Ampcontrol gasguard User manual

Version:2, APRIL 2016
Designed and manufactured in Australia by Ampcontrol Pty Ltd
GASGUARD
CO2 INFRARED TRANSMITTER / SENSOR UNITS
User Manual

Ampcontrol Pty Ltd – ABN 28 000 915 542
GASGUARD CO2 IR SENSOR USER MANUAL
GSB048 Version 2 – APR/16
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version Page 2 of 26
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Document Revision History
Version
Date
Description
0
03-JUN-2008
Original issue
1
04-SEP-2012
Certificate update
2
27-APR-2016
Removed old certificate, updated document formatting
WARNING!
The warning symbol highlights a potential risk of injury or death.
Please share these warnings with other operators.
CAUTION!
The caution symbol highlights a potential risk of damage to
equipment.
Please share these cautions with other operators.
NOTE
The note symbol highlights key information.
Please share these notes with other operators.
ENVIRO
The enviro (environmental) symbol highlights areas which may have an
impact on the surrounding fauna and/or flora.

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GASGUARD CO2 IR SENSOR USER MANUAL
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Copyright Notice
The Ampcontrol device described in this document is the property of AMPCONTROL PTY LTD. It is
furnished under a license agreement and is to be used 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
Thank you for purchasing the Ampcontrol Gasguard CO2 Infrared Transmitter / Sensor.
WARNING!
In the interests of safety and correct equipment operation, please
take the time to read and understand the content in this manual.
Ampcontrol Contact Details
7 Billbrooke Close, Cameron Park, NSW, 2285
P [phone] | F [phone]
EMAIL: customerservi[email protected]
WEB: ampcontrolgroup.com

Ampcontrol Pty Ltd – ABN 28 000 915 542
GASGUARD CO2 IR SENSOR USER MANUAL
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TABLE OF CONTENTS
1 SAFETY AND OTHER WARNINGS..................................................................6
1.1 Safe Use of Equipment..............................................................................6
2 RECEIVING AND STORAGE............................................................................7
2.1 Receiving...................................................................................................7
2.2 Inspection..................................................................................................7
2.3 Storage after Delivery................................................................................7
2.4 Unpacking of Equipment............................................................................8
3 PRODUCT OVERVIEW ....................................................................................9
3.1 Sensor.......................................................................................................9
3.2 Amplifier PCB ..........................................................................................10
3.3 Enclosure: Stainless Steel Housing .........................................................10
3.4 Sensor Wiring Assembly..........................................................................10
4 PRODUCT OPERATION.................................................................................12
5 INSTALLATION...............................................................................................13
5.1 General Warnings....................................................................................13
5.2 Mandatory Installation Practices..............................................................14
5.3 Installation Guidelines..............................................................................14
5.4 Mechanical Installation Information..........................................................16
5.5 Electrical Installation Information .............................................................17
6 COMMISSIONING AND CALIBRATION .........................................................20
6.1 Preliminary Checks..................................................................................20
6.2 System Calibration...................................................................................20
6.3 Zero Calibration.......................................................................................21
6.4 Span Calibration......................................................................................22
6.5 Calibration Troubleshooting.....................................................................23
7 SERVICE, MAINTENANCE & DISPOSAL.......................................................24
7.1 Equipment Service...................................................................................24
7.2 Equipment Maintenance..........................................................................25
7.3 Disposal...................................................................................................25
8 SPECIFICATIONS ..........................................................................................26
9 EQUIPMENT LIST ..........................................................................................26

