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
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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
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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

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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

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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

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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
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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
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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.

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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.

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2.5 Overview of the Gasguard Controller
2.5.1 Basic Description
The Gasguard Programmable Intrinsically Safe controller (Controller) produced by Ampcontrol is designed to operate
with a variety of hazardous area certified gas detectors. Compatible detectors are presently supplied by Ampcontrol
and other manufacturers.
The Controller is supplied with either two or four programmable input channels (see Parts List in Section 8 of this
Manual for details).
Input channels may be supplied to operate with a 4-20mA current input signal or a 0.4 - 2.0V voltage input signal.
This configuration is fixed by the manufacturer and is not user modifiable.
Each input channel is independent of the others and can be configured on a ‘per-channel’ basis allowing flexible
system configuration.
2.5.2 Input channels are user configurable, and may be:-
•Set to be ON orOFF.
•Given a name to represent its function.
•Selected to display one of a number of gas types.
•Configured to display oneof a number of measurement units.
•Configured to display fromnone to two decimal places.
•Scaled to a user definedmaximum value,ranging fromzero 9999.
Each input channel has three programmable ‘set-points’ which can be set to trip based on the signal input level.
2.5.3 Each set point may be:-
•Set to operate at a specific channel inputlevel.
•Set to operate with hysteresis.
•Set to operate in a particulardirection (rising signal or falling signal).
•Operate immediately or aftera user configured delay.
•Set to latch analarm indication or auto-reset.
In addition to the input based set-points, there are two ‘fault’ set-points. These set-points are referred to as High-
Fault and Low-Fault.
2.5.4 High and Low Fault set-points may be:-
•Set to operate at a specific channel inputlevel.
•Set to operate on a rising or falling inputsignal.
The controllerhas four relay outputs, mappable to alarm set-point from any channel.
2.5.5 Each of the four relays can be set to:-
•Latch. This feature may be used to preserve a record of a relay’s state in the event of a power failure or to
record an alarm event where there may be no one to respond to it at the time it occurs.
•Be normally energised or normally de-energised.

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. The Controller has six alarm‘zones’ that allow grouping of input channel set-points and output relays.
2.5.6 Each zone may be configured to:-
•Include a specific or multiple set-point(s) from a specific input channel.
•Include multiple set-points from multiple input channels.
•Include from zero to four ofthe output relays.
2.5.7 Analogue Outputs
The Controller has three 4-20 mA current repeateroutputs todrive remotedisplays or PLC/SCADA Systems.
The analogue outputs may be set to one of the following modes :-
•Follow a particular channel.
•Follow the highest reading from a number of selected channels.
•Follow the lowestreading from a number of selected channels.
During the start-up delay time when power is applied to the Controller, the follower outputs are
active and will pass on whatever input signal current is present via assigned channels.
The Controller is DIN rail compatible and has been approved to be intrinsically safe for use in a Zone 0 hazardous
area. The Controller must be powered from an Intrinsically Safe power supply with a maximum output of 16.5V.
The Controller is designed to operate witha minimum supply voltage of 12V dc.
A two line Liquid Crystal Display (LCD) combined with a keypad provides an intuitive user interface, providing easy
access and rapid adjustment to all controller settings.
CAUTION!
The user is responsible for maintaining the Ex ia Intrinsic Safety
rating by complying with
the “List of Special Conditions” outlined in the certificate (Appendix C – Approvals).
2.6 Understanding Gasguard Controller Functionality
The Controller’s operation can be modified via changes to its configuration settings. Configuration changes
must therefore be carried out with an understanding of the Controller’s functional specifications, its
limitations and the effect that configuration changes may have on the system into which it is installed.
Refer to the Controller functional diagrams in Appendix A of this manual.
These diagrams show:-
•Top level block diagramshowing connectivity of each Controller section
•Input Channel block showing signal path and user configurable settings.
•Zone block showing alarm routing and userconfigurable settings
•Relay block showing trigger sources and user configurable settings.
2.6.1 Controller Layout.
With reference to the top level block diagram, the controller is arranged as four input blocks, six zone blocks and four
relay blocks. The basic Controller operation is best understood by becoming familiar with the workings of the ‘Zone
Block’. Zone Blocks are essentially the coreof the Controllers input-to-output ‘logic’ functionality.
All six Zone Blocks may be configured to share the same alarm set-point signals and relays. Each configured and
enabled Zone Block will be simultaneously operational, creating relay events based on alarm set-point status,
included relays and vote count.

