Ampcontrol DIESELGUARD User manual

Version: 3, April 2016
Designed and manufactured in Australia by Ampcontrol Pty Ltd
DIESELGUARD
DIESELMACHINEMONITOR
UserManual

Ampcontrol Pty Ltd –ABN 28 000 915 542
DIESELGUARD USER MANUAL
MAG-179 Version 3 –APR/16
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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Revision History
Version
Date
Description
3
29-APR-2016
This version of the manual relates to firmware version
V5 of the Dieselguard.
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.

Ampcontrol Pty Ltd –ABN 28 000 915 542
DIESELGUARD USER MANUAL
MAG-179 Version 3 –APR/16
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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Copyright Notice
The Ampcontrol Dieselguard System 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 Dieselguard System.
WARNING!
This equipment has been designed to control the signals from
equipment that detects hazardous gases and vapours and to provide
warning and control signals before dangerous conditions are reached.
In order to ensure that the equipment will warn of dangerous situations
it is essential that the instructions in this manual and those of the
associated items be read, understood and followed. It is further
stressed that the effectiveness of the control system depends heavily
on the user who is responsible for its correct installation, application,
use and regular maintenance.
Ampcontrol Contact Details
7 Billbrooke Close, Cameron Park, NSW, 2285
P [phone] | F [phone]
EMAIL: [e-mail]
WEB: ampcontrolgroup.com

Ampcontrol Pty Ltd –ABN 28 000 915 542
DIESELGUARD USER MANUAL
MAG-179 Version 3 –APR/16
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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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............................................................................7
3 PRODUCT OVERVIEW ....................................................................................8
3.1 Diesel Machine Monitor .............................................................................8
3.2 Diesel Machine Monitor Wireless Antenna.................................................9
3.3 Gasguard Transmitter / CH4 Sensor........................................................10
3.4 IDA Display (Optional) .............................................................................10
3.5 I.S. Solenoid Valve ..................................................................................11
3.6 Pneumatic Bypass Assembly (c/w I.S. Solenoid Valve) ...........................11
4 INSTALLATION...............................................................................................12
4.1 General Warnings....................................................................................12
4.2 Mandatory Installation Practices..............................................................12
4.3 Mechanical Installation Information..........................................................14
4.4 Electrical Installation Information .............................................................16
5 COMMISSIONING AND CALIBRATION .........................................................20
5.1 Gasguard Sensor Calibration...................................................................20
5.2 Commissioning of the Dieselguard System..............................................20
6 PRODUCT OPERATION.................................................................................21
6.1 Start Sequence........................................................................................21
6.2 Machine Running.....................................................................................21
6.3 Optional Alarm Functions.........................................................................21
6.4 Deputy Override.......................................................................................21
6.5 Cold Start Function..................................................................................22
6.6 Charge Indication.....................................................................................22
7 SERVICE, MAINTENANCE & DISPOSAL.......................................................23
7.1 Equipment Service...................................................................................23
7.2 Equipment Maintenance..........................................................................24
7.3 Disposal...................................................................................................24
8 SPECIFICATIONS ..........................................................................................25
9 EQUIPMENT LIST ..........................................................................................27

Ampcontrol Pty Ltd –ABN 28 000 915 542
DIESELGUARD USER MANUAL
MAG-179 Version 3 –APR/16
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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TABLE OF FIGURES
Figure 3.1: Diesel Machine Monitor......................................................................8
Figure 3.2: Gasguard Transmitter with Integrated CH4 Sensor..........................10
Figure 3.3: IDA Display ......................................................................................10
Figure 3.4: I.S. Solenoid Valve...........................................................................11
Figure 3.5: Pneumatic Bypass Assembly ...........................................................11
Figure 4.1: Diesel Machine Monitor Dimensions.................................................14
Figure 4.2: Mounting Hole Locations..................................................................14
Figure 4.3: Terminal Layout for Diesel Machine Monitor.....................................15
Figure 4.4: Isometric View of Diesel Machine Monitor’s Terminal Block .............15
Figure 4.5: Typical Connection Diagram for the Dieselguard System.................16
Figure 4.6: Location of the Earth Stud on Diesel Machine Monitor .....................17

Ampcontrol Pty Ltd –ABN 28 000 915 542
DIESELGUARD USER MANUAL
MAG-179 Version 3 –APR/16
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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1 SAFETY AND OTHER WARNINGS
For safety reasons, the Dieselguard System 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 Dieselguard System 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 Dieselguard System functioning correctly it is highly recommended that all
safety functions of the Dieselguard System be periodically tested to ensure correct operation.

Ampcontrol Pty Ltd –ABN 28 000 915 542
DIESELGUARD USER MANUAL
MAG-179 Version 3 –APR/16
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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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.
In order to maximise the lifespan of the battery installed in the Dieselguard unit, it is recommended that
the Dieselguard be connected to a power supply during extended storage periods.
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.

