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Ampcontrol GASGUARD Installation, Operation & Maintenance Manual

Programmable intrinsically safe controller
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GASGUARD
Programmable Intrinsically Safe Controller
INSTALLATION, OPERATION & 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.

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  • Page 1 GASGUARD Programmable Intrinsically Safe Controller INSTALLATION, OPERATION & 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.
  • Page 2 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.
  • Page 3 Australia. Disclaimer Ampcontrol CSM 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.

  • Page 4: Table Of Contents

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 Table of Contents Receiving and Storage............................7 1.1 Receiving ................................ 7 1.2 Storage after Delivery ............................. 7 1.3 Unpacking of Equipment ..........................7 General Safety ..............................8 2.1 Personnel Safety Warnings ..........................8 2.1.1...
  • Page 5 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 2.9.4 Alarm Set-Point Delays ........................19 2.9.5 Alarm Set-Point Hysteresis ....................... 20 Menu Structure ..............................21 3.1 Key Pad Functions in Main Menu........................21 3.2 Main Menu ..............................21 3.3 Controller LED and Display Operation ......................22 3.3.1...
  • Page 6 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 4.4.1 Set Relay Status..........................27 4.4.2 Set Relay Type ..........................27 4.4.3 Set Tag Name ........................... 27 4.4.4 Set Relay 1 to Zone 1 ........................27 4.4.5 Set Relay Start-Up Mode ........................28 4.5 Output Configuration Menu (Nos.
  • Page 7 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 5.2.1 IP rating and Physical Protection ...................... 33 5.2.2 Ease of Access..........................33 5.3 Connecting to the Controller.......................... 33 5.3.1 Entity Parameters ..........................33 5.3.2 Type of Cable ............................ 34 5.3.3 Cable Termination ..........................

  • Page 8: Receiving And Storage

    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.

  • Page 9: General Safety

    Intended Use of the Equipment The Gasguard Programmable Intrinsically Safe Controller is designed to operate with a variety of Group I 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.

  • Page 10: Operational Restrictions And Limitations

    The Gasguard controller is NOT certified for use in Group II 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.

  • Page 11: Overview Of The Gasguard Controller

    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 of this Manual for details).

  • Page 12: Zone Configurations

    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.

  • Page 13: Adding Input Alarm Set-Points To A Zone Block

    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.
  • Page 14 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.
  • Page 15 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 ].

  • Page 16: Zone Block Configuration Warnings

    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 state via its relays. Failure to observe these points and select appropriate settings may result in alarm indication failure.
  • Page 17 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) • nnn (e.g. 250) •...

  • Page 18: Setting Alarm Set-Points

    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.

  • Page 19: Configuring Relay Operation

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 When setting alarm set-point thresholds, it is important to ensure that they comply with recognised 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.

  • Page 20: Relay Start-Up Mode

    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 ‘NC’ terminal (as marked on the terminal label).

  • Page 21: Alarm Set-Point Hysteresis

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 2.9.5 Alarm Set-Point Hysteresis 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.

  • Page 22: Menu Structure

    To 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.

  • Page 23: Controller Led And Display Operation

    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 ...

  • Page 24: Programming

    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 By using the ...

  • Page 25: Set Gas Name

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 4.2.3 Set Gas Name The controller has 6 pre-set gas types: CH , CO, O S, AV and DP. If another gas type is required the operator can select the User Function to input the desired gas type.

  • Page 26: Setting Alarm Or Fault Levels

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 4.2.8 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.

  • Page 27: Zone Configuration Menu (Nos. 5-10)

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 4.3 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.

  • Page 28: Set Zone 1 To Channel 1/High Fault Alarm

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 4.3.7 Set Zone 1 to Channel 1/High Fault Alarm 1. To modify ‘CH1 HF’ press the  key to enter 2. Use the  key to toggle between IN and NOT IN 3.

  • Page 29: Set Relay Start-Up Mode

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 4.4.5 Set Relay Start-Up Mode 5. To modify ‘PwrUpMode’ press the  key to enter 6. Use the  key to toggle between LIVE and LATCHED 7. To save, use the  key 8.

