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GDS Corp GASMAX GX Operation And Maintenance Manual

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Operation and
Maintenance
Manual
GASMAX GX Single Channel Gas Monitor
GASMAX GX-152 Single Channel Gas Monitor
GDS Corp
1245 Butler Road
League City, Texas 77573
409-927-2980
409-927-4180 (Fax)
www.gdscorp.com

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  • Page 1 Operation and Maintenance Manual GASMAX GX Single Channel Gas Monitor GASMAX GX-152 Single Channel Gas Monitor GDS Corp 1245 Butler Road League City, Texas 77573 409-927-2980 409-927-4180 (Fax) www.gdscorp.com...
  • Page 2 WALL TO COMPLY WITH THE HAZARDOUS LOCATION RATING OF THIS PRODUCT DANGER DANGER: THE GDS CORP GASMAX GX GAS DETECTOR IS AN AMBIENT AIR HAZARDOUS GAS SENSOR ASSEMBLY AND ONLY MONITORS IN THE IMMEDIATE VICINITY OF THE SENSOR HOUSING. A SITE SURVEY IS REQUIRED IN ORDER TO DETERMINE THE BEST PLACEMENT AND QUANTITY OF SENSOR ASSEMBLIES.

  • Page 3: Table Of Contents

    ZERO OFFSET SETTING ............................ 35 3.13.2 FULL-SCALE OFFSET SETTING ........................36 3.14 DISPLAY SCREEN CONTRAST SETTING ......................36 3.15 RETURN TO FACTORY DEFAULT SETTINGS ....................37 3.16 RESET NULL & CALIBRATION VALUES ......................39 OPERATION SETTINGS ............................. 40 GASMAX GX USER’S MANUAL REV 1.0...
  • Page 4 APPENDIX A: INTRODUCTION TO 4-20 mA CURRENT LOOP SIGNALS ................55 APPENDIX B: MODBUS COMMUNICATIONS......................... 57 APPENDIX C: MODBUS REGISTER MAP ..........................59 APPENDIX D: PRODUCT WARRANTY STATEMENT ......................61 APPENDIX E: INFORMATION ABOUT RMA SERVICE REPAIRS ..................63 GASMAX GX USER’S MANUAL REV 1.0...

  • Page 5: Product Overview

    Non-intrusive interface with the GASMAX GX is made possible by use of the GDS Corp Magnetic Tool included in the purchase of the device. The GASMAX GX display screen will always show the present concentration of gas being detected by the sensor assembly.

  • Page 6: Product Specifications

    Safety Approvals Enclosure Ratings Explosion/Flame-Proof Hazardous Location Certification Class I, Division 1, Groups C and D Ex db IIB T6 Gb Class I, Zone 1, AEx db IIB T6 Gb Tamb -40⁰C to +54⁰C GASMAX GX USER’S MANUAL REV 1.0...

  • Page 7: System Diagrams

    ② 13 Enclosure Lid Locking Screw ⑦ ⑪ 14 Display Screen 15 Optional Antenna Fitting (Replaces Item 4) 16 Optional Antenna 17 Enclosure Lid 18 Cal Kit (Sold Separately) ⑩ ⑧ ⑨ ⑰ ⑱ GASMAX GX USER’S MANUAL REV 1.0...

  • Page 8: Internal System Diagram

    Power Input/4-20mA Output Terminal Block Radio Module (If equipped) Sensor Housing Socket Antenna Fitting Connector (If equipped with a radio module) Relay 1 Terminal Block (If equipped with relays) Relay 2 Terminal Block (If equipped with relays) GASMAX GX USER’S MANUAL REV 1.0...

  • Page 9: Assembly Diagram

    Explosion Proof Plug (If not equipped with a radio module) Sensor Housing Base Sensor Element 10 Sensor Rain Guard 11 Sensor Housing Cap with Flame Arrestor 12 Analog Sensor Board 13 Sensor Housing Plug GASMAX GX USER’S MANUAL REV 1.0...

  • Page 10: Installation And Start-Up

    Industrial Hygiene (IH) professionals to determine the final quantity and placement of your gas detection devices. The primary purpose of the GASMAX GX is to provide early warning of the accumulation of hazardous gas to minimize hazards to people and property. Proper placement of the device is paramount to achieving this goal.

  • Page 11: Product Mounting

    The GASMAX GX has several basic wiring configurations, dependent upon the desired usage and functionality intended by the end-user. All GASMAX GX units require +12 to +35 Volts of wired DC power to operate. Data communication from the device, through either the 4-20 output or the RS-485 Modbus connection, to an external location are optional.