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GASGUARD CO2 IR SENSOR USER MANUAL
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TABLE OF FIGURES
Figure 3.1: Anti-Vibration Clip.............................................................................11
Figure 4.1: Sensor / Transmitter User Interface..................................................12
Figure 5.1: CO2 IR Sensor / Transmitter Dimensions.........................................16
Figure 5.2: Integral Infrared Sensor Wiring Diagram...........................................18
Figure 5.3: Remote Infrared Sensor Wiring Diagram..........................................19
Figure 6.1: Gasguard CO2 IR Transmitter / Sensor Control
Panel................................................................................................21
Figure 6.2: Gasguard CO2 IR Transmitter / Sensor Control
Panel................................................................................................22
TABLE OF TABLES
Table 1: Sensor / Transmitter User Interface Descriptors...................................12
Table 2: Gasguard Display Codes......................................................................12
Table 3: Gas Density Relative to Air...................................................................15
Table 4: Nominal Resistance Values for Typical Wire Sizes...............................17
Table 6: Corrective Maintenance Checks...........................................................25

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GASGUARD CO2 IR SENSOR USER MANUAL
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1 SAFETY AND OTHER WARNINGS
For safety reasons, the sensor/ transmitter must be installed, operated and serviced only by competent
personnel. Please 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.
1.1 Safe Use of Equipment
The equipment supplied has been designed and manufactured to ensure safe operation. The equipment
must only be used within the design parameters.
The instructions within this manual must be observed as an aid towards achieving the safest possible
installation.
Persons responsible for installation, maintenance, or operation, must observe the following
instructions:
1.1.1 Changes to Equipment
Changes in the design and modifications to the equipment are not permitted. Unauthorised changes
made to the hardware or operating firmware will void the manufacturer's warranty, and may
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, please read and understand this manual prior to use. Competency based
training courses are recommended and are available on request.
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 unit 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 unit functioning correctly it is highly recommended that all safety functions of
the unit be periodically tested to ensure correct operation.

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2 RECEIVING AND STORAGE
2.1 Receiving
All possible precautions are taken to protect the equipment against damage or losses during shipment,
however before accepting delivery, check all items against the packing list or bill of loading. If there is
evidence of physical damage, notify Ampcontrol immediately.
Notify Ampcontrol immediately in case of any discrepancies to the packing list. Keep a record of any
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, retain and store any approval documentation
for your safety file as applicable prior to wrapping being discarded.
2.2 Inspection
Equipment that is found to be damaged or has been modified away from its published specification must
not be used. Please contact Ampcontrol if the equipment is suspected to be different than that ordered or
if it does not match the published specifications.
2.3 Storage after Delivery
When the 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 between 0-40˚C, preferably on shelves and protected from
moisture and sunlight.
CAUTION!
The sensors should not be stored in areas that contain solvent
vapours. Some of these vapours are known to create false "high" 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.

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2.4 Unpacking of Equipment
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.
ENVIRO
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.
Where possible, dispose of all waste products i.e. oils, metals, plastic
and rubber products by using an approved recycling service centre.

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3 PRODUCT OVERVIEW
Ampcontrol’s Gasguard Infrared Carbon Dioxide Sensor / Transmitters are supplied complete with an
amplifier and a Liquid Crystal Display.
The Transmitter/Sensor assembly is an IEC Ex ia Group I certified assembly. The Certification is based
on the unit being sealed to IP 66 and the appropriate checks being made on the Intrinsically Safe
Parameters of the overall system the transmitter is connected into.
The Transmitter and Sensor can be mounted as an integral device but there is also an option to mount
the sensor separately up to 10m from the transmitter. In the remote configuration the sensor is factory
fitted with a type 2S cable which is potted directly into the sensor assembly.
The sensor is designed to provide a standardised output applicable for the gas range. This signal is not
for direct connection to other devices and so the amplifier PCB in the transmitter housing is used to
condition the signal, provide calibration functions and produce a 4-20mA signal.
The transmitter and amplifier assembly is configured in the factory for a specific gas range.
The Gasguard Infrared Carbon Dioxide Sensor / Transmitters operate on the Infrared Absorption
principal and provide a linear 4-20mA DC current output.
Unique part numbers in accordance with the following scheme identifies the sensor unit configurations:
Part Number 65-6552XXX series is for Infra-red sensor units.
Note: In the part numbers listed above, XXX represents the chemical symbol for the gas
detected by the unit. For example, 65-6552CO2-2 is the part number for an Infra-red
transmitter unit designed to detect Carbon Dioxide (CO2) in the range of 0 -2%.
Key Features:
•Economical Fixed Gas Sensor / Transmitter
•Rugged Construction
•Reliable
•Certified Intrinsically Safe – Ex ia
•LCD Display
•Non-Intrusive Closed Case Calibration
3.1 Sensor
3.1.1 Carbon Dioxide Gas Sensor
The Carbon Dioxide Gas Sensor works on the infra-red gas absorption principle. An infra-red light
source illuminates the sensor through a gas pathway with an optical filter that selects the appropriate
wavelength for the gas being detected; the presence of this gas reduces the amount of infra-red energy
reaching the detector. This difference in infra-red energy with and without gas is used to measure the
amount of gas present, and is converted to an electrical output of 4–20mA by the amplifier electronics.
3.1.2 Humidity
Sensors cannot operate in a condensing atmosphere. In such an environment, a thin film of water can
form across the membrane, effectively sealing it and stopping the passage of gas into the sensor. On
evaporation of this water the sensor usually resumes normal operation. Above 90% R.H. the sensor
accumulates water vapour and may form condensation to block the infra-red path used for gas
detection. Provided the exposure to these extremes of humidity has not been for a long period, the
sensors will recover when exposed to R.H. in the range 15% to 90%.

