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GDS Corp GASMAX BX Operation And Maintenance Manual

Single / dual channel gas monitor
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Operation and Maintenance
Manual
GASMAX BX Single / Dual Channel Gas Monitor
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 BX Single / Dual Channel Gas Monitor GDS Corp. 1245 Butler Road League City, TX 77573 409-927-2980 409-927-4180 (Fax) ww.gdscorp.com...
  • Page 2 GASMAX BX Operation & Maintenance Manual, Revision 1.0 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 GASMAX BX Operation & Maintenance Manual, Revision 1.0 THIS PAGE INTENTIONALLY LEFT BLANK Page 4...

  • Page 4: Table Of Contents

    GASMAX BX Operation & Maintenance Manual, Revision 1.0 CONTENTS SAFETY INFORMATION _______________________________________________ 7 OVERVIEW _________________________________________________________ 8 INSTALLATION & WIRING __________________________________________ 10 INITIAL STARTUP __________________________________________________ 19 CALIBRATION _____________________________________________________ 25 BUMP TEST MODE __________________________________________________ 30 MAINTENANCE ___________________________________________________ 32 USER MENUS _____________________________________________________ 34...
  • Page 5 FIGURE 4-3: GASMAX BX MAIN CHANNEL DISPLAY ..................21 FIGURE 4-4: GASMAX BX TREND GRAPH DISPLAY ................21 FIGURE 4-5: GASMAX BX CHANNEL / SENSOR INFO DISPLAY ..............22 FIGURE 4-6: ACCESSING THE GASMAX BX MENU SYSTEM ................23 FIGURE 5-1: CALIBRATION GAS SETUP ......................26 FIGURE 5-2: CALIBRATION FLOWCHART ....................

  • Page 6: Safety Information

    Users should have a detailed understanding of GASMAX BX operating and maintenance instructions. Use the GASMAX BX only as specified in this manual or detection of gases and the resulting protection provided may be impaired. Read the following WARNINGS prior to use.

  • Page 7: Overview

    The GASMAX BX is enclosed in a CSA / FM / IECEx certified anodized aluminum explosion proof yellow enclosure designed to protect the electronics and make it easy for workers to identify in industrial environments.

  • Page 8: Figure 2-1: Gasmax Bx Gas Detector

    Local sensors are contained in a CSA-certified stainless steel sensor head, typically attached to the bottom of the GASMAX BX as shown below. The normal sensor head includes an integrated stainless steel flame arrestor that must be removed for the detection of certain reactive gases such as chlorine or chlorine dioxide.

  • Page 9: Installation & Wiring

    Factors such as prevailing winds, target gas density, potential leak sources, air movement machinery and similar environmental variables are important when selecting a location for the GASMAX BX gas monitor or gas sensor. Even though the GASMAX BX is designed for rugged service, sensors and electronics should be protected from environmental damage due to water, snow, shock, vibration, and dirt.

  • Page 10: Figure 3-1: Gasmax Bx Power & Signal Wiring

    DC input and terminals “5” and “6” are connected in parallel for ground / common. Terminal “3” is the Channel 1 analog out and Terminal “4” is the Channel 2 analog out. GDS Corp always recommends using shielded wire for signal and power cable.

  • Page 11: Figure 3-2: Gasmax Bx Relay Board

    GASMAX BX Operation & Maintenance Manual, Revision 1.0 OPTIONAL RELAY / MODBUS INTERFACE The optional Relay / Modbus board is connected “piggyback” to the back of the GASMAX BX Display Assembly and provides two level alarm relays, a FAULT relay plus an RS-485 2-wire Modbus RTU serial port.

  • Page 12: Figure 3-3: Modbus Wiring Junction Box

    GASMAX BX power or MODBUS connections without affecting any other MODBUS device. The MODBUS wiring junction box is attached to the GASMAX BX, either on the bottom fitting or one of the side fittings, depending on installation requirements. Specify BOTTOM, LSIDE or RSIDE when ordering.

  • Page 13: Figure 3-4: Single Local Smart Toxic Sensor Configuration

    Channel 1 input on the Power Supply board as shown below. Smart sensors are automatically recognized on power-up and information on range, calibration and production date information is uploaded to the GASMAX BX for use during warmup, operation, and calibration.

  • Page 14: Figure 3-5: Dual Local Smart Sensors

    GASMAX BX Operation & Maintenance Manual, Revision 1.0 DUAL LOCAL SMART DIGITAL SENSORS If the Type 1 Digital Sensor Personality Module is installed, the GASMAX BX supports dual local digital sensors. As always, channel 1 supports any toxic, oxygen, PID or miniature infrared CO2 sensor.