  • Page 30: Set Output To Channel 3

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 4.5.6 Set Output to Channel 3 1. To modify ‘CH3’ press the  key to enter 2. Use the  key toggle between IN and NOT IN 3. To save, use the  key 4.

  • Page 31: Set Tag Name 1

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 4.6.6 Set Tag Name 1 1. To modify ‘TN1’ press the  key to enter 2. Use the  key to scroll through the alpha-numerals 3. Use the  key to move the cursor across to the next digit 4.

  • Page 32: Channel 1 Zero Calibration

    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 Channel 1 Zero Calibration 1. Press the  key to enter into ‘Channel 1 Calibration’ 2. Connect a calibrated 4 mA / 0.4V signal (depending on input type) to channel 1 contacts 3.

  • Page 33: Controller Installation

    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.

  • Page 34: Mounting The Controller

    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.

  • Page 35: Type Of Cable

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 5.3.2 Type 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.

  • Page 36: Controller Commissioning

    For any system supplied that involves a controller, there will be a commissioning test form. An example of such, is Ampcontrol document 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.

  • Page 37: Checking Controller Functionality

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 6.2.2 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 channel from a zero input signal all the way up to and beyond the channel’s full scale value.

  • Page 38: Service, Maintenance & Disposal

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 7 Service, Maintenance & Disposal 7.1 Equipment Service The Controller requires 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.

  • Page 39: Equipment Maintenance

    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 serviceable parts and is not provided with any user adjustments.

  • Page 40: Specifications

    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 -.

  • Page 41: Data Communication Specification

    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...

  • Page 42: Memory Type 3

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 10.1.3 Memory Type 3: Data Format Modbus Address Description 30001 Channel 1 Analogue Input Normalize Values: 30002 Channel 2 Analogue Input 4mA  4000 30003 Channel 3 Analogue Input 20mA  20000...

  • Page 43: Memory Type 4

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 10.1.4 Memory Type 4: Modbus Address Description Data Format 40001 Channel 1 Set-point LF Normalize Values: 40002 Channel 1 Set-point A1 4mA  4000 20mA  20000 40003 Channel 1 Set-point A2...
  • Page 44 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 40049 Channel 1 Alarm Delay Value in mSec. Value Range: 40050 Channel 2 Alarm Delay 0 - 9999 40051 Channel 3 Alarm Delay 40052 Channel 4 Alarm Delay 40053 Channel 1 Control Bit0 –Bit5 = N/A...
  • Page 45 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 40091 Output 1 Control Bit0 – Bit2 = Function ( 0= Follow, 40092 Output 2 Control 1=Highest, 40093 Output 3 Control 2=Lowest ) Bit3-Bit5 = N/A Bit6 = Hide ( 1 On , 0 Off) Bit7 = Status ( 1...

  • Page 46: Modbus Memory Map Part 2

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 10.2 Modbus Memory Map Part 2 Page 45...
  • Page 47 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 Page 46...

  • Page 48: Appendix A - Connection Diagram

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 Appendix A A1: Connection Diagram System Functional Block Diagrams – Key to Symbols. LOGICAL AND LOGICAL OR LOGICAL INVERSION LOGICAL EXLUSIVE OR Page 47...
  • Page 49 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 A2: Top Level Functional Block Diagram Page 48...
  • Page 50 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 Input Channel Functional Block Diagram Page 49...
  • Page 51 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 Zoning Functional Block Diagram Page 50...
  • Page 52 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 Relay Functional Block Diagram Page 51...

  • Page 53: Appendix A - Output Current Followers Performance Graph

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 Current Follower Outputs - Performance Graph. Page 52...

