CATALYTIC METHANE SENSOR User Manual
Contents
1. ao WA AMPCONTROL A gI Certificate Number Baseefa Ampcontrol Electronics Pty Ltd ABN 35 000 770 141 Gasguard CH4 Sensor User Manual Rev 5 4 14 Issued 13 December 2010 Baseefa09ATEX0204X Page 4 of 4 Number Sheet Issue Date Description 75 6551L 2 to 4 of 4 V4i 2008 04 30 Sensor CPU Catalytic Schematic 24 6551L 1 of 5 V4 2006 11 15 Sensor CPU Catalytic Top Overlay 24 6551L 2 of 5 V4 2006 11 15 Sensor CPU Catalytic Bottom Overlay 24 6551L 3 of 5 V4 2006 11 15 Sensor CPU Catalytic Top Layer 24 6551L 4 of 5 V4 2006 11 15 Sensor CPU Catalytic Bottom Layer 24 6551L 5 of 5 V4 2006 11 15 Sensor CPU Catalytic Drill Drawing 75 6556L l of 2 4 2004 05 13 GasGuard SM PSU Schematic 75 6556L 2 of 2 6 2008 04 30 GasGuard SM PSU Schematic 24 6556L V4 l of 4 4 2004 05 05 GasGuard SM PSU PCB Top Overlay 24 6556L V4 2 of 4 4 2004 05 05 GasGuard SM PSU PCB Top Layer 24 6556L V4 3 of 4 4 2004 05 05 GasGuard SM PSU PCB Bottom Layer 24 6556L V4 4 of 4 4 2004 05 05 GasGuard SM PSU PCB Drill Drawing 23 5503L 01 l of 1 5 2007 01 31 Fuse Intrinsically Safe General Arrangement 65 6551CH4 02 l of 11 2007 03 01 Catalytic Detector CH4 In Stainless Steel Enclosure Layout amp Wiring 61 0203GG 01 lof1 3 2004 04 28 Remote Head Catalytic Nemoto Detector Heavy Duty Enclosure General Assembly 23 6550LB 01 1 of 1 5 2005 10 13 Stainless Steel Box Gasguard Sensor Enclosure Manufacturing Details 23 6550LL 012. The method of packing used will depend on the size and quantity of the equipment The following cautions should be interpreted as appropriate CAUTION Take care when unpacking crates as the contents may have shifted during transport The disposal of packaging materials replaced parts or components must comply with environmental restrictions without polluting the soil air or water Ensure that any timber and cardboard used as packaging is disposed of in a safe and environmentally responsible manner ENVIRONMENTAL ALERT Where possible dispose of all waste products i e oils metals plastic and rubber products by using an approved recycling service centre Page 6 of 21 e lt a wi Ampconirol Electronics Pty Ltd ABN 35 000 770 141 AMPCONTROL Gasguard CH4 Sensor a A SIS ev 5 3 INSTALLATION 3 1 General Warnings These instructions have been designed to assist users of the Gasguard CH4 Sensor with installation Before the sensor can be installed there are a number of things that need to be considered and understood to prevent incorrect or unsafe operation of the sensor or the system into which it is installed Along with relevant competence and an understanding of the target application the following points should be considered 3 1 1 Ensure that the information provided in this user manual is fully understood It is extremely important that the limitations and functionality of the Gasguard CH4 Senso
3. Ampcontrol Electronics Pty Ltd ABN 35 000 770 141 AMPCONTROL Gasguard CH4 Sensor greng A SIS ev 5 5 3 Sensor Calibration Calibration can only be carried out once the installation is complete and fault free Before the start of calibration the sensor should be powered up and left to stabilise for at least two hours Following the stabilisation period sensor performance can be checked If performance is within the limits of error given in the product specification no calibration is required 5 3 1 Calibration Gas Sensor zero calibration must only be carried out using nitrogen or industrial grade clean air that is within its expiry date and carries a standards traceable specification Sensor span calibration must only be carried out using methane that is within its expiry date and carries a standards traceable concentration To achieve the required concentration for calibration purposes methane is mixed or balanced with a carrier gas This carrier gas must be air for the Gasguard s catalytic sensor to operate correctly Methane balanced with nitrogen must never be used to verify or calibrate the sensor since this will inhibit the function of the catalytic sensor bead Calibration gas should ideally be 50 of full scale However sometimes due to practical restraints and safety reasons the gas may need to be less than 50 Concentrations of less than 25 of full scale should not be used in order to avoid pote
4. LEN User Manual Part Number 165714 X V KS Designed and manufactured in Australia by Ampcontrol Electronics Pty Ltd CATALYTIC METHANE SENSOR User Manual P AMPCONTROL 41 A Gasguard e i wi Ampcontrol Electronics Pty Ltd ABN 35 000 770 141 AMPCONTROL Gasguard CH4 Sensor User Manual 41 e WARNING This safety alert symbol identifies important safety messages in this manual and indicates a potential risk of injury or even death to personnel When you see this symbol be alert your safety is involved carefully read the message that follows and inform other operators CAUTION This safety alert symbol identifies important information to be read in order to ensure the correct sequence of work and to avoid damage or even destruction of the equipment and reduce any potential risk of injury or death to personnel Supplementary information not directly affecting safety or damage to equipment Carefully read the message that follows and inform other relevant personnel Information concerning possible impact on the environment and actions required for prevention and proper response Rev 5 4 14 Page 2 of 21 e i wi Ampcontrol Electronics Pty Ltd ABN 35 000 770 141 AMPCONTROL Gasguard CH4 Sensor a A ev 5 Copyright Notice The Ampcontrol Gasguard Sensor described in this document is the property of AMPCONTROL PTY LTD Itis furnished under a license agreement and is to be us
