Gastech D-guard User manual

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D‐GuardTM

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DigitalGuard

IntrinsicallySafeIntelligentGasDetector

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PartNumber65‐1010xxx

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ManualRevisionv2.08(updated5June2009)

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TableofContents

1Introduction ............................................................................................................................................... 6

1.1 Features................................................................................................................................................ 6

2Installation ................................................................................................................................................. 7

2.1 Mounting .............................................................................................................................................. 7

2.2 OpeningTheEnclosure ......................................................................................................................... 8

2.3 Wiring ................................................................................................................................................. 10

2.3.1 ConnectiontoController ............................................................................................................. 10

2.3.2 ConnectiontoBarriers................................................................................................................. 11

2.3.3 OptionalRelayBoard ................................................................................................................... 14

2.4 Operation............................................................................................................................................ 17

3AdvancedSetup........................................................................................................................................ 18

3.1 ChangingthePCBorSensor ................................................................................................................ 18

3.2 PCBJumpersandCalibration............................................................................................................... 22

3.2.1 IsolateMode................................................................................................................................ 22

3.2.2 Normal/InvertJumper ................................................................................................................. 23

3.2.3 SensorBiasJumper...................................................................................................................... 24

3.2.4 SensorBiasVoltageAdjustmentTrimpot..................................................................................... 25

3.2.5 ShortingLinkJumper ................................................................................................................... 26

3.2.6 DisplayCurrentCalibrationTrimpot ............................................................................................ 27

3.2.7 OxygenLoadJumper ................................................................................................................... 27

3.3 SoftwareConfigurationandCalibration .............................................................................................. 28

3.3.1 Configuration............................................................................................................................... 28

3.3.2 Calibration ................................................................................................................................... 33

APPENDIXI. Troubleshooting.................................................................................................................... 38

APPENDIXII. FactorySetup ........................................................................................................................ 38

3.4 CalibratingZero/FullLoopCurrent ...................................................................................................... 38

APPENDIXIII. IECEXCertificate.................................................................................................................... 41

APPENDIXIV. SparePartsList...................................................................................................................... 44

APPENDIXV. Specifications ........................................................................................................................ 45

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©2008GastechAustraliaPtyLtdPage2 

PROPRIETARYSTATEMENT

GasTechAustraliaownsproprietaryrightsintheinformationdisclosedwithin.Byreceivingthisdocument,the

recipientagreesthatneitherthisdocumentnortheinformationdisclosedwithinnoranypartshallbe

reproducedortransferredtootherdocumentsorusedordisclosedtoothersformanufacturingorforany

otherpurposeexceptasspecificallyauthorisedinwritingbyGasTechAustralia.

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Informationcontainedinthisdocumentisprotectedbycopyright.Nopartofthisdocumentmaybe

photocopied,reproduced,ortranslatedtoanotherprogramorsystemwithoutpriorwrittenauthorisation

fromGasTechAustralia.

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TRADEMARKSTATEMENT

Protectedthroughuseand/orregistrationintheUnitedStatesandmanyforeigncountriesarethetrademarks

andservicemarksofGasTechAustralia.Theuseofthe®symbolindicatesregistrationintheUnitedStates

onlyandthe“TM”isinAustralia;registrationsmaynothavebeenissuedatpresentinothercountries.Allother

productnamesandlogosaretrademarksoftheirrespectiveowners.

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DISCLAIMER

UndernocircumstanceswillGasTechAustraliabeliableforanyclaims,losses,ordamagesresultingfromor

arisingoutoftherepairormodificationoftheequipmentbyapartyotherthanGasTechAustraliaorits

authorisedservicerepresentatives,orbyoperationoruseoftheequipmentotherthaninaccordancewiththe

printedinstructionsprovidedbyGasTechAustraliaoriftheequipmenthasbeenimproperlymaintainedor

subjecttoneglectoraccident.Anyoftheforegoingwillvoidthewarranty.

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REVISIONSTOMANUAL

Allinformationcontainedinthismanualisbelievedtobetrueandcorrectatthetimeofprinting.However,as

partofitscontinuingeffortstoimproveitsproductsandtheirdocumentation,GasTechAustraliareservesthe

righttomakechangesatanytimewithoutnotice.Anyrevisedcopiesofthismanualcanbeobtainedby

contactingGasTechAustralia.

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Page3©2008GastechAustraliaPtyLtd 

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SERVICEPOLICY

GasTechAustraliamaintainsaninstrumentservicefacilityatthefactoryaswellasauthorisedservicefacilities

aroundtheworld.Shouldyourinstrumentrequireservice,youmaycontactustollfreeat1800999902within

Australiaonlyor61‐8‐9242‐1869,orvisitourwebsitewww.gastech.com.auforauthorisedservicelocations.