  • Page 12: Opening The Enclosure

    2.3.2 CONNECTING POWER To provide power to the GASMAX GX, connect the power cable from the sensor terminal block on a GDS Corp controller, or alternate user supplied power source, to the GASMAX GX power terminal block located on the back of the control board.
  • Page 13 To utilize the added functionality of the device, additional wiring is necessary. If a GDS Controller is not used, the GASMAX GX can be powered from any +12 to +35 VDC power supply capable of supplying at least 250 mA.

  • Page 14: Connecting 4-20 Ma Output

    2.3.3 CONNECTING 4-20 MA OUTPUT To utilize the 4-20 mA wired data output feature of the GASMAX GX, you will need to connect the signal cable from your GDS Corp Controller sensor terminal block to the GASMAX GX power terminal block located on the control board.
  • Page 15 INSTALLATION AND STARTUP GDS CONTROLLER GASMAX GX SENSOR TERMINAL POWER TERMINAL +12 to +35 VDC WHITE +12 to +35 VDC WHITE BLACK BLACK 4-20 mA GREEN 4-20 mA GREEN CONTROLLER GASMAX GX GASMAX GX USER’S MANUAL REV 1.0...

  • Page 16: Connecting Rs-485

    Modbus data communications, you will need to connect the Modbus cable from the controller RS-485 input terminal block to the GASMAX GX RS-485 output terminal block located on the control board of the unit. Refer to the following instructions for how to wire your device: On the GASMAX GX Detector: 1.
  • Page 17 GASMAX GX NOTICE If a GDS Corp controller is not used, the GASMAX GX can be connected to a Programmable Logic Controller (PLC) for RS-485 Modbus data communications. For integration and setup, refer to the Modbus Register Map found in Appendix C of this manual.

  • Page 18: Connecting Relays/Alarms

    INSTALLATION AND STARTUP 2.3.5 CONNECTING RELAYS/ALARMS The GASMAX GX relays are commonly used to power and control external alarming devices, such as alarm lights (visual) and horns (audio). Refer to the following for how to wire your device. If you do not have relays in your GASMAX GX skip to section 2.3.6 CONNECTING THE FAULT TERMINAL.
  • Page 19 +12 to +35 VDC BLUE 4-20 mA BLUE NOTICE It is recommended that the relay connections are wired as normally-open (NO). However, normally- closed (NC) wiring configurations provide an inherent fail-safe and may be preferred. GASMAX GX USER’S MANUAL REV 1.0...
  • Page 20 3. Locate the power terminal block on the control board and complete the following: a. Connect the external alarm device ground (BLACK) wire to the “GND” terminal. EXTERNAL GASMAX GX GASMAX GX ALARMING DEVICE RELAY 1 TERMINAL POWER TERMINAL +12 to +35 VDC BLACK BLACK 4-20 mA GASMAX GX USER’S MANUAL REV 1.0...
  • Page 21 3. Locate the power terminal block on the control board and complete the following: a. Connect the external alarm device ground (BLACK) wire to the “GND” terminal. EXTERNAL GASMAX GX GASMAX GX ALARMING DEVICE RELAY 1 TERMINAL POWER TERMINAL +12 to +35 VDC BLACK BLACK 4-20 mA GASMAX GX USER’S MANUAL REV 1.0...
  • Page 22 2. Locate the Relay 2 terminal block on the radio/relay board and complete the following: a. Connect the power (BLUE) wire from the “COM” terminal of Relay 1 to the “COM” terminal. GASMAX GX-152 GASMAX GX-152 RELAY 1 TERMINAL RELAY 2 TERMINAL BLUE BLUE GASMAX GX USER’S MANUAL REV 1.0...
  • Page 23 3. Locate the power terminal block on the control board and complete the following: a. Connect the external alarm device ground (BLACK) wire to the “GND” terminal. EXTERNAL GASMAX GX-152 GASMAX GX-152 ALARMING DEVICE RELAY 2 TERMINAL POWER TERMINAL +12 to +35 VDC BLACK BLACK 4-20 mA GASMAX GX USER’S MANUAL REV 1.0...
  • Page 24 3. Locate the power terminal block on the control board and complete the following: a. Connect the external alarm device ground (BLACK) wire to the “GND” terminal. EXTERNAL GASMAX GX-152 GASMAX GX-152 ALARMING DEVICE RELAY 2 TERMINAL POWER TERMINAL +12 to +35 VDC BLACK BLACK 4-20 mA GASMAX GX USER’S MANUAL REV 1.0...

