAY menus accessed from the ALARM OUTPUTS menu show in Figure 2-12.

  • Page 33: Channel Configuration Menus

    C64 Controller Users Manual Revision 2.0a 2.4.1 CHANNEL CONFIGURATION MENUS Once the appropriate channel has been selected its configuration menu allows the following parameters to be accessed: Alarm 1, Alarm 2, Alarm 3, Fault Alarm, Data From, Linearize, and Configure. Figure 2-14...

  • Page 34: Alarm 1 / Alarm 2 / Alarm 3 Menu

    C64 Controller Users Manual Revision 2.0a 2.4.2 ALARM 1 / ALARM 2 / ALARM 3 MENU The ALARM MENU parameters are listed only once, because alarms 1, 2, and 3 are identical except A1 does not have the option to change the color, it is always yellow, and only A3 can be turned off if not needed.

  • Page 35: Color

    C64 Controller Users Manual Revision 2.0a turn the horn relay on steady, or, to pulse it depending upon horn configuration in the system menu (see section 2.3.2.1). 2.4.2.6 COLOR COLOR gives the option of assigning A2 or A3 alarms different colors besides the default RED.

  • Page 36: Source

    C64 Controller Users Manual Revision 2.0a numbers define the location of the variable representing the input value and must be obtained from the manufacturer of the Modbus RTU device. • One of our Radio Modem kits may be connected to the Modbus RS-485 master port to enable wireless communication to GASMAX/RF wireless sensor transmitters.

  • Page 37: Filter Sample Count

    C64 Controller Users Manual Revision 2.0a 100% if these values are unknown. Forcing the input device to read zero should provide the A/D counts value needed to make this channel’s display also read zero. Likewise, forcing the input device to read 100% should provide the A/D counts value needed to make the C64 channel’s display also read 100%.

  • Page 38: Marker Menu

    C64 Controller Users Manual Revision 2.0a any other key will exit. The procedure for span calibration is identical. For example, if a gas sensor is to be spanned with 50% span gas, the span set-point must be 50%. If 45% is to be used later, the span set-point must be changed to 45% to match the span calibration gas.

  • Page 39: Remote Id

    C64 Controller Users Manual Revision 2.0a for use when interfacing the C64 to GDS Corp GASMAX Sensor Transmitters which may be configured to transmit sensor life values after each calibration (Figure 2-19). For Sensor Life to record properly the monitor must perform as follows: After the Calibration Marker interval, 4.0mA transmits for 10 seconds to indicate its calibration...

  • Page 40: Linearize

    C64 Controller Users Manual Revision 2.0a 2.4.5 LINEARIZE The linearization menu allows each channel to have its own linearization curve stored in the controller’s non-volatile memory. Input versus output points must be entered in percent of full scale values. This means if the range is 0-200 ppmH2S then 100 ppm is 50% of full scale.

  • Page 41: Info / Measurement Name

    C64 Controller Users Manual Revision 2.0a 2.4.6.1 INFO / MEASUREMENT NAME The first two items in this menu are for entering the 16 character Measurement Name and 6 character engineering unit ASCII fields. Eunits should define the units of measure for what this channel is to display.

  • Page 42: Deadband

    C64 Controller Users Manual Revision 2.0a 2.4.6.6 DEADBAND DEADBAND allows forcing low values to continue to read zero. This is useful when there are small amounts of background gases that cause fluctuating readouts above zero. The highest amount of deadband allowed is 5%. The 4-20mA output is affected by this menu item and will remain at 4mA until the input gets above the programmed deadband level.

  • Page 43: Communication Settings Menu

    C64 Controller Users Manual Revision 2.0a 2.5 COMMUNICATION SETTINGS MENU COMMUNICATION SETTINGS menu is accessed through the MAIN MENU. This menu is used to configure the four possible communication ports. Once in the COMMUNICATION SETTINGS entry menu, show on left in Figure 2-22; use to scroll up or down to select the communication port that is to be configured.

  • Page 44: Com 1-4 Settings

    C64 Controller Users Manual Revision 2.0a 2.5.1 COM 1-4 SETTINGS The four Modbus RS-485 ports can be individually configured multiple ways using the following menus. Figure 2-23 2.5.1.1 FUNCTION The Function parameter allows the communication ports to be set as Modbus Master, Modbus Slave, Wireless Monitor, Redundant Port, or Disabled.

  • Page 45: Baudrate

    C64 Controller Users Manual Revision 2.0a port. If the user chooses to test the port and it passes, a success message will appear and the error message will be cleared. Before a Primary port switches to its redundant port, a scan must fail 3 times. All channels setup to use the primary port are polled.

