Ampcontrol gasguard Instruction manual

GASGUARD
Programmable Intrinsically Safe Controller
INSTALLATION, OPERATION & MAINTENANCE MANUAL
Revision 2 Issued: 04/10/2011
CRN: 7502
Ampcontrol User Manual Part No: 120875
Designed and Manufactured in Australia by Ampcontrol CSM Pty Limited.

GASGUARD ISCONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502
Page 1
Safety and other Warnings
WARNING!
Identifies important safety messages contained within this manual. These
messages highlight potential risks, the occurrence of which may result in serious
injury or death to personnel. When you see this symbol, pay close attention to the
message that follows, understand its meaning and ensure other operators are
made aware of the risk.
CAUTION!
Identifies important technical information
contained within this manual. Information
of this type provides instruction or guidance that will help ensure safe installation,
operation and maintenance of the Controller. This information must be understood
and applied in order to reduce the possibility of injury to personnel
. Correct
application of these instructions will also reduce the possibility of damage to the
Controller and/or other connected equipment.
Supplementary information not directly affecting safety or integrity of the equipment.
Information concerning possible impact on the environment, along with actions
required to reduce environmental risk.
Applying This User Manual
The contents of this user manual relate to the full range of Gasguard Sensor Controllers, across a number of system
firmware revisions. The following list covers the differences between Controller versions and the features described
by this Manual.
For all Controller types loaded with system firmware V2.7-09-2011 and above, all of the functional descriptions
covered in this Manual are applicable.
For all Controller types fitted with system firmware prior to V2.7-09-2011, the following functional descriptions do
NOT apply since these functions are not present within the Controller:-
[i] Relay start-up behaviour (section 2.9.1 )
[ii] Relay start-up latch function and configuration (sections 2.9.1 and 4.4.5 )
[iii] Enabling / Disabling of alarm reset via theleft navigation key(section 2.8‘Resetting Alarms’ )
[iv] Supply voltage measurment value available within the Modbus registerset (section 10.1.3 address 30013 )
[v] Memory check failure notification (section 6.2.1)

GASGUARD ISCONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502
Page 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 CSM Pty Ltd, 7 Billbrooke Close, Cameron Park. NSW 2285,
Australia.
Disclaimer
Ampcontrol CSM Pty Ltd makes 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 manualwithout obligation to notify
any person ororganisation of these changes.
Before You Begin
We would like to take a moment to thank you for purchasing the Gasguard ISController.
Gasguard Controller Certification Information
The Gasguard Controller is certified for use in underground hazardous area applications and carries the following
certification and marking.
Type of Protection: Exia
Marking: Ex ia I
Certificate No.: IECExITA07.0003X
For conditions of safe use, see the certificate of conformity at the end of this manual.
Ampcontrol Electronics Contact details:
Ampcontrol CSM Pty Ltd
7 Billbrooke Close, CameronPark, NSW, 2285
P [phone]| F [phone]
EMAIL: [e-mail]
WEB: www.ampcontrolgroup.com
WARNING!
To minimise the possibility of unsafe operation of this equipment, the user
must be competent, via appropriate training,
in regards to international
standards and safety requirements relating to its installation, operation and
maintenance.
Safety related Information contained within this manual is
supplementary to such standards, but must be equally understood and
applied to both maximise
safe use of this equipment and minimise risk to
persons or other equipment.

GASGUARD ISCONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502
Page 3
Table of Contents
1. Receiving and Storage.........................................................................................................................................7
1.1 Receiving........................................................................................................................................................7
1.2 Storage after Delivery .....................................................................................................................................7
1.3 Unpacking of Equipment.................................................................................................................................7
2General Safety.....................................................................................................................................................8
2.1 Personnel Safety Warnings.............................................................................................................................8
2.1.1 Relevant Personnel.............................................................................................................................8
2.1.2 Safety Communication........................................................................................................................8
2.2 Safe Use of Equipment...................................................................................................................................8
2.2.1 Intended Use of the Equipment...........................................................................................................8
2.2.2 Changes to Equipment........................................................................................................................8
2.2.3 Equipment Knowledge........................................................................................................................8
2.3 Operational Restrictions and Limitations.........................................................................................................9
2.4 Conditions of Conformity – Ex ia.....................................................................................................................9
2.5 Overview of the Gasguard Controller............................................................................................................10
2.5.1 Basic Description...............................................................................................................................10
2.5.2 Input channels are configurable........................................................................................................10
2.5.3 Set point modes:-...............................................................................................................................10
2.5.4 High and LowFault set-points...........................................................................................................10
2.5.5 Possible relays settings.....................................................................................................................10
2.5.6 Zone configurations:-.........................................................................................................................11
2.5.7Analogue outputs..............................................................................................................................11
2.6 Understanding Gasguard Controller Functionality ........................................................................................11
2.6.1 Controller Layout...............................................................................................................................11
2.6.2 Adding Input Alarm set-points to a Zone Block ................................................................................12
2.6.3 Adding Relays to Zone Blocks .........................................................................................................12
2.6.4 Zone Voting.......................................................................................................................................12
2.6.5 Zone Active Status............................................................................................................................12
2.6.6 Zone Block Configuration Warnings..................................................................................................15
2.7 Setting Input channel Parameters.................................................................................................................15
2.8 Setting Alarm Set-Points...............................................................................................................................17
2.9 Configuring Relay Operation.........................................................................................................................18
2.9.1Relay Start-Up Mode.........................................................................................................................19
2.9.2Normally De-Energised Relays.........................................................................................................19
2.9.3Normally Energised Relays...............................................................................................................19

