GASTRON GIR-3000 User manual

Design, development, production, installation,
and servicing of Gas Dectector
GIR3000
Instruction Manual
Revision: 2.0
Copyright ⒞GASTRON, Co., LTD. All rights reserved.
Please read this manual carefully for proper use of the device

GIR-3000 Instruction Manual
PAGE 2 of 44 Rev 2.0, 2012.8.21
Thank you for purchasing the product of us Gastron Co., Ltd.
Gastron has been recognized from many consumers for its top quality and ease of use as a
professional company of Gas detectors & Gas Monitors. We are constantly researching and
striving to help consumers to find with required products nearby and to develop consumer
satisfied Gas detectors. From now on, Gastron detectors will resolve all the troubles you have and
satisfy your needs.
This manual contains method for the installation, operation method, and simple maintenance
methods on GIR-3000 IR Gas detector. Read it carefully and keep it for further reference in case
you have questions.
If there are any problems with our products, please contact us at the address below.
Address: Gastron Co., Ltd.
18-8 Dogeumdanji 1gil(Palgogi-dong), Sanglok-gu, Ansan-city,
Gyeonggi-do, Korea
Tel : [phone]
Fax : [phone]
URL : www.gastron.com
e-mail : [e-mail]
Note
•
Inspection and calibration are recommended at least once every 3
months to ensure accurate operation of the Gas detector using
calibration gas depending on the type of gas.
•Negligence of periodic inspection
and calibration may cause
malfunction of the device due to the aging of the Sensor.
•Only qualified personnel with professional skills on Gas detector may
disassemble the unit if necessary.
•For further information on Gas detector inspection and correction,
please contact us at our technical department, e-mail or web site.

GIR-3000 Instruction Manual
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GIR-3000 Instruction Manual
PAGE 4 of 44 Rev 2.0, 2012.8.21
TABLE OF CONTENTS
1. Introduction ........................................................................................................................................................................ 6
2. Structure ............................................................................................................................................................................... 6
3. Specification........................................................................................................................................................................ 7
4. Name of Components and Main features............................................................................................................ 8
4.1. Components........................................................................................................................................................... 8
4.2. Components Description.................................................................................................................................. 9
5. Terminal wiring diagram .............................................................................................................................................11
5.1. Separation of Detector Body and Cover.................................................................................................11
5.2. Main PCB configuration..................................................................................................................................12
5.2.1. Main PCB configuration .....................................................................................................................12
5.2.2. HART Board configuration................................................................................................................13
5.3. Main PCB terminal description and wiring method ..........................................................................14
5.3.1. Relay drive type wiring method.....................................................................................................15
5.3.2. 4~20mA Source drive type wiring method ..............................................................................16
5.3.3. 4~20mA Sink drive type wiring method....................................................................................17
5.3.1. Connection method with our main Control Unit...................................................................18
6. Standard Type outside view and Dimensions...................................................................................................19
7. Warning light type: Outside view and Dimensions ........................................................................................20
8. Raincover type: Outside view and Dimensions.................................................................................................21
9. Menu Configuration Table .........................................................................................................................................22
10. Detector activation Flow and KEY operation ..................................................................................................25
10.1. Sensor activation Flow ..................................................................................................................................25
10.2. Sensor KEY configuration and description ..........................................................................................25
11. Detailed Description of Operational States and Menu ..............................................................................26
11.1. Initial State (Power On) ................................................................................................................................26
11.2. Gas Measuring Mode....................................................................................................................................26

GIR-3000 Instruction Manual
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11.3. How to Set PROGRAMMABLE MODE....................................................................................................27
11.4. How to use Calibration Mode...................................................................................................................28
11.4.1. Zero Calibration and Span Calibration .....................................................................................28
11.5. How to set alarm in Alarm mode............................................................................................................30
11.1. How to use Test Mode.................................................................................................................................33
11.2. How to use IR SENSOR DATA MODE....................................................................................................34
11.3. How to use VERSION MODE .....................................................................................................................35
11.4. How to set Maintenance Mode................................................................................................................36
11.1. How to configure 485 MODBUS..............................................................................................................38
11.2. How to configure in Device Mode..........................................................................................................39
11.3. How to use INSPECTION MODE ..............................................................................................................40
11.4. Data initialization.............................................................................................................................................40
11.5. Correction data initialization......................................................................................................................40
12. Troubleshooting ...........................................................................................................................................................41
13. Caution before installation ......................................................................................................................................42
13.1. Selection of installation location (Occupational Safety and Health Law)..............................42
13.2. Selection of installation location (High Pressure Gas Safety Management Regulations)
............................................................................................................................................................................................42
13.3. Precaution before installation....................................................................................................................43
14. Revision history.............................................................................................................................................................44

