DIESEL MACHINE MONITOR
Contents
1. 38 5011 3 NOILSINNOD 0X3 52 AdAL 0 13530 DIESELGUARD USER MANUAL ISSUE 2 2 5 Gasguard Transmitter Sensor 65 6551 CH4 The Gasguard transmitter may include an integral or remote head sensor pictured below In either case the sensor should be mounted pointing vertically downwards and sufficient space left around and beneath the sensor for fitting of the calibration cup The front panel of the transmitter has to be accessible for calibration 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 to be replaced easy removal in installation of the cable is an advantage See Gasguard sensor manual for further information Part NoE08975 2 6 IDA Display E09232 The IDA display is optional and alternative display panels using LED and other equipment can be used If the IDA display is used it should be mounted in a position where the driver can see it without it being in his direct line of vision See IDA data sheet 655 006 for more detail 10 DIESELGUARD USER MANUAL ISSUE 2 2 7 IS Solenoid Valve WPISB314 The IS Solenoid Valve can be mounted in any suitable location It is supplied with a weatherproof enclosure which has two M4 x 8 mm mounting h2. AMPCONTROL 41 T Dieseiguard DIESEL MACHINE MONITOR No copies of the information or drawings within this manual shall be made without the prior consent of Ampcontrol Designed and Manufactured in Australia by Ampcontrol Pty Limited ACN 000 915 542 Phone 02 4956 5899 Fax 02 4956 5985 www ampcontrol com au USER MANUAL E09819 ISSUE 2 19 10 06 Dieselguard Manual Issue 2 09819 191006 DIESELGUARD USER MANUAL ISSUE 2 Copyright Notice No part of this publication may be reproduced transmitted or transcribed into any language by any means without the express written permission of Ampcontrol Pty Ltd 250 Macquarie Road Warners Bay NSW 2282 Australia Disclaimer Ampcontrol Pty Ltd will make no warranties as to the contents of this documentation and specifically disclaims any implied warranties or fitness for any particular purpose Ampcontrol further reserves the right to alter the specification of the system and or manual without obligation to notify any person or organisation of these changes Before You Begin We would like to thank you for purchasing the Ampcontrol Dieselguard and Gasguard Products To become completely familiar with this equipment and to ensure correct operation we recommend that you take the time to read this user manual thoroughly CRN 5541 IMPORTANT WARNINGS AND ADVICE This equipment has been designed to control the signals from equipment that detects
3. Machine Monitor is designed to withstand these conditions without operational problems The unit will withstand a 90V repetitive overload condition via its internal auto reset protection barrier The input power supply circuitry is galvanically isolated from the rest of the system The unit is designed as a component approved device and can be used with Intrinsically Safe and simple apparatus accessories such as Gas transmitters RTD s Pressure and level switches LED indicators Solenoid valves and Intrinsically Safe display systems The Dieselguard Machine Monitor is housed in an IP 66 enclosure which once fitted to the machine does not need to be accessed The system can supplied as a basic Blind gas detection and alarm control unit to shut down the fuel supply on diesel machines or as a Smart machine monitoring and data acquisition system The Diesel Machine Monitor is pre configured to detect Methane gas around the vehicle and to provide a normally energised solenoid supply which will de energise and hence de pressurise the vehicle safety loop diesel supply valve in event of high gas readings The Basic unit is a Blind control system whose operation is factory set during manufacture This model does not include the radio link or data logging function It is preset as a Gas Monitor and control unit to provide a warning signal at 1 00 and trip function by de energising the solenoid at 1 25 CH4 Models wi
4. in a suitable location This is an IS circuit and the switch is considered simple apparatus Some machines have two stage safety pressure loop and this function could also be derived from a pressure switch mounted in the primary pressure circuit The monitor has a deputy override input which if required the installer would mount a suitable lockable switch This is an IS circuit as above If the unit is used in a manual reset mode the keyswitch can also be used to reset the system Take care during installation not to damage the hydrophobic barrier the battery compartment breather vent as the IP rating of the enclosure will be impaired DIESELGUARD USER MANUAL ISSUE 2 1C 2 4 Dieselguard Connection Schemat 31545 01123130 SVD 3NIHIVW 135310 5065 58 0 95 9 AINO SNOILYANdd YDA SAT A 11 H d 18915 8311430 Al3dvVS N3Hl 3A1VA 440 LNHS 135310 3ATYA UIUN3 105 409 di dOD1 1335 3 2 Padwy wey joke od eoque pup PAP muse mj as ae pod q jamu ioe cg 14 aera gn pmekod supu Qv3H 310W3H Li 3eBi S011N3 HILIMS SLINn Z 158 50 NOILISOd 13538 3018340 HA3LIMSA35 Alnd3n HILIIWSNYal 05 0 14510 SISS HI Ul
5. and IDA Green Alarm output drives at 12V DC 30mA One for each alarm level Aux Output Auxiliay output for displays and alarms 12VDC 160mA 220mA max short circuit limit 4 20mA Output 4 20mA output proportional to gas level Common OV to Dieselguard system Solenoid Drive output Solenoid output NE 24V DC 84mA Off in alarm State 1 4 1 Connection Terminals The electronics of the Diesel Machine Monitor are fully encapsulated Inside the enclosure the only accessible connections are IS circuits The Intrinsically Safe Parameters are shown on page 4 and 5 of the Certificate of conformity A detail of the connection panel is shown below The power supply connection is via a type 2s cable encapsulated into the electronics of the enclosure The cable should be connected to the vehicle alternator system in a suitably rated enclosure NOTE When installing connections to the run button please install a link between the run terminal and the speedo connection If no connection is made between these two terminals the system will not wake when the run button is pressed Non battery cut off versions only See fault finding Manual Auto Reset modes If a wire link is permanently installed between reset and OV then at power up the unit will be set to auto reset mode This enables the unit to come out of alarm automatically once the gas levels have fallen below alarm 1 level 196 by
