GDS Corp GASMAX II + GDS-IR Operation And Maintenance Manual Download Page 3

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GASMAX II + GDS-IR Operation & Maintenance Manual, Revision 1.1

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CONTENTS

SAFETY INFORMATION _______________________________________________ 6

OVERVIEW _________________________________________________________ 7

INSTALLATION ______________________________________________________ 9

INITIAL SETUP _____________________________________________________ 16

CALIBRATION ______________________________________________________ 20

MAINTENANCE _____________________________________________________ 23

USER MENUS ______________________________________________________ 24

TROUBLESHOOTING ________________________________________________ 34

MODBUS INTERFACE ________________________________________________ 36

SPECIFICATIONS __________________________________________________ 40

SPARE PARTS ____________________________________________________ 41

DRAWINGS AND DIMENSIONS ______________________________________ 43

Summary of Contents for GASMAX II + GDS-IR

Page 1: ...5 Butler Road League City TX 77573 409 927 2980 409 927 4180 Fax ww gdscorp com Operation and Maintenance Manual GASMAX II GDS IR GASMAX Gas Detector with GDS IR Infrared Sensor for Combustibles and Carbon Dioxide ...

Page 2: ...BEFORE OPERATING OR SERVICING ATTENTION POUR DES RAISONS DE SÉCURITÉ CET ÉQUIPEMENT DOIT ÊTRE UTILISÉ ENTRETENU ET RÉPARÉ UNIQUEMENT PAR UN PERSONNEL QUALIFIÉ ÉTUDIER LE MANUE D INSTRUCTIONS EN ENTIER AVANT D UTILISER D ENTRETENIR OU DE RÉPARER L ÉQUIPEMENT REVISION HISTORY Revision 1 0 7 24 16 Initial Release Revision 1 1 6 29 18 Updated wiring diagrams Copyright 2016 GDS Corp All Rights Reserved...

Page 3: ... CALIBRATION ______________________________________________________ 20 6 MAINTENANCE_____________________________________________________ 23 7 USER MENUS ______________________________________________________ 24 8 TROUBLESHOOTING ________________________________________________ 34 9 MODBUS INTERFACE ________________________________________________ 36 10 SPECIFICATIONS _____________________________...

Page 4: ...T 20 FIGURE 5 2 LOCAL GDS IR CALIBRATION SETUP 21 FIGURE 5 3 REMOTE GDS IR CALIBRATION SETUP 21 FIGURE 6 1 GDS IR DISASSEMBLY CLEANING 23 FIGURE 7 1 MAIN MENU FLOWCHART 24 FIGURE 7 2 SYSTEM CONFIG MENU 25 FIGURE 7 3 SENSOR LIFE TRANSMISSION FORMAT 26 FIGURE 7 4 ALARM SETTINGS MENU 27 FIGURE 7 5 RS 485 MODBUS MENU 28 FIGURE 7 6 SENSOR SETTINGS MENU 28 FIGURE 7 7 CLOCK DELAY MENU 29 FIGURE 7 8 CONTR...

Page 5: ...URE 12 6 GDS IR RAIN SHIELD P N 20 0236 HORIZONTAL MOUNT 48 FIGURE 12 7 GDS IR RAIN GUARD P N 3000 9005 VERTICAL MOUNT KOOZIE 48 FIGURE 12 8 WIRING DIAGRAM LOCAL GDS IR SENSOR 49 FIGURE 12 9 WIRING DIAGRAM REMOTE GDS IR SENSOR 3 WIRE INTERFACE 50 FIGURE 12 10 WIRING DIAGRAM REMOTE GDS IR SENSOR 4 WIRE INTERFACE 51 FIGURE 12 11 WIRING DIAGRAM LOCAL GDS IR USING P N 20 0235 INTERFACE PCB 52 FIGURE 1...

Page 6: ...s monitor is designed and constructed to measure the level of certain gases in ambient air Accuracy in atmospheres containing steam or inert gases cannot be guaranteed The GDS IR may be mounted vertically or horizontally Do not mount the GDS IR upside down 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 component...

Page 7: ... enhanced diagnostics not found in previous generation products On board non volatile memory retains all configuration data during power interruptions Two independent 4 20 mA outputs allow for easy connection to control systems or other alarm instrumentation Additional output options include alarm relays and single channel MODBUS slave interface Built in user prompted calibration makes it easy for...