GIR-3000 Instruction Manual
PAGE 6 of 44 Rev 2.0, 2012.8.21
1. Introduction
The GIR-3000 is an infrared(IR)-type gas detector that is developed to prevent serious accidents
caused by gas leaks by detecting a variety of gases in hazardous areas such as industrial plants,
gas storage facilities and factories in the process of producing or consuming flammable gases,
CO or CO2.
When the GIR-3000, IR-type gas detector is installed in locations that may have gas leaks, it will
continuously monitor the ambient level of gas and display the measured gas value on its
integrated LCD or OLED. Additionally, it supplies DC 4-20mA standard output, isolated RS-485
communication signal, HART and relay contact signal on occurrence of gas alarms.
For standard output of DC 4-20mA, output receiver can support up to 500 meters distance away
from gas detector to receive output signal(When CVVS or CVVSB 2.0 sq↑shield cable is used).
And communication signal of RS-485 can be transmitted up to 1,000 meters (when RS-485
dedicated line is used).
2. Structure
The body of GIR-3000 is made of aluminum alloy and its structure is designed to be explosion-
proof(Ex d IIC T6). The product can be installed in areas that may have flammable gas leaks and
explosions. The integrated liquid crystal display(LCD or OLED) displays current gas leakage level
on the spot.
The internal structure consists of LCD for gas level, connector delivering output such as
measured value(DC 4-20mA) or isolated RS-485 communication signal(optional), HART
communication and alarm signal, and two PCB boards. The outer structure is composed of
sensing parts for detecting gas leakage and cable inlets(2ea). The gas detector can be calibrated
from outside of the device using magnet-bar, which makes maintenance easier.

GIR-3000 Instruction Manual
PAGE 7 of 44 Rev 2.0, 2012.8.21
3. Specification
I T E M S S P E C I F I C A T I O N
Measuring Type Diffusion
Measuring Value Display Local digital LCD(OLED) display
Means Value Display Back light, 2-line/16-characters LCD & OLED
Approval Ex d IIC T6, IP65
Detectible Gas
Combustible Gas
Carbon dioxide(CO2)
Carbon monoxide(CO)
Measuring Method Non-Dispersive Infrared(NDIR Cell)
Measuring Range
Combustible Gas : 0~10,000ppm / 0~100% LEL / 0~100%
VOL
CO2: 1.0% ~ 100% VOL
CO : 5% ~ 100% VOL
Response Time 90% of full scale in less than 10 seconds
Accuracy ±3% / Full scale
Zero Drift Less than 2% full scale
Operating Temperature -20 to 60°C
Operating Humidity 0 to 99% RH (Non-condensing)
Analogue Signal Output
Measurement output : 4-20mA DC/Full Scale
Diagnostic output : 3mA
Calibration output : 3mA
Faulty output : 2mA
HART ®Interface HART REV7 / Optional Board (*1)
Alarm Signal Output SPST Signal of Relay contact : 250V/1A
Calibration Work Magnetic interface to configure alarm
Cable Connection Length
Max. 500m : 4~20mA signal
Max. 1000m : Isolated RS-485 Signal
Power Supply 18-31V DC (DC 24V normal) / Max. 400mA
Conduit Connection 1/2" or 3/4"PF, NPT(Standard : 3/4" PF)
Signal cable Connection
Power source + current : CVVS or CVVSB 2.0sq↑
x 3wires
shield
RS-485 communication : 1 par(UL2919 RS-485)
Option
HART ® Interface board
GTL-100 (explosion proof LED)
Rain cover
Dimensions 156(W) x 322(H) x 110(D) mm
Weight Approx. 3.0kg
[Table 1. GIR3000 Specification ]
*Note 1) Regarding HART, refer to document on GIR3000 HART® Field Device Specification.