6. battery below Put machine In bypass and charge battery from alternator down before Start sequence completes minimum charge level or Disconnect the power supply cable from the machines electrical system and charge by connecting a 12Volt Power Supply to the Dieselguard Supply leads Core 4 positive and Cores 1 2 amp 3 negative Note Do not use a Battery Charger 4 DIESELGUARD USER MANUAL ISSUE 2 Symptom Cause Solution Solenoid Ambient gas level is Follow plant procedure to leave area until deemed safe does not has been above second energise alarm point e 20 Solenoid disconnected Check the voltage between the SOL OV and V terminals on Term 1 should be second stat or defective approx 16V for an instant when the Solenoid should be closing and approx 12V SEJUENCE after that Repeat the above tests at the terminals of the solenoid If the supply to the solenoid is correct repair the connection or replace the solenoid as required Internal Fault Consult factory IDA Display No signal to IDA Check the sensor to see if itis in fault refer to the Gasguard Sensor Fault Indicates 3 Display Finding Table on Page 5 dashes If the sensor is operating correctly disconnect the wire from the 4 20mA In terminal on Term 5 and connect a milliamp meter between the disconnected wire and the terminal there should be approximately 4mA indicated on the milliamp meter if the sensor is i
7. minute run and may shut down shortly after the machine engine is stopped It would be necessary to re start the machine in bypass mode and run it for a longer period Consideration should be given to the storage of the unit If the unit remains in storage for a length of time prior to installation a re charge will be required before it can be used The unit can be charged directly by connecting a 12 30V supply directly to the type 2S power lead It is therefore recommended that the unit is re charged on a supply prior to installation The required re charge time is around 12 hours from a completely discharged battery A battery charger can not be used for this function because of the resistance of the Dieselguard s internal circuit SECTION 4 MAINTENANCE The Dieselguard Diesel Machine Monitor has few maintenance requirements The unit is basically an exchange item as all the internal electronics are encapsulated and serviceable 4 1 Visual Inspection It is recommended that periodic visual inspection of the unit is performed to confirm the integrity of the enclosure cable glands and labels 4 2 Close Inspection A check should be made for the correct screw tightness and that the lid is sealed correctly The integrity of the seal is dependant on the lid screws being tightened to the correct torque 4 3 Hydrophobic Barrier The enclosure breather is fitted with a hydrophobic barrier and this should be inspected t
8. volume If no link is installed then the unit is set to manual reset This mode requires a manually operated reset button to clear the alarm state n 0 p 3 3 v z c M a E 3 5 1 0 z B 8 a 710 9 WI n 75 26611B TERMS O SS T i Eola zu LO QTO1 et DIESELGUARD USER MANUAL ISSUE 2 1 5 Dieselguard Diesel Machine Monitor Specifications Power to the DMCS is provided by connection to the diesel machine s alternator The supply input has the following specification Voltage input range 9 5 VDC min to 36 VDC max Input current at full load 1 4A Supply ripple tolerance Will operate within the min max limits Maximum voltage overload 90V for 100mS No stress Certified input voltage Um 90V Overvoltage protection concept Triplicated barrier with transient suppression and auto reset Circuits beyond the barrier are limited to 16 2V maximum overload Input Supply Filtering Common mode DC choke Input transient suppression Metal Oxide Varistor MOV Input Reverse supply protection Diode Alternator Drop out tolerance During drop outs the system will fall onto internal battery Drop outs with durations less than 2 minutes will not be registered by the software Drop outs greater than
9. 2 minutes will shut the machine down Internal Battery The internal battery provides initial power to the unit to run the methanometer auxiliary sensors and status displays prior to starting the machine Battery power is also used to activate the compressed air solenoid that allows the starter circuit to operate The battery also provides protection against momentary alternator drop outs Battery Type Sealed Gel type Lead Acid Life Up to 5 years Charge cycle Two stage hardware software controlled Maximum charge current Limited to 420mA max Outgassing Relief Battery pressure valve and sintered vent on enclosure Standby Life 3 weeks before recharge required 4 6 months on Battery cut off version Designated by cut outs in terminal PCB Charge time to first use from flat battery 3 hours min for 5 re starts following 3 weeks standby Output Supplies There are three main power supply outputs from the unit These are to power the methanometer status display unit and solenoid All three outputs are certified ia Methanometer Supply 10 8V max at full load input supply active or full battery 8 5V min at full load input supply off battery in empty state 12 0V max no load Uo 16 2V max Io 2 51A max Lo Ro 45 e Status indicator Supply Solenoid Supply Sensor inputs DIESELGUARD USER MANUAL ISSUE 2 10 8V max at full load 8 5V min at full load 12 0V max no load Uo 16 2V max Io 2 51A ma
