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Ampcontrol Pty Ltd 

– ABN 28 000 915 542 

GASGUARD CH4 GAS SENSOR USER MANUAL 

GSB076 Version 6 

– March/2019 

 

 

Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version 

 

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INSTALLATION 

4.1 General Warnings 

These instructions have been designed to assist users of the Gasguard CH4 Sensor with installation. 

Before the unit can be installed, there are a number of things that need to be considered and understood 
to prevent incorrect or unsafe operation of the unit 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 Gasguard CH4 Sensor 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 Gasguard CH4 Sensor 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 Gasguard CH4 Sensor will properly perform the required functions 
within the system design. 

It is important to understand how the Gasguard CH4 Sensor is intended to interact with other 
equipment within a system. For safe and reliable use, it is crucial that neither the Gasguard CH4 
Sensor logical operation nor its signalling be compromised by incompatibilities with connected 
equipment. 

4.1.4 Modifications of any form to the Gasguard CH4 Sensor are prohibited. 

The Gasguard CH4 Sensor as supplied has been designed and manufactured to comply with the 
requirements of protection standards. If modifications of any form are made to the Gasguard CH4 
Sensor, the equipment may no longer be fit for use. If any modifications or damage to the [Gasguard 
CH4 Sensor is evident, do not use the equipment and contact Ampcontrol for advice. 

4.2 Product Safety Markings 

The ATEX Gasguard methane sensor carries the following information as part of its front panel labelling: 

 

Equipment Type: 

Gas Sensor/Transmitter 

Product Type: 

Gasguard Series 65-6551CH4 

Cert No: 

Baseefa09ATEX0204X 

Ex marking: 

I M1 Ex ia I [-20

C ≤ Ta ≤ +40

C] 

 

These markings provide information identifying the sensor type, certificate number and its safety 
classification. This information, along with that provided on the certificate must be taken into account 
when installing, operating and maintaining this sensor. 

Summary of Contents for Gasguard 65-6551-CH4 Series

Page 1: ...User Manual Part Number 165714 Version 6 March 2019 Designed and manufactured in Australia by Ampcontrol Pty Ltd CATALYTIC METHANE SENSOR ATEX CERTIFIEDMODEL User Manual ...

Page 2: ...N PART 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 operators ENVIRO The enviro environmental symbol highlights...

Page 3: ...ssions in this document or from misuse of the information obtained herein The information in this document has been carefully checked and is believed to be entirely reliable with all of the necessary information included AMPCONTROL 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...

Page 4: ...DUCT OVERVIEW 8 3 1 Sensor Details 9 3 2 Amplifier Electronics PCB 10 3 3 Enclosures 10 4 INSTALLATION 11 4 1 General Warnings 11 4 2 Product Safety Markings 11 4 3 Recommendations 12 4 4 Sensor Location 12 4 5 Mandatory Installation Practices 12 4 6 Mechanical Installation Information 13 4 7 Electrical Installation Information 14 5 COMMISSIONING AND CALIBRATION 15 5 1 Preliminary Checks 15 5 2 Ga...

Page 5: ... TABLE OF FIGURES Figure 3 1 Gasguard CH4 Sensor Stainless Steel Housing 10 Figure 4 1 Catalytic Sensor Dimensions 13 Figure 4 2 Electrical Connection Diagram 14 Figure 4 3 Analogue Output Maximum Loop Resistance 14 Figure 5 1 Gasguard Sensor Control Panel 17 TABLE OF TABLES Table 1 Sensor Cell Cross Sensitivity 9 Table 2 Gasguard Sensor Display Status Codes 15 Table 3 Manufacturer s Periodic Main...

Page 6: ...ual must be observed as an aid towards achieving the safest possible installation Persons responsible for installation maintenance or operation must observe the following instructions 1 1 1 Changes to Equipment Changes in the 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 comp...

Page 7: ...proval documentation for your safety file as applicable prior to wrapping being discarded 2 2 Inspection 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 eq...

Page 8: ...uction Reliable Certified Intrinsically Safe Ex ia LCD Display Non Intrusive Closed Case Calibration NOTE This manual provides commissioning calibration and maintenance instructions for the Ampcontrol Gasguard Sensor Units Because the units are passive monitoring devices operating instructions are not applicable to this equipment NOTE The chemical symbols for toxic gases and oxygen are used extens...

Page 9: ...tively detect the presence of all flammable gases It is unable to distinguish the difference between gases so the sensor will display a reading if any flammable gas is present The table below details the cross sensitivity data for a methane sensor Table 1 Sensor Cell Cross Sensitivity Gas Concentration Reading v v Acetic Acid 4 0 1 45 Acetone 2 6 2 5 Ammonia 15 6 25 Benzene 1 2 2 0 n Butane 1 8 2 ...