5. 6 SERVICE MAINTENANCE amp DISPOSAL 6 1 Equipment Service The Gasguard CH4 Sensor requires no internal servicing during its normal operating life A number of external system based checks should however be completed on a regular basis These routine inspections must be carried out by suitably trained people with knowledge of the sensor and the systems into which it is fitted Routine inspections may take the form of either visual only checks or visual and hands on checks 6 1 1 Visual Only Inspections A basic visual inspection focuses on looking at the installation for signs of physical damage water or dust ingress and the condition of cables and labels This level of inspection may also include cleaning display windows that have become obscured by dirt Observations would typically be e Check that equipment enclosures cable trays conduits etc are in good order with no physical damage e Check that sealed wall boxes are free from water and dust ingress internally Door seals are in good condition e Check that connected cables are free from cuts abrasions and obvious signs of damage Cable restraints are in good order and correctly fitted e Check that labels on equipment wall boxes and cables are present and in good condition especially certification labels e Check that no modifications have been carried out to installed equipment 6 1 2 Hands On Detailed Inspections A more detailed inspection would incl
6. 2006 14 09 2006 2004 05 12 Description GasGuard IR CO2 Optical Bench Interface Board GasGuard IR CO2 Processor Board GasGuard IR CO2 Sensor Board GasGuard IR CO2 Lamp Board GasGuard IR CO2 Isolation Board GasGuard IR CO2 Optical Bench Interface Board GasGuard IR CO2 Processor Board GasGuard IR CO2 Sensor Board GasGuard IR CO2 Lamp Board GasGuard IR CO2 Isolation Board Retaining Ring H D I R Sensor Manufacturing Details Sinter Cupro Nickel H D I R Sensor Manufacturing Details Housing Body H D I R Sensor Manufacturing Details Housing Top H D I R Sensor Manufacturing Details Mounting Plate H D I R Sensor Manufacturing Details Mount Detector H D I R Sensor Manufacturing Details Mount Light Source H D I R Sensor Manufacturing Details Lamp Detr Block amp Mounting Plate Heavy Duty Infrared Sensor Assembly Details Sensor CO2 Gasguard Infrared General Assembly Lamp Block Heavy Duty Infrared Sensor General Assembly Detector Block Heavy Duty Infrared Sensor General Assembly Reflector amp Lamp Detr Block CO2 Heavy Duty Infra Red Sensor General Arrangement CO2 H D LR Transmitter With Display In Stainless Steel Enclosure Layout amp Wiring Detector CO2 Remote In Stainless Steel Enclosure Layout amp Wiring Detector CO2 Remote With Cable Box Connector General Arrangement Label CO2 in S Steel Enclosure Manufacturing Details Label CO2 2 in S Steel Enclosure Manufacturing Details Sensor CPU Catalytic Schematic
7. against damage or losses during shipment however before accepting delivery check all items against the packing list or bill of loading If there are shortages or evidence of physical damage notify Ampcontrol immediately Notify Ampcontrol within 7 days maximum in case of shortages or discrepancies according to the packing list This action will help ensure a speedy resolution to any perceived problems Keep a record of all claims and correspondence Photographs are recommended Where practicable do not remove protective covers prior to installation unless there are indications of damage Boxes opened for inspection and inventory should be carefully repacked to ensure protection of the contents or else the parts should be packaged and stored in a safe place Examine all packing boxes wrappings and covers for items attached to them especially if the wrappings are to be discarded 2 2 Inspection Equipment that is found to be damaged or has been modified away from its published specification must not be used Please contact Ampconirol if the equipment is suspected to be different than that ordered or if it does not match the published specifications 2 3 Storage after Delivery When the equipment is not to be installed immediately proper storage is important to ensure protection of equipment and validity of warranty All equipment should be stored indoors preferably on shelves and protected from the elements 2 4 Unpacking of Equipment
8. calibration pen over the CAL symbol 1 for 5 seconds c Now that the CAL mode is accessed place the magnetic tip over the ZERO symbol 3 for 5 seconds d The display should have a zero reading To save the zero setting place the magnetic tip over the CAL symbol 1 for 5 seconds e The sensor display 5 will show SAV to confirm that it has saved the zero setting f Turn off the gas flow to the sensor 5 5 Span Calibration Perform a span calibration as follows noting that the gas must be flowing for the duration of the operation a Apply methane to the sensor at the rate of 0 5 to1 litre per minute and allow the reading to stabilise b Ifthe reading lies outside the error limits given in the product specification adjustment will be necessary c To adjust the sensor reading so that it reads the correct value for the applied methane concentration enter calibration mode by placing the magnetic tip of the Calibration pen over the CAL symbol 1 for 5 seconds d Place the magnetic tip of the pen over the UP symbol 4 to increase the display reading and over the DOWN symbol 6 to decrease the display reading Use these actions to set the reading to the correct value e To save the calibration value place the magnetic tip over the CAL symbol 1 for 5 seconds f Turn off the gas flow to the sensor Page 17 of 21 e ai wi Ampcontrol Electronics Pty Ltd ABN 35 000 770 141 AMPOCONTROL Gasguard CH4 Sensor a A ev 5