  • Page 15: Figure 3-6: Analog Two-Wire Sensor

    GASMAX BX Operation & Maintenance Manual, Revision 1.0 ANALOG TWO-WIRE SENSOR If the Type 2 Analog Sensor Personality Module is installed, the GASMAX BX supports two-, three- and four-wire analog sensors on both Channel 1 and Channel 2. Two-wire analog sensors typically sink +24VDC and source a 4-20mA signal that represents the sensor’s output.

  • Page 16: Figure 3-7: Analog Three-Wire Sensor

    GASMAX BX Operation & Maintenance Manual, Revision 1.0 ANALOG THREE-WIRE SENSOR If the Type 2 Analog Sensor Personality Module is installed, the GASMAX BX supports two-, three- and four-wire analog sensors on both Channel 1 and Channel 2. Three-wire analog sensors are typically wired for +24V and common input with a non- isolated 4-20mA source output.

  • Page 17: Figure 3-8: Analog Gds-Ir Sensor

    GDS-IR sensors are considered “4-wire” sensors in that they have a fourth wire that can be used to command the sensor to perform a local zero. The GASMAX BX can be programmed to automatically trigger the ‘white wire’ during calibration to ensure that the sensor is properly zero’d each time.

  • Page 18: Initial Startup

    25%. GASMAX USER INTERFACE The GASMAX BX display is shown in Figure 4-1. There are four magnetic switches on the face of the GASMAX BX, arranged in a quadrant around the LCD display; these are labeled NEXT, EDIT, DOWN/CAL and UP/RESET. To activate, or “press” a magnetic switch, swipe the magnetic wand near the switch.

  • Page 19: Figure 4-2: Gasmax Bx Single Channel Display Sequence

    BUMP TEST MODE. DOWN Key – When the Main Channel Display is showing, pressing the DOWN Key will cause the GASMAX BX to enter CAL MODE for the selected channel. See Chapter 5 for more information on CAL MODE.

  • Page 20: Figure 4-3: Gasmax Bx Main Channel Display

    GASMAX BX Operation & Maintenance Manual, Revision 1.0 MORE INFORMATION ON DISPLAY SCREENS The GASMAX BX display is programmed to return to the Main Channel Display after five minutes have passed since any keystroke. If both channels are enabled, the display will show the Dual Channel display.

  • Page 21: Figure 4-5: Gasmax Bx Channel / Sensor Info Display

    Digital, Remote Digital and Analog. A Digital connection allows detailed information from the sensor to be displayed by the GASMAX BX. Local Digital sensors are connected directly to the detector while Remote Digital sensors can be located up to 25 feet.

  • Page 22: Figure 4-6: Accessing The Gasmax Bx Menu System

    GASMAX BX Operation & Maintenance Manual, Revision 1.0 ACCESSING THE GASMAX BX MENU SYSTEM The GASMAX BX has an extensive set of user-accessible menus that enable the operator to modify alarm levels, calibration settings, security settings. The menu also includes an Event Log that stores information on system events such as alarms IN/OUT, calibration and bump test events, POWER-ON events and more.
  • Page 23 GASMAX BX Operation & Maintenance Manual, Revision 1.0 GAS DETECTOR INSTALLATION CHECKLIST To properly install a GASMAX BX gas detector, GDS Corp recommends the following steps be done in order. PROCEDURE Before installation, visually inspect the gas detector and sensor for damage.

  • Page 24: Calibration

    ZERO and SPAN calibration requires only four keystrokes. During CAL MODE the sensor output is disconnected and the GASMAX BX transmits a fixed mA value called the CAL OUTPUT. This value is 4.0 mA (“0”) except In the case of local or remote Oxygen sensors when the output simulates a typical atmospheric reading of 20.8%.

  • Page 25: Figure 5-1: Calibration Gas Setup

    ✓ A fixed flow regulator and appropriate calibration adapter connected to the regulator via a length of flexible tubing. GDS Corp recommends a flow rate of 0.5 liters / minute for standard gases and a flow rate of 1.0 liters / minute for highly reactive gases such as chlorine or chlorine dioxide.