10. L ISSUE 2 SECTION7 CERTIFICATION DOCUMENTATION ROTECTED Certificate of Conformity Addendum Certificate ANZEx 05 4010 Issue No Date of Issue 12 2006 4 Certificate Holder Ampcontrol Pty Ltd 250 Macquarie Road Warners Bay New South Wales 2282 Electrical Apparatus Dieselguard Diesel Machine Gas Monitor Types 09464 E09465 E09481 E09484 09485 E09482 E09483 109486 and 09487 Type of Protection Ex m ia Marking Code Ex m ia 1 150 IP66 20 C to 70 Manufacturing Location s AUSTECH INSTRUMENTS Pty Ltd 8 Ponderosa Parade Warriewood New South Wales 2102 The certification database located at wwwy sai globat com shows the validity of this Certificate This certificate and schedule shall not be reproduced except in full Certificate issued by Y ITACS Pty Ltd C 4 6 Second Street SA 5007 Australia PO Box 300 Hindmarsh SA 5007 Australia Accreditation by the Joint Accreditation System of ABN 06 098 886 563 Phone 61 8 8346 8680 Fax 61 8 8346 7072 Australia and New Zealand Acc No Z2870404AA Email itacs itacslab com age of 8 19 DIESELGUARD USER MANUAL ISSUE 2 Certifi cate of Conformity Addendum Certificate No ANZEx 05 4010X Issue No 2 Date of Issuc 12 May 2006 This Certificate Addendum supplements the Original Issue of this Certificate Issue 0 and is granted subject to the conditions as set
11. Machine Monitor Main System PCB Bottom Layer 2006 02 03 24 2660 MI Diesel Machine Monitor Main System PCB Mid Layer 1 D 2006 02 03 This certificate and schedule shall not be reproduced except in full Page 3 of 8 UT DIESELGUARD USER MANUAL ISSUE 2 Certificate of Conformity Addendum Certificate No ANZEx 05 4010X Issue Nos 2 Date of Issue 12 2006 Document No 24 2660 M2 Diesel Machine Monitor Main System PCB Mid Layer 2 D 2006 02 03 24 2660 TO Diesel Machine Monitor Main System PCB Top Overla D 2006 02 03 24 2660 TT Diesel Machine Monitor Main System PCB Top D 24 2663 BT Wireless Link PCB Bottom Trace D 2006 02 03 24 2663 TO Wireless Link PCB Top Overlay D 2006 02 03 24 2663 TT Wireless Link PCB Top Trace D 2006 02 03 25 6600ASSY Enclosure lid amp accessories diesel gas sampler general 3 2006 03 01 assembly EST 28 6601 LEB Label certification 9464eb diesel gas sampler with 0 2006 01 31 external battery manufacturing details 28 6603LEB Label certification 9465eb diesel gas sampler with 0 2006 01 31 external battery manufacturing details 28 6604LEB Label certification 9481eb diesel gas sampler with 0 2006 01 31 external battery manufacturing details 28 6605LEB Label certification 9482eb diesel gas sampler with 0 2006 01 31 external batter
12. N 3 1 Introduction The system is designed for simple operation compromising of a start switch input which energises the Gas detection system for two minutes from its own back up battery During the two minute period normal starting procedures can be followed if the gas level is acceptable after a 20 second test The Dieselguard Machine Monitor is a blind control unit that can be mounted in any convenient position Gas sensor Gasguard would normally be mounted near the front of the vehicle adjacent to the air filter intake and a robust 3 digit display IDA or LED status panel indicates the status of the system for the driver 3 2 Start Sequence The IDA display is activated when the start contact operates The display flashes green for 20 seconds to allow the gas sensor to stabilise Following this 20 second period the display shows a continuous display and will indicate the gas level measured 3 3 First Level alarm If the display level is below 1 by volume CH4 the display will be Green For gas readings between 1 by volume and 1 25 by volume the display will be Orange Since these gas levels are below the shutdown level normal starting procedures can be followed Once the machine is started the alternator charges the battery of the Dieselguard unit Apart from on some of the early versions the display will flicker to indicate the charge is being received There are two level of charge rate high leve
13. display Gasguard Sensor This is nota fault itis an indication that the unit has only just had power applied indicates PU is powering up and is powering up Output is held at 4mA The display Calibration mode This is not a fault if Calibration mode is not required place the magnetic tip of indicates initiated display blinks the calibration pen over the CAL symbol for 5 seconds until the display flashes CAL or when in calibration SAV flashes mode The display Calibration settings This is not a fault indicates have been saved SAV The display There is no sensor Check the electrical connections between the sensor and the amplifier PCB in indicates 777 plugged into the amplifier the Sensor Transmitter Note The Sensor Transmitter also indicates 777 when the supplied voltage is low i e the Dieselguard s internal battery voltage is low The display Sensor is faulty Return the Sensor Transmitter to Ampcontrol for repair indicates 888 display Amplifier needs Return the Sensor Transmitter to Ampcontrol for repair indicates 999 reconfiguration The display If this code appears The code indicates that the output of the sensor is insufficient and the sensor indicates during the span will need to be returned to Ampcontrol for repair ERR calibration of the sensor Several things should be checked before changing the sensor 1 Check the calibration gas It should be a 2 5 CH4 in air mixture a