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3.1.3 Pressure Effects
The infra-red sensors do not exhibit a permanent response to changes of pressure. The CO2 sensor
responds to pressure on a directly proportional basis.
3.1.4 Operational Restrictions
For proper operation, infra-red detectors need to be in a position which is free from damaging vibration
and within the temperature range of -10C to +40C.
3.2 Amplifier PCB
The purpose of the Amplifier PCB is to convert the low- level electrical output of the sensor into a signal
capable of driving various types of external indicator equipment such as the Ampcontrol Gasguard 4
Channel Controller.
The Amplifier PCB requires a 12VDC operating voltage and transmits a signal of 4-20mA. At the lower
end of the range, the 4mA signal level indicates a zero gas concentration. At the upper end of the range
the 20mA signal indicates that the sensor has detected a full span gas concentration. ZERO and SPAN
adjustment reed relays located on the PCB are used for calibration of the instrument.
3.3 Enclosure: Stainless Steel Housing
The standard Stainless Steel Housing incorporates the I/R Sensor 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.
3.4 Sensor Wiring Assembly
3.4.1 Connections
Electrical connections for the sensor are by means of a shielded cable from the Sensor Assembly.
A sensor wiring assembly provides the electrical interface between the sensor and the Amplifier PCB.
The sensor wiring plugs into the Amplifier PCB connector J4.
A second wiring assembly connects the customer supply and signal connections from the incoming
terminals to the Amplifier PCB connector J5.
The Sensor and Amplifier assemblies are intrinsically safe items and as such are only serviceable by
authorised factory personnel.
See Section 5.5 for wiring details.
NOTE
Only sensor assembly 105990 may be connected to the main amplifier
in this unit. Connection of any other type of sensor head will render the
unit non-operational.
NOTE
Sensor and Transmitter assemblies are matched together and cannot
be replaced or interchanged by unauthorised personnel.

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3.4.2 Anti-Vibration Clip
An Anti-Vibration clip Pt/No. 121647 is fitted to the connectors J4 & J5 on the rear of the Amplifier PCB.
Figure 3.1: Anti-Vibration Clip

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4 PRODUCT OPERATION
The user interface for the Sensor / Transmitter is shown in Figure 4.1, with the numbered items being
explained in Table 1.
Figure 4.1: Sensor / Transmitter User Interface
Table 1: Sensor / Transmitter User Interface Descriptors
Item
Name
Function
1
CAL
Button operated using the magnetic calibration tool.
2
Sensor Type
Label displaying Sensor Type
3
ZERO
Button operated using the magnetic calibration tool.
4
UP
Button operated using the magnetic calibration tool.
5
Screen
Used to display the detected gas level or display codes (see Table 2).
6
DOWN
Button operated using the magnetic calibration tool.
Table 2: Gasguard Display Codes
Display
Description
-777
There is no sensor plugged into the amplifier
-999
Amplifier needs reconfiguration
Er
Error has occurred
CAL
Calibration mode initiated (display blinks when in calibration mode)
SAU
Calibration settings have been saved
PU/Ir
Power Up – Infrared Unit

