user manual
Contents
1. SW GAS WARNING 1 GAS WARNING 2 GAS TRIP i LEVEL LEVEL LEVEL 1 000 1 125 1 250 0 7 2mA 7 6mA 8 0mA 700mV 760mV 800mV 0 750 0 875 1 000 1 6 4mA 6 8mA 7 2mA 640mV 680mV 720mV 0 500 0 625 0 750 2 5 6mA 6 0mA 6 4mA 560mV 600mV 640mV 0 250 0 350 0 500 3 4 8mA 5 12mA 5 6mA 480mV 512mV 560mV 0 200 0 225 0 250 4 4 64mA 4 72mA 4 8mA 464mV 472mV 480mV 0 200 0 200 0 250 5 4 64mA 4 64mA 4 8mA 464mV 464mV 480mV 6 7 8 9 Table 8 Gas Warning Trip Levels DIESEL VEHICLE GAS MONITORING SYSTEM 16 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 UNCONTROLLED COPY Check validity before use D 6 2 2 Power Reset Timeout SW3 Auto off time for when the alternator is not running and powering the system Must be set longer than the gas sensor warm up time otherwise system will shut down before the gas sensor has warmed up co so so Table 9 Power Timeout 6 2 3 Gas Sensor Warm up Time SW4 Switch sets the gas sensor warm up time 20 default oo 1 Oo O1 AOIN o Table 10 Gas Sensor Time 6 2 4 LED Duty Cycle SW5 Engineering use only Switch used to set the brightness of the LED display 12 5 25 37 5 50 62 5 75 87 5 100 100 100 Table 11 LED Duty Cyc2. 8 211 IF PtIcoM 8 3 STORAGE INSTALLATION MAINTAINANCE AND REPAIR REQUIREMENTS 9 Noo i c PC nS 9 CM icri T P 9 3 1 3 Maintenance a 00 1 0 70 5 0 0 11 setatis saecu mS M abe o uc Ma E rc Ete 11 4 FRONT PANEL LAYOUT 12 4 1 1 Eight LED BATTERY bar graph 12 4 1 2 Eight LED gas level r 13 4 1 3 Green ALTERNATOR POWER indicator 13 4 1 4 Green FAST CHARGE indicator 13 4 1 5 Green TRICKLE CHARGE indicator r 13 4 1 6 Green OK TO START indicator 13 4 1 7 Amber FAULT SERVICE indicator LED rr 14 4 1 8 Green SYSTEM OK indicator LED tori ia talea 14 4 1 9 One push button labelled POWER 14 ee miege Pete 15 5 1 Power jer 15 stum RO rer RT 15 6 REAR SIDE OF DISPLAY PANEL oue ee ee ee 16 6 1 LED Indicator S u
3. E ER 16 6 2 Rotary SWilIch 8_ m 16 6 2 1 Gas Warning and Trip Levels 2 16 6 2 2 Power Reset Timeout 9 3 17 6 2 3 Gas Sensor Warm up Time 5 4 17 6 2 4 LED Duly Gycle SW5 uuu neha amen 17 p 3 JIAG Port X3 DWAO EET 18 6 4 Console Port X2 4way 18 7 GONFIGURATION 19 7 1 CONSOLE PORT OPERATION obe feum 19 7 2 HELP COMMAND HE 20 T S REPEAT edt 20 7 4 VERSION COMMAND Display 21 7 5 VERSION COMMAND POWER 21 7 6 Solenoid Kick i i o OTT 21 7 7 Battery Charge Shutoff Temperature 21 7 8 Power Board Temperalure Uo netta tous un di ra tUa san db 22 regc itc rr 22 7 10 Battery VO AQ Gee m 22 7 11 Alternator Voltage T eee er ee 22
4. 16 Table 8 Gas Warning and Trip dE MEE DE 16 Table 9 vets teabndenveceeaictoeenceausas suse tecceutasuoe yeceneaneucasadeayaateannesaameasyeassdonete 17 Table 10 Gas Sensor Warm up Time sicccciccissccsecacecetonecicasetcsscetweastdassaciecsdenastenissadenatenentaneentiedenes 17 Table 11 LED Duty Wie cm 17 Table 12 NGVG3 LED Codes Mem 30 FIGURES Figure 1 Vehicle gas monitoring 6 Figure 2 Engine shutdown solenoid 6 Figure 3 Engine shutdown valve and optional quick release exhaust valve 7 Figure 4 Engine shutdown valve body separated from the coil 7 Figure 5 View of Datel y 11 Figure 6 Front Panel o o m om 12 Figure 7 Rear Side of the 18 DIESEL VEHICLE GAS MONITORING SYSTEM 4 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 austdac COPY Check validity befo in II 1 GENERAL DESCRIPTION The Austdac type NGVG3 explosion protected diesel vehicle gas monitoring system is designed to be fitted to an
5. 10 2 1 Table 12 NGVG3 LED Codes COLD START NGVG3 has restarted normally due to swapping batteries May indicate a firmware crash or watch dog trip State is cleared once deputy has checked the system and used the deputy key to reset the vehicle gas monitoring system This can only be done in Normal Mode so if the unit has expired into Sleep mode it must woken using the POWER RESET key 10 2 2 POWER BOARD FAULT Communications lost to the power board Return for service 10 2 3 SENSOR FAILURE Gas sensor is not present open circuit or the 4 20mA 0 4 2 0V levels are below 3 6mA 0 36 10 2 4 GAS TRIP Gas TRIP indicator LED will flash and TO START LED will be extinguished The solenoid will be de energized and will remain in this state until both the gas has dispersed and the deputy has monitored the system and used the deputy key to reset the vehicle gas monitoring system This can only be done in Normal Mode so if the unit has expired into Sleep mode it must woken using the POWER RESET key DIESEL VEHICLE GAS MONITORING SYSTEM 30 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 UNCONTROLLED COPY Check validity before use a Ig 10 2 5 BATTERY TRIP Battery capacity is to low to run the gas sensor and solenoid Exchange the battery pack with a freshly charged battery The unit will then be in a cold start fault which will need to be reset by the deputy 10 2 6 WARM
6. 9 3 WARM UP The unit will start communication to the second microprocessor and it may be briefly observed that the gas trip and battery empty LEDs may flash alternatively until the link between the two processors is active Once communication is established the two gas warning indicators WARN 1 and WARN 2 will alternate flashing while the gas sensor warms up to operating condition After a short delay the READY indicator will be illuminated signifying that the gas detector has warmed up and is providing correct readings of gas concentration DIESEL VEHICLE GAS MONITORING SYSTEM 27 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 Check validity b COPY 9 4 READY TO START After another short delay and if there is not a dangerous level of gas the OK TO START indicator will flash At the same time the engine shutdown solenoid valve will be energized to close the dump port of the engine pneumatic control system The normal start sequence for the host vehicle may now be followed 9 5 RUNNING Once the engine is running at a well established idle speed the alternator will begin to produce power The vehicle gas monitoring system will detect the availability of alternator power and illuminate the ALTERNATOR POWER indicator This indicator will remain on whilst ever the alternator is producing enough power to charge the NGVG3 internal battery If the internal battery is not fully charged the