14. e system and comprises a Stainless Steel IP 66 low profile enclosure fitted with encapsulated electronics and IS terminations to external sensors and displays The Diesel Machine Monitor is an Exm ia certified product that is powered from the alternator supply of the vehicle Apart from the supply power all other connections to the Dieselguard Control unit are Ex ia Intrinsically Safe IS circuits In operation the Dieselguard system monitors ambient gas levels methane for the standard installation and provides indication and control based on the measured gas levels The system prevents unsafe starting of a machine in the presence of dangerous levels of explosive gas Similarly if a machine is running the Dieselguard system will shut the machine down if surrounding gas levels rise above the set alarm point This prevents continuing unsafe operation of a machine in a potentially dangerous atmosphere The Diesel Machine Monitor provides the control via a solenoid valve incorporated into the diesel machine s safety pressure circuit When released the solenoid allows the system to de pressurise and as a result shut down the machine Input power is provided via the integral encapsulated cable and is non polarity sensitive The input circuitry has been designed to withstand a wide variety of dirty power supply types Many alternators provide power that has a high level of ripple and high voltage noise spikes The Dieselguard Diesel
15. hazardous gases and vapours and to provide warning and control signals before dangerous conditions are reached In order to ensure that the equipment will warn of dangerous situations it is essential that the instructions in this manual and those of the associated items be read understood and followed It is further stressed that the effectiveness of the control system depends heavily on the user who is responsible for its correct installation application use and regular maintenance CONTENTS DIESELGUARD USER MANUAL ISSUE 2 SECTION 1 DESCRIPTION 1 1 Introduction efe 1 1 2 Dieselguard Description 2 1 3 Typical Application 3 1 4 3 1 4 1 Connection Terminals 4 1 5 Specifications 5 SECTION 2 INSTALLATION 2 1 Installation Guidelines 8 2 2 Itis a condition of safe use 8 2 3 Signal connections 8 2 4 Dieselguard schematic 9 2 5 Gasguard transmitter 10 2 6 IDA display m 10 2 7 IS Solenoid valve 11 2 8 Cable system eee 11 2 9 Wireless Comms Antenna 11 SECTION 3 OPERATION 3 1 Introduction 12 3 2 Start 12 3 3 First alarm level 12 3 4 Second alarm level 12 3 5 System shutdown 12 3 6 Deputy override 12 3 7 Cold
16. it is designed to operate on an AC DC supply of 9 5 36V but will withstand 90V The input to the Diesel Machine Monitor is isolated from the enclosure for use with non earthed alternator systems Start input Is a momentary switch contact to start the system This switch should be normally open and close to OV Reset alarm input Is a momentary switch contact to reset alarms This switch should be normally open and close to OV Alarm output override input Latched or locking contact to turn on the output drive This switch input directly overrides the alarm state of the controller allowing the machine to be started following or during a high alarm condition Temperature sensor inputs 3 RTD Inputs Two inputs RTD 2 and 3 are simple 2 wire connections Connection for each sensor is between drive and OV RTD 1 input is a 4 wire connection RTDI drive and RTDI hi connect to one end of the RTD at the sensor RTD1 return and RTD1 low connect to the other end of the RTD at the sensor The RTD values can be logged on the Smart version of the controller but are not used on the Basic unit DIESELGUARD USER MANUAL ISSUE 2 Gas Sensor input Is a 4 20mA signal sinking to OV inside the Diesel Machine Monitor Fault detection on sensor connection open or shorted Dieselguard Outputs Gas Sensor Supply 12V DC output at up to 160mA 220mA max short circuit limit Alarm indicator drives IDA Red
17. l for when the battery is low which flickers Red and trickle charge that keeps the battery topped up which flickers Amber 3 4 Second Level Alarm If the gas level rises above 1 25 by volume the display will turn Red Under this condition the solenoid will not be energised the machine can not start and the monitoring system will shut down after 2 minutes For operation in auto reset mode if during the 2 minute monitoring period the gas level falls below the Shutdown point the engine can be started In 212 the manual reset mode an external switch must reset the shutdown alarm before the machine can be started The display will flash Amber if the system has been tripped and is waiting for a reset 3 5 System Shutdown The system remains in operation while the engine is running If the gas level exceeds the shutdown level the solenoid de energises hence de pressurise the control circuit and closing the fuel supply line Once the engine stops the Gas detection system operates for about 1 minute 40 seconds before going to sleep 3 6 Deputy Override A deputy override switch input is provided so that the vehicle can be moved under supervision in an emergency This switch could also be used for the reset function 3 7 Cold Start Function In regular use the Dieselguard Diesel Machine Monitor s battery will keep the system ready for operation After periods of non use the battery drain in standby mode may mean tha
18. lthough other trace gases may be present Lower gas mixtures like 2 will reduce the output leading to premature change out of the sensor 2 Check the gas flow to ensure it is within the required range of 0 5 to 1 0 I m 3 Check the surrounding air flow If the ambient air flow is above 1 5 l m it can dilute the calibration gas Using the Gassing ring E09385 allows calibration in all conditions 4 Check the sensor is not blocked with dust or mud The sensor can be washed out and calibration carried out after a short drying out period 5 If all the above are ok and confirmation of output is required the sensor output can be measured with a DVM The voltage dropped across the sensor can be measure at zero and 2 5 CH4 A DVM set to DC mV can measure these voltages on the RH and adjacent upper terminal block on the rear left hand side of the amplifier PCB If this code appears The Zero Balance of the sensor is outside the preset limit and the during the zero Sensor Transmitter will need to be returned to Ampcontrol for repair Check the calibration of the sensor surrounding air is not effecting the zero calibration as per 3 above No4 20A Supply voltage is low or Check that voltage applied to the Amplifier PCB is 12VDC and that polarity is Output incorrect polarity correct Loose plug and terminal connections Check connections and repair as required If all of the above are correct the Sensor Transmitter will need to be retur