  • Page 46: Radio Setup

    C64 Controller Users Manual Revision 2.0a 2.5.1.6.1 FAULT TRANSMIT When set to YES the C64 broadcasts the Fault alarm flag out of the communication port. This option is only available if SYMPATHY ENABLED is set to YES. 2.5.1.6.2 A1 TRANSMIT When set to YES the C64 broadcasts the alarm 1 alarm flag out of the communication port.

  • Page 47: Modbus Tcp Settings

    C64 Controller Users Manual Revision 2.0a 2.5.2 MODBUS TCP SETTINGS Figure 2-24 2.5.2.1 SLAVE BYTE ORDER If Modbus Slave is selected, a BYTE ODER entry appears in the menu. This determines WORD and BYTE alignment of data at the remote Modbus transmitter when Edit sending its 4 byte IEEE Floating Point values.

  • Page 48: Dhcp Enabled

    C64 Controller Users Manual Revision 2.0a 2.5.3.1 DHCP ENABLED Enable this parameter to allow the IP address to be set automatically by an external DHCP server. When this parameter is enabled, the unit can be accessed by its hostname or IP address, although the IP address will be dependent on the DHCP server and could potentially change.

  • Page 49: View Comm Failures

    C64 Controller Users Manual Revision 2.0a 2.5.4.1 VIEW COMM FAILURES When VIEW COMM FAILURES is selected the screen in Figure 2-27 is shown. Each individual channel is shown and it is color coded by the communication port that it is configured for in its own Data From menu (see section 2.4.4).

  • Page 50: Clear Failure Counts

    C64 Controller Users Manual Revision 2.0a 2.5.4.2 CLEAR FAILURE COUNTS Selecting this option clears the communication failure counter so test can be run or old data can be cleared after communication ports are configured. 2.6 SECURITY MENU A password entered in the SECURITY menu allows locking all menus. Viewing menus is not denied but attempts to edit variables flashes the Locked message on the LCD.
  • Page 51 C64 Controller Users Manual Revision 2.0a Figure 2-29...

  • Page 52: Version

    C64 Controller Users Manual Revision 2.0a 2.7.1 VERSION The VERSION line in the System menu displays the version of firmware that is programmed in the controller. Figure 2-30 2.7.2 CONFIGURE Some items needing configuration are not specific to a channel but affect the entire C64 system.

  • Page 53: Name

    C64 Controller Users Manual Revision 2.0a 2.7.2.1 NAME Assign the controller a name for use in the backup configuration file name on the SD card. The controller name is limited to 16 characters. 2.7.2.2 CONTRAST The Configure menu item identified as CONTRAST allows users to adjust the LCD contrast to a level suitable to the ambient lighting.

  • Page 54: Zone Names

    C64 Controller Users Manual Revision 2.0a 2.7.3 ZONE NAMES ZONES 1-8 names can be edited for a quick reference while in the zone screen. These 16 character names show up in the title bar of each zone. Figure 2-32 2.7.4 MIMIC MODE When mimic mode is enabled, the C64 will duplicate the data and alarms of another C64 which can be connected with RS485 or TCP/IP.

  • Page 55: Sd Card

    C64 Controller Users Manual Revision 2.0a 2.7.5 SD CARD A two gigabyte SD card comes standard with each C64. This SD card is not needed for normal operation, but is useful for data logging and backing up configuration. When the data logger is enabled, every ten minutes the Min, Max, Average, Alarm 1/2/3 status, Fault status, Calibration status, and Alarm reset for each active channel is written to the SD card in one minute intervals.

  • Page 56: Logger Enabled

    C64 Controller Users Manual Revision 2.0a 2.7.5.2 LOGGER ENABLED Enabling the Data Logger allows the C64 to record the channel data for all active channels. 2.7.5.3 SAVE CONFIGURATION FILE By selecting SAVE CONFIG FILE the current configuration file will be backed up on the SD card.

  • Page 57: View Event Log

    C64 Controller Users Manual Revision 2.0a 2.7.6 VIEW EVENT LOG The C64 logs the last 2000 events, first in first out, in non-volatile memory so a SD card is NOT necessary to view the event log. The events are time and date stamped and if channel specific the number is shown in the right column.

  • Page 58: Clear Event Log

    C64 Controller Users Manual Revision 2.0a 2.7.7 CLEAR EVENT LOG After initial setup and testing of the controller, CLEAR EVENT LOG is used to manually clear all events in the log file. If the event log is not cleared the older events will be pushed out as new ones occur.