GASGUARD ISCONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502
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2.9.4Alarm Set-Point Delays.....................................................................................................................19
2.9.5Alarm Set-Point Hysteresis...............................................................................................................20
3Menu Structure..................................................................................................................................................21
3.1 Key Pad Functions in Main Menu..................................................................................................................21
3.2 Main Menu....................................................................................................................................................21
3.3 Controller LED and Display Operation..........................................................................................................22
3.3.1 In the event ofa non-latched alarm:..................................................................................................22
3.3.2 In the event ofan alarm in latched mode:.........................................................................................22
3.3.3 In the event ofa fault indication:........................................................................................................22
4Programming.....................................................................................................................................................23
4.1 Programming Overview.................................................................................................................................23
4.1.1 Key Pad Functions in Modify Menu...................................................................................................23
4.1.2 To enter the Configuration Menu:......................................................................................................23
4.2 Channel Configuration Menu (Nos. 1-4)........................................................................................................23
4.2.1 Input Type.........................................................................................................................................23
4.2.2 Set Input Status.................................................................................................................................23
4.2.3 Set Gas Name...................................................................................................................................24
4.2.4 Set Decimal Point..............................................................................................................................24
4.2.5 Set Full Scale....................................................................................................................................24
4.2.6 Set Units of Measure.........................................................................................................................24
4.2.7 Set Tag Name...................................................................................................................................24
4.2.8 Setting alarm or fault levels...............................................................................................................25
4.2.9 Set Low / High Fault Alarm Level......................................................................................................25
4.2.10 Set Low / High Fault Alarm Direction................................................................................................25
4.2.11 Set Low / High Fault Alarm Latch......................................................................................................25
4.2.12 Set Alarm Delay................................................................................................................................25
4.2.13 Set Alarm Hysteresis.........................................................................................................................25
4.3 Zone Configuration Menu (Nos. 5-10)...........................................................................................................26
4.3.1 Set Zone Status.................................................................................................................................26
4.3.2 Set Zone TagName..........................................................................................................................26
4.3.3 Set Zone 1 to Channel 1 /Low Fault Alarm........................................................................................26
4.3.4 Set Zone 1 to Channel 1/Alarm 1......................................................................................................26
4.3.5 Set Zone 1 to Channel 1/Alarm 2......................................................................................................26
4.3.6 Set Zone 1 to Channel 1/Alarm 3......................................................................................................26
4.3.7 Set Zone 1 to Channel 1/HighFault Alarm........................................................................................27
4.3.8 Set Voting Configuration...................................................................................................................27
4.4 Relay Configuration Menu (Nos. 11-14)........................................................................................................27