19. m D 200mm H 80mm End flange 4 x M8 holes Encapsulated to m standard Operational and certification parameters 10 kg approx 16 20mm cable glands with armour retention Connections made via barrier screw terminals Nine 9 1000 shocks 40g 3 planes 0 25mm ppk sinusoidal 10Hz to 100Hz 3 planes 2g ppk sinusoidal 10Hz to 600Hz 3 planes Compliant with required standards DIESELGUARD USER MANUAL ISSUE 2 SECTION 2 INSTALLATION 2 1 Installation Guidelines 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 1 Nm This is required to comply with the certification and IP rating Space should be allowed to ensure the lid is fitted correctly and the screws are torqued as required Power connections SAFETY NOTE The controller has an earth stud that must be infallibly connected to the chassis of the vehicle to comply with the certification requirements The unit has a type 2S power input cable up to 6m long which has to be terminated in a suitable Exd or Exe enclosure to pick up the alternator supply The installer would normally add this into the hours run enclosure but if all the gla
20. minations that are fixed in their mountings without possibility of self loosening and shall be constructed such that the conductors cannot slip out of their intended location 4 The apparatus is not suitable for use in areas where the equipment may be subject to corrosion eg areas where acetic acid gases mists vapours or liquids are present 5 Connections to the Programming port are only to be used in the non hazardous area This certificate and schedule shall not be reproduced except in full Page 8 of 8 2265
21. n clean air Apply 2 5 Span Gas to the sensor when the sensor reading displays 2 5 there should be approximately 12mA indicated on the milliamp meter For terminal details see section 1 4 1 If there is the correct output from the sensor as detailed above disconnect the wire from the IDA signal terminal and connect 4 20mA In wire and the IDA Signal wire to the 4 20mA In terminal on Term 5 The IDA should indicate approximately the same as the gas level indicated on the Gasguard Sensor display Or Connect a Loop Calibrator between the OV Terminal in the IDA and the 4 20mA input signal terminal Input a 4mA signal should read 0 and then input a 20mA signal should read 5 If there is a correct reading on the IDA in either of the above tests there is an internal fault in the Dieselguard If the second test fails the input fuse on the IDA may have been blown and the IDA should be replaced Battery Charging indication is indicated on the IDA by a quick red pulse for full charge rate or amber pulse on trickle charge when alternator is operating Battery not charging Input power connection faulty Repair connection Faulty alternator Internal battery faulty Replace alternator Replace internal battery factory re fit Internal Fault Consult factory 15 DIESELGUARD USER MANUAL ISSUE 2 Table 2 Gasguard Sensor Transmitter Fault Finding Symptom Cause Solution The
22. nd holes are already allocated a separate enclosure may be required Cable markings for the type 2S input cable are 1 2 3 nominally OV 4 nominally ve The system is not polarity sensitive and so if the connections are reversed it is not a problem These markings are present for variants with a non isolated OV referenced input supply 2 2 It is a condition of safe use that The apparatus must be installed such that the integral wires are terminated in a suitably certified Ex e or Ex d enclosure having a minimum Ingress Protection IP rating of IP55 If the wires are terminated in an Ex e enclosure suitably certified Ex e terminals must be used for terminating the wires The apparatus is not suitable for use in areas with acetic acid gases mists vapours or liquids are present The unit is infallibly connected via the earth stud to the chassis of the vehicle 2 3 Signal Connections All of the connections to the Diesel Machine Monitor are IS circuits and should be wired accordingly In some locations it may be necessary to protect IS cables from mechanical damage The unit is not supplied with interconnecting cables the installer is responsible for providing cabling to suit the application Please refer to table 2 in the products test report for details on permitted cable groupings To operate the Dieselguard Diesel Machine Monitor it requires a momentary switch input The installer would normally fit a push button
23. ned to Ampcontrol for repair 16 DIESELGUARD USER MANUAL ISSUE 2 Symptom Cause Solution The Supply voltage is low Check that voltage applied to the Amplifier PCB is 12VDC and that polarity Sensor Transmitter or incorrect polarity is correct Dieselguard may need charging E i Loose plug and Check connections and repair as required OF terminal connections Zeroed During Cal gas level If all of the above are correct the Sensor Transmitter will need to be returned to Ampcontrol for repair increases and then drops back Erratic Output Loose plug and Check screw connections at PCB Fit anti vibration clip E10051 if required terminal connections Supply voltage is low Check that voltage applied to the Amplifier PCB is 12VDC and that polarity or incorrect polarity is correct Severe supply voltage Intermittent fault in the connections to and from the Dieselguard Swings If all of the above are correct the Sensor Transmitter will need to be returned to Ampcontrol for repair sz DIESELGUARD USER MANUAL ISSUE 2 SECTION 8 APPLICATION NOTES Note 1 If Dieselguard is connected to Mining Repairs Flameproof Alternator Part Number MR110 with DCBR module ensure the MR110 alternator firmware is Version 1 88 or higher Failure to comply may cause operational difficulties resulting in an alternator overload trip at low revolutions 18 DIESELGUARD USER MANUA