9. of the Sensor Page 11 of 21 e lt a wi Ampconirol Electronics Pty Ltd ABN 35 000 770 141 AMPCONTROL Gasguard CH4 Sensor weree A ev5 a 2 INCOMING Di wo 3 TERMINALS 1 2 3 4 f 3 E 1 X T lt q gt a i TRANSMITTER DISPLAY J4 SENSOR Figure 2 Catalytic Sensor electrical connections 4 3 Sensors Details 4 3 1 Methane Gas Sensor The Methane Gas Sensor which operates on the catalytic combustible gas detection principle is a small platinum element coated in a catalyst Electrical current is passed through the platinum wire and the potential of the catalytic element is monitored by a simple Wheatstone Bridge arrangement Combustible gases once in contact with the heated catalytic surface of the measuring element react and cause the surface temperature of the element to rise Any increase in temperature affects the resistance of the platinum wire causing a small shift in potential across the Wheatstone Bridge proportional to the concentration of the combustible gas The sensor is temperature compensated and provides a 4 20mA linear output Page 12 of 21 BW e wi Ampcontrol Electronics Pty Ltd ABN 35 000 770 141 AMPCONTROL Gasguard CH4 Sensor a A ev 5 4 3 2 Sensor Cell Cross Sensitivity Methane gas sensors positively detect the presence of all flammable gases Itis unable
10. to distinguish the difference between gases so the sensor will display a reading if any flammable gas is present The table below details the cross sensitivity data for a methane sensor Gas Concentration Reading vv 2 5 1 2 1 2 an 5 0 Toluene 4 3 3 Poisoning of Sensors Contamination High levels of or long exposure to certain compounds may poison the catalytically active detector filament thereby reducing or destroying its sensitivity Among these compounds are halides sulphur compounds leaded petrol silanes silicates and other produces with silicon Products such as aerosol sprays polishes waxes and lubricants with silicones and non catalysed silicone rubbers such as silastic phosphate esters and hydraulic fluids all damage catalytic sensors GAUTONI Exposure to Hydrogen Sulphide gas H2S may affect the performance of the detector by reducing its sensitivity to methane If the sensor is exposed to H2S gas then the detector must be recalibrated 4 4 Amplifier electronics PCB The purpose of the amplifier electronics is to convert the low level electrical output of the sensor into a signal capable of driving external indicator equipment such as the Ampcontrol Gasguard 4 Channel Controller The Gasguard amplifier electronics are designed to operate as a 3 wire unit with connections provided for input power power supply return and current loop signal output The electronics require 12VDC op
11. ATION CERTIFICATE 2 Equipment or Protective System Intended for use in Potentially Explosive Atmospheres Directive 94 9 EC 3 EC Type Examination Baseefa09ATEX0204X Certificate Number 4 Equipment or Protective System Gas Sensor Transmitter Gasguard Series 65 655x 5 Manufacturer Ampcontrol Pty Ltd 6 Address Cameron Park NSW 2285 Australia 7 This equipment or protective system and any acceptable variation thereto is specified in the schedule to this certificate and the documents therein referred to 8 Baseefa Notified Body number 1180 in accordance with Article 9 of the Council Directive 94 9 EC of 23 March 1994 certifies that this equipment or protective system has been found to comply with the Essential Health and Safety Requirements relating to the design and construction of equipment and protective systems intended for use in potentially explosive atmospheres given in Annex II to the Directive The examination and test results are recorded in confidential Report No 09 C 0334 9 Compliance with the Essential Health and Safety Requirements has been assured by compliance with EN 60079 0 2006 EN 60079 11 2007 EN 50303 2000 EN 61779 1 2000 EN 61779 2 2000 Only applicable to the Gasguard 65 6551 CH4 except in respect of those requirements listed at item 18 of the Schedule 10 Ifthe sign X is placed after the certificate number it indicates that the equipment or protective system is subject to special conditions for s
12. a Je nean Baseefa09ATEX0204X 13 Schedule 14 Certificate Number Baseefa09ATEX0204X 15 Description of Equipment or Protective System The Gas Sensor Transmitter Gasguard 65 655x series use a common transmitter section with alternate sensors to suit the gas being sensed The transmitter uses an external d c power supply A serial communication port an RS 485 port and a programming port available internally within in the apparatus are only to be used by the manufacturer in a safe area The sensor reading is displayed on an LCD display panel The Gasguard 65 6552 CO2 has an infrared CO sensor head The sensor head can either be fixed on the transmitter or remotely connected by a specified cable The Gasguard 65 6551 CH4 has a catalytic sensor head The sensor head can either be fixed on the transmitter or remotely connected by a specified cable Gasguard 65 6551 CH4 and 65 6552 CO2 terminal parameters Power amp Signal Terminals J5 Sensor Terminals J4 U 16 5 Vdc U 16 5 Vdc C 40 nF k 0 8 A L 0 Ps 2 171 W Co 300nF Lo 100 uH These are suitable for connection to the sensor and its associated cable up to 10 metres in length 16 Report Number 09 C 0334 17 Special Conditions for Safe Use 1 The accuracy of the equipment when tested according to EN 60079 1 2000 and EN 61779 2 2000 at 10 C is outside the specified limits of 2 of the gas concentration The equipment is however within limits between the temperatur