7. Unit will shut down in 10 seconds Table 1 Battery gauge indicator DIESEL VEHICLE GAS MONITORING SYSTEM 12 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 UNCONTROLLED COPY Check validity TRUM 4 1 2 Eight LED gas level indicator INDICATOR GAS LEVEL Gas concentration exceeds the trip level all LEDs flash for 0 1s every 0 4s Gas concentration exceeds the warning 2 set point flash for 0 1s every 0 4s Gas concentration exceeds the warning 1 set point flash for 0 1s every 0 8s Gas concentration exceeds 80 of warning 2 level Gas concentration exceeds 60 of warning 2 level Gas concentration exceeds 40 of warning 2 level Gas concentration exceeds 20 of warning 2 level Gas concentration exceeds 10 of warning 2 level Table 2 Gas level indicator 4 1 3 Green ALTERNATOR POWER indicator LED Illuminated whenever the alternator is producing enough power to charge and run the gas monitoring system 4 1 4 Green FAST CHARGE indicator LED LED is illuminated whenever the battery is receiving full charge current Typically up to until the battery reaches 95 full charge capacity 4 1 5 Green TRICKLE CHARGE indicator LED Flashes whenever the battery has reached full charge 9596 capacity and only requires a small charge rate to maintain battery condition 4 1 6 Green OK TO START indicator LED Indicator is illumina
8. 7 12 Gas Sensor Voltage assnrrrssssssssssssssssnsssssnssssssssssssrssrssssa 22 1 13 Battery Monilor PEE 23 7 14 EEPROM Gomrdands u u H 23 7 15 Battery Logger Data uuu RERO 24 CALIBRATE ADG 24 7 17 Firmware Download e HR 24 UNIAN ul m mE 25 DIESEL VEHICLE GAS MONITORING SYSTEM 3 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 R UNCONTROLLED COPY austdac lt Cheek validity before use 7 19 PASSWOTO E ARE 25 B TYPICAL OPERATION GY GLE 26 9 OPERATING INSTRUCTIONS nm utt nhan anim ttu 27 So uu nn S ass mus MED oe 27 cuiii 27 S o Walja CT r 27 9 4 Ready IO SUIT oii uu E UR ERU I ERI NUR M IM IM asas DURUM DAN 28 9 5 SWINE OE DO LO T 28 9 6 GaS 75 c r ee 28 o A 28 9 8 Battery Mec EE 29 10 SYSTEM INDICATORS AND ERROR 29 10 1 Mod s o Operation 29 10
9. UP Gas sensor is in the warming up phase 11 GAS INPUT CALIBRATION This is the procedure to calibrate the gas input channel Process is similar for both the voltage and current input models i Enter the password command and set gain to 1 0 and offset to 0 0V NGVG3 PWD NGVG3 gt CALADC SET 1 GAIN 1 0 NGVG3 gt CALADC SET 1 OFFSET 0 0 ii Apply 0 4V 4mA to the gas input a Measure voltage current with calibrated multimeter This is measurement M b Get voltage reading from ADC This is reading R4 NGVG3 PGASC iii Apply 2 0V 20mA to the gas input a Measure voltage current with calibrated multimeter This is measurement M3 b Get voltage reading from ADC This is reading Ro NGVG3 PGASC iv Calculate gain if current source used multiply Mz amp by 100 GAIN M Mi v Calculate offset if current source used multiply by 100Ohm OFFSET Mi R GAIN vi Enter parameters NGVG3 CALADC SET 1 GAIN GAIN NGVG3 gt CALADC SET 1 OFFSET OFFSET vii Confirm calibration a Apply 0 4V 4mA to the gas input b Measure voltage current with calibrated multimeter This is measurement M c Get voltage reading from ADC This is reading R4 NGVG3 PGASC DIESEL VEHICLE GAS MONITORING SYSTEM 31 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 UNCONTROLLED COPY Check validity before use d If if current source used multiply M by 100
10. can be invoked as shown in the following example NGVG3 VER NGVG3 Software 1 01 OxCE6E Configuration OXxFFFF SN 13050001 NGVG3 5 This command is useful when the user needs to know the software version or serial number The program memory checksum is useful to confirm that a software update has completed successfully without any programming errors 7 5 VERSION COMMAND POWER BOARD The power board is potted making the console port in accessible The version of the power board s firmware can be obtained with the PVER command NGVG3 PVER lt Power Board F W Ver 1 2 NGVG3 5 7 6 SOLENOID KICK TIME The solenoid is initially driven by a higher kick current before being held open by a hold current Solenoid kick current time is configurable but should only be changed on advice from Austdac engineering The default time is 100ms SKICK lt SET gt lt time gt Where time is in milli seconds 7 7 BATTERY CHARGE SHUTOFF TEMPERATURE Batteries should not be charged if they are over a pre defined temperature to protect the battery from damage This parameter sets the temperature up to which the NGVG3 will continue to charge the battery Parameter should only be changed on advice from Austdac engineering The default temperature is 70 C lt SET gt temperature Where temperature is in degrees Celsius DIESEL VEHICLE GAS MONITORING SYSTEM 21 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 UNC