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5 INSTALLATION
5.1 General Warnings
These instructions have been designed to assist users of the Gasguard CO2 IR Transmitter / Sensor
with installation.
Before the unit can be installed, there are a number of things that need to be considered and understood
to prevent incorrect or unsafe operation of the unit or the system into which it is installed.
Along with relevant competence, and an understanding of the target application, the following points
should be considered:
5.1.1 Ensure that the information provided in this user manual is fully understood.
It is extremely important that the limitations and functionality of the unit 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.
5.1.2 Ensure that the application into which the unit 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.
5.1.3 Ensure that the unit will properly perform the required functions within the system
design.
It is important to understand how the unit is intended to interact with other equipment within a system.
For safe and reliable use, it is crucial that neither the unit logical operation nor its signalling be
compromised by incompatibilities with connected equipment.
5.1.4 Modifications of any form to the unit are prohibited.
The unit as supplied has been designed and manufactured to comply with the requirements of
protection standards. If modifications of any form are made to the unit, the equipment may no longer be
fit for use. If any modifications or damage to the unit is evident, do not use the equipment and contact
Ampcontrol for advice.

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5.2 Mandatory Installation Practices
The following information must be adhered to when installing the Gasguard CO2 IR Transmitter /
Sensor. Failure to adhere to this information may give rise to unsafe operation.
Using the unit 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.
•The unit must be powered within the specified voltage range.
•The installation of the unit must be carried out by suitably trained and qualified personnel.
•Identification labels fixed to the unit must not be damaged, removed or covered before, during or
after installation.
•The installation is to be in accordance with the relevant installation Standards/Codes of Practice.
•Modifications must not be made to any part of the unit. As supplied, the unit is built to, and
complies with the relevant standards. Modifications to its construction will render the unit non-
compliant.
•Complete and accurate records of the installation must be kept as part of the site installation.
•Confirm the Intrinsically Safe parameters of the transmitter, cables and power supply are suitable
for the application.
•Ensure that the Conditions of Use, listed in the certificate, are adhered to.
5.3 Installation Guidelines
5.3.1 Mounting Location
To ensure continued reliable operation of the sensor system, the following should be considered when
mounting the unit:
•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.
•Mount the sensor unit in a position that reduces the risk of mechanical damage.
•Mounting should be to a vertical surface, pointing downwards, 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.
•Allow sufficient space under the sensor for fitting of calibration cups or accessories.
•Ensure to account for the relative density to air of the gas that is being detected.

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5.3.2 Relative Density of Gas Type
The relative density or buoyancy of the gas or vapour with respect to air 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 and accumulate in concentrations over
long periods of time. Normal air movements in and around such gas concentrations will have the
inevitable effect of producing zones of highly toxic mixtures.
This knowledge of the characteristics of the gas assists when determining the location of the gas
sensor. See Table 3 for gas density values.
For monitoring of heavier-than-air gases, mount the sensor as close as practical to the floor or ground.
For monitoring of lighter than air gases, install the sensor unit as high as practical.
The services of a Risk Assessment Engineer or specialist should be used if additional assistance is
required in selecting the position of, or the number of sensors required for the application.
Table 3: Gas Density Relative to Air
Gas
Density
Hydrogen
Lighter than Air
Ammonia
Methane
Carbon Monoxide
Carbon Dioxide
Heavier than Air
Nitric Oxide
Oxygen
Hydrogen Sulphide
Chlorine
Nitrogen Dioxide

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5.4 Mechanical Installation Information
5.4.1 Enclosure Dimensions
Figure 5.1: CO2 IR Sensor / Transmitter Dimensions
5.4.2 Mounting Arrangements
The Gasguard CO2 IR Sensor / Transmitter is a panel mounted unit. See Figure 5.1 for hole centre
locations.
5.4.3 Terminal Layout
The connection terminals for the Gasguard CO2 IR Sensor / Transmitter are located within the
enclosure. In order connect the incoming cable to the unit, the cable must be feed through the side
mounted cable gland.