  • Page 26: Figure 5-2: Calibration Flowchart

    GASMAX BX Operation & Maintenance Manual, Revision 1.0 CALIBRATION PROCEDURE FLOWCHART To start a calibration, use the NEXT key show the Main Channel Display for the desired channel and then press the DOWN/CAL key. If the channel is in WARMUP or if calibration is disabled, a warning message will appear.
  • Page 27 Channel Display for the desired channel. Attach the cal adapter and cylinder or Zero Air to the GASMAX BX as shown in Figure 5-1 and Press the DOWN/CAL key to initiate calibration mode. Verify the proper channel and desired Cal Span value as shown on the Calibrate screen.
  • Page 28 GASMAX BX Operation & Maintenance Manual, Revision 1.0 If the Zero Air and Span gas response is acceptable, a message will appear asking the user to remove the Span gas and calibration adapter. Calibration will fail if the resting zero value is greater than +5% of scale or less than -5% of scale.

  • Page 29: Bump Test Mode

    BUMP TEST mode allows the user to apply actual gas to the detector to ensure that the entire unit is operating safely. During the BUMP TEST, the GASMAX BX records the minimum and maximum values while holding the relay, MODBUS and analog outputs to known safe values.

  • Page 30: Figure 6-2: Bump Test Display

    GASMAX BX Operation & Maintenance Manual, Revision 1.0 Figure 6-2: BUMP TEST Display BUMP TEST will automatically exit after 10 minutes of no user activity. The user can add additional time to the BUMP TEST timer by pressing the EDIT key while BUMP TEST is in progress.

  • Page 31: Maintenance

    FAULT, does not respond to gas or can no longer be calibrated, before replacing the sensor check the wiring between the sensor and GASMAX BX for electrical continuity. In addition, check for signs of moisture or corrosion in any of the cabling or junction boxes.

  • Page 32: Figure 7-1: Gasmax Sensor Replacement

    Figure 7-1: GASMAX Sensor Replacement SENSOR REPLACEMENT – LOCAL TOXIC SMART SENSORS For local toxic sensors use GDS Corp type 10-98XX-RYYYY sensors, where “XX” is the gas type and “YYYY” is the full scale range. For example, a replacement H2S (“15”) sensor for 0-100 ppm (“0100”) connected directly to the GASMAX BX would be part number “10-9815-R0100”.

  • Page 33: User Menus

    GASMAX BX Operation & Maintenance Manual, Revision 1.0 USER MENUS To access the GASMAX BX Main Menu, press the EDIT key with a magnetic wand. Use the UP and DOWN keys to select the desired menu and press EDIT to select. Accessing the menu does not affect gas detector operation.
  • Page 34 GASMAX BX Operation & Maintenance Manual, Revision 1.0 SYSTEM CONFIG MENU DEVICE NAME: User programmable System Name. CH 1 SENSOR: Selects sensor input (local, remote, analog) CH2 SENSOR: Selects sensor input (local, remote, analog) DATE: Set real time clock date.

  • Page 35: Figure 8-2: Gasmax Bx Channel Menu

    GASMAX BX Operation & Maintenance Manual, Revision 1.0 CHANNEL MAIN MENU Figure 8-2: GASMAX BX Channel Menu Page 36...
  • Page 36 Allows calibration to be enabled or disabled for this channel. This should be set to NO for analog sensors with local calibration capability. CALIBRATION REMINDER: The GASMAX BX can be programmed to generate a calibration reminder message on 30, 60-, 90-, 120- or 180-day intervals. NONE disables the calibration reminder.
  • Page 37 GASMAX BX Operation & Maintenance Manual, Revision 1.0 CAL HISTORY DESCRIPTOR: Each entry includes the date of the calibration and an indication of PASS or FAIL. These entries cannot be edited. DATE / TIME: The date and time at which the BUMP TEST was started.
  • Page 38 WARMUP The length of time from power-on to normal operation. Value based on sensor. MARKER MSG When using analog sensors, the GASMAX BX can be programmed to display up to three different messages depending on the analog input value. RANGE: The full scale range of the sensor.
  • Page 39 Can be set to 4-20mA or 0-20mA. If set the 0-20 mA, input error values below 4 mA will be transmitted out of the GASMAX BX. If set to 4-20mA, the GASMAX BX will not pass values below 4 mA and instead show FAULT (0 mA) MB ENABLE: Enables the serial MODBUS slave interface.
  • Page 40 PASSCODE: A numeric value that must be entered in the Wireless App to connect to the GASMAX BX. If the code is “0” then no entry has to be made. RESET: Forces the wireless chip to reset.
  • Page 41 GASMAX BX Operation & Maintenance Manual, Revision 1.0 SYSTEM SECURITY MENU SECURE LEVEL: The select SECURE CODE: Mode settings are NORMAL and FAILSAFE. In NORMAL mode, the relay is DIAGNOSTICS MENU SOURCE: The selected source of the relay alarm signal. Can include A1, A2 or A3 alarms, calibration events or external MODBUS inputs.
  • Page 42 GASMAX BX Operation & Maintenance Manual, Revision 1.0 MAINTENANCE MENU SOURCE: The selected source of the relay alarm signal. Can include A1, A2 or A3 alarms, calibration events or external MODBUS inputs. MODE: Mode settings are NORMAL and FAILSAFE. In NORMAL mode,...