  • Page 25: Connecting The Fault Terminal

    Connect the external fault device power (RED) wire to the “+” terminal. b. Connect the external fault device ground (BLACK) wire to the “-” terminal. EXTERNAL GASMAX GX FAULT DEVICE FAULT TERMINAL PWR/+ GND/- BLACK BLACK GASMAX GX USER’S MANUAL REV 1.0...
  • Page 26 INSTALLATION AND STARTUP GASMAX GX USER’S MANUAL REV 1.0...

  • Page 27: Closing The Enclosure

    2. Using the thumbscrews, gently push to seat the internal system into the mounting posts. NOTICE The thumbscrews on the GASMAX GX function ONLY as thumb-holds for ease in removal of the internal system from the base of the enclosure. Do NOT attempt to loosen or tighten the thumbscrews when opening or closing the enclosure.

  • Page 28: Normal Operating Mode

    When the fault is corrected, the unit will return to normal operating mode. For a list of the fault codes and warning symbols of the GASMAX GX, and their associated meaning, refer to the Product Troubleshooting section of this manual.

  • Page 29: Product Settings And Configuration

    NOTICE Triggering relays at the GASMAX GX will also simulate low- and high-level alarm relays at the controller. Controllers cannot distinguish between real and simulated data received. When the controller relays are triggered, alarming devices will perform as intended, initiating emergency procedures as if a harmful or toxic gas was actually present.

  • Page 30: Performing The Relay Test

    3. Press the MENU button to advance to the System Information screen. 3.2 NETWORK ID The Network ID is used to synchronize wireless communication between the GASMAX GX and controller: There are 52 networks available with the 900 MHz radio.

  • Page 31: System Information

    The days since the sensor assembly was last calibrated, only updates while the unit is turned on. The calibration number of the sensor, used for diagnostic purposes. ◼ This screen is for informational purposes only. 1. Press the MENU button to advance to the Unit Information screen. GASMAX GX USER’S MANUAL REV 1.0...

  • Page 32: Unit Information

    1. Press the ADD or SUB button until the Background is set to the desired level. 2. Press the MENU button to advance to the Relay 1 latching/non-latching setting screen. NOTICE This page will not appear if no radio module is installed. Please skip to section 3.7. GASMAX GX USER’S MANUAL REV 1.0...

  • Page 33: Latching And Non-Latching Relay Settings

    MUST be manually reset at the device, regardless of the change in gas detection level readings. The factory default settings on the GASMAX GX-152 for Relay 1 and Relay 2 are non-latching. During installation and setup, Relay 1 and Relay 2 are commonly customized as the following:...

  • Page 34: Relay 2: Latching/Non-Latching Setting

    The fail-safe setting should ONLY be enabled to provide enhanced safety protection when the fault terminal CANNOT be used. The factory default settings on the GASMAX GX for Relay 1 and Relay 2 fail-safe are No (Off). GASMAX GX USER’S MANUAL REV 1.0...

  • Page 35: Relay 1: Fail-Safe Setting

    PRODUCT SETTINGS AND CONFIGURATION If the fault terminal cannot be used, GDS Corp recommends one of the following configurations: Recommended Configurations for Relay Fail-Safe Setting Power Source Relay Wiring Fail-Safe Outcome GASMAX GX Normally-Closed (NC) No (Off) Normal Operation: Closed...

  • Page 36: Fault Terminal Fail-Safe Setting

    1. Use the ADD button to select manual calibration and the SUB button to select auto calibration. 2. Press the MENU button to advance to the Modbus Address Setting screen. GASMAX GX USER’S MANUAL REV 1.0...

  • Page 37: Modbus Address Setting

    1 to 255. Eight of the addresses are used for internal system settings, leaving addresses 1 to 247 available for your device. The RS-485 Modbus communication parameters used in GDS Corp devices is 8 data bits, no parity, and 1 stop bit; these parameters are fixed and cannot be changed. The floating-point data values are presented with the least significant bytes first.

  • Page 38: Modbus Baud Setting

    MUST match the baud rate setting on the attached GDS Corp controller, or other Modbus device. All GDS Corp devices have factory default Modbus baud settings of 9600 bps. The RS-485 Modbus communication parameters used in all GDS Corp GASMAX GX devices are...

  • Page 39: Ma Offset Settings

    GASMAX GX no longer matches the reading on the monitoring device, the 4-20 mA offset will need to be recalibrated. The factory default settings on the GASMAX GX for the 4-20 mA offset are 4.00 mA for the zero offset and 20.00 mA for the full-scale offset.