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2.6.2 Adding Input Alarm set-points to a Zone Block (Refer to Zone Functional Diagram in appendix A )
A Zone Block groups together alarm set-point signals and ‘maps’ them to selected relays. A Zone Block input can be
any or all of the alarm set-point signals from any/all input channel (a max. total of 20 set-points).A set-point can be
configured to be included or not included in a Zone Block’s input. Included alarm set-point signals are effectively
‘OR’ed’ together, such that any active set-point may potentially operate a relay.
Note: A set-point, even if active, is ignored if it is not included in a Zone Block input.
2.6.3 Adding Relays to Zone Blocks (Refer to Relay Functional Diagram in appendix A)
Any or all of the four relays may be included in a Zone Block’s output. Including a relay into a Zone Block output,
maps it to the selected alarm set-points at the Zone Block’s input. A relay may be included in any one, or all of the
six ZoneBlocks simultaneously.
Note: If there are no relays selected in any of the six Zone Blocks, then the Controller will not indicate alarm
states via the relays.
A relay may be set to be ‘ON’ or ‘OFF’. If a relay is set to ‘OFF’ it cannot be activated irrespective of other settings
within the relay configuration menu, orvia anyconditions set within a Zone Block.
Relays may be set to beon, off, in or out of a Zone Block via the relay configuration menu.
2.6.4 Zone Voting
The Zone Voting function allows the operator to select the number of active, included set-points that are required to
activate an included relay. In total there are up to 20 alarm set-points that can be included in a Zone Block’s input,
and accordingly, the vote number canbe set from1 to 20.
Note: The vote count value is important since it controls the logical behaviour of the included relay.
If a vote count of 1 is set, then the set-point signals are effectively ‘OR’ed’ together and any included set-point will
potentially activate the included relay.
If the vote count is set equal to the number of included set-points, then the logic effectively becomes an ‘AND’
function. Under this condition a relay will only be activated when the number of active set-points is equal to, or
greater than thevote count. Single set-points becoming active, or multiple active set-points below the vote count will
not activate an included relay.
The vote count does not allow for specific set-points to be included in the number that must be active. Any set-point
from any channel will be considered in the comparison. For example, if 12 set-points are included and the vote count
is set to 5, any 5 of the 12 set-points will potentially activate anincluded relay.
2.6.5 Zone Active Status
A Zone Block may be set to be inactive, irrespective of included set-points and relays. A Zone block that is set to
‘OFF’ will not allow its included relay to be activated via the included input set-points. A relay included in a Zone
Block that is setto ‘OFF’ may stillbe activated if it is included in another Zone Block that is set to ‘ON’.
Example Settings for a Zone Block (Refer to Section 4 for nomenclature relating to Controller settings ).
Alarm Set-Point inclusionis made in the Zoneconfiguration menu.
Relay inclusion isset via the Relay configuration menu.

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Example 1:
Assume set-points and relay inclusions not shown, to be set as [ NOT IN].
RELAY 1:
Status [ ON ]
Zn1 [ IN ] Allocate Relay1 to Zone Block 1.
ZONE 1:
Status [ ON ]
Ch1 LF [ IN ] (include Chan 1Low Fault set-point ).
Voting [ 1 ] (only a single set-point needs to be active to activate the relay).
For the above settings, Relay 1 will become active when there is a Low Fault on channel 1.
Example 2: Inclusion of multiple set-points across multiple channels (vote = set-points).
Assume set-points and relay inclusions not shown, tobe setas [ NOT IN ].
RELAY 1:
Status [ ON ]
Zn1 [ IN ] Allocate Relay1 to Zone Block 1.
ZONE 1:
Status [ ON ]
Ch1 A1 [ IN ] (include Chan 1A1 set-point )
Ch2 A1 [ IN ] (include Chan 2 A1 set-point )
Ch4 A3 [ IN ] (include Chan 4 A3 set-point )
Voting [ 3 ]
Relay 1 will become active when:- Ch1 A1is active AND CH2 A1 is active AND Ch4 A3 is active.
Example 3: Inclusion of multiple set-points across multiple channels (vote = 1).
Assume set-points and relay inclusions not shown, tobe setas [ NOT IN ].
RELAY 1:
Status [ ON ]
Zn1 [ IN ] Allocate Relay1 to Zone Block 1.
ZONE 1:
Status [ ON ]
Ch1 A1 [ IN ] (include Chan 1 A1 set-point )
Ch2 A1 [ IN ] (include Chan 2 A1 set-point )
Ch4 A3 [ IN ] (include Chan 4 A3 set-point )
Voting [ 1 ]
Relay 1 will become active when:- Ch1 A1is active OR CH2 A1 is active OR Ch4 A3 is active.