24. newed Page 2 of 8 520 DIESELGUARD USER MANUAL ISSUE 2 Certift cate of Conformity Addendum Certificate No ANZEx 05 4010X Issue 2 Date of Issue 12 May 2006 Variation covered by this Addendum EQUIPMENT VARIATIONS Changes covered by this by Addendum include the following 1 Minor electrical changes and minor mechanical changes the main and wireless printed wiring boards 2 Replacement of the internal battery by an integral cable Models incorporating this change are Dieselguard Diesel Machine Gas Monitor Model E09464EB Dieselguard Diesel Machine Gas Monitor Model E09465EB Dieselguard Diesel Machine Gas Monitor Model E09481EB Dieselguard Diesel Machine Gas Monitor Model E09482EB Dieselguard Diesel Machine Gas Monitor Model E09483EB Dieselguard Diesel Machine Gas Monitor Model E09484EB Dieselguard Diesel Machine Gas Monitor Model E09485EB Dieselguard Diesel Machine Gas Monitor Model E09486EB Dieselguard Diesel Machine Gas Monitor Model 09487 Please refer to the previous Issues of this Certificate Issue 0 and Issue 1 for full product details MANUFACTURER S DOCUMENTS Manufacturer s Documents associated with Issue 2 of this Certificate include those listed below Refer to Issue 0 and 1 of this Certificate for the full range of manufacturers Documents Document No ps Doc ment Title uw 1 E Issue Date ied Gyyylau d 24 2660 BT Diesel
25. o ensure it is not damaged This barrier is essential to the IP rating of the enclosure and must be intact to maintain a rating of IP66 4 4 System Check Procedure We recommend the user develops a site procedure for checking the operation of the installed system The inspection regime will most likely be dictated by the associated equipment used with the Dieselguard Machine Monitor such as the gas transmitters The manuals for these products will provide information on the requirements 4 5 Calibration When the analogue output of the Dieselguard Diesel Machine Monitor is used with an indicator we recommend that part of the routine checking of the installation involve comparing the calibration reading on the gas transmitter with the display 4 6 Changing the Internal Battery After a period of use the internal battery will need to be replaced The length of time before this becomes necessary will vary depending on charge usage cycle but will be typically 3 to 5 years Because the construction of the battery housing forms part of the products certification this operation must be done by the manufacturer This will entail removing the unit from the vehicle and returning it to Ampcontrol Because of the infrequency of replacing the battery this could be done as part of a vehicle routine major service Section 5 Equipment List E09464 Dieselguard Controller Basic E09481 Dieselguard Base Station RF Receiver E09484 Die
26. ocessor and User I O 2006 02 01 Sheet 5 of 11 4 72 6600 Main Signal I O VIC 2006 02 01 Sheet 6 of 11 72 6600 Radio Data Link Version 2 VIE 2006 02 01 Sheet 7 of 11 72 6600 Root Schematic connectors VIC 2006 02 01 Sheet 8 of U1 72 6600 Diesel Machine Monitor Certified Parts List C 2006 03 06 Sheet 11 of 11 75 2660ENCEB Main components diesel gas sampler with external battery 0 epoxy resin encapsulation This certificate and schedule shall not be reproduced except in full 2006 03 01 Page 5 of 8 Bey ce DIESELGUARD USER MANUAL ISSUE 2 Certificate of Conformity Addendum Certificate No ANZEx 05 4010X 21 Issue No 2 Date of Issue 12 May 2006 75 2660ENC Main components diesel gas sampler epoxy resin encapsulation CONDITIONS OF CERTIFICATION Conditions of manufacture Conditions of manufacturer are 1 The apparatus must be manufactured in accordance with the certified drawings y The apparatus shall be subjected to a 1000 V r m s test voltage applied between input terminals and case for not less than 1 minute Conditions of safe use 1 The following parameters are not exceeded Input Parameters Integral Cable 90 V 12to24 V rogramming Header External Batter This certificate and schedule shall not be reproduced except in full Page 6 of 8 24 DIESELGUARD USER MANUAL ISSUE 2 Certificate of Conformity Addendum Certifica
27. oles in the base 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 2 8 Cable Systems The external connections to the Dieselguard Diesel Machine Monitor apart from the power connection mentioned above are Intrinsically Safe Circuits and as such should be installed to comply with the requirements of AS 2381 7 or the applicable mine standard As such normal IS cables can be used although extra protection from mechanical damage may be required in non enclosed areas or adjacent to rotating or moving components 2 9 Wireless Communications Antenna For units fitted with a wireless communications link it will be necessary to mount the small whip antenna to the vehicle The antenna is located at the end of the free coax cable and is protected by a rugged sheath When mounting the antenna consideration should be given to keeping the actual receiving part the last 200mm of the cable assembly away from the metalwork of the vehicle If the antenna is too close to the vehicle then the useable range may be reduced Ideally the antenna should be mounted vertically 11 DIESELGUARD USER MANUAL ISSUE 2 SECTION 3 OPERATIO