13. afe use specified in the schedule to this certificate 11 This EC TYPE EXAMINATION CERTIFICATE relates only to the design and construction of the specified equipment or protective system Further requirements of the Directive apply to the manufacturing process and supply of this equipment or protective system These are not covered by this certificate 12 The marking of the equipment or protective system shall include the following GO IM1 Ex ia I 20 C lt Ta 40 C EN 61779 1 2000 EN 61779 2 2000 Gasguard 65 6551 CH4 x MI Ex ia I 20 C lt Ta 40 C Gasguard 65 6551 CO2 This certificate may only be reproduced in its entirety without any change schedule included Baseefa Customer Reference No 6368 Project File No 09 0334 This certificate is granted subject to the general terms and conditions of i Baseefa It does not necessarily indicate that the equipment may be used in particular industries or circumstances Baseefa R S SINCLAIR Rockhead Business Park Staden Lane IRE Buxton Derbyshire SK17 9RZ 2 b G Telephone 44 0 1298 766600 Fax 44 0 1298 766601 n oenalt o e mail info baseefa com web site www baseefa com Baseefa Baseefa is a trading name of Baseefa Ltd Registered in England No 4305578 Registered address as above Page 2 of 5 e Wi Ampcontrol Electronics Pty Ltd ABN 35 000 770 141 Gasguard CH4 Sensor User Manual QMPCONTROL SE Certificate Number Issued 13 December 2010 Baseef
14. d modifications to the equipment are not permitted Unauthorised changes made to the hardware or operating firmware will void the manufacturer s warranty and may compromise the integrity of the system into which it is installed and other connected equipment 1 1 2 Equipment Knowledge Experience with or understanding of this equipment is essential for the safe installation and removal of the equipment Therefore in case of a question on how to safely proceed contact Ampcontrol immediately 1 1 3 Manual Handling Precautions have been taken to ensure all equipment is safe to handle and free from sharp edges However care should always be taken when handling enclosures and gloves should be worn 1 1 4 Installation Correct operation and safety depend on the Gasguard CH4 Sensor and associated equipment being installed correctly Mechanical and or electrical installation and maintenance of plant and equipment must only be carried out by appropriately qualified personnel and must be tested thoroughly prior to operation 1 1 5 Operation As safety depends on the Gasguard CH4 Sensor functioning correctly it is highly recommended that all safety functions of the unit be periodically tested to ensure correct operation Page 5 of 21 Wi Ampcontrol Electronics Pty Ltd ABN 35 000 770 141 AMPOCONTROL Gasguard CH4 Sensor a A ev 5 2 RECEIVING AND STORAGE 2 1 Receiving All possible precautions are taken to protect the equipment
15. e the optimum sensor location 3 9 Mandatory Installation Practices Using the Gasguard CH4 Sensor in a manner that exceeds its electrical functional or physical specifications or in a way that is contrary to its operating restrictions may create risks to personnel and or equipment resulting in injury or death e The sensor must be powered from an intrinsically safe source of power This may be either o An intrinsically safe power supply OR o A safe area located non intrinsically safe power supply via the use of an appropriate zener barrier e The sensor must not be directly powered from a non intrinsically safe power supply i e without the use of an intervening appropriate barrier e Connections to and from this sensor must only be to equipment with compatible entity parameters e The installation of this sensor must be carried out by suitably trained and qualified personnel Page 8 of 21 e a wi Ampcontrol Electronics Pty Ltd ABN 35 000 770 141 AMPCONTROL Gasguard CH4 Sensor s A ee e Certification and identification labels fixed to this sensor must not be damaged removed or covered before during or after installation e Modifications must not be made to any part of the sensor As supplied the unit is built to and complies with the standards against which it has been certified Modifications to its construction will render the unit incompatible with its certificate e Complete and accurate records of the installation
16. ed only in accordance with the terms of the agreement No part of the hardware or documentation may be reproduced transmitted transcribed stored in a retrieval system or translated into any language or computer language in any form or by any means without prior written permission of AMPCONTROL PTY LTD Disclaimer While every effort has been made to assure the accuracy and clarity of this document AMPCONTROL PTY LTD assumes no liability resulting from any omissions in this document or from misuse of the information obtained herein The information in this document has been carefully checked and is believed to be entirely reliable with all of the necessary information included AMPCONTROL PTY LTD reserves the right to make changes to any products described herein to improve reliability function or design and reserves the right to revise this document and make changes from time to time in content hereof with no obligation to notify any persons of revisions or changes AMPCONTROL PTY LTD does not assume any liability arising out of the application or any use of any product or circuit described herein neither does it convey license under its patent rights or the rights of others Before You Begin We would like to thank you for purchasing the Ampcontrol Gasguard Products WARNING To become completely familiar with this equipment and to OF ensure correct operation we strongly recommend that you take the time to read and thoroughly u