11. configured to latch a high methane gas concentration shut down the engine and prevent vehicle operation A deputy is always required to clear the latch via a separately mounted deputy key reset switch The key switch uses a standard Lockwood barrel that may be keyed to suit the mine site key system The diesel vehicle gas monitoring system is available in two models NGVG3 I for a 4 20mA Current input signal from the gas sensor NGVG3 V for a 0 4 2V Voltage input signal from the gas sensor An optional quick release dump valve is available to augment the dumping or release capacity of the standard 6014 valve in large host pneumatic systems that may need to release a large capacity of control air to secure an engine shutdown To indicate that the engine is running the NGVG3 can provide power to run up to four strobes Type MFLA3 06 xx DIESEL VEHICLE GAS MONITORING SYSTEM 5 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 UNCONTROLLED COPY Check validity before use Photograph of diesel vehicle gas monitoring system console M lt gy fi s s F 4 Figure 1 Vehicle gas monitoring system Photograph of engine shutdown valve 6014 with solenoid magnetic coil type AC10 Z3 6 PD94 and 1 55 terminal gland fitted Figure 2 Engine shutdown solenoid valve DIESEL VEHICLE GAS MONITORING SYSTEM 6 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 II x UNCONTROLLED COPY Check vali
12. head may render the vehicle gas monitoring system useless Australian standard 61779 6 should be used as a guide when installing the gas sensor The methane gas sensor could be poisoned and rendered useless if any silicone substances are used near the gas sensor The end user should do a risk analysis at the site to determine the gas levels for the warning and trip levels of the vehicle gas monitoring system The risk assessment should also include the requirement for over ride or bypass facilities to allow evacuation during a medical emergency etc The use of a deputy reset key will also impact on this assessment The application of a Megger to any part of or circuit connected to the vehicle gas monitoring system will result in irreparable damage Welding should not be carried out on the host vehicle if the NGVG3 or gas sensor is fitted Ensure that the NGVG3 is adequately secured to the mounting area Ensure that all screws washers and sealing gaskets are fitted DIESEL VEHICLE GAS MONITORING SYSTEM 10 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 UNCONTROLLED COPY Check validity before use E 5 3 1 3 Maintenance The NGVG3 requires a periodical confirmation that the unit operates as described in the operation instructions The unit is also to be inspected for damage Damaged units are to be returned to Austdac for repairs The Austdac battery type 4 4 is the only item that may be replaced by a suitable quali
13. incu edd E 304 stainless steel Supply o 12VDC nominal Supply Voltage Range o ceti ences st tun iu ted 10 2eVDC Supply CUr qM 1 5A max Solenoid Output Voltage deena 18VDC nominal Sensor Power Output 12VDC nominal Strobe Power Output 5 5VDC nominal Battery standby time full load r Pu EE UE 2 hours minimum Battery standby time in sleep 30 days DIESEL VEHICLE GAS MONITORING SYSTEM 33 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01
14. the POWER RESET push button and enables the gas concentration bar graph display to be easily read The main unit can be mounted above or below the dashboard by simply removing and rotating the two combined terminal chamber cover mounting brackets DIESEL VEHICLE GAS MONITORING SYSTEM 9 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 UNCONTROLLED COPY Check validity before use The main unit should be mounted such that the power cable from the alternator can be easily routed to the rear of the gas monitoring system a Ig Consideration should also be given to the wiring to the engine run shutdown solenoid valve which is typically mounted in the engine compartment of the host vehicle The wiring to and from the gas sensor should also be designed such that it is well protected from physical damage A DEPUTY KEY RESET when fitted to the vehicle should be located such that it can t be damaged when the host vehicle is being used in its normal way The main control unit should not be placed in a location that would subject the unit to vibration directly from the diesel engine of the host vehicle The gas sensor head should not be placed in a location where it will be subject to direct exhaust fumes engine or transmission oils and excessive heat The gas sensor head should not be placed in a heavily shrouded location that has little air movement when the vehicle is moving Failure to correctly position the gas sensing
15. the vehicle and the gas monitoring system installation for any damage and confirm that it is in good functional condition and report to the mine management as necessary The gas sensing head on some installations may be in a location that can gather coal or rock dust The dust must be cleared away before operating the vehicle The diesel vehicle gas monitoring system shall be system checked in accordance with AS2290 3 on a daily weekly and monthly basis The gas sensor component of the installation shall carry a valid NATA calibration certificate The NATA certificate shall be updated every six months 9 2 POWER UP To allow the host vehicle engine to be started the vehicle gas monitoring system must be on operating providing power to the gas sensor and have determined that there is no flammable gas hazard Only after all these conditions have been met will the vehicle gas monitoring system energize the engine shutdown solenoid The vehicle gas monitoring system can be powered up by pressing and holding for three seconds the POWER RESET button in the lower right corner of the main unit As the unit comes out of sleep mode the display will light up all LEDs in a chase sequence The operator should observe that all LEDs have lit up the unit should be returned for repair if LEDs fail to light up The SYSTEM OK indicator will begin to flash approximately once every second to indicate that the system is powered up and functioning correctly