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Example 4: Inclusion of a relay across twoZone Blocks. Vote counts set to allow basic alarm logic decoding.
Assume set-points and relay inclusions not shown, tobe setas [ NOT IN ].
RELAY 1:
Status [ ON ]
Zn1 [ IN ] Allocate Relay1 to Zone Block 1.
Zn2 [ IN ] Also allocate Relay 1 to ZoneBlock 2.
ZONE 1:
Status [ ON ]
Ch1 A1 [ IN ] (include Chan 1 A1 set-point )
Ch2 A1 [ IN ] (include Chan 2 A1 set-point )
Voting [ 2 ]
ZONE 2:
Status [ ON ]
Ch3 A2 [ IN ] (include Chan 3 A2 set-point )
Voting [ 1 ]
Relay 1 will become active when:- Ch1 A1 is active AND CH2 A1 is active, OR Ch3 A2 is active.

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2.6.6 Zone Block Configuration Warnings
The following points must be observed to ensure that the Controller can predictably signal an alarm
state via its relays. Failure to observe these points andselect appropriate settings may result in
alarm indication failure.
•Do NOT set a Zone Block Vote Count to a value greater than the number of included alarms. For
example, if a Vote Count of 3 is set, but there are only 2 included set-points, the included relay will
not become active even if both set-points are active.
•Ensure that the vote count setting is such as to provide the desired logic in relation to active set-
points and relay operation (see examples 2 and 3 above)
•Ensure that a required relay is included in a Zone Block’s setting.
•Make sure that all relays included in aZone Blockare set to‘ON’
•Make sure that the Zone Block being configured for useis set to ‘ON’
•Multiple Zone Blocks may beconfigured, eachsharing the same set-point signals and relays. It is important
to ensure that the use of multiple Zone Blocks with possibly different settings, does not create conflict in
triggering relay events.
2.7 Setting Input channel Parameters.
Each of the fourinput channels may be configured tomatchthe characteristics ofthe equipment connected to it.
Note: In all cases, the input signal type is fixed during manufacture to either:-
•Current input. This input willnormally operate over the range 4 – 20mA. Fault levels lie outside this range.
•Voltage input. This input will normally operate over the range 0.4 – 2V. Fault levels lie outside this range.
A channel may be set to operate according to the following:-
Channel Activity
A channel may be set to be active or non-active. Inactive channels provide no process signals or alarm outputs to
functions further downstream.
•A non-activechannel is displayed as ‘OFF’.
•An active channel is displayedas ‘ON’.
Gas Name
A channel may be identified by selection of one of six standard types, or a userspecified type, namely:-
•CH4 (methane)
•CO (carbon monoxide)
•O2 (oxygen)
•H2S (hydrogen sulphide)
•AV (Air Velocity)
•DP (Differential Pressure
•User (7 charactername maybe input)

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Decimal Point
Each Input channel may haveits display reading configured to correctly indicate the process value.
The available settings fordecimal places are:-
•nnnn (e.g. 2500)
•nnn (e.g. 250)
•nn.n (e.g. 25.0)
•n.nn (e.g. 2.50)
Full Scale Reading
Input process signals to the controller are typically in the range 4 – 20mA and as such may represent a variety of
actual process scaling. To set the relationship between 4-20mA input and the process scaling, the channel full scale
value may be set. Settings are per digit, with up to four digits available. The displayed value of this setting will
depend on the decimal place setting.
The maximum value that maybe set is tobe 9999 (999/ 99.9 / 9.99 depending on decimal point position)
Units
The process displayed readings can be given units of measurement indicator. There are ten pre-set unit types
available for selection, namely:-
•%v/v (percent volume per volume)
•ppm (parts per million)
•LEL (Lower Explosive Limit)
•% (percent)
•V (volts)
•mV (millivolts)
•rpm (revolutions per minute)
•Hz (cycles per second)
•kHz (thousands of cycles per second)
•m/s (meters per second)
Tag
A channel may be given an identification name that provides meaningful representation of its purpose/function within
a system. The tag input isentered asa 9 character name consisting of the following characters:-
•Symbols: blank * - + .
•Numeric: 0 – 9
•Alpha A-Z (uppercase only)