17. eegene 21 APPENDIX rn ne nt ee ee ee ee ee ee A Page 4 of 21 e i wi Ampcontrol Electronics Pty Ltd ABN 35 000 770 141 AMPCONTROL Gasguard CH4 Sensor a A ev 5 1 SAFETY AND OTHER WARNINGS For safety reasons the Gasguard CH4 Sensor must be installed operated and serviced only by competent personnel Read and understand this instruction manual completely before installing operating or servicing this equipment Failure to install or operate this instrument in accordance with the instructions contained in this manual may create hazardous operating conditions WARNING 1 The sensors should not be stored in areas that contain solvent vapours Some of these vapours are known to create false high STOP zero points and may even damage the sensor electrodes Similarly the sensor should not be exposed to high levels of solvent vapours while in operation 2 This equipment has been designed to detect explosive gases and vapours and to give warning before they reach dangerous conditions 1 1 Safe Use of Equipment The equipment supplied has been manufactured according to the state of the art and designed to ensure a safe operation The equipment may only be used within the design parameters The instructions within this manual must be observed as an aid towards achieving maximum safety during operation The owner user is responsible for observing the following instructions 1 1 1 Changes to Equipment Changes in the design an
18. entry holes and filter membranes becoming blocked by water or debris If this occurs the sensor will likely suffer reduced sensitivity and or extended response times e It is recommended that the sensor is not mounted next to electrical cables or equipment that is likely to produce large amounts of electrical or magnetic switching noise 3 4 Sensor Location The relative density or buoyancy of the gas or vapour with respect to air is a very important consideration This determines its propensity to rise or fall when released into the atmosphere Gases or vapours with buoyancy less than air will tend to rise from the source of release Conversely gases or vapours heavier than air will tend to fall from the source of release Over time all gases will disperse and become mixed into the general surrounding atmosphere Methane is lighter than air and can therefore become trapped in elevated areas where low air currents prevent mixing Places such as corners roof or cable spaces are examples For monitoring in areas where there are no air currents mount the sensor as high as possible For areas that are ventilated and have good airflow positioning is not as critical since general mixing will occur For these areas it is recommended to locate the sensor around or just above head height For applications requiring specific detection characteristics such as at the point of potential release proper analysis of the site should be undertaken to determin
19. erating voltage and transmits a signal in the range of 4 20mA Page 13 of 21 e lt a wi Ampcontrol Electronics Pty Ltd ABN 35 000 770 141 AMPCONTROL Gasguard CH4 Sensor a A SIS ev 5 The 4mA signal level indicates a zero gas concentration The 20mA signal indicates that the sensor cell has detected a full sopan gas concentration ZERO and SPAN adjustment reed relays located on the PCB are used for calibration of the sensor 4 5 Enclosures Stainless Steel Housing The standard Stainless Steel Housing Item Number 23 6550LB shown in Figure 1 incorporates the Sensor Cell and Amplifier PCB The housing is robust and is corrosion resistant It is suitable for almost all applications and provides for easy installation and maintenance When properly used it gives many years of efficient operation Page 14 of 21 Wi Ampcontrol Electronics Pty Ltd ABN 35 000 770 141 AMPCONTROL Gasguard CH4 Sensor a A SIS ev 5 5 COMMISSIONING AND CALIBRATION Commissioning is the process of carrying out initial checks adjustments and calibration prior to placing the system into operation for the first time Sensor calibration although forming part of the commissioning process is also performed periodically throughout its operational life Calibration is also required immediately following any repair to the sensor During commissioning and subsequent recalibration it is important to ensure that appropriate steps are taken to pre
20. es of 0 C and 40 C 2 This equipment is not intended to be aspirated apparatus ao WA AMPCONTROL A gI Certificate Number Baseefa09ATEX0204X Ampcontrol Electronics Pty Ltd ABN 35 000 770 141 Gasguard CH4 Sensor User Manual Rev 5 4 14 Issued 13 December 2010 Page 3 of 4 18 Essential Health and Safety Requirements All relevant Essential Health and Safety Requirements are covered by the standards listed at item 9 19 Drawings and Documents Number Sheet 75 6561L VE1 1 of 1 75 6562L VE3 1 of 1 75 6563L VE l of 1 75 6564L VE 1 of 1 75 6565L VE2 1 of 1 24 6561L VE l to4 24 6562L VE2 l to4 24 6563L VE l to3 24 6564L VE l to 3 24 6565L VE1 l to3 25 0020L 01 l of 1 25 0021L 01 l of 1 25 0022L 01 1 of 1 25 0023L 01 1 of 1 35 S5501L l of 35 5502L 1 of 1 35 5503L 1 of 1 35 5504L 1 of 1 61 6552CO2 01 1 of 61 6552CO2 02 1 of 61 6552CO2 03 1 of 1 61 6552CO2 04 1 of 1 65 6552CO2 01 1 of 65 6552CO2 02 LI of 1 65 6552CO2 R 01 1 of 1 29 6554CO2 01 1 of 1 29 6555CO2 01 1 of 1 75 6551L l of 4 Issue El E3 E E E2 E E2 E E El Fe Fe El ke V4H Date 16 11 2006 16 11 2006 09 07 2006 15 06 2006 13 09 2006 13 04 2006 13 04 2006 13 04 2006 13 04 2006 15 06 2006 11 01 2006 27 07 2006 06 02 2006 06 02 2006 12 09 2006 12 09 2006 12 09 2006 23 02 2006 12 09 2006 12 09 2006 16 05 2006 12 09 2006 11 09 2006 15 09 2006 15 09 2006 14 09