28. out in Standards Australia Standards New Zealand Miscellaneous Publication MP87 STANDARDS The electrical apparatus and any acceptable variations to it specified in the schedule of this certificate and the identified documents was found to comply with the following standards AS NZS 60079 0 2000 Electrical apparatus for explosive gas atmospheres Part 0 General requirements AS NZS 60079 11 2000 Electrical apparatus for explosive gas agi coda inc Al Part 11 Intrinsic safety i AS2431 1981 Electrical equipment for explosive atmospheres Encapsulated apparatus Type of protection m This Certificate does not indicate compliance with electrical safety and performance requirements other than those expressly included in the Standards listed above TEST amp ASSESSMENT REPORTS The equipment listed has successfully met the examination and test requirements as recorded in Original Test Report No and Issuing TR3177 IFACS Body Test Report Covering this Addendum TR 3743 ITACS Quality Assessment Report No and Issuing Body ANZEx 05 4010 06 01 ITACS supporting this Addendum Tile Reference ANZ Ex 05 4010X Signed for and on behalf of issuing body General Manager 12 May 2006 Position Date of Issue This certificate and sch shall not be reproduced except in full This certificate is not transferable and remains the property of the issuing body and must be returned in the event of it being revoked or not re
29. selguard Controller Radio Version E09819 Dieselguard User Manual E09232 IDA display E0942 Gas Detector Calibration kit 65 655 1 CH4 Methane Gas Transmitter Sensor c w Display 65 655 1 CH4 RO5 Methane Gas Transmitter Sensor c w Remote Head on a 5m lead and Display 61 6551 CH4 R10 Methane Gas Transmitter Sensor c w remote head on a 10m lead and Display WPISB314 Asco 3 2 solenoid valve DIESELGUARD USER MANUAL ISSUE 2 SECTION 6 FAULT FINDING The following fault finding tables are provided as an indication of the possible faults the symptoms and solutions associated with the Dieselguard System Refer to Table 1 for faults associated with the entire Dieselguard System and to Table 2 for faults specifically associated with the Gasguard Sensor Table 1 Dieselguard System Fault Finding Symptom Cause Solution Display Internal battery below Put machine In bypass and charge battery from alternator one does minimum charge level Disconnect the power supply cable from the machines electrical system and ee RES charge by connecting a 12Volt Power Supply to the Dieselguard Supply leads Y x Core 4 positive and Cores 1 2 amp 3 negative Note Do not use a Battery esa Charger See section 1 5 for recommended charge time Run button disconnected or broken Repair connection or replace button Check connections for the Run Button in the Dieselguard Control Unit IDA Display system fault Internal fa
30. start function 12 SECTION 4 MAINTENANCE 4 Visual inspection 13 4 2 Close 1 13 4 3 Hydrophobic barrier 13 4 4 System check procedure 13 4 5 Calibration o cire 13 4 6 Changing internal battery 13 SECTION 5 Equipment List eios 13 SECTION 6 Fault Finding use teer te 14 SECTION 7 Application 18 SECTION 7 Certification Documentation 19 CONTENTS DIESELGUARD USER MANUAL ISSUE 2 SECTION 1 DESCRIPTION 1 1 Introduction This manual provides installation commissioning operation and maintenance instructions for the Ampcontrol Dieselguard Control Units The Dieselguard Control Unit consists of two types e Blind type Preset configuration without data logging or communications e Smart type With communications link that permits on site configuration and logging of data Part Numbers The following Dieselguard Control Units are covered in this manual E09464 Dieselguard Controller Basic E09481 Dieselguard Base Station RF Receiver E09484 Dieselguard Controller Radio Version Dieselguard Control Unit Dimensions 290mm 180mm 80mm DIESELGUARD USER MANUAL ISSUE 2 1 2 Dieselguard Description The Ampcontrol Dieselguard Machine Monitor forms part of the Diesel Machine monitoring system The Diesel Machine Monitor is the centre of th
31. t eventually the unit will not have sufficient power to start the system Typically the Diesel Machine Monitor can typically be left for 10 to 11 days before a bypass or cold start is required Later versions of the Dieselguard have an internal battery disconnect ability when not in use These units are identified by scooped edges of the internal terminal connection board The batteries of these units will hold the charge for many months typically 6 months without further charging being required Lockable bypass ball valves on the solenoid valve can be used to override the gas system When the valves are used the vehicle can be started without the use of the detection system Depending on the valve configuration as soon as the vehicle has started in the bypass mode the gas system can be energised and when a stable indication is shown the valves can be reset The alternator charges the battery and within 20 30 minutes normal function of the system is 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 DIESELGUARD USER MANUAL ISSUE 2 voltage requirement to operate the system The Diesel Machine Monitor has a battery saver cut off voltage and the monitor will not operate from the battery until the minimum charge has brought the battery voltage above that level In this case the Diesel Machine Monitor may not complete its 2
