Ampcontrol GASGUARD 65-6550 Series User manual

Version:7, February 2019
User Manual Part #: 161297
Designed and manufactured in Australia by Ampcontrol Pty Ltd
GASGUARD
CH4CATALYTIC DETECTOR UNIT
User Manual

Ampcontrol Pty Ltd – ABN 28 000 915 542
GASGUARD CH
4
DETECTOR USER MANUAL
GSB093 Version 7 – FEB/19
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 2 of 25
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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
GASGUARD CH
4
DETECTOR USER MANUAL
GSB093 Version 7 – FEB/19
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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Copyright Notice
The Ampcontrol GasGuard detector unit 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 from the Ampcontrol GasGuard range.
WARNING!
In the interests of safety and correct equipment operation, please
take the time to read and understand the content in this manual.
Ampcontrol Contact Details
7 Billbrooke Close, Cameron Park, NSW, 2285
P [phone] | F [phone]
EMAIL: [email protected]
WEB: ampcontrolgroup.com

Ampcontrol Pty Ltd – ABN 28 000 915 542
GASGUARD CH
4
DETECTOR USER MANUAL
GSB093 Version 7 – FEB/19
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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TABLE OF CONTENTS
1 SAFETY AND OTHER WARNINGS..................................................................7
1.1 Safe Use of Equipment..............................................................................7
2 RECEIVING AND STORAGE............................................................................8
2.1 Receiving...................................................................................................8
2.2 Inspection..................................................................................................8
2.3 Storage after Delivery................................................................................8
2.4 Unpacking of Equipment............................................................................8
3 PRODUCT OVERVIEW ....................................................................................9
3.1 Methane Gas Sensor...............................................................................10
3.2 Amplifier PCB ..........................................................................................11
3.3 Stainless Steel Enclosure........................................................................11
3.4 Sensor Wiring Assembly..........................................................................11
4 PRODUCT OPERATION.................................................................................12
5 INSTALLATION...............................................................................................13
5.1 General Warnings....................................................................................13
5.2 Mandatory Installation Practices..............................................................13
5.3 Installation Guidelines..............................................................................14
5.4 Mechanical Installation Information..........................................................15
5.5 Electrical Installation Information .............................................................16
6 COMMISSIONING AND CALIBRATION .........................................................19
6.1 Preliminary Checks..................................................................................19
6.2 System Calibration...................................................................................19
6.3 Zero Calibration.......................................................................................20
6.4 Span Calibration......................................................................................20
6.5 Response time testing .............................................................................21
7 SERVICE, MAINTENANCE & DISPOSAL.......................................................22
7.1 Equipment Service...................................................................................22
7.2 Equipment Maintenance..........................................................................23
7.3 Disposal...................................................................................................23
8 SPECIFICATIONS ..........................................................................................24
9 EQUIPMENT LIST ..........................................................................................25

Ampcontrol Pty Ltd – ABN 28 000 915 542
GASGUARD CH
4
DETECTOR USER MANUAL
GSB093 Version 7 – FEB/19
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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TABLE OF FIGURES
Figure 3.1: Anti-vibration clip.....................................................................................11
Figure 4.1: Sensor / Transmitter User Interface ........................................................12
Figure 5.1: Catalytic detector dimensions .................................................................15
Figure 5.2: Catalytic sensor unit wiring diagram........................................................17
Figure 5.3: Remote catalytic sensor unit wiring diagram...........................................18
Figure 6.1: GasGuard detector control panel ............................................................20
TABLE OF TABLES
Table 1: Methane cross-sensitivity............................................................................10
Table 2: Sensor / Transmitter User Interface Descriptors..........................................12
Table 3: GasGuard Display Codes............................................................................12
Table 4: Gas Density Relative to Air .........................................................................14
Table 5: Nominal Resistance Values for Typical Wire Sizes .....................................16
Table 6: Corrective Maintenance Checks..................................................................23

Ampcontrol Pty Ltd – ABN 28 000 915 542
GASGUARD CH
4
DETECTOR USER MANUAL
GSB093 Version 7 – FEB/19
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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DEFINITIONS
Term Definition
Detector
Complete apparatus purchased by end user comprised of a sensor head and
amplifier PCB in a stainless steel enclosure that detects gas and converts to a 4-
20mA signal as well as displays a reading on the LCD screen
Sensor head The assembly attached to the bottom of the detector which houses the sensor cell
Amplifier PCB
The PCB inside the detector that amplifies the sensor cell signal into a usable 4-
20mA loop
CH4Methane
NATA National Association of Testing Authorities, Australia

Ampcontrol Pty Ltd – ABN 28 000 915 542
GASGUARD CH
4
DETECTOR USER MANUAL
GSB093 Version 7 – FEB/19
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
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1 SAFETY AND OTHER WARNINGS
For safety reasons, the GasGuard detectors 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 these instruments 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 GasGuard detector and associated equipment being
installed correctly. Mechanical and/or electrical installation and maintenance of plant and equipment
must only be carried out by appropriately qualified personnel and must be tested thoroughly prior to
operation.
1.1.5 Operation
As safety depends on the GasGuard detector functioning correctly it is highly recommended that all
safety functions of the product be periodically tested to ensure correct operation.