  • Page 59: Section 3 Input/Output Boards

    C64 Controller Users Manual Revision 2.0a INPUT/OUTPUT BOARDS SECTION 3 3.1 MAIN I/O INTERFACE BOARD # 10-0331 The most basic C64 Controller requires only the I/O Board shown in Figure 3-1 for interfacing to field wiring. The C64 primary power supply is applied to terminals 1 & 3(+) and 5 &...

  • Page 60: Input / Output Option Boards

    C64 Controller Users Manual Revision 2.0a TB1. RS-485 terminating resistors are installed by moving the jumpers at JP1 (com port 3) and JP4 (com port 4) to position 1. These resistors should not be installed if the port is not at the end of the communication line. TB1 allowes J9 is 40 pin ribbon to main external Alarm...

  • Page 61: Optional Analog Input Board # 10-0334

    C64 Controller Users Manual Revision 2.0a 3.2.1 OPTIONAL ANALOG INPUT BOARD # 10-0334 In compliance with CSA C22.2 No. 152 certification, the 4-20 ma input does not include or imply approval of the LEL gas detection apparatus such as sensors, transmitters, or devices connected to the system. In order to maintain CSA Certification of the system, all 4-20 ma gas detection instruments connected to the input must also be CSA Certified.
  • Page 62 C64 Controller Users Manual Revision 2.0a LEDs indicate board configuration. J3 & J4 are interchangeable Ch.01-16 Ch.17-32 I2C connectors used to add Status Ch.33-48 option PCB assemblies to Ch.49-64 the ST-72 Power Supply 24VDC 24VDC TB3 & TB4 24VDC inputs Common are tied together making Plus (+) Signal...

  • Page 63: Optional Discrete Relay Board # 10-0345

    C64 Controller Users Manual Revision 2.0a 3.2.2 OPTIONAL DISCRETE RELAY BOARD # 10-0345 An optional Discrete Relay Board, shown in Figure 3-3, adds sixteen 5 amp (resistive) form C relays per sixteen channel alarm board. Each BOARD may be configured via Diagnostics Menu in the C64 for ALARM 1, ALARM 2, ALARM 3 or FAULT for channels 1- 16, 17-32, 33-48 or 49-64.

  • Page 64: Optional *Bridge Sensor Input Board #10-0347

    C64 Controller Users Manual Revision 2.0a LEDs indicate board configuration. TB3 & TB4 24VDC inputs are tied together making daisy chaining J3 & J4 are interchangeable I2C connectors the options easier. used to add other option PCB assemblies to the controller. JP5 allows "zoning"...

  • Page 65: Bridge Sensor Input Board Initial Setup

    C64 Controller Users Manual Revision 2.0a *Catalytic sensors connected directly to the C64 should be limited to ranges of 0- 1000ppm. 3.2.4 BRIDGE SENSOR INPUT BOARD INITIAL SETUP Catalytic bead sensors vary widely in power requirements and sensitivity. It is therefore important to configure each channel to match the sensor with which it will operate.

  • Page 66: Optional 4-20Ma Analog Output Board #10-0348

    C64 Controller Users Manual Revision 2.0a LEDs indicate board configuration. J3 & J4 are interchangeable I2C connectors used to add other option PCB assemblies to the controller. .4-2.0 VDC SENSOR VOLTS ADJUST GAIN Up to 8, 10-0192 JUMPER BALANCE Dual Bridge input ADJUST modules may be .4-2.0 VDC...

  • Page 67: Optional Programmable Relay Board # 10-0350

    C64 Controller Users Manual Revision 2.0a The analog output board has a failure detection circuit. If the output board’s processor fails, or if communication is lost with the CPU board, then the outputs of all channels go to 0mA. LEDs indicate board configuration.
  • Page 68 C64 Controller Users Manual Revision 2.0a relay contact for each channel. The Programmable Relay Board is a viable cost effective option. It gives the flexibility of an additional 16 fully programmable relays. Each 10-0350 is powered with 24 VDC at TB3 and TB4. Each relay has a LED associated with it indicating whether the relay is energized.

  • Page 69: Optional 24Vdc 600 Watt Power Supply

    C64 Controller Users Manual Revision 2.0a 3.2.7 OPTIONAL 24VDC 600 WATT POWER SUPPLY The C64 Controller may be powered from 10-30VDC. However, many applications require 24VDC power for the monitors or transmitters providing inputs to the C64. A 600 watt AC / DC power supply may be included for these applications (115VAC or 230VAC).