21. ifies the sensor unit configurations o Item Number 65 6551 CH4 is for Catalytic sensor units In the part numbers listed above CH4 represents the chemical symbol for methane the gas detected by this sensor Page 10 of 21 e lt a wi Ampconirol Electronics Pty Ltd ABN 35 000 770 141 AMPCONTROL Gasguard CH4 Sensor weree 41 e 4 1 Mechanical Arrangement The dimensions of the sensor unit are shown in Figure 1 below 110 D i i i E gees ON d e z be O V CH Sa E ZS Q ILO Ee Es b O LIMITOF i TOXIC SENSOR Figure 1 Catalytic Sensor dimensions 4 2 Electrical Connections Electrical connections to the catalytic sensor are by means of a cable encapsulated into the sensor and terminated with a cable mounted plug The sensor plugs into the Amplifier electronics PCB Connector J4 The amplifier PCB is fitted with plug screw connectors This allows the connector to be unplugged from the PCB to attach the wiring and then be plugged back into the board A second wiring assembly connects the supply and signal connections from the incoming terminals to the Amplifier electronics PCB Connector J5 Figure 2 shows the electrical connection
22. ions There are only two active replaceable units in the sensor system the Amplifier electronics PCB and the gas sensor Therefore fault isolation is limited to the following possible faults and remedies 6 2 2 1 4 20mA output not functioning a Verify all connections are correct and are not damaged or disconnected b Verify that the fault does not lie with connected equipment such as controllers etc c Verify the supply voltage applied to the Amplifier PCB is within specification d Check for loose plug and terminal connections If the above checks indicate no faults replace the Amplifier electronics PCB D 6 2 2 2 Sensor cannot be Spanned or Zeroed a Check the supply voltage to the sensor is within specification b Check for loose plug and terminal connections c Verify the calibration gas being used is of the correct type and is within its expiry date d Verify that the gas entry ports are free from obstruction by water or debris Rev 5 4 14 Page 19 of 21 e lt a wi Ampcontrol Electronics Pty Ltd ABN 35 000 770 141 AMPCONTROL Gasguard CH4 Sensor User Manual 41 A Rev 5 4 14 e If the above is correct and the problem persists replace the sensor f Ifthe sensor still cannot be Spanned or Zeroed replace the Amplifier PCB 6 2 2 3 Erratic Output a Check that voltage and polarity applied to the Amplifier PCB is correct Also check that there are no severe voltage swings indicating an intermittent fa
23. l of 7 2003 09 16 Stainless Steel Box Lid Various Sensor Enclosure Manufacturing Details 110020 01 00 MD 01 LI of 1 l 2008 04 30 Label CH4 in S Steel Enclosure Manufacturing Details Ka 110924 00 00 MD 01 l of 1 0 2008 04 17 Support Membrane H D I R Sensor Manufacturing Details 110015 00 01 GA 01 1 of 1 0 2008 04 16 Sensor Gasguard Infrared General Assembly 142025 00 00 MD 01 1 of 1 0 5 11 10 Overlay Gasguard CO2 IR Sensor 5 ATEX Manufacturing Details 142026 00 00 MD 01 1 of 0 5 11 10 Overlay Gasguard CO2 IR Sensor 2 ATEX Manufacturing Details 142027 00 00 MD 01 lof 1 0 5 11 10 Overlay Gasguard CH4 CAT Sensor 5 ATEX Manufacturing Details 143426 00 00 MD 01 l of 1 0 5 11 10 Label Gasguard CO2 IR Sensor 5 ATEX Manufacturing Details 143427 00 00 MD 01 1 of 1 0 5 11 10 Label Gasguard CO2 IR Sensor 2 ATEX Manufacturing Details 143343 00 00 MD 01 1 of 1 0 SALI Label Gasguard CH4 CAT Sensor 5 ATEX Not required for ATEX certification Manufacturing Details
24. must be kept as part of the site installation dossier Page 9 of 21 Wi Ampcontrol Electronics Pty Ltd ABN 35 000 770 141 AMPCONTROL Gasguard CH4 Sensor a A SIS ev 5 4 GASGUARD CATALYTIC METHANE SENSOR OVERVIEW Ampcontrol s Gasguard Flammable Gas Sensor Transmitter is supplied complete with an amplifier and a Liquid Crystal Display The Gas sensor is housed in a cast stainless steel enclosure has been approved to be intrinsically safe and is suitable for use in a Zone 0 hazardous area A remote head version with up to ten metres of cable is also available for use on mobile machinery such as roof bolters and continuous miners Key Features e Rugged Construction e Reliable e Certified Intrinsically Safe Ex ia e LCD Display e Non Intrusive Closed Case Calibration 1 This manual provides commissioning calibration and maintenance instructions for the Ampcontrol Gasguard Sensor Units Because the units are passive monitoring devices operating instructions are not applicable to this equipment 2 The chemical symbols for toxic gases and oxygen are used extensively throughout this manual The Gasguard sensor units consist of e Catalytic Methane Sensor CH4 For which the following instructions and diagrams are included in this manual e Amplifier PCB Description e Sensor Wiring Diagrams e Stainless Steel Housing Enclosure Dimensions Unique part numbers in accordance with the following scheme ident
