Ampcontrol DIESELGUARD User Manual Download Page 12

 

Ampcontrol Pty Ltd 

– ABN 28 000 915 542 

DIESELGUARD USER MANUAL 

MAG-179 Version 3 

– APR/16 

 

 

Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version 

 

 Page 12 of 27 

 

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INSTALLATION 

4.1 General Warnings 

These instructions have been designed to assist users of the Dieselguard System with installation. 

Before the Dieselguard System can be installed, there are a number of things that need to be considered 
and understood to prevent incorrect or unsafe operation of the Dieselguard System or the system into 
which it is installed. 

Along with relevant competence, and an understanding of the target application, the following points 
should be considered: 

4.1.1 Ensure that the information provided in this user manual is fully understood. 

It is extremely important that the limitations and functionality of the Dieselguard System 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 technical representative. 

4.1.2 Ensure that the application into which the Dieselguard System is being installed 
has been properly defined, designed and approved. 

Any system intended to mitigate the risk of injury needs to be properly designed and implemented. Such 
a system must be the result of structured risk analysis with the outcomes used to define the system 
requirements. These requirements, in turn, will guide the choice of instrumentation, logic solvers and 
actuators needed to implement the system. Understanding the needs of the system will ensure proper 
selection of equipment. 

4.1.3 Ensure that the Dieselguard System will properly perform the required functions 
within the system design. 

It is important to understand how the Dieselguard System is intended to interact with other equipment 
within a system. For safe and reliable use, it is crucial that neither the Dieselguard System logical 
operation nor its signalling be compromised by incompatibilities with connected equipment. 

4.1.4 Modifications of any form to the Dieselguard System are prohibited. 

The Dieselguard System as supplied has been designed and manufactured to comply with the 
requirements of protection standards. If modifications of any form are made to the Dieselguard System, 
the equipment may no longer be fit for use. If any modifications or damage to the Dieselguard System is 
evident, do not use the equipment and contact Ampcontrol for advice. 

4.2 Mandatory Installation Practices 

The following information must be adhered to when installing the Dieselguard System. Failure to adhere 
to this information may give rise to unsafe operation. 

Using the Dieselguard System in a manner that exceeds its electrical, functional or physical 
specifications, or in a way that is contrary to its operating restrictions, may create risks to personnel 
and/or equipment resulting in injury or death. 

 

The Dieselguard System must be powered within the specified voltage range. 

 

The installation of the Dieselguard System must be carried out by suitably trained and qualified 
personnel. 

 

Identification labels fixed to the Dieselguard System must not be damaged, removed or covered 
before, during or after installation. 

 

The installation is to be in accordance with the relevant installation Standards/Codes of Practice. 

Summary of Contents for DIESELGUARD

Page 1: ...Version 3 April 2016 Designed and manufactured in Australia by Ampcontrol Pty Ltd DIESELGUARD DIESEL MACHINE MONITOR User Manual ...

Page 2: ...n of the manual relates to firmware version V5 of the Dieselguard WARNING The warning symbol highlights a potential risk of injury or death Please share these warnings with other operators CAUTION The caution symbol highlights a potential risk of damage to equipment Please share these cautions with other operators NOTE The note symbol highlights key information Please share these notes with other ...

Page 3: ...ROL PTY LTD reserves the right to make changes to any products described herein to improve reliability function or design and reserves the right to revise this document and make changes from time to time in content hereof with no obligation to notify any persons of revisions or changes AMPCONTROL PTY LTD does not assume any liability arising out of the application or any use of any product or circ...

Page 4: ... 3 Gasguard Transmitter CH4 Sensor 10 3 4 IDA Display Optional 10 3 5 I S Solenoid Valve 11 3 6 Pneumatic Bypass Assembly c w I S Solenoid Valve 11 4 INSTALLATION 12 4 1 General Warnings 12 4 2 Mandatory Installation Practices 12 4 3 Mechanical Installation Information 14 4 4 Electrical Installation Information 16 5 COMMISSIONING AND CALIBRATION 20 5 1 Gasguard Sensor Calibration 20 5 2 Commission...

