GDS Corp GASMAX II + GDS-IR Operation And Maintenance Manual
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GDS Corp GASMAX II + GDS-IR Operation And Maintenance Manual

Gas detector with infrared sensor for combustibles and carbon dioxide
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Operation and Maintenance
Manual
GASMAX II + GDS-IR
GASMAX Gas Detector with GDS-IR Infrared Sensor
for Combustibles and Carbon Dioxide
GDS Corp.
1245 Butler Road
League City, TX 77573
409-927-2980
409-927-4180 (Fax)
ww.gdscorp.com

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  • Page 1 Operation and Maintenance Manual GASMAX II + GDS-IR GASMAX Gas Detector with GDS-IR Infrared Sensor for Combustibles and Carbon Dioxide GDS Corp. 1245 Butler Road League City, TX 77573 409-927-2980 409-927-4180 (Fax) ww.gdscorp.com...
  • Page 2 GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 CAUTION: FOR SAFETY REASONS THIS EQUIPMENT MUST BE OPERATED AND SERVICED BY QUALIFIED PERSONNEL ONLY. READ AND UNDERSTAND INSTRUCTION MANUAL COMPLETELY BEFORE OPERATING OR SERVICING. ATTENTION: POUR DES RAISONS DE SÉCURITÉ, CET ÉQUIPEMENT DOIT ÊTRE UTILISÉ, ENTRETENU ET RÉPARÉ...

  • Page 3: Table Of Contents

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 CONTENTS SAFETY INFORMATION _______________________________________________ 6 OVERVIEW _________________________________________________________ 7 INSTALLATION ______________________________________________________ 9 INITIAL SETUP _____________________________________________________ 16 CALIBRATION ______________________________________________________ 20 MAINTENANCE _____________________________________________________ 23 USER MENUS ______________________________________________________ 24 TROUBLESHOOTING ________________________________________________ 34 MODBUS INTERFACE ________________________________________________ 36...
  • Page 4 GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 TABLE OF FIGURES FIGURE 3-1: GASMAX II + GDS-IR POWER & SIGNAL WIRING ..............11 FIGURE 3-2: OPTIONAL RELAY / MODBUS INTERFACE BOARD..............12 FIGURE 3-3: MODBUS WIRING (TYPICAL) ..................... 13 FIGURE 3-4: MODBUS WIRING (MODBUS JUNCTION BOX)................
  • Page 5 GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 FIGURE 12-2: GASMAX II + GDS-IR DIMENSIONS (LOCAL HORIZONTAL SENSOR) ........44 FIGURE 12-3: GDS-IR DIMENSIONS (REMOTE VERTICAL SENSOR) ............... 45 FIGURE 12-4: GDS-IR DIMENSIONS (REMOTE VERTICAL SENSOR WITH DUCT MOUNT) ......46 FIGURE 12-5: GDS-IR DUCT MOUNT HOLE CUTOUT PATTERN ..............

  • Page 6: Safety Information

    Do not paint transmitter or sensor assembly. • Do not operate the GASMAX II + GDS-IR if its enclosure is damaged or cracked or has missing components. Make sure the cover, internal PCB’s and field wiring are securely in place before applying power.

  • Page 7: Overview

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 2 OVERVIEW The GASMAX II + GDS-IR gas monitor integrates the GASMAX II gas monitor with the GDS-IR standalone infrared gas sensor. The combination provides an ideal solution with local or remote display, built-in calibration, convenient IR % L E L Zero options and diagnostics with Fault display.
  • Page 8 GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 GDS-IR INFRARED SENSOR FOR COMBUSTIBLES AND CO2 The GDS-IR is ideally suited for use in harsh environments and where the cost of required maintenance for conventional catalytic detectors is prohibitive. The GDS-IR Infrared gas detector will perform reliably in the...

  • Page 9: Installation

    To make calibration easier, GDS Corp recommends the remote sensor configuration for heavy gases. This allows the display to be located at eye level while the sensor is located near the floor.
  • Page 10 CAUTION: KEEP EXPLOSION PROOF COVER TIGHT WHILE CIRCUITS ARE ALIVE MISE EN GARDE : GARDER EXPLOSION COUVERTURE PREUVE TIGHT CIRCUITS PENDANT QUE SONT ALIVE INTRINSICALLY SAFE INSTALLATION The GASMAX II + GDS-IR is not certified for use as an Intrinsically Safe device. Page 10...

  • Page 11: Figure 3-1: Gasmax Ii + Gds-Ir Power & Signal Wiring

    Plus 24VDC connects to TB2-1. DC Ground connects to TB2-4. Channel One 4-20mA output is available on TB2-2 and Channel Two 4-20mA output is available on TB2-3. GDS Corp always recommends using shielded wire for signal and power cable. TB2 – 1: +12-30VDC Input TB2 –...