32. te ANZEx 05 4010X Issue Date of Issue 12 May 2006 Output Parameters Terminal ID U L LR V pH uH O T B 1 pin l wet OV e g pin 2 16 2 10 45 T B 1 pin 3 wrt e g pin4 10 45 1 pin5 wrt OV e g pin6 10 T B 3 4 T B 5 Antenna Header Not applicable see note 5 below Pin 1 wrt pin 6 Not applicable sce note 5 below Programming Header Pin 2 wrt pin 6 Programming Header Not applicable see note 5 below Pin 3 wrt pin 6 Programming Header 16 2 1715 Not applicable see note 5 below Pin 4 wrt pin 6 Programming Header 16 2 1715 3014 Not applicable note 5 below Pin 5 wrt pin 6 2 The apparatus must be installed such that the integral wires are housed in a suitably certified Ex e or Ex d enclosure having a minimum Ingress Protection IP rating of IP55 If the wires are terminated in an Ex e enclosure suitably certified Ex e terminals must be used for terminating the wires This certificate and schedule shall not be reproduced except in full Page 7 of 8 295 DIESELGUARD USER MANUAL ISSUE 2 Certificate of Conformity Addendum Certificate No ANZEx 05 4010X TEN Issue No Date of Issue 12 2006 3 The earth bonding conductor must be infallibly connected to the chassis earth via ter
33. th Smart Monitoring are used with the wireless base station to 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 The only replaceable item is the internal battery which will require changing after 3 to 5 years 1 3 Typical Application DIESELGUARD USER MANUAL ISSUE 2 The Dieselguard Machine Monitor receives signals from an external device such as a Gas Transmitter and provides outputs to give indications and control A typical scheme of a system is shown below Diesel Machine Gas Detection System Intrinsically Safe Alarm Display Unit Gasguard Transmitter 65 6551 CH4 Integral Or Remote CH4 Sensor RTD Inputs Analogue input Alternator Power I P Gas Detection control unit Dieselguard Start Deputy Alarm IS Vehicle push override Reset solenoid Pneumatic button switch button Valve safety circuit Lockable Manual Override valve Vent 1 4 Connections Dieselguard Inputs Power supply The Diesel Machine Monitor can be powered from a nominal 12 24V supply The Intrinsically Safe features of the unit require it to be capable of standing the fault conditions of a vehicle alternator including back EMF from equipment isolation The un
34. ult Check the voltage between the IDA 0V and V terminals on Term 1 should be approx 12V Check the voltage between the IDA OV terminal on Term 1 and the IDA Green terminal on Term 3 Check the voltage between the IDA OV terminal on Term 1 and the IDA Red terminal on Term 3 Note There must be approximately 12V from the IDA OV and V terminals on Term 1 AND either 12V at the Green or Red terminals on Term3 for the IDA to indicate If the Gas Sensor indicates a gas level and the IDA does not either the battery voltage is low or there is an Internal Fault refer below Call manufacturer Display system does not flash green when the run button is activated or assumes one of the following states after the initial 20 second sequence 1 Steady Input power present Normal start up does not expect input power Green prior to start sequence st Allow unitto shut down normally 2 min and restart If unit has not been charged it may be necessary to Bypass and charge the system first used due to low battery 9 y bii 9 2 Steady Ambient gas level Check ambient gas levels and report Amber above first alarm point 3 Steady Ambient gas level Follow site procedure to leave area until deemed safe Red above second alarm point Allow control unit to shut down Re start unit 4 Flashing System has sensed gas Check ambient gas level and operate reset button Amber above second alarm Unit powers Internal
35. x Lo Ro 45 18 0V max holding solenoid Uo 29 85V max Io 116 4mA max Lo Ro 537 The unit is fed by a number of sensors whose function is to monitor the machines status Temperature No of Inputs Type Scaling Excitation current Resolution Accuracy Fault modes Oil Pressure Type Range Gas Detection Type Digital Input levels Analogue Input levels Three 3 RTD 100 Ohm at 0 C 0 to 200 C 1 0mA 1 0 C 3 0 C Open sensor up scale Shorted sensor down scale Digital OV to 16 5V max Application specific Catalytic Methane 0 to 5 V V 3 wire 4 20mA signal return Ui 16 5V max High level 3 0V min Low level 0 5V max Ui 16 5Vmax Max scaled current 25mA Min scaled current OmA Data Communications advanced units only Type Connection Range Communication functions Mechanical Details Enclosure Rating Material Finish Dimensions Mounting Protection Concept Labelling Weight Connections Type No of glands Environmental Shock Vibration Low Frequency Medium Frequency EMC DIESELGUARD USER MANUAL ISSUE 2 2 4GHz Wireless link using proprietary protocol with option to use ZigBee protocol stack Antenna fed from internal radio section to exterior via 16 20mm gland Up to 50m line of sight Download of logged data and setup Upload of configuration settings IP66 Stainless Steel 316 1 6mm Polished W 300m
36. y manufacturing details 28 6606LEB Label certification 9483eb diesel gas sampler with lt 0 2006 01 31 external battery manufacturing details 28 6607LEB Label certification 9484eb diesel gas sampler with 0 2006 01 31 external battery manufacturing details 28 6608 LEB Label certification 9485eb diesel gas sampler with 0 2006 01 31 external battery manufacturing details 28 6609LEB Label certification 9486eb diesel gas sampler with 0 2006 01 31 external battery manufacturing details 28 6610LEB Label certification 9487eb diesel gas sampler with 0 2006 01 31 external battery manufacturing details This certificate and schedule shatl not be reproduced except in full Page 4 of 8 222 DIESELGUARD USER MANUAL ISSUE 2 Certificate of Conformity Addendum certificate No ANZEx 05 4010 IssieNo 2 Date of Issue 12 May 2006 Document No yyy 2006 02 02 47 6601 L 01 Antenna co axial monopole assembly with fittings general 2 arrangement 72 6600GAEB Main components diesel gas sampler with external battery 0 2006 03 01 general arrangement 72 6600GA Main components diesel gas sampler general arrangement 3 2006 03 01 72 6600 Battery Charging Circuits VIC 2006 02 01 Sheet 2 of 11 72 6600 Power Switching and Supply Monitor VIC 2006 02 01 Sheet 3 of 11 72 6600 ia Output Supplies 2006 02 01 Sheet 4 of 11 72 6600 Pr
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