16. 0hm Ry 100 gt 2 I then calibration has failed e Apply 2 0V 20mA to the gas input f Measure voltage current with calibrated multimeter This is measurement g Get voltage reading from ADC This is reading Ro NGVG3 PGAS C h If if current source used multiply M by 1000hm R2 100 M gt 2 then calibration has failed 12 CERTIFICATION The diesel vehicle gas monitoring system type NGVG3 has been assessed and tested to IEC 60079 0 2007 5th Edition IEC 60079 11 2006 5th Edition IEC 60079 18 2009 3rd Edition 12 1 IECEx Certificate No IECEx TSA 14 0040X Marking Alternator Power Ex mb ia Ma Mb Battery Power Ma Port Parameters Refer to Certificate Conditions of Use Refer to Certificate DIESEL VEHICLE GAS MONITORING SYSTEM 32 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 l UNCONTROLLED COPY i Check validity before use 13 SPECIFICATIONS AME ocean Diesel Vehicle Gas Monitoring System IR tec NGVG3 Temperaturerfange u uuu RE aane Aa EA KE EEn REAREN EE EEN ERES 20 C to 40 C Console port configuration 19200 baud 8 data 1 stop No parity cra 290mm W x 135mm H x 200mm D ccc eR RT T 8 5kg Enclosure material urere b tias rue
17. 1 1 Normal operation mode 29 Faut MOde er 29 TD ONS f E 29 LO Slee gt og MOGE 29 10 2 Mod Indicat r NV REKE 30 102 1 pesNrllyp qe 30 10 2 2 POWER BOARD FAULL 30 orucr celi48 lr cmm 30 10 24 GAS TRIP u 30 1025 c NIS GUI CT 31 1026 WARM UPuuu uu 31 TT GAS INPUT CALIBRATION u uuu u eena reaa EKE REEE EE RE EEEE NETES 31 12 CERTIFICATION uu u uuu u ee 32 ee E 32 13 SPECIFIGATIONS u ullu nasuta 33 TABLES Table 1 Battery gauge indicator 12 Table 2 Gas level indicator 13 Table 3 Alternator Power 15 Table 4 Gas Sensor Connection 15 Table 5 Solenoid Connection p 15 Table 6 Deputy and Strobe Connection 15 Table 7 Display Panel Rear Side LED
18. FAST CHARGE indicator will be illuminated indicating that the battery is being charged at the maximum rate If the internal battery is fully charged or has become fully charged after some time the TRICKLE CHARGE indicator will be illuminated and the FAST CHARGE indicator extinguished This indicates that the internal battery is near fully charged 9 6 GAS LEVELS The gas bar graph display will be showing the gas concentration of the vehicle surrounding atmosphere As the gas level increases the number of bars in the display will increase upwards until the gas concentration level exceeds that of the first warning level this point the WARN 1 indicator will be illuminated The vehicle will continue to operate normally If the gas level further increases until it exceeds the second warning level the WARN 2 indicator will be illuminated The vehicle will continue to operate normally 9 7 GAS TRIP If the gas level increases to a level higher than that of the trip level set point the TRIP indicator will be illuminated The engine shutdown solenoid valve will be de energized causing the engine to stop The TRIP red indicator will flash along with all the gas level LEDs The OK TO START indicator will also be extinguished and at this point power to the solenoid will be removed stopping the engine or preventing the engine from starting A deputy will be required to reset the vehicle gas monitoring system after the da
19. MANUAL Issue 01 4 Es Er UNCONTROLLE COPY E Check validity be 7 2 HELP COMMAND The HELP command prints a list of all available commands and shows the syntax for each command Optional command modifiers are shown within while mandatory modifiers are shown within lt gt An example of a screen output follows NGVG3 gt HELP Software 1V01D OxCE6E Configuration OxFFFF SN 13050001 Commands ok ok Level 1 Standard Menu KK K K HELP 1 7 Level of Help all Optional Required Or VER Firmware version of Product REPEAT LF CR Secs between lines Repeat Cmd Linefeed Carriage PBATV Get ADC Battery Voltage PALTV Get ADC Alternator Voltage PGAS Get ADC Gas Sensor Voltage PVER Get Power board F W version PTEMP Get Power board temps Level 2 PARAMETER MENUS SKICK lt SET gt lt time gt Solenoid kick time in ms BTEMP lt SET gt lt temp gt Max battery temp for charging PRTC lt SET gt lt YY MM DD hh mm ss gt Set Get Powerboard RTC LOGGER lt DUMP gt Log commands oh K 2k KE ok ok k k Level 3 SPECIAL MENUS KK 2k ok ok k k kK k k k CALADC lt SET gt lt CHAN gt lt Gain Offset gt lt Val gt Cal Gain float Offset mV PBATM SET lt register gt value Get Set batt monitor registers EEPROM lt MID gt lt DID gt lt DEL gt lt SR gt lt RD a 1 gt lt WR a d gt EEPROM commands SLOAD lt S Record Hex file g
20. ONTROLLED COPY austdac k Check validity before use 7 8 POWER BOARD TEMPERATURE There are two temperature sensors on the battery and another on the power board This command displays the values of those three temperature sensors PTEMP 7 9 REAL TIME CLOCK There is a real time clock RTC on the battery This command may be used to read and set the time and date Time and date are required for the logging functions of the NGVG3 PRTC lt SET gt YY MM DD hh mm ss Where YY 2 digit year e g 13 for 2013 MM 2 digit month e g 09 for September DD 2 digit day e g 07 for the 7th day of the month e hh 2 digit hour e g 15 for 3pm mm 2 digit minute e g 27 655 2 digit seconds e g 59 7 10 BATTERY VOLTAGE Displays the battery voltage as read by the microcontrollers ADC input User may also use the battery monitor to read the battery voltage PBATV 7 11 ALTERNATOR VOLTAGE Displays the alternator output voltage as read by the microcontrollers ADC input PALTV 7 12 GAS SENSOR VOLTAGE Displays the gas sensor value as a voltage read by the microcontrollers ADC input PGAS DIESEL VEHICLE GAS MONITORING SYSTEM 22 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 UNCONTROLLED COPY Check validity before use 7 13 BATTERY MONITOR The battery has a monitor device which may be interrogated and configured via the console port These are very low level registers and should only be configured b