25. nderstand this user manual Ampcontrol Electronics Contact Details 7 Billbrooke Close Cameron Park NSW 2285 P 61 2 4903 4800 F 61 2 4903 4888 EMAIL electronicsorders ampcontrolgroup com WEB www ampconirolgroup com Page 3 of 21 e a wi Ampconirol Electronics Pty Ltd ABN 35 000 770 141 AMPCONTROL Gasguard CH4 Sensor s A ee TABLE OF CONTENTS 1 SAFETY AND OTHER WARNINGS sito ccgecanseccasitetdenspeGaceeeteenctdeateetadendeeneriecies 5 1 1 Safe Use of Eoupment nannan naa naaa a Ea a aE 5 2 RECEIVING AND STORAGE tee casos esc E EEEE 6 Bol GEES 6 22 MIS DC CON et 6 2 9 StOlade alter DEVET E 6 2 4 Unpacking Of Eoumpment EE 6 INS TATA TON oen A TA E ceases 7 Steel EU Ee 7 3 2 Product Safety Making 7 SEN Ee uer EE 8 eA DENISON Ee 8 3 5 Mandatory Installation Practices 00nnenannneennnnannnnannnnnnnnennnnnnrenernennrenne 8 4 GASGUARD CATALYTIC METHANE SENSOR OVERVIEW 10 4 1 Mechanical Arrangement 11 4 2 Electrical CONNECTIONS ccccccececccceeeceeeeeeeceesseeeeeeseeeeceesseaeeeeseaeeeessaaeeees 11 Ee RE 12 4 4 Amplifier electronics DCH 13 AO ele 14 5 COMMISSIONING AND CATIDDATION 15 5 1 Preliminary Checks 15 5 2 Gasguard Display Ciel EEN 15 5 3 Sensor Calibra RE 16 DALO O r EE E EE 17 0 PN GUNN O eaa T E E E 17 6 SERVICE MAINTENANCE amp DISPOSAL cece cececceeceeeee tees eeeeeeeeeeaaneeeeeeeaas 18 SS keier 18 6 2 Equipment OM ln En Ee 18 BIS EE 20 E Te age E 21 GENEE NS Pr
26. ntial calibration inaccuracies 5 3 2 Flow Rate Calibration gas should be applied to the sensor at a rate of approximately 0 5 to 1 0 litres per minute Itis not necessary to leave the gas flowing to the sensor for any longer than is needed for the output to stabilise and the calibration adjustment to be made 5 3 3 Safety Because sensor calibration involves the use of gas appropriate safety procedures must be observed in regard to its safe handling and use Proper regard to site safety practices must be given including the creation of safe work method statements where necessary Specific conditions relating to the site into which the sensor is located may also need to be considered It may be necessary to use equipment that is approved for use within the area where the sensor is located Page 16 of 21 e lt a wi Ampconirol Electronics Pty Ltd ABN 35 000 770 141 AMPCONTROL Gasguard CH4 Sensor weree ff 1 4 5 2 3 6 i AMPCONTROL T Gas Sensor Transmitter Gasguard Series 65 655x BaseefaOQA TE X0204X amp 1 M1 Ex ia 20 C lt Ta lt 40 C EN 61779 1 2000 EN 61779 2 2000 C n ampcontrolgroup cam N Figure 3 Gasguard Control Panel 5 4 Zero Calibration Perform a zero calibration as follows noting that the gas must be flowing for the duration of the operation a Apply nitrogen clean air to the sensor via the calibration hood and allow the reading to stabilise b Place the magnetic tip of the
27. r are understood to prevent incorrect installation and use from creating a potentially dangerous risk If in doubt as to the nature of the limitations or their implication consult a competent authority such as a supervisor or Ampcontrol technical representative 3 1 2 Ensure that the application into which the sensor is being installed has been properly defined designed and approved Any system intended to mitigate the risk of injury needs to be properly designed and implemented Such a system must be the result of structured risk analysis with the outcomes used to define the system requirements These requirements in turn will guide the choice of instrumentation logic solvers and actuators needed to implement the system Understanding the needs of the system will ensure proper selection of equipment 3 1 3 Ensure that the sensor will properly perform the required functions within the system design It is important to understand how the sensor is intended to interact with other equipment within a system For safe and reliable use it is crucial that neither the sensor s logical operation nor its signalling be compromised by incompatibilities with connected equipment 3 1 4 Modifications of any form to the Gasguard CH4 Sensor are prohibited The sensor as supplied has been designed and manufactured to comply with the requirements of protection standards If modifications of any form are made the equipment may no longer be fit for use If an
28. ty and electrical performance checks The schedule given below is the manufacturer s recommendations 6 2 1 1 Daily Verify operation by visually checking the reading on the respective control unit monitor Investigate any abnormal deviations from Zero reading Clean any dirt from display window to maintain a clear view of readings This should be done carefully to avoid scratching the window and rendering the display unreadable 6 2 1 2 Monthly a Check the Zero reading in fresh air or by applying nitrogen clean air Readjust as necessary b Check the Span calibration with a known concentration of methane Readjust as necessary 6 2 1 3 As Required Replace the catalytic gas sensor whenever it becomes impossible to adjust to Zero or when the Span adjustment is insufficient to enable adjustment to the calibration gas value If this occurs recalibrate the unit as described in Section 5 Commissioning and Calibration 6 2 1 4 Following Power Removal If power has been removed from the unit for a long period of time a re commissioning check should be carried out 6 2 2 Corrective Maintenance During maintenance and subsequent recalibration it is important to ensure that appropriate steps are taken to prevent the sensor output signal from initiating a fault warn or alarm condition or inappropriately driving an equipment control function Consult the relevant equipment user manuals for specific details on how to isolate alarms and funct