Ampcontrol Pty Ltd –ABN 28 000 915 542
DIESELGUARD USER MANUAL
MAG-179 Version 3 –APR/16
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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3 PRODUCT OVERVIEW
The Dieselguard System monitors ambient gas levels (methane for a standard installation) and provides
indication and control based upon the measured gas levels. The system prevents unsafe starting of a
machine in the presence of dangerous levels of explosive gas. Similarly, if a machine is running, the
Dieselguard System will shut the machine down if surrounding gas levels rise above the set alarm point.
This prevents continuing unsafe operation of a machine in a potentially dangerous atmosphere.
Key Features
Gas monitoring and control functionality
IP66 stainless steel enclosure
Ex ‘m’ ia certified product
Powered from machine’s alternator
CH4 transmitters with integrated or remote sensor heads
Standard external control enclosures available
Intrinsically safe solenoid valve
3.1 Diesel Machine Monitor
Figure 3.1: Diesel Machine Monitor
The Ampcontrol Dieselguard Machine Monitor is the central connection point for the Dieselguard system,
which comprises of external sensors, external display, control box and the I.S. solenoid valve. The
Ampcontrol Dieselguard Machine Monitor is housed in a low-profile IP66 stainless steel enclosure, with
all internal electronics being encapsulated.
The Diesel Machine Monitor is an Exm ia certified product that is powered from the alternator supply of
the vehicle. Apart from the supply power all other connection to the Dieselguard Control unit are Ex ia
Intrinsically Safe (IS) circuits.
The Diesel Machine Monitor provides the control via a solenoid incorporated into the diesel machine’s
safety pressure circuit. When released the solenoid allows the system to de-pressurise and as a result,
shut down the machine
Input power is provided via the integral encapsulated cable and is not polarity sensitive. The input
circuitry has been designed to withstand a wide variety of ‘dirty’ power supply types. Many alternators
provide power that has a high level of ripple and high voltage noise spikes. The Dieselguard Diesel
Machine Monitor is designed to withstand these conditions without operational problems. The unit will
withstand a 90V repetitive overload condition via its internal auto-reset protection barrier. The input
power supply circuitry is galvanically isolated from the rest of the system.
The unit is designed as a component approved device and can be used with Intrinsically Safe and

Ampcontrol Pty Ltd –ABN 28 000 915 542
DIESELGUARD USER MANUAL
MAG-179 Version 3 –APR/16
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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“simple apparatus” accessories provided that the entity requirements are adhered to. Accessories for the
Dieselguard System include: Gas transmitters, RTD’s, Pressure and level switches, LED indicators,
Solenoid valves and Intrinsically Safe display systems.
The Diesel Machine Monitor is pre-configured to detect Methane gas around the vehicle and to provide a
normally energised solenoid supply which will de-energise and hence de-pressurise the vehicle safety
loop (diesel supply valve) in event of high gas readings. The warning signal is pre-set at 1.00% and the
trip function is pre-set to de-energise the solenoid at 1.25% CH4 (as per the requirements of AS/NZS
4871.6:2013 Section 6.4.4).
The Dieselguard Machine Monitor is equipped with wireless capability that allows the user to connect to
the unit, through the use of the Dieselguard Base Station, and configure alarm trip points, provide real
time status information and download logged data.
The Diesel Machine Monitor is designed not to need regular maintenance or access, as such, once fitted
to the machine it does not need to be accessed.
3.2 Diesel Machine Monitor Wireless Antenna
In order for the Diesel Machine Monitor to communicate with the Dieselguard Base Station, it is
necessary to mount the small whip antenna to the vehicle. The antenna is located at the end of the free
coax cable and is protected by a rugged sheath.
When mounting the antenna, consideration should be given to keeping the actual receiving part (the last
200mm of the cable assembly) away from the metalwork of the vehicle. If the antenna is too close to the
vehicle, then the useable range may be reduced. Ideally, the antenna should be mounted in the same
orientation as the receiver.
NOTE
If the wireless capability is not required, it is not necessary to cut off
the antenna. The coaxial cable can be unplugged inside of the Diesel
Machine Monitor’s enclosure.

Ampcontrol Pty Ltd –ABN 28 000 915 542
DIESELGUARD USER MANUAL
MAG-179 Version 3 –APR/16
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3.3 Gasguard Transmitter / CH4 Sensor
Figure 3.2: Gasguard Transmitter with Integrated CH4 Sensor
The Gasguard transmitter may include an integral or remote head sensor. In either case the sensor
should be mounted pointing vertically downwards and sufficient space left around and beneath the
sensor for fitting of the calibration cup.
The front panel of the transmitter has to be accessible for calibration and service of the sensor and
should be mounted in a position to allow for the magnetic screwdrivers to be used and the reading on the
screen viewed.
It is not necessary for the transmitter to be viewed by the driver.
If the remote head sensor is used bear in mind that if the sensor needs to be replaced, easy removal and
re-installation of the cable is advantageous.
See Gasguard sensor manual for further information.
3.4 IDA Display (Optional)
Figure 3.3: IDA Display
The IDA display provides feedback to the operator of the diesel machine as to the ambient CH4 levels.
The IDA display is optional and alternative display panels using LED and other equipment can be used.
If the IDA display is used it should be mounted in a position where the driver can see it without it being in
his direct line of vision. See IDA technical datasheet for more detail.