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The following information should be understood to ensure that the Controller reliably signals alarm
states at appropriate levels. Failure to observe correct settings may result in system alarm failure.
2.8 Setting Alarm Set-Points
There are five available alarm set-points per channel, givinga total of 20 alarm signals. The available alarms cover
high fault, lowfault and three process level alarms. Each channel’s alarm group is independent of other channels.
The high andlow fault alarms are active for process signals that rise above or drop below the baseline ‘zero. The
high and low alarm threshold points are set in terms of input milliamps. The high fault and low fault alarms are
named ‘HF’ and ‘LF’ respectively in the menu system.
The process level alarms, named A1, A2, and A3, are configurablebased on the units setfor thatchannel. Each
alarm may be set to trip based on an inputsignal’s ‘position’ relative to the set-point (i.e.input above set-point, or
input below set-point).
Note: Alarms that activate above or below a user set threshold are often referred to as ‘rising’ or ‘falling’
alarms. For the Gasguard controller, alarms become active only when an input crosses the set threshold.
An alarm is not activated by sensing a change in signal direction, or by a rate of change of input signal level.
The following alarm parameters may be set by the user:-
•LF alarm level (in mA, 0 to 99.99)
•HF alarm level (in mA, 0 to 99.99)
•A1 alarm level (in process units, pos/neg value, 0 to value scaled by decimal place setting)
•A2 alarm level (in process units, pos/neg value, 0 to value scaled by decimal place setting)
•A3 alarm level (in process units, pos/neg value, 0 to value scaled by decimal place setting)
•LF alarm direction ( Falling / Rising)
•HF alarm direction (Falling / Rising)
•A1 alarm direction (Falling / Rising)
•A2 alarm direction (Falling / Rising)
•A3 alarm direction (Falling / Rising)
•LF alarm latching mode (mask bit, Latch = YES, non-latch = NO)
•HF alarm latching mode (mask bit, Latch = YES, non-latch = NO)
•A1 alarm latching mode (mask bit, Latch = YES, non-latch = NO)
•A2 alarm latching mode (mask bit, Latch = YES, non-latch = NO)
•A3 alarm latching mode (mask bit, Latch = YES, non-latch = NO)
•Alarm Delay (in mS, 0 to 9999). Sets time delay from process input matching set threshold, to alarm signal becoming
active. Operates on any/all 5 channel alarms and is not configurable per individual alarm.
Within each channel, an alarm threshold cannot be set that exceeds the full scale for that channel. The controller
scales all set-point values according to the full scale setting.
For example, a channel with a full scale reading initially set to 1000 and set-point configured to 500, the set-point is
50% of the scalevalue.
If the channel full scale value is now changed to 2000, the Controller will automatically rescale the trip-point to 1000.
This maintainsthe trip point at the same proportionof full scale ( 50% in this example).