  • Page 12: Figure 3-2: Optional Relay / Modbus Interface Board

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 OPTIONAL RELAY + MODBUS INTERFACE The optional 10-0234 Relay / Modbus board is connected “piggyback” to the back of the GASMAX II Display Assembly and supplies two level alarm relays (“K ” and “K ”), a FAULT relay (“K3”) and an RS-485 Modbus RTU slave port.

  • Page 13: Figure 3-3: Modbus Wiring (Typical)

    MODBUS / RS-485 transmissions use low-voltage differential signaling to achieve reasonable data rates over very long distances, up to 4000 feet without a repeater. For MODBUS data signals, GDS Corp recommends 24GA shielded cable for best results. Power distribution, however may require larger gauge wire since it is critical that the supply voltage for the GASMAX at the far end of the string not fall below 18VDC during power-up and normal operation.

  • Page 14: Figure 3-4: Modbus Wiring (Modbus Junction Box)

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 disconnect the GASMAX II power or MODBUS connections without affecting any other MODBUS devices. “ ” “B” - 33- IO/Power upply ibbon to isplay “ ” “B” Figure 3-4: MODBUS Wiring (MODBUS Junction Box) The MODBUS wiring junction box is attached to the GASMAX, either on the bottom fitting or one of the side fittings, depending on installation requirements.

  • Page 15: Figure 3-6: Optional Isolated 4-20Ma Output Board

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 OPTIONAL ISOLATED 4-20MA OUTPUT BOARD The optional 10-0250 Isolated 4-20mA output board provides two 4-20mA outputs that are electrically isolated from sensor inputs and the 24 VDC power source. Each 4-20mA output shares the same common ground and are therefore not isolated from each other.

  • Page 16: Initial Setup

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 4 INITIAL SETUP When power is applied to the GASMAX II, the screen will show ‘G M II”. G -IR sensors may initially indicate off-scale high or low values, but should quickly return to zero within a few minutes if no target gas is present.

  • Page 17: Figure 4-3: User Menu Screen

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 Press the EDIT key to access the USER MENU display mode. When in user menu display mode, use UP and DOWN to select an item, EDIT to change an item, and NEXT to exit the menu or function and return the GASMAX II to display mode.

  • Page 18: Figure 4-5: Gasmax Data Display

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 Above the LCD display, three LEDs indicate the status of the level and fault alarms. If relays are installed, the LEDs indicate whether the relays are active. Note that if any relay is set for FAILSAFE operation, if LED is ON the relay will be de-energized.
  • Page 19 GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 ALARM 1, ALARM 2 Alarm 1 and Alarm 2 are identical functions that will trigger front panel LED indicators and (if installed) optional alarm relays. Both can be set to activate whenever the input signal goes above or below a given...

  • Page 20: Calibration

    5 minutes. Follow these GASMAX II calibration guidelines: • Calibration accuracy is only as good as the calibration gas accuracy. GDS Corp calibration gases are traceable to NIST (National Institute of Standards and Technology). • Never use calibration gas that has passed its expiration date.

  • Page 21: Figure 5-2: Local Gds-Ir Calibration Setup

    % nitrogen. If the GDS-IR is configured to detect Carbon Dioxide, the zero air mixture should contain nitrogen 99.9% by volume. 3) A fixed flow regulator and a length of flexible tubing. GDS Corp recommends a flow rate of 0.5 liters / minute for standard combustible gases.
  • Page 22 GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 IR ZERO PROCEDURE NOTE: This step should be performed initially and every 3 months for the first year, then every six months thereafter. If not performing the IR Zero procedure, proceed to GASMAX CALIBRATION PROCEDURE shown below.

  • Page 23: Maintenance

    6 MAINTENANCE NORMAL MAINTENANCE Normal maintenance for the GASMAX II + GDS-IR primarily involves periodic inspection of the unit followed by zeroing the GDS-IR and then calibrating the GASMAX + GDS-IR combination. GDS Corp recommends calibration at least every three to six months, or more often if temperature extremes, vibration, the presence of incompatible gases or other environmental factors may exist.

  • Page 24: User Menus

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 7 USER MENUS MAIN MENU GASMAX II setup variables are stored in non-volatile memory and can be modified by the end user to better match a particular application. The GASMAX II Main Menu tree is shown below. To access the Main Menu, swipe the magnetic wand over the EDIT key.

  • Page 25: Figure 7-2: System Config Menu

    0, 1 & 2 decimal points displays as “0”, “0.0” & “0.00”. CAL SPAN VALUE sets the engineering units value of the calibration gas. GDS Corp recommends that the calibration gas value be between 25% and 75% of full scale. Calibrating at 100% of scale is not recommended.