Page 5: ...8 Figure 3 2 Gasguard Transmitter with Integrated CH4 Sensor 10 Figure 3 3 IDA Display 10 Figure 3 4 I S Solenoid Valve 11 Figure 3 5 Pneumatic Bypass Assembly 11 Figure 4 1 Diesel Machine Monitor Dimensions 14 Figure 4 2 Mounting Hole Locations 14 Figure 4 3 Terminal Layout for Diesel Machine Monitor 15 Figure 4 4 Isometric View of Diesel Machine Monitor s Terminal Block 15 Figure 4 5 Typical Con...

Page 6: ...e design and modifications to the equipment are not permitted Unauthorised changes made to the hardware or operating firmware will void the manufacturer s warranty and may compromise the integrity of the system into which it is installed and other connected equipment 1 1 2 Equipment Knowledge Experience with or understanding of this equipment is essential for the safe installation and removal of t...

Page 7: ...tion Equipment that is found to be damaged or has been modified away from its published specification must not be used Please contact Ampcontrol if the equipment is suspected to be different than that ordered or if it does not match the published specifications 2 3 Storage after Delivery When the equipment is not to be installed immediately proper storage is important to ensure protection of equip...

Page 8: ...Dieselguard system which comprises of external sensors external display control box and the I S solenoid valve The Ampcontrol Dieselguard Machine Monitor is housed in a low profile IP66 stainless steel enclosure with all internal electronics being encapsulated The Diesel Machine Monitor is an Exm ia certified product that is powered from the alternator supply of the vehicle Apart from the supply p...

Page 9: ...nitor is equipped with wireless capability that allows the user to connect to the unit through the use of the Dieselguard Base Station and configure alarm trip points provide real time status information and download logged data The Diesel Machine Monitor is designed not to need regular maintenance or access as such once fitted to the machine it does not need to be accessed 3 2 Diesel Machine Moni...

Page 10: ...libration and service of the sensor and should be mounted in a position to allow for the magnetic screwdrivers to be used and the reading on the screen viewed It is not necessary for the transmitter to be viewed by the driver If the remote head sensor is used bear in mind that if the sensor needs to be replaced easy removal and re installation of the cable is advantageous See Gasguard sensor manua...

Page 11: ...tion The pneumatic connections are Ports 1 and 2 are normally connected when the solenoid is energised Ports 1 to 3 the vent port are connected when the valve is de energised The valve should be connected so that the pressure is released from the downstream side of the valve when de energised See manufacturer s installation and maintenance sheet for additional information 3 6 Pneumatic Bypass Asse...

Page 12: ...s and actuators needed to implement the system Understanding the needs of the system will ensure proper selection of equipment 4 1 3 Ensure that the Dieselguard System will properly perform the required functions within the system design It is important to understand how the Dieselguard System is intended to interact with other equipment within a system For safe and reliable use it is crucial that...

Page 13: ... REPRODUCED IN PART Modifications must not be made to any part of the Dieselguard System As supplied the unit is built to and complies with the relevant standards Modifications to its construction will render the unit non compliant Complete and accurate records of the installation must be kept as part of the site installation WARNING The apparatus is not suitable for use in areas where acetic acid...

Page 14: ...Arrangements The Dieselguard Diesel Machine Monitor can be mounted in any orientation without affecting its operation Since the unit does not require routine servicing it can be mounted in a position that is not normally accessible The lid of the enclosure must be fitted correctly with the Dubbo seals and M6 stainless steel button head screws tightened to at least 0 1Nm This is required to comply ...

Page 15: ...RNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART 4 3 3 Terminal Layout Figure 4 3 Terminal Layout for Diesel Machine Monitor Figure 4 4 Isometric View of Diesel Machine Monitor s Terminal Block 4 20mA 0V SPEEDO 0V OIL 0V RUN 0V ALM RST 0V DEPUTY 0V IDA Sig 0V IDA RED 0V IDA GRN 0V RTD3 RTD2 RTD1 Drv RTD1 Ret RTD1 LO RTD1 HI 0V SOL V 0V IDA V 0V SENSOR V ...

Page 16: ...lied with interconnecting cables the installer is responsible for providing cabling to suit the application Customer Supply Alternator Ex d or Ex e Enclosure Dieselguard Diesel Machine Monitor Control Enclosure 0V TERM 1 TERM 2 TERM 3 TERM 4 TERM 5 PT100 RTD1 RED1 WHITE1 WHITE2 RED2 RTD1 Drv RTD1 Ref RTD1 LO RTD1 HI RTD3 PT100 RTD3 RED1 WHITE1 WHITE2 RED2 PT100 RTD2 RED1 WHITE1 WHITE2 RED2 RTD2 4 ...