Page 8: ...y Key Features Certified for use in Class I Division 1 Groups B C D hazardous areas CSA performance certified C22 2 No 152 Approved for use in SIL 2 safety systems Standard 4 to 20 mA output current source Requires no routine span calibration Continuous self test automatically indicates a fault Multi layered filtering system protects optics from dirt and water ingress Straight optical path elimina...

Page 9: ...ed flush against a wall GDS Corp recommends that the GDS IR sensor be located in such a way as to allow air to flow past the sensor from any direction In addition space around the GDS IR will allow a Rain Guard p n 3000 9005 to be installed if necessary The type of gas to be detected will determine the recommended height above ground To detect heavy gases such as propane or ethylene mount the sens...

Page 10: ...vailable between the GASMAX display and the GDS IR then the combination will work but the GDS IR hardware zero will have to be done locally at the GDS IR junction box See the chapter on Drawings and Dimensions for details of the remote wiring options HAZARDOUS AREA INSTALLATION GASMAX II monitors and GDS IR Infrared Sensors are certified for use in Class 1 Division 1 hazardous areas Installation i...

Page 11: ...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 Figure 3 1 GASMAX II GDS IR Power Signal Wiring ibbon to isplay IO Power upply Bridge ensor E COM C PW O O G B B TB2 1 12 30VDC Input TB2 2 Channel 1 4 20mA Out TB2 3 Channel 2 4 20mA Out TB2 4 Power S...

Page 12: ...activates if either Channel 1 or Channel 2 exceed the programmed alarm 1 threshold and cannot be acknowledged Relay K2 activates if either Channel 1 or Channel 2 exceed the programmed alarm 2 threshold and can be acknowledged reset from the front panel or via TB3 Relay K3 indicates sensor failure and is always failsafe normally open held closed Remote Alarm Reset TB3 can be used to acknowledge an ...

Page 13: ...ts of wiring terminals for MO B and B signals daisy chain power wiring requires that two wires be installed in the and G terminals on the G M I O Power Supply board This can be difficult if wire sizes are larger than 18ga Further the addition of multiple MODBUS and power wires inside the GASMAX enclosure can create problems and possibly damage components if the display has to be forced into place ...

Page 14: ...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 Specify BOTTOM LSIDE or RSIDE when ordering See Fig 4 8 Figure 3 5 MODBUS Junction Box Installation Options G B G B PW to G M MO B to G M ibbon to isplay IO Power upply 33 PW I COM PW O O G B B I G B G B MO B I MO B I MO B O MO B O ...

Page 15: ...h 4 20mA output shares the same common ground and are therefore not isolated from each other This board is connected piggyback to the back of the GASMAX II Display Assembly GASMAX II units may be field upgraded with this option at any time NOTE THE ISOLATED 4 20MA AND MODBUS RELAY BOARDS SHARE THE SAME CONNECTOR AND THEREFORE CANNOT BE INSTALLED AT THE SAME TIME Figure 3 6 Optional Isolated 4 20mA...

Page 16: ... II arranged in a quadrant around the LCD display these are labeled NEXT EDIT DOWN CAL and UP To activate or press a magnetic switch swipe the magnetic wand near the switch For the balance of this manual the term press will be used to describe activation of any key via the magnetic wand Figure 4 1 Gasmax Single Channel Display Pressing the NEXT key causes the GASMAX display to switch display scree...

Page 17: ...calibration is critically important to the continued safe operation of any gas detection system See Chapter 6 for more information on calibration Figure 4 4 Accessing Cal Mode NOTE TAKE CARE WHEN APPLYING CALIBRATION GAS TO THE GASMAX WHILE NOT IN CALIBRATION MODE THIS WILL CAUSE AN INCREASE IN THE 4 20MA OUTPUT SIGNAL AND MAY RESULT IN UNINTENDED AND UNEXPECTED ALARM CONDITIONS MORE INFORMATION O...

Page 18: ...TS value is shown at the top and Alarm 1 and Alarm 2 levels are shown as dotted A1 and dashed A2 lines PROGRAMMING ALARM SETTINGS GASMAX II gas monitors have front panel LED indicators for ALARM 1 ALARM 2 and ALARM 3 FAULT as well as optional alarm relays Alarm processing will trigger an alarm condition when the input exceeds the programmed value and includes hysteresis to keep the alarm from rapi...