  • Page 26: Figure 7-3: Sensor Life Transmission Format

    75%, the GASMAX II transmits 4.75mA during the 5-second interval NOTE: TX SENSOR LIFE SHOULD ALWAYS BE SET FOR NO UNLESS THE 4-20MA RECEIVER IS CAPABLE OF INTERPRETING THE SENSOR LIFE SIGNAL. MOST GDS CORP PROTECTOR SERIES CONTROLLERS INCLUDE THIS CAPABILITY.

  • Page 27: Figure 7-4: Alarm Settings Menu

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 ALARM SETTINGS PAGE The Alarm Settings page covers the Alarm 1, 2, 3 Setup and Event Log menu items. Alarm 1, Alarm 2 and Alarm 3/Fail menus are identical and are therefore described only once. If the optional alarm relays are not installed, the alarm settings only affect the operation of the front panel LEDs.

  • Page 28: Figure 7-5: Rs-485 Modbus Menu

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 DISPLAY EVENT LOG displays the stored events in the Event Log. These include power-on, cold-boot, alarms and alarm acknowledge events. The event log stores the date and time of the most recent 300 events.

  • Page 29: Figure 7-7: Clock Delay Menu

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 INPUT TYPE indicates what kind of input or sensor the GASMAX II is configured to accept and is typically pre-configured at the factory. When installed, Smart Sensors upload sensor type and other data to the GASMAX II and this data may be viewed on the SMART SENSOR information screen.

  • Page 30: Figure 7-9: Diagnostics Menu

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 HELP SCREEN PAGE The Help screen contains several pages of information describing GASMAX II operation. DIAGNOSTICS PAGE The Diagnostics page provides tools for use during setup or testing. Since relays are not available on the GASMAX II, the Relay Test option is not functional.

  • Page 31: Figure 7-11: Xmitter Config Menu

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 CAL Mode until the correct Pass Code is entered. LOW and HIGH security levels always allow static viewing of configuration menus. TECHNICIANS MENU GROUP The TECHNICIANS MENU group consists of the XMITTER CONFIG menu and TECHNICAL PAGE menu. These menus contain items that are typically factory configured depending upon the type sensor and input connected.

  • Page 32: Figure 7-12: Technical Page Menu

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 TECHNICAL PAGE MENU The TECHNICAL PAGE menu is used to adjust certain parameters associated with local or remote sensors. To access the TECHNICAL PAGE menu, enter the Main Menu, move the cursor to the second page and select Technicians Only.

  • Page 33: Figure 7-13: Sensor Balance & Voltage Set Menu

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 WARNING: E CEE I G O ’ E E CI IO VO GE M Y M GE O OY HE SENSOR. Figure 7-13: Sensor Balance & Voltage Set Menu SET GAIN TO UNITY clears any previous calibration O E and G I values to “...

  • Page 34: Troubleshooting

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 TROUBLESHOOTING GDS-IR SHOWS FAULT INDICATION • GDS-IR output < 4mA due to internal error condition. See Maintenance for more information. • Incorrect channel activated. Verify channel connected to GDS-IR is enabled.
  • Page 35 GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 • 03 – Sensor Calibration Error – Contact factory. • 04 – Zero calibration failure – Zero readings must be within 10% of zero. For example, if the range is 0-100 ppm, the zero reading cannot be above 10 ppm. For bridge-type sensors, it may be possible to readjust the balance to restore a zero reading.

  • Page 36: Modbus Interface

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 9 MODBUS INTERFACE The GASMAX II features a full complement of user-accessible MODBUS registers that can provide a complete snapshot of each gas detectors configuration. This includes all real-time data, preset zero, span and calibration values and user-programmable text.
  • Page 37 GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 CH 2 Floating Point 33002 See Channel Floating Point definition Ch 1 Measurement Name 40401 - 40408 16 ASCII characters (2 per register) Ch 2 Measurement Name 40409 – 40416...
  • Page 38 GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 Ch 2 Span Real 41027 Ch 2 Span Divisor 41028 Ch 2 Fault Real 41029 Ch 2 Fault Divisor 41030 Ch 2 Alarm 1 Real 41031 Ch 2 Alarm 1 Divisor...
  • Page 39 GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 ALARM STATUS WORD BIT DEFINITION Alarm Status Word Bit 0 Ch 1 Alarm 1 (1), no alarm (0) Bit 1 Ch 1 Alarm 2 (1), no alarm (0) Bit 2...

  • Page 40: Specifications

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 10 SPECIFICATIONS Model GASMAX II + GDS-IR Single / Dual Channel Gas Monitor Power Input 18-30VDC at < 9 watts (375 mA) with relay board. Max Inrush current < 5x steady state current for < 33 mSec.