Fornon‐warrantyrepairs,youwillneedtoprovideapurchaseordernumber.Ifyouneedtosetalimittothe

repairscosts,statea“NottoExceed”figure.Ifyouneedaquotationbeforeyoucanauthoriserepaircosts,so

state,butunderstandthiswillincuradditionalcostsandmaydelayprocessingoftherepair.

Ifyouwishtosetalimittotheauthorisedrepaircost,statea“nottoexceed”figure.GasTechAustralia’spolicy

istoperformallneededrepairstorestoretheinstrumenttofulloperatingcondition,includingreactivationor

replacementofallout‐of‐warrantyelectrochemicalcells.

originalpacking)andanyspecial

instructions.Repairsarewarrantedfor90daysfromthedateofshipment.Sensorshaveindividualwarranties.

Alwaysincludeyouraddress,purchaseordernumber,shippingandbillinginformation,andadescriptionofthe

defectasyouperceiveit.Ifthisisthefirsttimeyouaredealingdirectlywiththefactory,youwillbeaskedto

providecreditreferences,prepay,orauthoriseCODshipment.

NOTE:GasTechAustraliaassumesnoliabilityforworkperformedbyunauthorisedservicefacilities.

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Youmaysendtheunit,freightprepaid,to:GasTechAustraliaPtyLtd,24 Baretta Rd, Wangara, Western Australia 6065

Attn.:ServiceDepartment.Enclose the copy of your contact details.

Packtheinstrumentandallitsaccessories(preferablyinits

©2008GastechAustraliaPtyLtdPage4 

WARRANTYSTATEMENT

1. ConsumershavethebenefitofconditionsandwarrantiesimpliedbytheTradePracticesAct1974(TPA)

andsimilarprovisionsofStateandTerritoryenactmentsandnothingintheseconditionsisintendedto

exclude,restrictormodifyanystatutoryobligationofGASTECHAUSTRALIAPTYLTD(Company)ifthat

cannotlawfullybeeffected.

2. ThiswarrantyrelatesonlytoEquipmentmanufacturedandservicessuppliedbytheCompany,itsrelated

corporationsandsubsidiaries.EquipmentoranypartthereofwhichisreturnedtotheCompany,

transportationprepaid,within15monthsfromthedateofdispatchfromtheCompany’spremisesor12

monthsfromthedateofshipmenttotheultimateuser(whicheveroccursfirst)andisfoundbythe

Company,afterexamination,tobedefectiveinworkmanshipormaterials,willbeeitherrepairedor

replacedasdeterminedbytheCompany,freeofcharge.Thetermsofthisparagraphapplyunlessstated

otherwiseinthisinstructionmanual.

3. Thiswarrantydoesnotapplyto:

a) replacementorrepairswhicharerequiredasaresultsofimproperinstallation,misuse,

maladjustmentmodificationorlackofroutinemaintenancebyothers;

b) itemssubjecttodeteriorationorconsumptioninnormalservice,thatis,thosewhichmustbe

cleaned,repairedorreplacedroutinelysuchas(butnotlimitedto)lamps,bulbsandfuses,pump

diaphragmsandvalves,absorbentcartridges,filterelementsandbatteries;or

c) goods,materialsorpartssuppliedormanufacturedbyunrelatedthirdpartiesandprovidedto

thePurchaseratthespecificrequestofthePurchaserandsuchgoods,materialsorpartswillbe

repairedorreplacedonlytotheextentoftheoriginalsupplierswarranty.

4. ShouldtheCompanybeliableforbreachofaconditionorwarranty(otherthanthepursuanttosection69

oftheTPA)impliedbyDivision2ofPartVoftheAct(otherthanthatimpliedbysection69oftheTPA)the

liabilityoftheCompanyforsuchbreachshall,subjecttosection68A(2)oftheTPA,belimitedtooneof

thefollowingasdeterminedbytheCompany.

a) thereplacementoftheEquipmentorthesupplyofequivalentEquipment‐,

b) thepaymentofthecostofreplacingtheEquipmentorofacquiringequivalentEquipment.