Page 19: ...ALARM 3 USE AS 3rd ALARM ALARM 3 is typically used to indicate FAULT conditions that suggest sensor failure or out of measurement range conditions However some applications require a third level alarm he LARM 3 menu is identical to ALARM 1 and ALARM 2 and may be set to trip at any level NOTE ALARM 3 WILL ALSO TRIP WITH MISSING OR FAILED SENSORS REGARDLESS OF THE PROGRAMMED LEVEL VALUE FINAL TRANSM...

Page 20: ...SMAX 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 Check the SPAN GAS VALUE setting and make sure it matches the calibration gas See Fig 6 2 Always use a GDS Corp calibration cup that completel...

Page 21: ...rd combustible gases 4 A magnetic wand CALIBRATION SETUP The GDS IR infrared sensor has a barbed push on cal gas inlet fitting on the bottom of the sensor Attach the fixed flow regulator and flexible tubing as shown below Calibration may be performed on the GDS IR sensor in either the vertical or horizontal configuration Figure 5 2 Local GDS IR Calibration Setup Figure 5 3 Remote GDS IR Calibratio...

Page 22: ... 1 For dual channel units press the NEXT key on the GASMAX until that the DATA Display screen for the GDS IR channel is shown 2 Enter CAL MODE by pressing the DOWN CAL key and within 5 seconds press the EDIT key The screen will display an APPLY ZERO message With zero air still flowing to the GDS IR press the EDIT key to complete the ZERO calibration 3 If the zero calibration value is within limits...

Page 23: ...low The cover unscrews counterclockwise when viewed from below Inspect the hydrophobic filter for any buildup of dirt or dust If the filter requires cleaning carefully unscrew the setscrew and slide the filter down and away from the GDS IR Clean the filter using compressed air Reinstall the filter setscrew and sensor cover If the sensor indicates a fault condition remove the sensor cover and filte...

Page 24: ...N 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 Figure 7 1 Main Menu Flowchart ...

Page 25: ...eadings and may be set for 0 1 or 2 For example ZERO readings for 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 READOUT DEADBAND forces low values to continue to read zero This is useful when there ...

Page 26: ...R DATA allows the user to manually upload the entire smart sensor database to the GASMAX II from the smart sensor CAL MARKER allows the user to set the 4 20mA output value that is transmitted during ZERO and SPAN calibration This setting is limited to between 2ma and 20mA and is a useful way to indicate to a GDS controller that the unit is in CAL MODE TX SENSOR LIFE causes the GASMAX II 4 20mA out...

Page 27: ...ter tripping at 20 ppm the value must drop below 15 ppm to reset ON DELAY allows entering a maximum 10 second delay before this alarm becomes active This is useful for preventing nuisance alarms caused by brief spikes beyond the set point OFF DELAY allows entering a maximum 120 minute delay before clearing an alarm after the alarm condition is gone This is useful for continuing an alarm function s...

Page 28: ...rical CAL data and sets sensor life to 100 after initial calibration of the new simple sensor The GASMAX II Smart Sensor interface will automatically detect new Smart Sensors and this menu is therefore not available with a Smart Sensor connected RECALL CAL HISTORY recalls each successful calibration These dates may be reviewed by scrolling with the UP DOWN keys R S 4 8 5 M O D B U S S E T U P R T ...

Page 29: ...e zone during installation to make sure that time stamped Event Log entries are correct Figure 7 7 Clock Delay Menu TIME adjusts time of day in hours minutes and seconds DATE adjusts date in month day year WARM UP DELAY sets the amount of time from power on until the 4 20mA output signal begins to track the sensor output Default setting is 60 seconds Maximum value is 255 seconds CAL PURGE DELAY se...

Page 30: ...n against operation by unauthorized personnel or those with malicious intent Figure 7 10 System Security Menu CONTACT NAME is a 12 character ASCII field available for displaying a phone or name of personal who knows the Pass Code Lost Pass Codes may be recovered by entering the locked security menu and holding the UP key for 5 seconds The 4 digit code appears near the bottom of the screen SECURE L...

Page 31: ... key for 5 seconds until the screen appears requesting the special key sequence WARNING TARGET GAS MONITORING AND ALARM PROCESSING ARE NOT ACTIVE WHILE IN THIS MENU Figure 7 11 Xmitter Config Menu O2 TOXIC when set to YES enables the Oxygen Toxic channel Channel 1 LEL CURRENT when set to YES enables the LEL Current channel Channel 2 OUTPUT ZERO SPAN TRIM provides a way to precisely set the GASMAX ...