  • Page 54: Appendix A - Sample Test Forms

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 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 55 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 GAS STATION - TEST REPORT 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)
  • Page 56 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 Channel 1 Range 5% v/v Verified mA / V Engineering Value Sensor Input Type 4-20mA Apply minimum range to channel, zero if necessary 0.00 (-0.02 – 0.02) Channel Delay 1s Delay...
  • Page 57 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 Channel 2 Range 5% v/v Verified mA / V Engineering Value Sensor Input Type 4-20mA Apply minimum range to channel, zero if necessary 4.0mA 0.00 (-0.02 – 0.02) Channel Delay 1s Delay Apply maximum to channel, adjust span if required 20.0mA...
  • Page 58 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 Channel 3 Range 5% v/v Verified mA / V Engineering Value Sensor Input Type 4-20mA Apply minimum range to channel, zero if necessary 4.0mA 0.00 (-0.02 – 0.02) Channel Delay 1s Delay Apply maximum to channel, adjust span if required 20.0mA...
  • Page 59 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 Channel 4 Range 5% v/v Verified mA / V Engineering Value Sensor Input Type 4-20mA Apply minimum range to channel, zero if necessary 4.0mA 0.00 (-0.02 – 0.02) Channel Delay 1s Delay Apply maximum to channel, adjust span if required 20.0mA...
  • Page 60 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 Output Configuration Output 1 Output 2 Output 3 Status Verified Verified Verified IDA-VALUE Verified Output Type HIGHEST Verified Channel 1. Verified Channel 2. Verified Channel 3. Verified Channel 4. Verified Tested By:...

  • Page 61: Appendix B - System Flow Chart

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 Appendix B – System Flow Chart B1: Flow Chart Legend Page 60...
  • Page 62 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 B2: Main Menu Flowchart Page 61...
  • Page 63 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 B3: Calibration Flowchart Page 62...
  • Page 64 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 B4: Configuration Flowchart Page 63...
  • Page 65 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 Configuration Flowchart (con’t) Page 64...

  • Page 66: Appendix B - Default Settings Table

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 Configuration Flowchart (con’t) Page 65...
  • Page 67 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 B5: System Default Table CHANNEL INFORMATION CHANNEL 2 DEFAULT CHANNEL 1 DEFAULT PARAMETER PARAMETER INPUT TYPE 4-20mA INPUT TYPE 4-20mA STATUS STATUS GAS NAME GAS NAME DECPT 25.00 %v/v DECPT 5.00 %v/v 25.00 %v/v...
  • Page 68 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 CHANNEL 3 DEFAULT CHANNEL 4 DEFAULT PARAMETER PARAMETER INPUT TYPE 4-20mA INPUT TYPE 4-20mA STATUS STATUS GAS NAME GAS NAME DECPT 50.00 ppm DECPT 5.00 %v/v 50.00 ppm 5.00 %v/v UNIT...
  • Page 69 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 ZONE INFORMATION ZONE 2 DEFAULT ZONE 1 DEFAULT PARAMETER PARAMETER STATUS STATUS ZONE 2 ZONE 1 CH1 LF NOT IN CH1 LF NOT IN CH1 A1 NOT IN CH1 A1 CH1 A2...
  • Page 70 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 ZONE 4 DEFAULT ZONE 3 DEFAULT PARAMETER PARAMETER STATUS STATUS ZONE 4 ZONE 3 CH1 LF NOT IN CH1 LF NOT IN CH1 A1 NOT IN CH1 A1 NOT IN CH1 A2...
  • Page 71 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 ZONE 6 DEFAULT ZONE 5 DEFAULT PARAMETER PARAMETER STATUS STATUS ZONE 6 ZONE 5 CH1 LF NOT IN CH1 LF NOT IN CH1 A1 NOT IN CH1 A1 NOT IN CH1 A2...
  • Page 72 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 RELAY INFORMATION RELAY 1 DEFAULT RELAY 2 DEFAULT PARAMETER PARAMETER STATUS STATUS RLY TYPE RLY TYPE RELAY 1 RELAY 2 NOT IN NOT IN NOT IN NOT IN NOT IN NOT IN...
  • Page 73 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 OUTPUT INFORMATION OUTPUT 1 DEFAULT OUTPUT 2 DEFAULT PARAMETER PARAMETER STATUS STATUS OUTPUT 1 OUTPUT 2 OP TYPE FOLLOW OP TYPE FOLLOW NOT IN NOT IN NOT IN NOT IN NOT IN...

  • Page 74: Appendix C - Approvals

    GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 Appendix C – Approvals Page 73...
  • Page 75 GASGUARD IS CONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502 Page 74...
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