  • Page 70: Optional 24Vdc 150 Watt Power Supply #10-0172

    C64 Controller Users Manual Revision 2.0a 3.2.8 OPTIONAL 24VDC 150 WATT POWER SUPPLY #10-0172 The C64 Controller may be powered from 10-30VDC. However, many applications require 24VDC power for the monitors or transmitters providing inputs to the C64. A 150 watt AC / DC power supply may be included for these applications (115VAC or 230 VAC selected via slide switch).

  • Page 71: Section 4 Diagnostics

    C64 Controller Users Manual Revision 2.0a DIAGNOSTICS SECTION 4 A System Diagnostic Mode shown in Figure 2-5 - Figure 2-7 may be entered during normal operation from the MAIN menu. The entry menu, shown below, offers useful routines for testing front panel LED’s, relays, serial ports and analog I/O. It is exited Next manually by pressing and automatically if no keys are pressed for 5...

  • Page 72: Discrete Relays

    C64 Controller Users Manual Revision 2.0a 4.2 DISCRETE RELAYS DISCRETE RELAYS allows manual actuation of the connected Discrete Relays while Edit in the Diagnostic mode. Highlight the channel group to be actuated and press Edit Then select the alarm group and press .

  • Page 73: Analog Inputs

    C64 Controller Users Manual Revision 2.0a 4.4 ANALOG INPUTS By selecting a channel group you can VIEW INPUTS or CALIBRATE BOARD. Figure 4-4 4.4.1 VIEW INPUTS The channel inputs are displayed as raw counts and can be useful for trouble shooting. These counts have no calibration applied to them so the user can see if a particular channel’s Analog to Digital counts.

  • Page 74: Analog Outputs

    C64 Controller Users Manual Revision 2.0a 4.5 ANALOG OUTPUTS If the C64 is equipped with an analog output option board the output can be manually stimulated by selecting the channel group then the channel to be ramped up. Pressing Edit increases the output value in 4mA increments from 0mA to 20mA.

  • Page 75: Leds

    C64 Controller Users Manual Revision 2.0a 4.7 LEDS Selecting LEDs from the diagnostics menu causes the six LEDs on the front panel to blink without affecting their corresponding relays. All six relay will cycle individually as indicated on the screen. Figure 4-7...

  • Page 76: Serial Ports

    C64 Controller Users Manual Revision 2.0a 4.8 SERIAL PORTS Testing the controllers 2 standard and 2 optional communication ports is made easy by connecting the ports together as shown in Figure 4-8 and selecting SERIAL PORTS in the diagnostic menu. The controller does a self diagnostic by polling one communication port with the other to ensure correct operation.

  • Page 77: I/O Board Configuration

    C64 Controller Users Manual Revision 2.0a 4.9 I/O BOARD CONFIGURATION The board configuration screen shows all connected I/O options. This is also the menu where the user must go if they want to change the configuration or channel group of an option board.

  • Page 78: Section 5 Modbus

    C64 Controller Users Manual Revision 2.0a MODBUS SECTION 5 In compliance with CSA C22.2 No. 152 certification, the Wireless / MODBUS interface to a LEL gas detector may only be used for data collection or record keeping with regard to combustible gas detection and not for performance verification.

  • Page 79: Coils

    C64 Controller Users Manual Revision 2.0a 5.3.1 COILS All coils are duplicated in the holding register table. These values can be read or written using either the coil register or the holding register. Actions Alarm Write 1 to simulate pressing Reset the alarm reset button Save...
  • Page 80 C64 Controller Users Manual Revision 2.0a Standard 12026 12020 False = 0, True = 1. Relay 1 Indicates whether Flashing standard relay 1 has been acknowledged. Standard 12027 12027 False = 0, True = 1. Relay 2 Indicates whether Flashing standard relay 2 has been acknowledged.

  • Page 81: Input Registers

    C64 Controller Users Manual Revision 2.0a Cal Flag 1-64 14089 14152 Off = 0, On = 1 Marker 1-64 14153 14216 Off = 0, On = 1 Detected Linearizing 1-64 14217 14280 Set if the channel’s linearize map is non default.
  • Page 82 C64 Controller Users Manual Revision 2.0a Standard 32020 32020 Off = 0, On = 1, doesn’t Relay 1 take into account failsafe State Standard 32021 32021 Off = 0, On = 1, doesn’t Relay 2 take into account failsafe State Standard 32022 32022...
  • Page 83 C64 Controller Users Manual Revision 2.0a Active Port 32031 32031 See active port for COM1. for COM2 (1) or the port number of the redundant port (0,2,3). (PortNumber – 1) Active Port 32032 32032 See active port for COM1. for COM3 (2) or the port number of the redundant port (0,1,3).
  • Page 84 C64 Controller Users Manual Revision 2.0a Fault 1-64 33833 33896 Off = 0, On = 1 Status Comm 1-64 33897 33960 Off = 0, On = 1 Error Config 1-64 33961 34024 Off = 0, On = 1 Error IO Error 1-64 34025 34088...