21. UNCONTROLLED COPY Check validity before use E austdac DIESEL VEHICLE GAS MONITORING SYSTEM TYPE NGVG3 USER S MANUAL ocument Number 01 UNCONTROLLED COPY austdac pa Check validity before use REVISION CONTROL 01 Original 2014 11 24 NI MC NI PC Issue Details Date Written Designed Approved Austdac Pty Ltd Unit 1 4 Packard Avenue Castle Hill NSW 2154 Australia PO Box 6486 Baulkham Hills Business Centre NSW 2153 Australia Phone 61 2 8851 5000 Fax 4 61 2 9899 2490 Website www austdac com au Austdac Inc 455 Lowries Run Rd Pittsburgh PA 15237 USA Phone 1 888 254 9155 Fax 1 412 635 0179 Copyright 2014 10 29 This document remains the property of Austdac Pty Ltd It is subject to its recall and must not be reproduced in part or whole or its contents divulged to third parties without prior written approval from Austdac Pty Ltd DIESEL VEHICLE GAS MONITORING SYSTEM 2 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 le UNCONTROLLED COPY austdac am Cheek validity before use TABLE OF CONTENTS pde esee gne M 2 TABLE OF ee ic ppm 3 TABLES uie HO eM CNN D UE DM Og Nd 4 gei 4 1 GENERAL DESCRIPTION HEX 5 2 WARNINGS AND
22. clic but this command gives the next position 7 16 CALIBRATE ADC This command is used to calibrate the NGVG3 s analogue to digital inputs This is to be used only by Austdac manufacturing and service CALADC lt SET gt CHAN GAIN OFFSET val Where e CHAN GAIN value Sets the gain of value which is a floating point number e CHAN OFFSET value Sets the DC offset as given by value in Volts See section 11 for gas input channel calibration procedure 7 17 FIRMWARE DOWNLOAD New firmware which may have firmware fixes or new features may be uploaded to the NGVGS via the console port Both the display board and the potted power board may be updated After the SLOAD command is issued S Records from a hex file may be pasted into the terminal emulation program It is recommended that there is a minimum of 1ms delays after each line or S Record and software flow control is enabled in the terminal emulation software SLOAD S Record Hex file The display board will determine if the update firmware is intended for itself or the remote power board microprocessor The target microprocessor will then erase the upper portion of the FLASH memory and the uploaded firmware will be stored there DIESEL VEHICLE GAS MONITORING SYSTEM 24 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 austdac UNCONTROLLED COPY de Cheek validity befo 7 18 FIRMWARE BURN After firmware has been uploaded and stored to the u
23. d valve is energized and the alternator is not running This indicates that the engine can now be started 10 1 2 Fault mode The vehicle gas monitoring system will enter this mode whenever a sensor or key fault has occurred The FAULT LED will illuminate Return the unit to Austdac for servicing by qualified technicians 10 1 3 Trip mode The vehicle has had a gas trip This mode may be cleared and returned to Normal mode with the deputy key if gas levels are within safe levels 10 1 4 Sleep mode The vehicle gas monitoring system will be automatically placed in this mode after the power reset timer has expired i e after the engine has been stopped The power reset timer is typically set at 90 seconds DIESEL VEHICLE GAS MONITORING SYSTEM 29 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 9 I UNCONTROLLE Check validity befo 10 2 MODE INDICATOR The table below shows the meaning of the LEDs when the vehicle gas monitoring system is in fault trip or other operational modes WARNING 1 WARNING 2 TRIP BATTERY LED LED LED EMPTY BAUER COLD START Flash for 0 1 secevery 0 4sec after warm up period POWER BOARD Alternate flash for ON FAULT 0 1sec every 0 2sec SENSOR FAILURE Qanpas ON every 1 6sec Depends on 0 1sec every GAS TRIP gas levels 0 4 TRIP Flash for 0 1sec every 0 4sec WARM UP Alternate flash for 0 1sec every 0 2sec
24. d via the rear of the front panel To use the console port an Austdac MEAN interface to B USB cable and laptop computer running Hyper Terminal or some other terminal emulation software are required For more detail on the console port MEAN1 interface and their use refer to Austdac document 53 018 11 7 1 CONSOLE PORT OPERATION The console port should be connected to a laptop running a terminal emulation program such as Hyper Terminal via the Austdac interface type MEAN1 and a USB cable The NGVG3 certification places restrictions on what may be connected to the console port the connection of an interface other than the Austdac MEAN to the console port will invalidate the certification of the diesel vehicle gas monitoring system The terminal emulation program should be configured to 19200 baud 8 data bits one stop bit no parity XON XOFF flow control and DEC VT100 terminal emulation Once communications have been established with the NGVG3 it will display a screen of information that includes software version software checksum and a list of commands followed by the console port prompt The prompt includes an abbreviation of the transmitter type number NGVG3 gt Commands are invoked by entering the command name followed by any optional modifiers keywords and the ENTER key The enter key is shown in the following examples as symbol DIESEL VEHICLE GAS MONITORING SYSTEM 19 OF 33 13 323 12 NGVG3 USER S