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When setting alarm set-point thresholds, it is important to ensure that they comply with recognised
standards applicable to the application into which the controller is installed. If no standards exist to
specify the alarm thresholds, they should be set based on a full understanding of the application by
a suitably authorised person or body.
•Alarm levels should be used in the order of their nomenclature, i.e. the first alarm level is A1, the
second is A2 and the third is A3.
•An alarm that sits higher in the naming order (A1, A2, A3) should be set to a higher trip threshold
than one that sits below it.
Latching Alarms
If an alarm state could be missed because there is likely to be nobody present to observe an event as it occurs, a
latching alarm should be set. A latched alarm will remain active even when the event triggering it is no longer
present. If the Controller undergoes a power cycle following the triggering of a latched alarm, the latched status will
be re-instated once the Controller has re-booted.
Resetting Alarms
A latched alarm may be manually reset by the use of either the ‘LEFT’ key held for 5 seconds (only if the left key
reset feature is enabled in the configuration settings), or by the remote reset terminals.The Controller configuration
allows the left key reset feature to be enabled or disabled. When disabled, only authorised users who know the
Controller system passwords are able to change this to an enabled status. If the left key reset is enabled, a latched
alarm can be reset by any person whether authorised or not. It is up to the user to control access to and/ or
permissions relating to theresetting oflatched alarm conditions.
Note: Alarm and relay states are NOT intentionally preserved during the time power is removed from the
controller. Alarm and relay states are re-established once power is restored and the Controller has
completed its self-test. The interpretation of a relay contact state during a power failure, will depend on how
it has been configured to operate.
2.9 Configuring Relay Operation
Each of the four relays within the Controller is a single pole change-over type.
There are three connections associated with each relay, namely ‘Common – C’, ‘NormallyOpen – NO’ and ‘Normally
Closed – NC’. At any given time, the ‘Common’ terminal will be connected to either the ‘NO’ or ‘NC’ terminal
depending onthe relayconfiguration and the logic of the Zone Block drivingit.
Relays can be configured to be ‘Normally Energised – NE’, or ‘Normally de-energised – ND’ (see below).
The context of ‘NC’ and ‘NO’ will change depending on whether a relay coil has been configured to be normally
energised or normally de-energised under non-alarm conditions.
2.9.1 Relay Start-Up Conditions
When the Controller powers up it enters a period of self test for a number of seconds. Following this self-test, there
may be a further start-up delay if this has been configured by the user. During the self test and start-up delay
periods, the relays are held in an ‘alarm’ condition. The state of each relay is set based on the user configuration for
the relay operation. A normally-energised relay (non-alarm state) will sit in the de-energised state during the power
up delay period. A normally de-energised relay (non-alarm state) will sit in the energised state during the power up
delay period. This start-up behaviouris not user-configurable except for the length of the start-up delay.
Once the delay period has expired, the condition of the relays will depend upon how the relay start-up mode has
been defined in the Controller relay configuration.Each relay may independently be set to one of two start-up
modes, namely :- [1] LIVE and [2] LATCHED. In Latched mode, a relay will remain latched in the alarm state after
the start-up delay has expired. To clear this latchedcondition, a ‘left-key’ reset or a remote reset is required.
For relays set to ‘LIVE’ mode,the relays will assume operation according to the state of the inputchannel signals and
alarm settings once the start-up delay has expired.

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2.9.2 Normally De-Energised Relays
A relay set to be ‘ND’, will, under normal (non-alarm) conditions, have no power applied to its coil. With no power
applied to the coil, the ‘Common’ relay terminal will be connected to the ‘NC’ terminal (as marked on the terminal
label).
When an alarm state exists that is configured to drive an ‘ND’ relay, power is switched to the coil and the contacts
change state. The ‘Common’ relay terminal will now be connected to the ‘NO’ terminal. The changing state of the
contact signals an alarm condition.
If the Controller is operating with no active alarm conditions, all relays set to ‘ND’ will be unpowered and inactive. If,
during this condition, power is removed from the Controller, there will be no change of state of any of the relay
contacts. Relays set to ‘ND’ cannot signal a fault condition due to power loss. Although the state of the relay
contacts is ‘preserved’ (i.e. not changed) under non-powered conditions, this is not an intentional state preservation,
rather it is just an outcome of having normally inactive (unpowered) relays.
2.9.3 Normally Energised Relays
If it is required to signal a fault due to power loss, relays should be configured to ‘Normally Energised – NE’
operation.
Relays set to ‘NE’ will have power applied to their coils during the normal (non-alarm) state. Under these conditions,
the ‘Common’ relay terminal will be connected to the ‘NO’ terminal (as marked on the terminal label). For ‘NE’
configured relays, the function of the contacts, as marked on the terminal label, is reversed (i.e. ‘NO’ becomes ‘NC’
and vice versa).
When an alarm state exists that is configured to drive an ‘NE’ relay, power is removed from the coil and the contacts
change state. The ‘Common’ relay terminal will now be connected to the ‘NC’ terminal (as marked on the terminal
label). The changing state of the contact signals an alarm condition.
If the Controller is operating with no active alarm conditions, all relays set to ‘NE’ will be powered.If, during this
condition, power is removed from the Controller, there will be a change of state of any of the relay contacts since the
coils are no longer being supplied with power. Relays set to ‘NE’ are therefore able to signal a fault condition due to
power loss.
2.9.4 Alarm Set-Point Delays
Under some conditions, it maybe desirable to trigger a set-point, only if an alarm conditionhas existed greater than a
certain periodof time. This allows transientconditions to occur without triggering an alarmevent.
The Controller allows a delay to be set from 0 – 9999mS (9.999 seconds). The delay is common to all 5 trip-points
within a channel but each channel may have a different delay.
When setting alarm set-point delays, it is important to ensure that the time set before a relay is
triggered, does not create a hazardous situation. Delays must set based on an understanding of
their effect on the system into which the controller is fitted.