  • Page 85: Holding Registers

    C64 Controller Users Manual Revision 2.0a 5.3.4 HOLDING REGISTERS Type Channel First Last Block Read Write Notes Size Alarm 40001 40001 6, 16 Simulates the alarm reset Reset button. Write a value of 1 to activate. System 40010 40017 6, 16 Character string, 2 Name characters per register...

  • Page 86: Standard Relay 1

    C64 Controller Users Manual Revision 2.0a Zone 8 40086 40093 6, 16 Character string, 2 Name characters per register Actions Save 40095 40095 Saves configuration now Config Config 40096 40096 This register is set to 1 Changed when a configuration parameter has changed.
  • Page 87 C64 Controller Users Manual Revision 2.0a Zone 5 40109 40109 6, 16 Use zone 5 channels for voting. No = 0, Yes = 1 Enable Zone 6 40110 40110 6, 16 Use zone 6 channels for Enable voting. No = 0, Yes = 1 Zone 7 40111 40111...
  • Page 88 C64 Controller Users Manual Revision 2.0a Override 4 40120 40120 6, 16 Alarm for this override Alarm channel to use. Alarm 1 = 0, Alarm 2 = 1, Alarm 3 = 2 Override 5 40121 40121 6, 16 Create an override Channel channel.

  • Page 89: Standard Relay 2

    C64 Controller Users Manual Revision 2.0a Override 8 40128 40128 6, 16 Alarm for this override Alarm channel to use. Alarm 1 = 0, Alarm 2 = 1, Alarm 3 = 2 5.3.6 STANDARD RELAY 2 Type Channel First Last Block Read Write...
  • Page 90 C64 Controller Users Manual Revision 2.0a Override 1 40154 40154 6, 16 Alarm for this override Alarm channel to use. Alarm 1 = 0, Alarm 2 = 1, Alarm 3 = 2 Override 2 40155 40155 6, 16 Create an override Channel channel.

  • Page 91: Standard Relay 3

    C64 Controller Users Manual Revision 2.0a Override 5 40162 40162 6, 16 Alarm for this override Alarm channel to use. Alarm 1 = 0, Alarm 2 = 1, Alarm 3 = 2 Override 6 40163 40163 6, 16 Create an override Channel channel.
  • Page 92 C64 Controller Users Manual Revision 2.0a A3 Votes 40182 40182 6, 16 Alarm 3 channels required. 0 - 64 Acknowledge N/A 40183 40183 6, 16 Relay is acknowledgeable. No = 0, Yes = 1 Failsafe 40184 40184 6, 16 Relay is failsafe. No = 0, Yes = 1 Zone 1 40185...
  • Page 93 C64 Controller Users Manual Revision 2.0a Override 2 40196 40196 6, 16 Alarm for this override Alarm channel to use. Alarm 1 = 0, Alarm 2 = 1, Alarm 3 = 2 Override 3 40197 40197 6, 16 Create an override Channel channel.

  • Page 94: Discrete Relays

    C64 Controller Users Manual Revision 2.0a Override 7 40205 40205 6, 16 Create an override channel. 0 is disabled. 0 - Channel Override 7 40206 40206 6, 16 Alarm for this override Alarm channel to use. Alarm 1 = 0, Alarm 2 = 1, Alarm 3 = 2 Override 8...

  • Page 95: Channel Configuration

    C64 Controller Users Manual Revision 2.0a Alarm 2 40231 40231 6, 16 Off = 0, Mode On = 1, Beep = 2 Alarm 3 40232 40232 6, 16 Off = 0, Mode On = 1, Beep = 2 Acknowledge N/A 40233 40233 6, 16...
  • Page 96 C64 Controller Users Manual Revision 2.0a Off Delay 1-64 42897 42960 6, 16 Time in minutes. 0 - 120 Horn Drive 1-64 42961 43024 6, 16 No = 0, Yes = 1 Color 1-64 43025 43088 6, 16 Alarm color displayed on the unit Red = 0, Blue = 1,...
  • Page 97 C64 Controller Users Manual Revision 2.0a Max Raw 1-64 44497 44560 6, 16 Integer Remote ID 1-64 44561 44624 6, 16 0 – 247 Interface 1-64 44625 44688 6, 16 COM1 = 0 COM2 = 1 COM3 = 2 COM4 = 3 TCP/IP = 4 Filter Count 1-64...