Ampcontrol Pty Ltd – ABN 28 000 915 542
GASGUARD CH
4
DETECTOR USER MANUAL
GSB093 Version 7 – FEB/19
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 8 of 25
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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 the 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 specifications
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 3-20˚C, preferably on shelves and protected from
moisture and sunlight.
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
GASGUARD CH
4
DETECTOR USER MANUAL
GSB093 Version 7 – FEB/19
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 9 of 25
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3 PRODUCT OVERVIEW
Ampcontrol’s GasGuard Methane Sensor / Transmitters are supplied complete with an amplifier and a
Liquid Crystal Display.
The Transmitter/Sensor assembly is an IEC Ex ia Group I certified assembly. The Certification is based
on the unit being sealed to IP66 in a stainless steel enclosure and the appropriate checks being made on
the Intrinsically Safe Parameters of the overall system the transmitter is connected into.
The Transmitter and Sensor can be mounted as an integral device but there is also an option to mount
the sensor separately up to 10m from the transmitter. In the remote configuration the sensor is factory
fitted with a type 2S cable which is potted directly into the sensor assembly.
The sensor is designed to provide a standardised output applicable for the gas range. This signal is not
for direct connection to other devices and so the amplifier PCB in the transmitter housing is used to
condition the signal, provide calibration functions and produce a 4-20mA signal.
The transmitter and amplifier assembly is configured in the factory for a specific gas range.
Key Features
•Economical Fixed Gas Sensor / Transmitter
•Rugged Construction
•Reliable
•Certified Intrinsically Safe – Ex ia
•LCD Display
•Non-Intrusive Closed Case Calibration
This document covers the catalytic range of GasGuard detectors. The GasGuard range of detectors
consists of electrochemical, catalytic and infrared sensor types and each provides a linear 4-20mA DC
current output. The full range consists of:
Electrochemical:
•Oxygen (O2)
•Carbon Monoxide (CO)
•Hydrogen Sulphide (H2S)
•Nitric Oxide (NO)
•Nitrogen Dioxide (NO2)
Catalytic
•Methane (CH4)
Infrared:
•Carbon Dioxide (CO2)
The sensor unit part numbers are unique and are identified in accordance with the following scheme:
Model Number 65-6550XXX series is for electrochemical detector units.
Model Number 65-6551XXX series is for catalytic detector units.
Model Number 65-6552XXX series is for Infrared sensor units.
Where XXX represents the chemical symbols for the gas detected by the unit. For example, 65-
6550CH4 is the Model number for an electrochemical unit designed to detect Methane (CH4).

Ampcontrol Pty Ltd – ABN 28 000 915 542
GASGUARD CH
4
DETECTOR USER MANUAL
GSB093 Version 7 – FEB/19
Uncontrolled Copy - Refer to Ampcontrol Website for Latest Version
Page 10 of 25
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3.1 Methane Gas Sensor
The Methane Gas Sensor, which operates on the catalytic combustible gas detection principle, is a small
platinum element coated in a catalyst. Electrical current is passed through the platinum wire and the
potential of the catalytic element is monitored by a simple Wheatstone bridge arrangement. Combustible
gases, once in contact with the heated catalytic surface of the measuring element, react and cause the
surface temperature of the element to rise. Any increase in temperature affects the resistance of the
platinum wire, causing a small shift in potential across the Wheatstone bridge proportional to the
concentration of the combustible gas.
3.1.1 Sensor Cell Cross Sensitivity
The cross sensitivity of the methane sensor cells to commonly occurring gases are listed below in Table
1.
Methane (CH4) gas sensors positively detect the presence of all flammable gases. They are unable to
distinguish the difference between gases so the sensor will display a reading if any flammable gas is
present.
CAUTION!
Exposure to Hydrogen Sulphide gas (H2S) may affect the performance
of the Methane sensor (i.e. it may reduce its sensitivity). If the sensor is
exposed to H2S gas then it should be recalibrated.
3.1.1.1 Cross-sensitivity Data Table 1: Methane cross-sensitivity
Methane Cross-Sensitivity
Gas
Concentration
Reading (% v/v)
Acetic Acid
4.0%
1.45
Acetone
2.6%
2.5
Ammonia
15%
6.25
Benzene
1.2%
2.0
n-Butane
1.8%
2.5
Carbon Monoxide
12.5%
4.0
Chlorobenzene
1.3%
1.7
Ethanol
3.3ppm
2.95
n-Hexane
1.2%
2.0
Hydrogen
4.0%
4.0
Methane
5.0%
5.0
Methanol
6.7%
4.25
Methyl ethyl kentone
1.9%
2.0
n-Pentane
1.4%
2.0
Propane
2.1%
2.5
Toluene
1.2%
2.0
3.1.2 Humidity
Sensors can operate in a condensing atmosphere. In such an environment, a thin film of water can form
across the membrane, effectively sealing it and stopping the passage of gas into the sensor. On
evaporation of this water the sensor usually resumes normal operation.
3.1.3 Poisoning of Sensors (Contamination)
High levels of or long exposure to certain compounds may poison the catalytically active detector
filament thereby reducing or destroying its sensitivity.
Among these compounds are halides, sulphur compounds, leaded petrol, silanes, silicates and other
products with silicon. Products such as aerosol sprays, polishes, waxes and lubricants with silicones and
non-catalysed silicone rubbers such as “silastic”, phosphate esters, and hydraulic fluids – will all damage
catalytic sensors.