  • Page 41: Spare Parts

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 11 SPARE PARTS DISPLAY AND ENCLOSURE I/O Power Supply (Ch1 / Ch2): 10-0233-420 Toxic / 4-20mA 10-0233-D4 4-20mA / 4-20mA 20-0148 GDS-IR interface PCB Bridge ensor IO/Power upply % L E L...

  • Page 42: Figure 11-3: Gds-Ir Remote Sensor Spare Parts

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 Yellow Enclosure: 20-0100 Remote Sensor Yellow Enclosure 20-0152 GDS-IR Junction Box Interface PCB Sensor: GDS-IR-1-110-1 (Methane) GDS-IR-1-111-1 (Propane) GDS-IR-1-116-1 (Ethanol) GDS-IR-1-132-1 (Carbon Monoxide) Contact GDS Corp for additional gases Sensor Accessories...

  • Page 43: Drawings And Dimensions

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 12 DRAWINGS AND DIMENSIONS 5.00 ” ¾” NPT (2x) 2.5” M E A S U R E M E N T N A M E xx.00” Cal Gas Inlet Figure 12-1: GASMAX II + GDS-IR Dimensions (Local Vertical Sensor)

  • Page 44: Figure 12-2: Gasmax Ii + Gds-Ir Dimensions (Local Horizontal Sensor)

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 5.00 ” 2.5” Cal Gas Inlet M E A S U R E M E N T N A M E xx.00” xx.00” Figure 12-2: GASMAX II + GDS-IR Dimensions (Local Horizontal Sensor)

  • Page 45: Figure 12-3: Gds-Ir Dimensions (Remote Vertical Sensor)

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 5.00 ” ¾” NPT (2x) 2.5” xx.00” Cal Gas Inlet Figure 12-3: GDS-IR Dimensions (Remote Vertical Sensor) Page 45...

  • Page 46: Figure 12-4: Gds-Ir Dimensions (Remote Vertical Sensor With Duct Mount)

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 5.0” 2.5” Cal Gas Inlet 6.7” 15.25” / ” – 27 NPT Customer-Supplied Tubing & Fittings 8.25” (Optional) Figure 12-4: GDS-IR Dimensions (Remote Vertical Sensor with Duct Mount) Page 46...

  • Page 47: Figure 12-5: Gds-Ir Duct Mount Hole Cutout Pattern

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 ”  ” ” Figure 12-5: GDS-IR Duct Mount Hole Cutout Pattern Page 47...

  • Page 48: Figure 12-6: Gds-Ir Rain Shield P/N 20-0236 (Horizontal Mount)

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 4.5” 5.10” Figure 12-6: GDS-IR Rain Shield p/n 20-0236 (Horizontal Mount) Figure 12-7: GDS-IR Rain Guard p/n 3000-9005 (Vertical Mount “Koozie”) Page 48...

  • Page 49: Figure 12-8: Wiring Diagram - Local Gds-Ir Sensor

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 m Input IO/Power upply ibbon to isplay Use magnetic wand or local pushbutton to Set Zero Figure 12-8: Wiring Diagram - Local GDS-IR Sensor Page 49...

  • Page 50: Figure 12-9: Wiring Diagram - Remote Gds-Ir Sensor (3-Wire Interface)

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 Use magnetic wand or local pushbutton to Set Zero at IR Sensor m Input IO/Power upply ibbon to isplay IR Zero Unavailable at Display Figure 12-9: Wiring Diagram - Remote GDS-IR Sensor (3-wire Interface)

  • Page 51: Figure 12-10: Wiring Diagram - Remote Gds-Ir Sensor (4-Wire Interface)

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 Use magnetic wand or local pushbutton to Set Zero at IR Sensor m Input IO/Power upply ibbon to isplay Use magnetic wand or local pushbutton to Set Zero at Display...

  • Page 52: Figure 12-11: Wiring Diagram - Local Gds-Ir Using P/N 20-0235 Interface Pcb

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 - m Output - 33-B IO/Power upply ibbon to isplay + V Input Power Common ocal G -I Infrared ensor ocal G -I Figure 12-11: Wiring Diagram - Local GDS-IR using p/n 20-0235 Interface PCB...

  • Page 53: Figure 12-12: Wiring Diagram - Remote Gds-Ir Using P/N 20-0235 Interface Pcb

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 - m Output - 33-B IO/Power upply ibbon to isplay + V Input Power Common emote G -I Infrared ensor emote G Figure 12-12: Wiring Diagram - Remote GDS-IR using p/n 20-0235 Interface PCB...

  • Page 54: Figure 12-13: Wiring Diagram - Dual Remote Gds-Ir

    GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1 - 33- IO/Power upply ibbon to isplay Figure 12-13: Wiring Diagram - Dual Remote GDS-IR Page 54...
  • Page 56 GDS Corp. 1245 Butler Road League City, TX 77573 409-927-2980 409-927-4180 (Fax) ww.gdscorp.com...

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