  • Page 98: Programmable Relays

    C64 Controller Users Manual Revision 2.0a Point 8 1-64 47121 47376 2x 32bit IEEE Floats, Input and Output Point 9 1-64 47377 47632 2x 32bit IEEE Floats, Input and Output Configure Decimal 1-64 47633 47696 6, 16 0 = 0, Points 1 = 1, 2 = 2,...
  • Page 99 C64 Controller Users Manual Revision 2.0a Relay 8 49280 Relay 9 49320 Relay 10 49360 Relay 11 49400 Relay 12 49440 Relay 13 49480 Relay 14 49520 Relay 15 49560 Relay 16 49600 The register for each relay parameter is determined by adding the offset to that relay’s base address.
  • Page 100 C64 Controller Users Manual Revision 2.0a Zone 8 6, 16 Use zone 8 channels for voting. No = 0, Yes = 1 Enable Override 1 6, 16 Create an override channel. 0 is Channel disabled. 0 - 64 Override 1 6, 16 Alarm for this override channel Alarm...
  • Page 101 C64 Controller Users Manual Revision 2.0a Override 5 6, 16 Alarm for this override channel Alarm to use. Alarm 1 = 0, Alarm 2 = 1, Alarm 3 = 2 Create an override channel. 0 is Override 6 6, 16 Channel disabled.

  • Page 102: Section 6 Enclosure Options

    C64 Controller Users Manual Revision 2.0a ENCLOSURE OPTIONS SECTION 6 6.1 C64-PM PANEL / RACK MOUNT ENCLOSURE The C64PM shown in Figure 6-1 is a half width 19” rack enclosure. It is supplied with hardware that allows mounting in either a 1/2 width 19” rack style cabinet or it may be panel mounted in a rectangular cutout (7.1”...
  • Page 103 C64 Controller Users Manual Revision 2.0a 6.2 C64-N4 NEMA 4X LARGE WALL MOUNT FIBERGLASS ENCLOSURE The C64N4 shown in Figure 6-2 is a fiberglass NEMA 4X wall mount enclosure. Eleven, 16 channel I/O option boards, such as analog input or discrete relays, may be mounted inside this enclosure with the addition of a 0010-1269 expansion plate.
  • Page 104 C64 Controller Users Manual Revision 2.0a 6.3 C64-CP NEMA 4X COMPACT WALL MOUNT FIBERGLASS ENCLOSURE The C64CP shown in Figure 6-3 is a fiberglass NEMA 4X wall mount enclosure. One, 16 channel I/O option PCB’s, such as analog input or relays, may be mounted inside this enclosure making it ideal for Modbus or wireless applications.
  • Page 105 C64 Controller Users Manual Revision 2.0a Figure 6-4...
  • Page 106 C64 Controller Users Manual Revision 2.0a 6.4 C64-XP NEMA 7 WALL MOUNT ALUMINUM ENCLOSURE The C64XP shown in Figure 6-5 is an aluminum NEMA 4X / 7 wall mount enclosure designed for mounting into DIV 1&2 Groups B,C,D potentially hazardous areas. Five, 16 channel I/O option PCB’s, such as analog inputs or discrete relays, may be mounted inside this enclosure with the addition of a 0010-1284 expansion plate.
  • Page 107 C64 Controller Users Manual Revision 2.0a 6.5 C64 MAIN I/O & OPTION PCB FOOTPRINT DIMENSIONS AND ENCLOSURE CAPACITIES C64 controllers have virtually unlimited possibilities for configuration of options such as analog I/O, relays, and others. Figure 6-6 provides the Main I/O and all option PCB dimensions and mounting footprint.
  • Page 108 C64 Controller Users Manual Revision 2.0a 6.875 6.722 .152 igur 6-6 ti n rd Dim n i n unting t rint...

  • Page 109: Section 7 Wireless Option

    Each transceiver on a wireless network must have their RADIO SETUP menus configured to share the same hopping channel (0-32) and System ID (0-255) to communicate. All GDS Corp wireless transceivers utilize a Server-Client network where Clients synchronize their hopping to the Server. The Server transmits a beacon at the beginning of every hop (50 times per second).

  • Page 110: Radio Setup Menu

    C64 Controller Users Manual Revision 2.0a 2.4 GHz Radio Modem 900 MHz Radio Modem Note: Note: 10-0357 Has One Radio Module Installed 10-0364 Has One Radio Module Installed 10-0358 Has Two Radio Modules Installed 10-0365 Has Two Radio Modules Installed Figure7-1 7.1 RADIO SETUP MENU Radio modules connected to the C64’s communication port may be configured through...