5. SubjecttoClauses2and4andanylegislationtothecontrary:

a) representativesandagreementsnotexpresslycontainedhereinshallnotbebindinguponthe

Companyasconditions,warrantiesorrepresentations;allsuchconditions,warranties,and

representationsonthepartoftheCompany,whetherexpressorimplied,statutoryorotherwise,

whethercollateralorantecedentorotherwiseareherebyexpresslynegativedandexcluded;

b) theCompanyshallbeundernoliabilitytothePurchaserforanyloss(includingbutnotlimitedto

lossofprofitsandconsequentialloss)orfordamagetopersonsorpropertyorfordeathorinjury

causedbyanyactoromission(includingnegligentactsoromissions)oftheCompanyorthe

Company’sagents,whereveroccurring,arisingfromthesubjectmatterofthisagreement;

c) thePurchasershallindemnifytheCompanyagainstanyclaimsmadeagainsttheCompanybyany

thirdpartyinrespectofanysuchloss,damage,deathorinjuryasissetoutinsub‐paragraphb)

hereof;thePurchaserfurtheragreestoindemnifytheCompanyagainstalllossesandexpenses

whichtheCompanymaysufferorincurduetothefailureofthePurchaserfullytoobserveits

obligationsunderthiscontract;and

d) nowarrantyisgivenandnoresponsibilityisacceptedbytheCompanytoensuretheEquipment

suppliedcomplieswithanystatutoryrequirementsrelatingtothemarketingofgoods.

CompliancewithsuchlegislationshallbethesoleresponsibilityofthePurchaser.

e) theCompanyspecificallydeniesanyliabilityfortheoverallperformanceofanyplantorthe

resultsofanyprocesswithwhichtheEquipmentisintegrated.

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Page5©2008GastechAustraliaPtyLtd 



MANUALCONVENTIONS

Thisinstrumentisdesignedtodetectoneormoreofthefollowing:flammablevapours,oxygencontentand/or

toxicgasandtogivewarningbeforetheyreachharmfullevels.Inordertoensurethatitwillwarnof

dangerousconcentrations,itisessentialthattheinstructionsinthismanual,particularlythoseconcerning

startup,operation,calibration,andmaintenance,beread,understood,andfollowed.

Noticesareusedinthisoperator’smanualtoalertyoutohazardousconditionstopersonorinstrumentandto

notifyyouofadditionalinformation.Thisoperator’smanualusesthefollowingnotices.



NOTE:Notifiesyouofadditionalinformation.

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CAUTION:Notifiesyouofpotentialdamagetoequipment.



WARNING:Notifiesyouofpotentialdangerthatcanresultinpersonalinjuryordeath.

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©2008GastechAustraliaPtyLtdPage6 

1Introduction

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GasTechAustraliaisproudtointroducethenextstepinfixedgasdetectionequipment.TheD‐GuardTM(Digital

Guard)isanintelligentgasdetectorwhichisdesignedaroundtheoperatorsrequirements.Easytocalibrate,

easytosetup,andhighlystable,fixed‐pointtoxicandOxygengasdetector.

TheD‐GuardTMisanindustrystandardtwowire24VDC4‐20mAdevice.

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1.1 Features

•Nonintrusivecalibration

•Noalarmsduringcalibration

•OnePCBcardforallgasesdetected

•Notoolcalibration

•Sensordrifteliminationprogram

•Long‐termsensordeteriationdrifteliminationprogram

•Permanentbacklight

•Fail‐safemode

•Noncorrosivehousing

•Highimpacthousing

•Splashguardstandardsupply

•IP66design

•IECEXiaIICT4

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Page7©2008GastechAustraliaPtyLtd 

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2Installation



WARNING:Performallinstallationproceduresinafreshairenvironment(knowntobefreeof

combustibleandtoxicgasandhavingnormaloxygencontent).TheD‐GuardTMisnotinoperationasa

systemuntilthestartupprocedureiscomplete.



2.1 Mounting

NOTE:ThepackingslipindicatestheserialnumberofyourD‐GuardTM.Theserialnumberisalsoona

labelonthesideoftheD‐GuardTM.Pleaserecordtheserialnumberonthefrontofthismanual.



Theinstallationshouldbeintheareawithmostpotentialtodetectthegasasquicklyaspossible.Takenoteof

thegasdensityasthiswillhelpinfindingthebestlocationfortheD‐GuardTM.Forexample,heaviergaseslike

H2SwouldhavethesensormountedlowerthanforHydrogenwhichisalightergas.

Securelymounttheunittothewallusingwallplugsandscrews.Dimensionsofthetwomountingholesonthe

D‐Guardenclosureareshownbelow.



©2008GastechAustraliaPtyLtdPage8 

2.2 OpeningTheEnclosure

Inorderforpowertobeconnectedinsidetheunit,theenclosuremustbeopened.