  • Page 43: Troubleshooting

    If requesting data from 31003 (Ch 1) and 31005 (Ch 2) and the received value is • corrupted, make sure the GASMAX BX Byte Order is set properly for the receiving device. When reading floating point numbers, also be sure to set the displayed decimal point properly.
  • Page 44 • SOFTWARE RESET (“COLD BOOT”) If the GASMAX BX display shows ‘nonsense’ characters or one or more of the settings appear to be corrupted, performing a “Cold Boot” will restore factory default values in the non- volatile memory and may clear the problem. To perform a ‘Cold Boot”, hold the magnetic wand over the EDIT key while applying power.

  • Page 45: Modbus Interface

    MODBUS INTERFACE MODBUS REGISTERS The GASMAX BX features a set of user-accessible MODBUS registers that provide a snapshot of the gas detector live readings and user configuration, including real-time data, preset zero, span and calibration values, alarm status, relay status and user-programmable text.
  • Page 46 GASMAX BX Operation & Maintenance Manual, Revision 1.0 Variable Name Alias Read Write Notes SENSOR 1 CONFIG Ch1 Zero Value 31011 32-bit float in engineering units Ch1 Full Scale Value 31013 32-bit float in engineering units Ch1 Alarm 1 Value...
  • Page 47 GASMAX BX Operation & Maintenance Manual, Revision 1.0 Variable Name Alias Read Write Notes SYSTEM CONFIG Device Type 31151 Packed ASCII Characters (2 / register) Identifier 31161 Packed ASCII Characters (2 / register) Serial Number 31171 Packed ASCII Characters (2 / register)

  • Page 48: System Events

    GASMAX BX Operation & Maintenance Manual, Revision 1.0 SYSTEM EVENTS The GASMAX BX includes a non-volatile event log that records channel-specific and system-level events such as alarms, calibration attempts, sensor installation and much more. Events are sourced from three sources. System events are those associated with the device and not any specific channel.
  • Page 49 GASMAX BX Operation & Maintenance Manual, Revision 1.0 CALS LOW Span calibration failed: Span reading too low CALS HI Span calibration failed: Span reading too high CALS TIM Span calibration failed: Length of time needed to establish the span- calibration reading exceeded the preset limits.

  • Page 50: Specifications

    Universal input supports all GDS Corp GASMAX BX smart sensor types Input include toxic gases, oxygen, photoionization and infrared CO2 sensors Channel Two Digital input for all GDS Corp GASMAX BX toxic and oxygen sensors Input Accuracy +/- 5% of full scale (typical)

  • Page 51: Spare Parts

    Power Supply Board 20-0257 Type 1 SPM 20-0258 Type 2 SPM Yellow Enclosure: 10-0160 GASMAX BX Enclosure Sensor Head Assembly: 50-0011 Toxic, PID, CO 50-0011R Toxic / Reactive Gas Figure 13-1: GASMAX BX + Local Sensor Spare Parts Page 52...

  • Page 52: Figure 14-2: Gasmax Sensor Head

    GASMAX BX Operation & Maintenance Manual, Revision 1.0 GASMAX BX SENSOR HEAD Sensor Head Assembly (See list above): 50-0011 Sensor head assembly Sensor: 50-95xx-Rxxxx Toxic, Oxygen, PID, CO2 Sensor Figure 13-2: GASMAX Sensor Head SENSOR HEAD ACCESSORIES Sensor Head Splash Guard...

  • Page 53: Drawings And Dimensions

    GASMAX BX Operation & Maintenance Manual, Revision 1.0 DRAWINGS AND DIMENSIONS 5.0” 4.25” 2.25” 3/4” NPT 7.75” (2x) 2.0” Figure 14-1: GASMAX BX DIMENSIONS Page 54 7.75”...
  • Page 54 GASMAX BX Operation & Maintenance Manual, Revision 1.0 Page 55...

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