  • Page 111: Hop Channel

    C64 Controller Users Manual Revision 2.0a 7.1.1 HOP CHANNEL Hop Channel may be set from 1-32 using the C64 keypad and assigns the pseudo- random radio frequency hopping pattern. A transceiver will not go InRange of or communicate with a transceiver operating on a different Hop Channel. 7.1.2 SYSTEM ID System ID may be set from 1-255 using the C64 keypad and is similar to a password...

  • Page 112: Radio Status Alarms - Wireless Monitor Mode

    C64 Controller Users Manual Revision 2.0a Figure 7-3 7.2.1 RADIO STATUS ALARMS - WIRELESS MONITOR MODE When an C64 channel’s INPUT DATA FROM menu is set for WIRELESS MONITOR, in addition to processing the GASMAX/RF’s 10-bit “counts” value, it also receives status bits indicating Communications Error, Low Battery and Calibration.

  • Page 113: Low Battery

    Modbus master such as a DCS, HMI or another C64 64 Channel Controller; also equipped with a radio modem. As in all GDS Corp wireless networks, one transceiver must be designated as Server and all others as Clients. No special configuration is required by the master or slave since this is a standard Modbus RTU network.

  • Page 114: Antenna Selection

    C64 Controller Users Manual Revision 2.0a 7.5 ANTENNA SELECTION 7.5.1 DIPOLE AND COLLINEAR ANTENNAS These antennas are connected to the Radio via a length of coax cable. If the cable is larger than 6mm diameter (1/4 inch), do not connect the cable directly to the radio connection on the C64 enclosure.

  • Page 115: Mounting Near Other Antennas

    C64 Controller Users Manual Revision 2.0a Two Yagis can be used for a point-to-to link. In this case they can be mounted with the elements horizontally to give horizontal polarity. There is a large degree of RF isolation between horizontal and vertical polarity (approx –30dB) so this installation method is a good idea if there is a large amount of interference from another system close by transmitting vertical polarity.

  • Page 116: Antenna Grounding

    C64 Controller Users Manual Revision 2.0a have a solid connection to earth via a ground stake or ground grid if the soil has poor conductivity. Solid connection means a large capacity conductor (not a small wire) with no coils or sharp bends. All other devices connected to the C64 need to be grounded to the same ground point.
  • Page 117 C64 Controller Users Manual Revision 2.0a Special care needs to be taken where the connected data device is remote from the wireless unit requiring a long data cable. As the data device and the wireless unit cannot be connected to the same ground point, different earth potentials can exist during surge conditions.

  • Page 118: Section 8 Web

    C64 Controller Users Manual Revision 2.0a WEBPAGE SECTION 8 All C64 controllers come standard with an embedded webpage. The webpage gives remote access to view and configure parameters inside the controller. There are two levels of security clearance. The first level allows the user to view channel status and configuration while the second level allows the user to change configuration parameters directly from the computer.

  • Page 119: System Screen

    C64 Controller Users Manual Revision 2.0a 8.1 SYSTEM SCREEN The System screen shown below (Figure 8-1) displays all active channels at once. It is capable of displaying 16, 32, 48 or 64 channels depending on the controller’s configuration. This screen, very similar to the Main Data screen, displays measurement name and uses a colored cells that flash with new alarms to indicate alarm conditions.

  • Page 120: Zone Screen

    C64 Controller Users Manual Revision 2.0a 8.2 ZONE SCREEN The webpage’s Zone screen (Figure 8-2) displays the eight possible zones simultaneously see section 1.3.5. If an alarm condition occurs the user will be able to quickly see in what zone the situation is occurring. Each active zone is divided into alarm levels which are green until an alarm is present.

  • Page 121: Channel Screen

    C64 Controller Users Manual Revision 2.0a 8.3 CHANNEL SCREEN The Channel screen shown in Figure 8-3 displays a 24 hour trend of input data for the channel selected. Vertical tic marks are each hour and horizontal tic marks are each 10% of full scale.

  • Page 122: Event Log Screen

    C64 Controller Users Manual Revision 2.0a 8.4 EVENT LOG SCREEN Displays the last 2000 events logged in the C64. The events are logged in a first in first out format, in non-volatile memory so a SD card is not necessary to view the event log. These events include Alarms In and Out, Alarm Resets, Calibrations, System and Cold Boots, and Communication and Configuration Error.