Page 32: ...refore if the sensor is mounted some distance away from the GASMAX II the excitation voltage may have to be higher to compensate for losses in field wiring S E N S O R B A L A N C E R e a d i n g 3 C o u n t s 4 9 6 U P D N t o C h a n g e N E X T t o E x i t S E N S O R V O L T A G E V o l t s 2 0 4 U P D N t o C h a n g e N E X T t o E x i t W A R N I N G H i g h v o l t a g e m a y d a m a g e ...

Page 33: ...ues and for standard sensors and applications these values should not be changed ZERO CAL VALUE should always be set to RAW MIN MAX COUNTS is factory preset and should not be changed MARKER ACTIVE enables an input level monitor on the channel 2 input if the input is set to accept a 4 20mA signal If Marker Active is set the YES the following actions may be programmed to occur when the input signal ...

Page 34: ...channel 2 combustible Verify that controller MI and M count settings are correct MI counts should be which corresponds to 4mA and MAX counts should be which corresponds to m Verify that the G M MO B address matches the address programmed into the controller s channel configuration CONTROLLER SHOWING MODBUS COMM ERROR Check for incorrect MO B polarity swap and B if unsure no damage will occur Verif...

Page 35: ...ct factory 10 Linearization Data CRC Fail Error in system data file Contact factory SOFTWARE RESET COLD BOOT If the G M display shows nonsense characters or one or more of the settings appear to be corrupted performing a Cold Boot will restore the default values in the non volatile memory and may clear the problem o perform a Cold Boot perform one of the two following procedures Disconnect power H...

Page 36: ... D2A Raw 31001 4 N A 10 bit value 200 4mA 1000 20mA Ch 2 D2A Raw 31002 4 N A 10 bit value 200 4mA 1000 20mA Ch 1 A2D Raw 31003 4 N A 10 bit value from A D converter Ch 2 A2D Raw 31004 4 N A 10 bit value from A D converter Ch 1 Status 31005 4 N A See Channel Status Word definition Ch 2 Status 31006 4 N A See Channel Status Word definition Alarm Status Word 31007 4 N A See Alarm Status Word definiti...

Page 37: ... Cal Zero Real 41001 3 N A Real value without decimal point Ch 1 Cal Zero Divisor 41002 3 N A Divisor 1 10 100 or 1000 Ch 1 Cal Span Real 41003 3 N A Ch 1 Cal Span Divisor 41004 3 N A Ch 1 Zero Real 41005 3 N A Ch 1 Zero Divisor 41006 3 N A Ch 1 Span Real 41007 3 N A Ch 1 Span Divisor 41008 3 N A Ch 1 Fault Real 41009 3 N A Ch 1 Fault Divisor 41010 3 N A Ch 1 Alarm 1 Real 41011 3 N A Ch 1 Alarm 1 ...

Page 38: ...D2A MIN 41043 3 N A Ch 1 D2A MAX 41044 3 N A Ch 2 A2D MIN 41045 3 N A Ch 2 A2D MAX 41046 3 N A Ch 2 D2A MIN 41047 3 N A Ch 2 D2A MAX 41048 3 N A CHANNEL STATUS WORD BIT DEFINITION Channel Status Word Bit 0 Alarm 1 Below 1 Alarm 1 Above 0 Bit 1 Alarm 2 Below 1 Alarm 2 Above 0 Bit 2 Alarm 3 Below 1 Alarm 3 Above 0 Bit 3 Alarm 1 Latch 1 Alarm 1 not latch 0 Bit 4 Alarm 2 Latch 1 Alarm 2 not latch 0 Bi...

Page 39: ...eserved Bit 8 Relay 1 Energized 1 no relay 0 Bit 9 Relay 2 Energized 1 no relay 0 Bit 10 Relay 3 Energized 1 no relay 0 Bit 11 15 Reserved TRANSMITTER STATUS WORD BIT DEFINITION Transmitter Status Word Bit 0 Ch 1 Active 1 Ch 1 inactive 0 Bit 1 Ch 2 Active 1 Ch 2 inactive 0 Bit 2 Secure Level 1 no security 0 Bit 3 Marker Tx LED 1 no marker 0 Bit 4 11 Reserved Bit 12 Relay 1 Failsafe 1 normal 0 Bit ...