GASGUARD ISCONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502
Page 5
4.4.1 Set Relay Status................................................................................................................................27
4.4.2 Set Relay Type..................................................................................................................................27
4.4.3 Set Tag Name...................................................................................................................................27
4.4.4 Set Relay 1 to Zone 1........................................................................................................................27
4.4.5 Set Relay Start-Up Mode ....................................................................................................................28
4.5 Output Configuration Menu (Nos. 15-17)......................................................................................................28
4.5.1 Set Output Status..............................................................................................................................28
4.5.2 Set Output Tag Name.......................................................................................................................28
4.5.3 Set Output Type................................................................................................................................28
4.5.4 Set Output to Channel 1....................................................................................................................28
4.5.5 Set Output to Channel 2....................................................................................................................28
4.5.6 Set Output to Channel 3....................................................................................................................29
4.5.7 Set Output to Channel 4....................................................................................................................29
4.6 System Configuration Menu (No 18).............................................................................................................29
4.6.1 Configuration Version........................................................................................................................29
4.6.2 Modbus Address...............................................................................................................................29
4.6.3 Set Baud Rate...................................................................................................................................29
4.6.4 Set Parity...........................................................................................................................................29
4.6.5 Set Start Up Delay.............................................................................................................................29
4.6.6 Set Tag Name1................................................................................................................................30
4.6.7 Set Tag Name2................................................................................................................................30
4.6.8 Change Configuration Password.......................................................................................................30
4.6.9 Change Fault Clear Setting...............................................................................................................30
4.7 Calibration Menu...........................................................................................................................................30
4.7.1 To Enter the CalibrationMenu:.........................................................................................................30
4.7.2 Channel 1 Zero Calibration...............................................................................................................31
4.7.3 Channel 1 Span Calibration..............................................................................................................31
4.7.4 10 Volt Supply Voltage Calibration....................................................................................................31
4.7.5 16 Volt Supply Voltage Calibration....................................................................................................31
4.7.6 Output 1 Zero Calibration..................................................................................................................31
4.7.7 Output 1 Span Calibration.................................................................................................................31
5Controller Installation.........................................................................................................................................32
5.1 Ensuring Safe Installation.............................................................................................................................32
5.1.4 Ensuring that the Controller will properly perform the required functions..........................................32
5.1.5 Ensuring that connected devices are compatible with the controller’s entity parameters ................32
5.2 Mounting the Controller.................................................................................................................................33

GASGUARD ISCONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502
Page 6
5.2.1 IP rating and Physical Protection......................................................................................................33
5.2.2 Ease of Access..................................................................................................................................33
5.3 Connecting to the Controller..........................................................................................................................33
5.3.1 Entity Parameters..............................................................................................................................33
5.3.2 Type of Cable....................................................................................................................................34
5.3.3 Cable Termination.............................................................................................................................34
5.3.4 Cable Marking...................................................................................................................................34
5.3.5 Cable Restraint..................................................................................................................................34
6Controller Commissioning..................................................................................................................................35
6.1 Completing a Controller TestForm (Common HeaderInformation)..............................................................35
6.2 Running through a Controller Commissioning...............................................................................................35
6.2.1 First power-up checks.......................................................................................................................35
6.2.2 Checking Controller Functionality......................................................................................................36
7Service, Maintenance & Disposal......................................................................................................................37
7.1 Equipment Service........................................................................................................................................37
7.1.1 Visual Only Inspections.....................................................................................................................37
7.1.2 Detailed Inspections..........................................................................................................................37
7.2 Equipment Maintenance...............................................................................................................................38
7.3 Disposal of System Parts..............................................................................................................................38
8Equipment List...................................................................................................................................................38
9Specifications.....................................................................................................................................................39
10 Data Communication Specification....................................................................................................................40
10.1 Modbus Memory Map Part 1......................................................................................................................40
10.1.1 Memory Type 0:................................................................................................................................40
10.1.2 Memory Type 1:................................................................................................................................40
10.1.3 Memory Type 3:................................................................................................................................41
10.1.4 Memory Type 4:................................................................................................................................42
10.2 Modbus Memory Map Part 2......................................................................................................................45
Appendix A – Connection Diagram.............................................................................................................................47
Appendix A – System Diagrams..................................................................................................................................47
Appendix A – Output Current Followers Performance Graph......................................................................................52
Appendix A – Sample Test Forms...............................................................................................................................53
Appendix B – System Flow Chart................................................................................................................................60
Appendix B – Default Settings Table...........................................................................................................................65
Appendix C – Approvals..............................................................................................................................................73

GASGUARD ISCONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502
Page 7
1. Receiving and Storage
1.1 Receiving
All possible precautions are taken to protect the Gasguard controller against damage or losses during shipment,
however before accepting delivery, check all items against the packing list or Bill of Lading. 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.
1.2 Storage after Delivery
Where 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 protected from the elements in a cool dry area. If storing on the ground,
ensure that thestorage area is not an area where water will collect.
1.3 Unpacking of Equipment
The method of packing usedwill depend onthe sizeand quantityof the equipment.
Take care when unpacking the Controller to avoid damaging its enclosure or display window.
The disposal of packaging
materials, replaced parts, or components must comply with
environmental restrictionswithout polluting thesoil, air or water.
Ensure that any timber and cardboard used as packaging is disposed of in a safe and
environmentally responsible manner.
Where pos
sible, dispose of all waste products i.e. oils, metals, plastic and rubber products
by using an approved recycling service centre.