  • Page 40: Full-Scale Offset Setting

    Due to varying external elements, such as extreme sunlight, the brightness of the display screen may need to be adjusted for optimum viewing. The factory default setting on the GASMAX GX for the display screen contrast is 29, approximately 45% of the contrast scale. The contrast setting ranges from 1 to 64.

  • Page 41: Return To Factory Default Settings

    3.15 RETURN TO FACTORY DEFAULT SETTINGS Returning the GASMAX GX to its factory default settings will reset all customization of the device, including the null and calibration settings of the sensor element. GM/GX Product and Configuration Factory Default Settings...
  • Page 42 SUB button to select “No” to continue to the Reset Null & Cal Only screen. NOTICE If the GASMAX GX is reset to the factory default settings, ALL configuration steps MUST be repeated and the device MUST then be nulled and calibrated for proper operation of the device.

  • Page 43: Reset Null & Calibration Values

    SUB button to select “No” to leave the product settings and configuration menu and to return the device to normal operating mode. NOTICE If the GASMAX GX stored Null and Calibration values are reset the device MUST be nulled and calibrated for proper and safe operation of the device. GASMAX GX USER’S MANUAL REV 1.0...

  • Page 44: Operation Settings

    4 OPERATION SETTINGS At the time of installation, when the power is first applied to the GASMAX GX, the unit is automatically powered on and begins the startup sequence. During the 1-minute warmup, the display will show a countdown of the time remaining until the system start-up is complete.

  • Page 45: Nulling The Sensor (Auto Null)

    SENSOR CALIBRATION Calibration is the process of evaluating and adjusting the precision and accuracy of measurement equipment. Although GDS Corp calibrates every device at the factory, for best accuracy, the detector SHOULD be calibrated in the environment where it is installed.
  • Page 46 4. The unit will automatically begin the 6-second null process. During null, the display will show a countdown of the time remaining until the process is complete. 5. When null process is complete, press the MENU button to advance to the calibration screen. GASMAX GX USER’S MANUAL REV 1.0...

  • Page 47: Calibrating The Sensor (Manual Cal)

    The sensor element will need to be replaced before completing the null and calibration process. 6. When calibration is complete, detach the Calibration Adapter Kit from the sensor housing and reaffix the sensor housing cap. Press the MENU button to advance to the Low Alarm Setting screen. GASMAX GX USER’S MANUAL REV 1.0...

  • Page 48: Calibrating The Sensor (Auto Cal)

    3. Use the ADD and SUB buttons to adjust the concentration to the calibration gas being used. Press the MENU button to save the gas concentration setting and to advance to the calibration start screen. 4. Affix a Calibration Adapter Kit (sold separately) to the sensor housing of the device. GASMAX GX USER’S MANUAL REV 1.0...
  • Page 49 8. When calibration is complete, detach the Calibration Adapter Kit from the sensor housing and reaffix the sensor housing cap. Press the MENU button to advance to the Low Alarm Setting screen GASMAX GX USER’S MANUAL REV 1.0...

  • Page 50: Sensor Alarm Settings

    All alarm set-points are field adjustable up to 60% of the full scale gas concentration. The factory default setting on the GASMAX GX for the LOW alarm is 10% of full scale and 15% of full scale for the HIGH alarm. The LOW alarm set-point should NEVER be programed to a higher setting than the HIGH alarm set-point.

  • Page 51: Sensor Low Alarm Rise/Fall Setting

    1. Use the ADD and SUB buttons to increase and decrease the HIGH alarm set-point, respectively. 2. Press the MENU button to save the desired setting and to advance to the sensor HIGH alarm rise/fall setting screen. GASMAX GX USER’S MANUAL REV 1.0...

  • Page 52: Sensor High Alarm Rise/Fall Setting

    4.3 SENSOR RADIO ADDRESS The GASMAX GX radio address is adjustable from 1 to 255, each sensor assembly on the network needs a unique radio address in order to avoid a fault at the receiving monitor. The default radio address is 1.

  • Page 53: Manual Reset For Activated Latching Alarms

    Press the MENU button ONLY once to deactivate the latching alarm(s). Pressing the MENU button more than once will activate and open the operation settings menu.  The alarms will NOT activate, even in the presence of gas, until you have exited the menu mode for approximately 1 minute. GASMAX GX USER’S MANUAL REV 1.0...

  • Page 54: Product Maintenance

    The presence of such substances in an area does not preclude the use of this device, but the likelihood of the shortened lifetime of the sensor element, as a result, should be noted. Use of the GASMAX GX in these environments may require more frequently scheduled maintenance to ensure safe and reliable system performance.