25. dity before use i ii Photograph of solenoid valve type 6014 and quick exhaust valve type VSC588 Quick Exhaust Valve VSC588 6014 Valv Figure 3 Engine shutdown valve and optional quick release exhaust valve Photograph of valve body type 6014 and solenoid magnetic coil type AC10 Z3 6 PD94 Solenoid Magnetic Coil Type AC10 Z3 6 PD94 Figure 4 Engine shutdown valve body separated from the coil assembly DIESEL VEHICLE GAS MONITORING SYSTEM 7 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 II a UNCONTROLLED COPY Check validity before use f 2 WARNINGS AND PRECAUTIONS WARNING e Battery voltages may be present within the NGVG3 at all times PRECAUTIONS e Only qualified personnel shall install maintain and service the NGVG3 e Only qualified personnel shall remove and install the battery type 4 NH 4 to the NGVG3 e The enclosure of the NGVG3 is not to be opened when the Alternator is supplying power 2 1 USER ACCESS There are no user serviceable parts within the NGVG3 The user should not attempt to service the NGVG3 or access the encapsulated electronics of the NGVG3 The only user accessible controls and displays are mounted on the cover of the NGVG3 DIESEL VEHICLE GAS MONITORING SYSTEM 8 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 UNCONTROLLED COPY austdac E Check validity before use 3 STORAGE INSTALLATION MAINTAINANCE AND REPAIR REQUIREMENTS The NGVG3 shou
26. fied person No other type of battery is to be connected to the NGVG3 Access to the battery is through the cover and the cover is not to be opened with the alternator supplying power The battery is only to be replaced when the unit is in Sleep Mode The battery can be changed by removal and replacement of four screws and the 4 way connector Figure 5 View of Battery 3 1 4 Repair The NGVG3 is not to be repaired by the User Damaged units are to be returned to Austdac for repairs DIESEL VEHICLE GAS MONITORING SYSTEM 11 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 e austdac UNCONTROLLED COPY Check validity before use d 4 FRONT PANEL LAYOUT Figure 6 Front Panel The front panel of the type NGVG3 vehicle gas monitoring system consists of the following items 4 1 1 Eight LED BATTERY bar graph Battery level is displayed for 10 seconds after start up and after POWER REST button pressed momentarily whilst the unit is not in sleep mode BATTERY CAPACITY INDICATOR I gt 80 gt 70 gt 60 gt 50 gt 40 gt 30 This and lower LEDs flash on for 0 1s at 0 85 intervals if 3096 4096 2096 This and lower LEDs flash on for 0 1s at 0 4s intervals if 2096 3096 lt 2096 This LED flashes on for 0 15 0 45 intervals if capacity lt 2096 Must replace battery solenoid will not energise to start vehicle
27. ld only be installed operated and maintained by qualified personnel Ensure that all instructions and warnings are observed 3 1 1 Storage The specified operating temperature must be maintained during storage It is recommended that the Battery of the NGVG3 is disconnected during storage exceeding 30days This will ensure that the NGVG3 is ready for operation The NGVG3 should be stored in a covered area 3 1 2 Installation Prior to installation the NGVG3 should be inspected for the following e Any external damage to the enclosure Any damage score marks or foreign debris to any glands or connectors e Ensure that the NGVG3 output has been turned off The NGVGS will usually require the lid to be removed for installation When the lid is removed the following inspection is required o Inspect for any damage or faults with the gasket o Inspect for any damage score marks or distortion of the gasket sealing surfaces o Inspect for any damage or foreign objects on the display pcb mounted on the lid o Check that the switch settings are correct on the display pcb Record the settings o Check that there are no foreign objects debris moisture or contaminants within the NGVG3 o Check the encapsulation for any signs of cracking o The battery is connected The main unit of the vehicle gas monitoring system is designed to fit within the cabin of most underground diesel powered vehicles This allows the operator access to
28. le DIESEL VEHICLE GAS MONITORING SYSTEM 17 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 E I austdac UNCONTROLLED COPY Check validity before use A 6 3 JTAG PORT X3 6WAY This is the display board s in circuit programming port Used by Austdac to re flash the microcontroller 6 4 CONSOLE PORT X2 AWAY The Console Port is not to be used in an explosive atmosphere Used for configuring the diesel vehicle gas monitoring system and for downloading firmware to the display and power microcontrollers An Austdac MEAN1 console to USB adaptor is required A description of commands available on the console port is given later in this document CPP switch must be in the ON position on the MEAN1 or the hardware watchdog will trip whilst in the console mode Figure 7 Rear Side of the Cover Display DIESEL VEHICLE GAS MONITORING SYSTEM 18 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 UNCONTROLLED COPY austdac hk Check validity before use 7 CONFIGURATION The diesel vehicle gas monitoring system has several operational parameters that require configuration prior to use All of these parameters can be viewed and changed via the console port The console port consists of a small four pin connector Access to the console port can be gaine