  • Page 123: Configure

    C64 Controller Users Manual Revision 2.0a 8.5 CONFIGURE The configuration pages allow viewing and editing of most system parameters. The exceptions are communication and security settings which must be set from the unit’s keypad interface. All changes made to the configuration parameters will not be saved until the user has entered the correct login password.

  • Page 124: Channel Configuration

    C64 Controller Users Manual Revision 2.0a 8.5.2 CHANNEL CONFIGURATION Figure 8-6 8.5.3 COPY CHANNELS Figure 8-7...

  • Page 125: Programmable Relays

    C64 Controller Users Manual Revision 2.0a 8.5.4 PROGRAMMABLE RELAYS Figure 8-8 8.5.5 SYSTEM CONFIGURATION Figure 8-9...

  • Page 126: Configuration Upload/Download

    C64 Controller Users Manual Revision 2.0a 8.5.6 CONFIGURATION UPLOAD/DOWNLOAD The configuration upload/download page allows transferring system configuration to or from the unit via the webpage. When the download link is clicked, the unit saves the current configuration into a file and transfers it to the user. It should be saved as a .cfg file.

  • Page 127: Section 9 Troubleshooting

    C64 Controller Users Manual Revision 2.0a TROUBLESHOOTING SECTION 9 9.1 CHANNEL ERRORS The following errors indicate potential hardware or configuration problems. If an error occurs, a message is displayed for that channel. 9.1.1 COMM ERROR Comm Error can occur for Modbus or wireless channels. This error indicates the data was not received.

  • Page 128: Reset To Factory Defaults

    C64 Controller Users Manual Revision 2.0a 9.2 RESET TO FACTORY DEFAULTS All C64 configuration can be reset to factory defaults at once. This is done through the Edit Coldboot menu shown in Figure 9-1. To access the Coldboot menu, hold the Edit cycle power.

  • Page 129: Section 10 Network Connection

    C64 Controller Users Manual Revision 2.0a NETWORK CONNECTION SECTION 10 10.1 DIRECT CONNECTION WITH CROSSOVER CABLE OR HUB/SWITCH If a network is not available, or if it is desired to keep the C64 and PC(s) completely separated from other computers, a simple network can be created. The simplest network can be created by connecting the C64 to a PC directly using an Ethernet crossover cable.
  • Page 130 C64 Controller Users Manual Revision 2.0a The recommended option for a permanent network is to setup a static IP on the C64 and any other devices (or computers) on the network. See section 10.4. 10.2 CONNECTING THE C64 TO AN EXISTING LAN Figure 10-3 A typical network will have a DHCP server, a switch (sometimes combined) and several devices connected to that switch.
  • Page 131 C64 Controller Users Manual Revision 2.0a 10.3 CONNECTING THE C64 ON AN ISOLATED NETWORK Figure 10-4 Another possible network configuration for the C64 involves connecting the controller, with ModbusTCP slave devices, and possibly computers on a network. This network can then be isolated from a larger company network using a router/firewall.

  • Page 132: Static Ip Configuration

    C64 Controller Users Manual Revision 2.0a In most cases, a router and firewall will separate the network from the internet. It is not recommended to forward ports from the internet to an C64. In cases where offsite access is needed, a VPN or tunnel connection could be used to get inside the network. 10.4 STATIC IP CONFIGURATION If you are setting up static IPs on a larger company network, make sure to consult your...
  • Page 133 C64 Controller Users Manual Revision 2.0a Figure 10-6 Click the properties button.
  • Page 134 C64 Controller Users Manual Revision 2.0a Figure 10-7 Select “Internet Protocol (TCP/IP)”, and then click the properties button. Figure 10-8...

  • Page 135: Dynamic Ip Configuration

    C64 Controller Users Manual Revision 2.0a Select “Use the following IP Address”. The IP address should be chosen different than the one set on the C64. For the network created in the ‘C64 Static IP configuration’, only the last digit can be changed. A typical choice is 192.168.0.1. The Subnet mask is set to 255.255.255.0.
  • Page 136 C64 Controller Users Manual Revision 2.0a C:\>ping 192.168.0.2 Pinging 192.168.0.2 with 32 bytes of data: Reply from 192.168.0.2: bytes=32 time<1ms TTL=128 Reply from 192.168.0.2: bytes=32 time<1ms TTL=128 Reply from 192.168.0.2: bytes=32 time<1ms TTL=128 Reply from 192.168.0.2: bytes=32 time<1ms TTL=128 Ping statistics for 192.168.0.2: Packets: Sent = 4, Received = 4, Lost = 0 (0% loss), Approximate round trip times in milli-seconds: Minimum = 0ms, Maximum = 0ms, Average = 0ms...

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