Page 17: ... 0V Core 4 of the Type 2S cable should be connected to the ve of the alternator supply The Dieselguard system is not polarity sensitive thus the connections can be reversed if required The polarity markings are present for variants with a non isolated 0V referenced input supply WARNING The apparatus must be installed such that the integral wires are terminated in a suitably certified Ex e or Ex d ...

Page 18: ...e machine to be started following or during a fault condition This should be implemented using a latched or locking contact on a selector switch This operator is normally installed in the control enclosure 4 4 5 IDA Display Connections Terminal Block 1 3 The IDA display output terminals provide supply and control of the Dieselguard System s intrinsically safe display Terminal Block 1 IDA V should ...

Page 19: ...use the Speedo Input should be connected to the 0V terminal to prevent the input from floating 4 4 9 Oil Auxiliary Input Terminal Block 5 The Diesel Machine Monitor is provided with an input for monitoring the voltage output of an auxiliary sensor typically an oil sensor The Oil input accepts a 0 5V input and records this information in the Diesel Machine Monitor s log NOTE If not in use the Oil I...

Page 20: ...sel Machine Monitor during commissioning This is not intended to provide an exhaustive commissioning checklist but should be considered to be a minimum set of tests 5 1 Gasguard Sensor Calibration Prior to being put into service the Gasguard CH4 sensor will need to be calibrated as per the instructions within its user manual 5 2 Commissioning of the Dieselguard System In order to confirm the corre...

Page 21: ...chine Monitor will prevent the diesel machine from being started 6 2 Machine Running The Dieselguard System remains in operation while the machine s engine is running If the ambient CH4 level increases above the allowable during this time the Diesel Machine Monitor will enter one of the two alarm states 6 2 1 First Level Alarm Warning For gas readings between 1 by volume and 1 25 by volume the IDA...

Page 22: ... Machine Monitor s internal battery and within 20 30 minutes the unit should have enough charge for the normal start sequence to be possible If the vehicle is started and the valves are reset and then the engine is not run for sufficient time the battery may not pass its minimum voltage requirement to operate the system The Diesel Machine Monitor has a battery saver cut off voltage and the monitor...

Page 23: ...ally certification labels Check that no modifications have been carried out to installed equipment 7 1 2 Hands On Detailed Inspections A more detailed inspection would include all of the elements of a visual inspection plus some checks that cover the integrity of connections fixtures and fittings In addition to basic visual observations more detailed integrity checks would involve Verify that equi...

Page 24: ... compromise the safety of the unit and voids product warranty It is recommended that the system incorporating the Diesel Machine Monitor be subject to regular functional tests at intervals determined by risk assessment or FMEA These intervals typically coincide with periodic maintenance checks and will cover but not limited to tests such as Calibrating the CH4 detector Comparing the calibration re...

Page 25: ...s before recharge required Charge Time to First Use 3 hours min for 5 re starts following 3 weeks standby Methanometer Supply Voltage Full Load Minimum 8 5Vdc input supply off or battery in empty state Maximum 10 8Vdc input supply active or full battery Voltage No Load 12Vdc Status Indicator Supply Voltage Full Load Minimum 8 5Vdc input supply off or battery in empty state Maximum 10 8Vdc input su...

Page 26: ...terial Stainless Steel 316 1 6mm Dimensions W 320mm D 200mm H 80mm Mounting End flange 4 x M6 6 holes 305x100 Rectangular Pattern Protection Concept Encapsulated to Ex m standard Weight Approximately 10kg Connections Type 16 20mm cable glands with armour retention Connections made via barrier screw terminals Number of Glands 9 Environmental Shock 1000 shocks 40g 3 planes Vibration Low Frequency 0 ...

Page 27: ...ST Part Number Certification Reference Description 121105 E09481 Dieselguard Base Station RF Receiver 106908 E09484 Dieselguard Base Station Radio Version 121425 Dieselguard User Manual 139995 IDA display 121047 Gas Detector Calibration kit 106198 Methane Gas Sensor c w Display 115217 Methane Gas Sensor c w Remote Head on a 5m lead and Display 101768 Methane Gas Sensor c w remote head on a 10m lea...

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