  • Page 55: Sensor Replacement

    5.2 SENSOR REPLACEMENT The sensor elements used in the GASMAX GX detects gas in either % or PPM concentrations, this element must be fully functional in order for the system to operate correctly. GDS Corp recommends replacing the sensing element whenever a slow response to gas is observed during the normal calibration process.

  • Page 56: Product Troubleshooting

    • Radio module is not working in the sensor 3. Replace sensor radio module. assembly When replacing the sensor element, the detector must be nulled and calibrated. System faults will activate the fault terminal on the device. GASMAX GX USER’S MANUAL REV 1.0...

  • Page 57: Product Replacement Parts And Accessories

    APPENDICES 5.4 PRODUCT REPLACEMENT PARTS AND ACCESSORIES While not all of the components on the GASMAX GX can be replaced in the field, there are several parts that are replaceable by an GDS Corp Approved Service Technician. To purchase accessories/replacement parts for your device, contact the sales representative of this product for assistance.
  • Page 58 INTRODUCTION TO 4-20 mA CURRENT LOOP SIGNALS APPENDIX B: MODBUS COMMUNICATIONS APPENDIX C: MODBUS REGISTER MAP APPENDIX D: PRODUCT WARRANTY STATEMENT APPENDIX E: INFORMATION ABOUT RMA SERVICE REPAIRS APPENDIX F: INFORMATION ABOUT RMA RETURNS FOR CREDIT GASMAX GX USER’S MANUAL REV 1.0...

  • Page 59: Appendix A: Introduction To 4-20 Ma Current Loop Signals

    4 mA representing the lowest end of the range and 20 mA the highest. The relationship between the current loop and the gas value is linear. In addition, GDS Corp devices use values below 4 mA to indicate special status conditions, as shown below:...
  • Page 60 A digital multi-meter (DMM), or current meter, may be used in conjunction with the monitoring device and/or to test the 4-20 mA current loop signal. To measure the current, place the meter probes in line with the current loop. GASMAX GX USER’S MANUAL REV 1.0...

  • Page 61: Appendix B: Modbus Communications

    Based on the type of circuit used, there is a limit on how many devices that can be connected to a Modbus sensor network. GDS Corp controllers currently allow a maximum of 32 devices on a single network. The data is transferred along the Modbus network at a specified Modbus baud, or rate of speed.
  • Page 62 Shielded, in areas of high noise Long* 1,000 Feet to 4,000 Feet 18 to 20 Gauge Shielded, in areas of high noise (*) Terminating resistor may be required for the last device in the daisy-chain. GASMAX GX USER’S MANUAL REV 1.0...

  • Page 63: Appendix C: Modbus Register Map

    Register Address 1: Hexadecimal numbers Register Address 2: Decimal numbers R/W: Read/Write capable data R: Read-only data FLOAT: Floating point number ENUM: Enumeration UINT: Unsigned integer INT: Integer BFLD: Bit Field (*): Limited by precision GASMAX GX USER’S MANUAL REV 1.0...
  • Page 64 APPENDICES GASMAX GX MODBUS REGISTER MAP ENUMERATION KEYS Register Address 4: Gas Type No Fault Loss of Communication with Sensor Board Response Gas Type Loss of Communication with Sensor H2S – Hydrogen Sulfide Element/Housing SO2 – Sulfur Dioxide Null Error O2 –...

  • Page 65: Appendix D: Product Warranty Statement

    Products”), contained in the original packaging, against defects in materials and workmanship when used normally in accordance with GDS Corp published guidelines for a period of ONE (1) YEAR from the date of original purchase by the end- user/purchaser from the manufacturer or from the product’s authorized sellers/distributors (“Warranty Period”). GDS Corp published guidelines include but are not limited to information contained in technical specifications, operation/user manuals and service communications.
  • Page 66 GDS Corp Warranty service, at their discretion, will (a) repair the device using new or previously used parts that are equivalent to new in performance and reliability, (b) replace the Product with a device that is at least functionally equivalent to the product and is formed from new and/or previously used parts that are equivalent to new in performance and reliability, or (c) exchange the Product for a refund of your purchase price, when an GDS Corp Product is submitted.

  • Page 67: Appendix E: Information About Rma Service Repairs

    To ensure that RMA Service repairs are processed as timely as possible, the RMA number provided to the Customer must be clearly marked on the outside of the shipping container. Any GDS Corp products returned for repair that do not show the RMA number will be returned (unrepaired) COD to the customer.

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