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5.5 Electrical Installation Information
5.5.1 Cable Resistance Considerations
The Infrared Amplifier PCB output is 4-20mA current. The voltage available to the amplifier must be a
minimum of 10VDC. With a supply voltage of 12VDC the maximum cable resistance, both +ve & -ve
leads combined, is 16 Ohms. The maximum resistance in the 4-20mA signal to ground at 12V DC
supply is 200 Ohms. See Table 4 for typical cable resistance values.
Table 4: Nominal Resistance Values for Typical Wire Sizes
Conductor Area (mm2)
Loop Resistance (Typical)
0.5
6.71Ω
1.0
3.36Ω
1.5
2.24Ω
2.0
1.72Ω
2.5
1.38Ω
5.5.2 Earthing Procedures
Consideration should be given to the earthing of the transmitters and cable screens of the incoming
customer cables.
Normal practice would be to isolate the cable screens at the Transmitter and connect the screens to
earth adjacent to the Control units or power supply to the system.
Remote sensor cable screens should be earthed at the transmitter.

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5.5.3 Integral Infrared Sensor Unit Wiring Details
Figure 5.2: Integral Infrared Sensor Wiring Diagram

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5.5.4 Remote Infrared Sensor Unit Wiring Details
Figure 5.3: Remote Infrared Sensor Wiring Diagram

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6 COMMISSIONING AND CALIBRATION
Commissioning is the performance of initial checks, adjustments and calibration prior to placing the
system in operation for the first time. Calibration, however, is not limited to performance of
commissioning. Calibration is also performed throughout the life of the system on a periodic basis and
after major repairs to the system.
During commissioning and subsequent re-calibration, it is vital to ensure that procedures are followed to
prevent any abnormal sensor signal from initiating any fault, warn or alarm status indicator or equipment
control function, on auxiliary equipment connected to the transmitter. Consult the relevant control unit
manual for details of how to do this.
The instruments supplied are NATA calibrated prior to delivery. However, before putting the system into
operation, it is recommended to check the calibration. This is especially important if the instruments are
commissioned sometime after delivery.
6.1 Preliminary Checks
Perform the following preliminary checks:
1. Verify that all connections are correct and installation complete as detailed in Section 5.
2. Check that voltage available to the amplifier is 12VDC
3. Apply power to the system.
Note: Following initial application of input power the display will alternate between PU & Ir for approx. 10
secs while it warms up, to show the unit is Infra-red. The output is held at a nominal 4mA during this
period, after which it displays -0.46 for up to 30 seconds before reading zero ±0.05% (Providing no gas
is present).
6.2 System Calibration
Before the start of calibration, the system should be left in a powered-up operational (no fault) state for
one hour to allow the gas sensors to stabilise. However, if such a delay is not practical, observe the
display indications with the sensor in a gas free atmosphere, until there is no appreciable display
movement for a period of time. The system should then be sufficiently stable to allow calibration. During
calibration, avoid breathing over unit, since carbon dioxide from exhaled breath will affect the readings.
Calibration of sensors can only be achieved by using the appropriate gas. That is the gas that the sensor
is designed to detect. A calibration gas should be at least 50% of full scale of the relevant monitor.
For gas detection, if reading inaccuracies cannot be avoided, sensors should always be calibrated on the
high side for safety reasons.
Calibration gas should be applied to the sensor at a rate of approximately 0.5 to 1.0 litres per minute,
using the Calibration Cup. Allow sufficient time, usually about 2 minutes, for sensor to stabilize before
adjustment.