29. ude all of the elements of a visual inspection plus some checks that cover the integrity of connections fixtures and fittings In addition to basic visual observations more detailed integrity checks would involve e Verify that equipment housings wall boxes and other mechanical fixtures are secured in place This includes terminal box lids tightness of cable glands integrity of wall box mountings security of equipment fixing to walls DIN rails etc e Verify all electrical connections are secure with no loose screw terminals or DIN rail terminals not fitted to rails etc 6 2 Equipment Maintenance WARNING The Gasguard CH4 Sensor has no user serviceable parts All repairs must be carried out by Ampcontrol only If a fault develops attempt be made to repair the unit as any attempt to dismantle or STOP return the relay to Ampcontrol for repair It is essential that no repair the sensor can seriously compromise the safety of the unit Page 18 of 21 e lt a wi Ampcontrol Electronics Pty Ltd ABN 35 000 770 141 AMPCONTROL Gasguard CH4 Sensor User Manual 41 A 6 2 1 Periodic Maintenance Periodic maintenance involves scheduled checks to ensure the instrument remains operating safely and performs within its specification The following maintenance schedule is recommended Specific site schedules may exist to perform visual close and detailed inspections of equipment These will include checks for both basic mechanical integri
30. ult in the field wiring or control unit b Check for loose plug and terminal connections c Ifthe above is correct and the problem persists replace the sensor d If the output is still erratic replace the Amplifier PCB 6 3 Disposal The electronic equipment discussed in this manual must not be treated as general waste By ensuring that this product is disposed of correctly you will be helping to prevent potentially negative horseman tt consequences for the environment and human health which could geg otherwise be caused by incorrect waste handling of this product Page 20 of 21 a Wi Ampcontrol Electronics Pty Ltd ABN 35 000 770 141 AMPCONTROL Gasguard CH4 Sensor User Manual A Rev 5 4 14 7 SPECIFICATIONS Operational Period Sensor Estimated Life gt 2 years in clean air 0 20 C Sensor Unit Maximum Drift Zero lt 5 FSS per month sensitivity lt 5 FSS per month lt 15 seconds typical 8 EQUIPMENT LIST sensor Only Integral Sensor Head 121012 Calibration Sealing Ring 101613 Calibration Magnetic Screwdriver 102284 Calibration Magnetic Pen 106024 Calibration Cup 121647 Vibration Clip 121016 Allen Key Page 21 of 21 APPENDIX Certifications H pst ae AIMPCONTROL Gasguard CF e lt a Ampcontrol Electronics Pty Ltd ABN 35 000 770 141 Gasguard CH4 Sensor User Manual QMPCONTROL taire e CEEE reen 12 December 201 l EC TYPE EXAMIN
31. vent the sensor output signal from initiating a fault warn or alarm condition or inappropriately driving an equipment control function Consult the relevant equipment user manuals for specific details on how to isolate alarms and functions The sensor as supplied has been factory calibrated to traceable standards However before putting the sensors into operation it is important to verify this calibration This is especially important if the instruments are commissioned sometime after delivery 5 1 Preliminary Checks Perform the following preliminary checks e Verify that electrical connections are correct and that they comply with the appropriate standards e Apply power to the sensor e Check the voltage applied to the Amplifier electronics is between 12VDC and the maximum permitted under the conditions of certification e Verify that the sensor is displaying a gas reading and has not entered a fault condition The reading may not sit at zero initially since the sensor needs to stabilise from the point of applying power 5 2 Gasguard Display Panel The Gasguard display provides a number of indications relating to its operational status The table below lists these along with their meaning 999 Amplifier needs reconfiguration o Er Error has occured o Error has occurred a Calibration mode initiated display blinks when in calibration mode Calibration settings have been saved pu Powering Up Page 15 of 21 e lt a
32. y modifications or damage to the sensor is evident do not use the equipment and contact Ampcontrol for advice 3 2 Product Safety Markings The Gasguard methane sensor carries the following information as part of its front panel labelling Equipment Type Gas Sensor Transmitter Product Type Gasguard Series 65 6551CH4 Cert No Baseefa09ATEX0204X Ex marking I M1 Ex ia I 20 C lt Ta lt 40 C Page 7 of 21 e lt a wi Ampconirol Electronics Pty Ltd ABN 35 000 770 141 AMPCONTROL Gasguard CH4 Sensor greng A SIS ev 5 These markings provide information identifying the sensor type certificate number and its safety classification This information along with that provided on the certificate must be taken into account when installing operating and maintaining this sensor 3 3 Recommendations e Select a suitable central location for mounting with good access The location should be as clean and dry as practicable and at a temperature as close to 20 C as practicable e Mount the sensor unit in a position that minimises the risk of mechanical damage e Mounting should be to a vertical surface allowing for easy wiring access and subsequent servicing It is essential that the sensor be positioned to take into account the expected flow of the gas to be measured see 3 4 Sensor Location e The sensor should not be mounted with the gas detection port pointing upwards Positioning the sensor in this manner could result in the gas
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