1. Removethe4housinglidscrews(4mmAlankey).Thescrewsareheldinwith“O”ringstostopthem

fallingoutandlosingthem.



2. Gentlyremovethelidmakingsurethatyoudon’tlosethe4lidscrewsorthelarge“O”ringthatseals

thelidtothebase.



3. Turnoverthelidtofindthegreenpowerconnector.



4mmHex

orAllan

screws

Screwretaining

“O”ring

Powerconnector



Page9©2008GastechAustraliaPtyLtd 



4. Runthepowercablesviathegrommettothegreenconnectorasdescribedinthenextsection.

5. Oncethewiringiscomplete,confirmthatthehousingsealing“O”ringisfittedandingoodcondition.



6. Fitlidandtightenthe4screwsusinga4mmAllankeytighteningthehousingevenly.



Housing“O”ring

seal

©2008GastechAustraliaPtyLtdPage10 



2.3 Wiring

TheD‐GuardTMsensorcanbeusedwithanystandard2wire,4to20mA24VDCcontroller.Typicalcontrollers

includetheGasTechAustraliaMicroRackTM.



LocatedonthePCB,bottomrightcornerthereisatwopinremovableplug.Ensurethepositiveandnegative

wiresareterminatedwiththecorrectpolarity,whichismarkedonthePCB.



2.3.1 ConnectiontoController

WhenconnectingaD‐GuardTMunittoacontrollersuchastheGasTech4100Rcontroller,followthepinoutsas

outlinedbelow.Otherthirdpartycontrollersarealsoconnectedinthesamemanner.



Removable2‐pinplug.

0VDCand+24VDC



Page11©2008GastechAustraliaPtyLtd 



2.3.2 ConnectiontoBarriers

Intrinsicsafetybarriersaredevicesthatlimitthecurrent,voltage,andtotalenergydeliveredtoasensorina

hazardousareaorflammableenvironmentinordertopreventanexplosion.

Thebarriersdesignedtoprotectthesystemmustbemountedoutsideofthehazardousareainanarea

designatedasNon‐hazardousorsafeinwhichthehazardisnotandwillnotbepresent.



IfyouareutilizingtheD‐GuardTMinaHazardousenvironment,youwillneedtoselectanappropriateISbarrier.

Selectionofthetypeofbarrierrequiresconsiderationofthevoltagedropsthatoccurinthesystem.AstheD‐

Guardrequiresaminimumof12VDCtooperate,thevoltagedropsinthebarriersystem,controllerload

resistorandcablingcannotexceedthepowersupplyvoltageless12VDC.

WARNING:InstallersshouldconsulttheIntrinsicallySafeBarriermanufactureandrefertoIEC

IntrinsicallySafeSystemStandardIEC60079‐25:2003orAS/NZS60079.25:2004beforeselectinga

suitablebarrier.

AD‐GuardoperatedwithoutabarrierwillrequiretheD‐Guardtobeinspectedbythemanufacture

toconfirmthatnoneofthesafetycomponentshavebeendamaged.



©2008GastechAustraliaPtyLtdPage12 



GasTechrecommendtheGasTech57‐9010‐02barrier(KFD2‐STC4‐Ex1)formostsystems.Thisbarrierwillwork

onallcontrollersat24VDC.



WiringoftheGasTech57‐9010‐02barrierisasfollows:



Page13©2008GastechAustraliaPtyLtd 



AsecondbarrierthatcanbeusedistheGasTech57‐9010‐01(MTL7787+).Thisbarriermustonlybeusedin

conjunctionwiththeGasTech4100Rcontrollercard,asthe4100Rcardhas100Ωload.

WARNING:Ifyouusethisbarrieronanothercontrollerthatusesaloadabove100OhmstheD‐Guardwill

turnoffwhenitseeahighgasreading(>15mA)asthevoltdropoverthisbarrierisgreater.



WiringoftheGasTech57‐9010‐01barrierisasfollows:



©2008GastechAustraliaPtyLtdPage14 

2.3.3 OptionalRelayBoard

TheD‐GuardTMcanbeorderedwithanoptionalrelayboard(Partnumber:65‐1011‐xxx)whichallowstheD‐

GuardTMtooperateasaindependentunit.

WARNING:IftheD‐Guardisusedwiththerelayboard,theunitisnolongerIntrinsicallySafe,evenif

usedinconjunctionwithanISbarrier.



TheimagebelowshowsvariousconnectorsontherelayPCB.