29. ngerous concentration of gas has dispersed before an engine start will be allowed NGVG3 will remain powered up after the gas trip for a time period displaying the current gas level before powering down The vehicle gas monitoring system can be powered up again at any time by pressing the POWER RESET button and once warmed up will display the current gas level and indicate a trip if not already reset by the deputy DIESEL VEHICLE GAS MONITORING SYSTEM 28 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 Il UNCONTROLLED COPY Check validity before use 9 8 BATTERY LEVEL The battery condition can be more accurately determined by pressing the POWER RESET button This will display the remaining battery capacity on the battery bar graph display Refer to the system indications and error codes section of this manual for a detailed description of all indicator lights on the front panel of the vehicle gas monitoring system 10 SYSTEM INDICATORS AND ERROR CODES 10 1 MODES OF OPERATION The diesel vehicle gas monitoring system can operated in one of four modes 10 1 1 Normal operation mode The vehicle is protected by the gas monitoring system and is able to be used in its usual way within the mine site The normal mode of operation is shown by the SYSTEM OK indicator steadily flashing once 0 8 second The OK TO START LED flashes for 0 1 seconds 0 8 seconds whenever the engine shutdown solenoi
30. or is via a Type 2S cable UNCONTROLLED COPY Check validity before use Core 2 Table 3 Alternator Power Connection 5 2 PLESSEY OUTPUTS The rear of the NGVG3 has three Plessey connectors A four way connector for the gas sensor a two way for the Solenoid and a 3 way for the strobes and deputy key input The NGVG3 is supplied with prefabricated cables that are manufactured to customer length requirements A Yellow Sig B Green Sig C Red V D Black OV Table 4 Gas Sensor Connection Black Table 5 Solenoid Connection EUIS Olour B Black 0V C Red Strobe V Table 6 Deputy and Strobe Connection DIESEL VEHICLE GAS MONITORING SYSTEM NGVG3 USER S MANUAL 15 OF 33 13 323 12 Issue 01 austdac UNCONTROLLED Check validity bef COPY ore d 6 REAR SIDE OF DISPLAY PANEL 6 1 LED INDICATORS There are four indicator LEDs on the rear side of the display panel These LEDs are currently inactive LED Designator Description LD7 Not Used LD8 Not Used LD100 Not Used LD101 Not Used Table 7 Display Panel Rear Side LED indicators 6 2 ROTARY SWITCHES There are four decimal rotary switches on the rear of the display panel Their settings are described below 6 2 1 Gas Warning and Trip Levels SW2 Sets LED warning levels and gas trip level
31. pper region of FLASH memory a BURN command must be issued to invalidate the currently running software and let the boot loader know to copy the new firmware to the operating portion of FLASH memory SBURN lt PWR DISP gt Where PWR is the power board microcontroller e DISP is the display board microcontroller Prior to invalidating the current operating firmware checks are performed to ensure the downloaded firmware has completed and has a valid and correct CRC 7 19 PASSWORD If the correct password follows the password command the unit will display and enable the use of level 3 commands These commands are intended for use by Austdac trained technicians only PWD XXXX Where XXXX is the Austdac factory password DIESEL VEHICLE GAS MONITORING SYSTEM 25 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 austdac UNCONTROLLED COPY A Check validity before use 8 TYPICAL OPERATION CYCLE The driver operator enters the vehicle and activates the gas monitoring system by pressing the POWER RESET button The system will start up and indicate that the driver must wait a short period of time for the gas sensor to stabilise configurable between 10 and 90 seconds During this stage the vehicle is prohibited from starting After completion of the wait period and provided that the explosive gas concentration is below the trip shutdown gas concentration the driver operator will receive an OK TO START indication The
32. solenoid valve will be energized enabling the engine pneumatic control system The driver operator may then start and operate the vehicle The gas monitoring system will monitor and display the gas concentration whenever the vehicle is operating Should the vehicle enter a potentially explosive atmosphere the system will indicate the gas concentration level and shut the engine down by dumping pneumatic control pressure via the now de energized solenoid valve If the operator stops the vehicle at any time the gas monitoring system will remain powered up for a predetermined time monitoring the surrounding gas concentration This feature allows immediate restart when the operator returns to the vehicle Should the driver operator be away from the vehicle for an extended period of time the gas monitoring system will power down to conserve battery power The internal battery and timer system will allow the gas monitoring system to execute a start sequence after several days of vehicle inactivity For longer period of inactivity the unit will need to be serviced and battery put through battery discharge charge cycle DIESEL VEHICLE GAS MONITORING SYSTEM 26 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 UNCONTROLLED COPY austdac Check validity before use 9 OPERATING INSTRUCTIONS 9 1 INSPECT Before starting any diesel powered underground vehicle fitted with a type NGVG3 vehicle gas monitoring system the operator driver should inspect