GASGUARD ISCONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502
Page 8
2 General Safety
2.1 Personnel Safety Warnings
2.1.1 Relevant Personnel
Ensure all personnel directly responsible or involved with the installation, operation and maintenance of the
equipment reference this manual in conjunction with information contained within any risk assessments conducted to
identify risks and hazards.
2.1.2 Safety Communication
All safety instructions and design requirements within this manual must be communicated to all users. These
requirements are necessary to identify and control any foreseeable risk associated with this piece of equipment. In
the event of any damage or malfunction that results in the potential to harm the health or safety of any person; the
owner/operatorshould notify the manufacturer immediately.
2.2 Safe Use of Equipment
This equipment has been manufactured in accordance with quality standard OD005 to ensure compliance to its
certificate of conformity. If there are any signs of modification or damage to this equipment, it must not be used until
it has been repaired and deemed fit for purpose by the equipment’s manufacturer or by an AS3800 accredited
workshop.
The instructions within this manual must be implemented asan aid towards achieving safe operation.
2.2.1 Intended Use of the Equipment
The Gasguard Programmable Intrinsically Safe Controller is designed to operate with a variety of Group I hazardous
area certified gas detectors and offerversatility of sensor management and data acquisition. The controller is used to
connect to a system that is responsible for activating ventilation and/or alarm systems. to reduce the probability of
potentially harmful situations. The Gasguard Controller is specifically intended for Group I mining applications.
2.2.2 Changes to Equipment
Changes in thedesign and modifications to the equipment are not permitted.
Unauthorised changes made to the Controller hardware or operating firmware will void the manufacturer’s warranty,
and may compromise the conditions of certification, the integrity of the system into which it is installed and other
connected equipment.
2.2.3 Equipment Knowledge
Experience with, or understanding of, this equipment is essential for the safe installation and removal of the
equipment. Ifin doubt, contact Ampcontrol.
Mechanical and or Electrical installation, and maintenance of plant and equipment, must only be carried out by
appropriately trained, qualified technical personnel.

GASGUARD ISCONTROLLER Issue: R2, Date: 26/09/2011, CRN: 7502
Page 9
2.3 Operational Restrictions and Limitations
The operational restrictions listed belowmust be understoodbefore considering using the Gasguard controller within
systems designed to ensure the safety of personnel. Using the Controller 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.
2.4 Conditions of Conformity – Ex ia
The Gasguard Controller is designed to operate as part of a Safety Instrumented System, alongside other
equipment that collectively form the means to minimise the risk of injury or death to personnel.
•The selection, installation, commissioning and use of this protective device should only be undertaken
following the application of a detail
ed risk assessment that is consistent with the methodology
outlined in AS/NZS ISO 31000 risk management. Additionally,
identified risk control measures
identified within the risk assessment additional
to safety controls and/or directions contained within
the products operating manual must be validated as effective before use of the product in any
capacity.
•
The Gasguard controller is NOT designed to be used as the sole means of ensuring safety to
personnel or equipment.
•The Gasguard controller does NOT have an associated Safe Failure Fraction (SFF).
•The Gasguard controller is NOT certified for use in Group II hazardous area applications
•
The Gasguard controller is NOT to be considered as a PLC since the device does not support full logic
decoding of input alarm conditions and output relay actions.
•
The Gasguard controller is NOT water resistant and must be mounted within a suitably IP rated
enclosure for use where the overall system is to be rated water resistant
•The Gasguard controller is NOT on-site repairable and contains no user serviceable parts.
•
The Gasguard controller must NOT be modified in any way. A controller that differs in any way from
its ‘as-certified’ condition must not be used.
•A Gasguard controllershowing any visible signs ofdamage must not be used.
•Sensors and Power Supply connected to the Gasguard controller must comply with the requirement
of I.S. configuration.
•Cleaning the controller may create an electrostatic hazard. Anti-static cleaning media must be used.
WARNING!
To comply with the Conditions of Certification, ensure full serviceable life of the product, and avoid
nullifying the warranty, it is essential to exercise great care with the installation, use and storage of the
System components. Failure to comply with the Conditions of Certification (Appendix C – Approvals) may
seriously compromise the integrity of the system and/or its components, and the consequence could be
fatal. The user must ensure that the “Conditions of Safe Use” outlined in the certificate are met or the
certificate (and the IS rating) will not be valid.