Thefunctionofthevariousconnectorsisasfollows:

FeatureDescription

24V Connectthistothepositivesideofthepowersupply.Suppliespowertotherelay

boardaswellastheD‐GuardTMmainPCB.

FB(feedback) Currentsourceloopoutput,forconnectiontoanexternalcontroller

0V Connectthistonegativesideofthepowersupply

DG+ Thisneedstobeconnectedtothe+connectorontheD‐GuardTMmainPCB.

DG‐Thisneedstobeconnectedtothe‐connectorontheD‐GuardTMmainPCB.

AL1LowAlarm ThisrelayisenergizedwhenAL1isactive.Thisalarmpointisadjustableinsoftwareas

describedinthenextsection.

AL2HighAlarm ThisrelayisenergizedwhenAL2isactive.Thisalarmpointisadjustableinsoftwareas

describedinthenextsection.

FaultRelay Thisrelayisnormallyenergized.Itbecomesde‐energizedwhenthereisasensor

failure,powerfailureorwhentheD‐GuardTMisinIsolatemode.

JumperThisjumperconnectstheFBand0Vlinestogether.ItallowstheD‐GuardTMmainPCB

tooperateinstandalonemodewhereasystemcontrollerisnotpresent

Connectionto

powersource

anda4‐20mA

loop(optional)

PowerforD‐GuardTM

mainPCB

AL1Low

Alarm

AL2High

Alarm

Fault

rela

Wireharness

toD‐GuardTM

mainPCB

Jumper



Page15©2008GastechAustraliaPtyLtd 



CAUTION:Therelaycontactsareratedat5A@48VDCmax.Mainsconnectionisnotpermitted.



TheD‐GuardTMwithrelayoptionisnormallyusedinstandalonemode,howeveritcanstillbeconnectedback

toacontrollersuchastheGastech4100R.Thediagrambelowshowshowtheunitsarewiredtogether.

NOTE:Inthisconfiguration,thejumperontherelayPCBmustberemoved.



InternalConnectiondiagrams:

REMOVE Lk1

(Do not insert)

Connect to

+24VDC

Connectto

0VDC

D-Guard to Relay Board Connections

(Current loop output configuration)

ConnecttoPLCcurrentloop

input(currentsinkonly)



Lk1 MUST BE

INSERTED

Connect to

+24VDC

Connect to

0VDC

D-Guard to Relay Board Connections

(Standalone configuration)



2.4 Operation

CompletethefollowingprocedurestoplacetheD‐GuardTMintonormaloperation.



1. Completethemountingandwiringproceduresdescribedintheprevioussections

2. Completeallinstallationproceduresdescribedinthismanual

3. Verifythatallwiringconnectionsarecorrectandsecure

4. Checkpowerbeingsuppliedtotheunitiscorrect(24VDC)

5. Turnontheincomingpoweratthepowersource



NOTE:TheD‐GuardTMstartsupinawarm‐upIsolatedmodewiththemAlockedat3mAfor90seconds

whilethesensorstabilisedandtheD‐GuardTMprograminitialisesandcompletesaseriesoffunctiontests.



Afterthestartupprocedureandalltestsarecompletedifoperatingiswithintolerancethedisplaywillgointo

normaloperatingmode,themAwillbereleasedandthesystemwillthenbefunctioning.TheLCDscreen

showsthestatusofthesystem.



Gasreading

Unitof

measurement

Fullscale

value

Gasbeing

detected

3AdvancedSetup

OneofthekeyfeaturesoftheD‐GuardTMisitsabilitytobeeasilyservicedandcalibratedinthefield.Theunit

willneedtobecalibratedand/orreconfiguredifyouareperforminganyofthefollowingtasks:

•ReplacingaPCB

•Replacingasensor

•Changingtoadifferentsensor

•Scheduledcalibrationormaintenance

•Reactivationafterprolongedshutdown



AllcalibrationvaluesarestoredintheD‐GuardTMnonvolatilememorybutasnomonitoringofthesensor

operationisperformedduringtheshutdownperiodthesensormighthavebeenpoisonedandmightnot

respondasexpected.



3.1 ChangingthePCBorSensor



1. Isolatethesensorbackatthecontrolpanelsoanopencircuitfaultwillnottriporcreateanyalarms.

2. Removethe4housinglidscrews(4mmAlankey).Thescrewsareheldinwith“O”ringstostopthem

fallingoutandlosingthem.



3. Gentlyremovethelidmakingsurethatyoudon’tlosethe4lidscrewsortheLarge“O”ringthatseals

thelidtothebase.



4mmHex

orAllan

screws

Screwretaining

“O”ring

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