Page 40: ...ource outputs with fault and overrange indication Maximum loop resistance is 750 ohms with standard 24VDC supply Fault output 0 0 mA for all fault conditions Optional Output Relay MODBUS interface with 3x 5A SPDT programmable alarm relays Dual isolated 4 20mA outputs Single or dual input MODBUS slave interface no relays Temperature Electronics 40 C to 60 C See Sensor Manual for additional details ...

Page 41: ...O C C O K K3 MO B elay 3 3 B Isolated ual m Output E Out E Out EC Out EC Out Isolated m 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 Display 10 0232 GASMAX Display Yellow Enclosure 10 0160 GASMAX Enclosure MODBUS Relay Board 10 0234 MODBUS Relays 2000 0135 MODBUS only ISOLATED 4 20mA Board 10 0250 Dual 4 20mA Output Sensor GDS IR 1 110 1 M...

Page 42: ...closure 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 20 0236 Rain Shield Horizontal Mount 2000 0057 Rain Guard Vertical Mount 1200 0811 Replacement hydrophobic filter 10 0270 Stainless steel duct mount ...

Page 43: ...R Operation Maintenance Manual Revision 1 1 Page 43 12 DRAWINGS AND DIMENSIONS Figure 12 1 GASMAX II GDS IR Dimensions Local Vertical Sensor M E A S U R E M E N T N A M E 12 E E I I NPT 2x 5 00 2 5 Cal Gas Inlet xx 00 ...

Page 44: ...SMAX II GDS IR Operation Maintenance Manual Revision 1 1 Page 44 Figure 12 2 GASMAX II GDS IR Dimensions Local Horizontal Sensor M E A S U R E M E N T N A M E 12 E E I I 5 00 2 5 Cal Gas Inlet xx 00 xx 00 ...

Page 45: ...GASMAX II GDS IR Operation Maintenance Manual Revision 1 1 Page 45 Figure 12 3 GDS IR Dimensions Remote Vertical Sensor NPT 2x 5 00 2 5 xx 00 Cal Gas Inlet ...

Page 46: ...GDS IR Operation Maintenance Manual Revision 1 1 Page 46 Figure 12 4 GDS IR Dimensions Remote Vertical Sensor with Duct Mount 5 0 2 5 15 25 6 7 Cal Gas Inlet 27 NPT Customer Supplied Tubing Fittings Optional 8 25 ...

Page 47: ...GASMAX II GDS IR Operation Maintenance Manual Revision 1 1 Page 47 Figure 12 5 GDS IR Duct Mount Hole Cutout Pattern ...

Page 48: ...GASMAX II GDS IR Operation Maintenance Manual Revision 1 1 Page 48 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 4 5 5 10 ...

Page 49: ...DS IR Operation Maintenance Manual Revision 1 1 Page 49 Figure 12 8 Wiring Diagram Local GDS IR Sensor ibbon to isplay IO Power upply m Input PW I COM PW O O G B B Use magnetic wand or local pushbutton to Set Zero ...

Page 50: ...ual Revision 1 1 Page 50 Figure 12 9 Wiring Diagram Remote GDS IR Sensor 3 wire Interface ibbon to isplay IO Power upply m Input PW I COM PW O O G B B Use magnetic wand or local pushbutton to Set Zero at IR Sensor IR Zero Unavailable at Display ...

Page 51: ... Page 51 Figure 12 10 Wiring Diagram Remote GDS IR Sensor 4 wire Interface ibbon to isplay IO Power upply m Input PW I COM PW O O G B B Use magnetic wand or local pushbutton to Set Zero at Display Use magnetic wand or local pushbutton to Set Zero at IR Sensor ...

Page 52: ...e Manual Revision 1 1 Page 52 Figure 12 11 Wiring Diagram Local GDS IR using p n 20 0235 Interface PCB ocal G I ibbon to isplay IO Power upply 33 B E COM C PW O O G B B I rom rom rom 3 m Output V Input Power Common ocal G I Infrared ensor ...

Page 53: ... Manual Revision 1 1 Page 53 Figure 12 12 Wiring Diagram Remote GDS IR using p n 20 0235 Interface PCB emote G I ibbon to isplay IO Power upply 33 B E COM C PW O O G B B I rom rom rom 3 m Output V Input Power Common emote G I Infrared ensor ...

Page 54: ...GASMAX II GDS IR Operation Maintenance Manual Revision 1 1 Page 54 Figure 12 13 Wiring Diagram Dual Remote GDS IR ibbon to isplay IO Power upply 33 PW I COM PW O O G B B I ...

Page 55: ......

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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