Page 10: ... provided for input power power supply return and current loop signal output The electronics require 12VDC operating voltage and transmits a signal in the range of 4 20mA The 4mA signal level indicates a zero gas concentration The 20mA signal indicates that the sensor cell has detected a full span gas concentration ZERO and SPAN adjustment reed relays located on the PCB are used for calibration of...

Page 11: ...sk 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 Gasguard CH4 Sensor will properly perform the required functions within the system design It is import...

Page 12: ...rrents prevent mixing Places such as corners roof or cable spaces are examples For monitoring in areas where there are no air currents mount the sensor as high as possible For areas that are ventilated and have good airflow positioning is not as critical since general mixing will occur For these areas it is recommended to locate the sensor around or just above head height For applications requirin...

Page 13: ... of 25 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART 4 6 Mechanical Installation Information 4 6 1 Enclosure Dimensions Figure 4 1 Catalytic Sensor Dimensions 4 6 2 Mounting Arrangements The Gasguard CH4 Catalytic Sensor is a panel mounted unit see enclosure dimensions for mounting point configuration TOXIC FLAMMABLE 170 198 ...

Page 14: ... allows the connector to be unplugged from the PCB to attach the wiring and then be plugged back into the board A second wiring assembly connects the supply and signal connections from the incoming terminals to the Amplifier electronics PCB Connector J5 within the sensor enclosure Connector J5 is the connection point for incoming cables Figure 4 2 shows these electrical connections Figure 4 2 Elec...

Page 15: ... calibrated to traceable standards However before putting the sensors into operation it is important to verify this calibration This is especially important if the instruments are commissioned sometime after delivery 5 1 Preliminary Checks Perform the following preliminary checks Verify that electrical connections are correct and that they comply with the appropriate standards Apply power to the s...

Page 16: ...ed with a carrier gas This carrier gas must be air for the Gasguard s catalytic sensor to operate correctly Methane balanced with nitrogen must never be used to verify or calibrate the sensor since this will inhibit the function of the catalytic sensor bead Calibration gas should ideally be 50 of full scale However sometimes due to practical restraints and safety reasons the gas may need to be les...

Page 17: ... for 5 seconds e The sensor display 5 will show SAV to confirm that it has saved the zero setting f Turn off the gas flow to the sensor 5 5 Span Calibration Perform a span calibration as follows noting that the gas must be flowing for the duration of the operation a Apply methane to the sensor at the rate of 0 5 to1 litre per minute and allow the reading to stabilise b If the reading lies outside ...

Page 18: ... become obscured by dirt Observations would typically be Check that equipment enclosures cable trays conduits etc are in good order with no physical damage Check that sealed wall boxes are free from water and dust ingress internally Door seals are in good condition Check that connected cables are free from cuts abrasions and obvious signs of damage Cable restraints are in good order and correctly ...

Page 19: ...nspections of equipment These will include checks for both basic mechanical integrity and electrical performance checks The schedule given below is the manufacturer s recommendations Table 3 Manufacturer s Periodic Maintenance Recommendation Time Frame Maintenance Daily Verify operation by visually checking the reading on the respective control unit monitor Investigate any abnormal deviations from...

Page 20: ... to the Amplifier PCB is within specification d Check for loose plug and terminal connections e If the above checks indicate no faults replace the Amplifier electronics PCB Sensor cannot be Spanned or Zeroed a Check the supply voltage to the sensor is within specification b Check for loose plug and terminal connections c Verify the calibration gas being used is of the correct type and is within it...

Page 21: ...nge 5 Max Gas Applied 6 Overall Linearity 5 FSS Maximum Drift Zero 5 FSS per month Sensitivity 5 FSS per month Response Time T90 15 seconds typical Sensing Element Life 2 years Temperature Range 10 to 50 C Resolution 0 10 Humidity 0 95 Storage Temperature 10 to 70 C Certification ATEX Baseefa09ATEX0204X see Appendix A 8 EQUIPMENT LIST Part Number Description 143346 ATEX Certified CH4 Sensor Transm...

Page 22: ...AS SENSOR USER MANUAL GSB076 Version 6 March 2019 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 22 of 25 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART APPENDIX A ATEX CERTIFICATION ...

Page 23: ... GASGUARD CH4 GAS SENSOR USER MANUAL GSB076 Version 6 March 2019 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 23 of 25 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART ...

Page 24: ... GASGUARD CH4 GAS SENSOR USER MANUAL GSB076 Version 6 March 2019 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 24 of 25 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART ...

Page 25: ... GASGUARD CH4 GAS SENSOR USER MANUAL GSB076 Version 6 March 2019 Uncontrolled Copy Refer to Ampcontrol Website for Latest Version Page 25 of 25 APPROVED FOR EXTERNAL DISTRIBUTION PROPERTY OF AMPCONTROL PTY LTD NOT TO BE REPRODUCED IN PART ...

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