33. t Download Srecords for upgrades SBURN PWR DISP Burn last download code NGVG3 gt 7 3 REPEAT COMMAND The REPEAT command is used after another command to continuously repeat that command As an example the PRTC command can be executed followed by the REPEAT command to provide a continuously updating display of the time and date The display will continue to update until any key is hit The NGVG3 will respond by displaying the prompt NGVG3 PRTC RTC Thu May 2 17 47 56 2013 NGVG3 gt RTC Thu May 2 17 48 32 2013 RTC Thu May 2 17 48 33 2013 RTC Thu May 2 17 48 34 2013 NGVG3 5 In this mode the repeat command writes over the previously displayed information if required the repeat command can be made to refresh the information on a new line by DIESEL VEHICLE GAS MONITORING SYSTEM 20 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 UNCONTROLLED COPY Check validity before use entering LF line feed as part of the command invocation The repeat command refreshes the display every one second by default The refresh rate can be slowed by entering the refresh rate in seconds as part of the repeat command as shown in the following command a Ig NGVG3 REPEAT LF 5 7 4 VERSION COMMAND DISPLAY BOARD The VERSION command is used to display the serial number abbreviated type number software version program memory checksum and configuration checksum of the NGVG3 The command
34. ted whenever the gas monitoring system will allow the driver operator to start the diesel engine DIESEL VEHICLE GAS MONITORING SYSTEM 13 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 UNCONTROLLED COPY Check validity before use I a 4 1 7 Amber FAULT SERVICE indicator LED Illuminated to indicate a fault with the NGVG3 or the external gas sensor Solenoid will not be energised so the vehicle will not be able to start in this state Remove the unit for service 4 1 8 Green SYSTEM OK indicator LED LED flashes for 0 1s every 1 6s to indicate that the system is in operating mode and correctly functioning 4 1 9 One push button labelled POWER RESET This button is pressed by the operator to wake up the vehicle gas monitoring system Pressing the POWER RESET button is the first step in the start sequence in using the host machine The POWER RESET button should be pressed for a minimum of 3 seconds During operation if button is pressed momentarily the current battery charge capacity will be displayed for 10 seconds If held for more than 3 seconds during operation the unit will shut down to low power mode If the solenoid was engaged it will be released and the engine should shut down if running DIESEL VEHICLE GAS MONITORING SYSTEM 14 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 D 06 austdac ii 5 CONNECTIONS 5 1 POWER INPUT The Power Input from the alternat
35. y Austdac engineering staff Access to each parameter is define but the definition and explanation of each register is beyond the scope of this document Refer to the datasheet for the Maxim DS2756 1 Wire Battery Fuel Gauge for detailed information on these registers PBATM lt register gt lt SET gt lt register gt lt value gt Where register may be SR STATUS REGISTER e ER EEPROM REGISTER SF SPECIAL FEATURE REGISTER CB CURRENT BIAS REGISTER VR VOLTAGE REGISTER e CURRENT REGISTER e AC ACCUMULATED CURRENT REGISTER e AR AVERAGE CURRENT REGISTER 7 14 EEPROM COMMANDS The EEPROM stores detailed log data on the display board This command allows for testing and diagnostics of the EEPROM device EEPROM MID DID DEL SR RD address gt lt WR address data Where e MID Manufacture Identification e DID Device Identification e DEL Delete entire EEPROM device e SR Read Status Register RD address Read address e WR address data Write data at given address DIESEL VEHICLE GAS MONITORING SYSTEM 23 OF 33 13 323 12 NGVG3 USER S MANUAL Issue 01 UNCONTROLLED COPY Check validity befe Lal 7 15 BATTERY LOGGER DATA The battery contains a small amount of FLASH memory which is used to store a brief event log This log can store up to 960 events LOGGER DUMP count NEXT Where DUMP count Prints the last event entries NEXT The events log is cy
36. y diesel powered vehicle to provide continuous monitoring of the ambient mine atmosphere as the vehicle moves about the mine The system provides a warning and eventual engine shutdown if the vehicle enters a pocket of methane oas CH4 of sufficient concentration The system can be fitted to any flameproof or fireproof diesel vehicle with an alternator with a nominal output of 12 volts DC The system draws operational and battery charging power from the alternator whenever the engine is running The internal battery is used to power the gas sensor when the engine is not running The solenoid valve supplied with the vehicle gas monitoring system can be easily installed in the vehicles pneumatic engine control system to provide a failsafe engine shutdown The Type NGVG3 system is a compact light weight combination of a trip amplifier display engine shut down solenoid valve battery charger and galvanic isolated power supply that only requires the addition of an industry standard methane gas sensor and a connection to the vehicle alternator The unit is small enough to fit within the cabin of most underground vehicles and robust enough to be mounted elsewhere if required The front panel display of the type NGVG3 system provides the machine operator or driver with a continuous indication of relative methane gas concentration via a simple bar graph and system status via a few easy to read indicator lights The diesel vehicle gas monitoring system is
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