GIR-3000 Instruction Manual
PAGE 8 of 44 Rev 2.0, 2012.8.21
4. Name of Components and Main features
4.1. Components
11
4
3
913 14
17
22
MITTER
TRON
TRANSMITTER
GASTRON
U
P
T
F
I
L
P
R
E
S
S
U
P
T
F
I
L
P
R
E
S
S
15 1611 12
10
19
18
21
8
21
18
4
5
2
7
23
20
19
24
25
6
26
GIR3000A_H_MAIN_SCH
REV0 2012-06-08
[485B][485A]
[ALM1][ALM2] [TRB] [VISO] [+V]
BABAB
AL2 AL1 TRB
A
[-V] [mA]
[H-] [H+]
C C C
[ETH]
CN1
CN10
CN11
CN2
CN3
CN4
CN6
CN7
CN8
CN9
D1
GH1
J1 J2 J3
J4
RY1 RY2 RY3
S1
TP3
TP4
Z1
GH5
GH2
+
C14
GH3
CN12
CN5
[Figure 1. GIR3000 Components]
No. Name No. Name
1 HOUSING 14 RESET SWITCH
2 MAIN PCB 15 ↑SWITCH
3 DISPLAY PCB 16 ↓SWITCH
4 POWER/SIGNAL TERMINAL 17 EXTERNAL EARTH (4sq ↑)
5 ALARM SIGNAL TERMINAL 18 MOUNT HOLES (2-Ø7)
6 RS-485 SIGNAL TERMINAL 19 COVER FIXED SCREW
7 SENSOR TERMINAL 20 SENSOR THREAD
8 POWER SWITCH 21 CABLE INLET
9 POWER LED LAMP 22 INTERNAL EARTH (2sq ↑)
10 TROUBLE LED LAMP 23 RS-485 Module or HART Module (Option)
11 ALARM1 LED LAMP 24 Relay Contact Type Selection
12 ALARM2 LED LAMP 25 Warning Light Connector
13 FUNCTION SWITCH 26 Program Downloading Connector
[Table 2. Components Reference Table]

GIR-3000 Instruction Manual
PAGE 9 of 44 Rev 2.0, 2012.8.21
4.2. Components Description
No. Name of component Description
1 Housing Protecting sensors and PCB boards equipped inside the device housing
against environmental variations and shocks
2. Main PCB
Amplifying the output signal generated by sensor, converting it to
standard output of DC 4-20mA and transmitting converted signal. And
transmitting isolated RS-485 communication signal and alarm relay
contact signal. Also delivering data which will be shown in display panel.
3. Display PCB Showing data sent by main PCB in LCD or OLED. Also displaying current
event status with using power lamp, alarm lamp and trouble lamp.
4. Power/Signal Terminal CN12 is composed of connection terminal for supplying DC18-24V
power and connection terminal for standard output (viso, +, mA, -).
5. Alarm signal Terminal CN8 is an alarm signal connection terminal which outputs relay contacts
of trouble, alarm1 and alarm 2.
6. RS-485 signal terminal CN3 is a signal connection terminal(A,B) for isolated RS-485
communication.
7. Sensor terminal C10 is a sensor connection terminal(RD, WH, BK, BE).
8. Power on/off switch
Turning on or off power of gas detector. The switch should be turned
off when cable work or A/S is performed. After finishing those works,
the switch can be on.
9. Power lamp When power switch turns on, this power lamp light will be on.
10. Trouble lamp When fault occurs in circuit or sensor sensitivity, the trouble lamp will
be on.
11. Alarm1 lamp The alarm1 lamp turns on when the measured value of gas becomes
over alarm1 level on gas leakage.
12. Alarm2 lamp The alarm2 lamp turns on when the measured value of gas becomes
over alarm2 level on gas leakage
13. Function switch
In order to set parameters, this function switch is used to allow the
device to enter program mode by touching it with magnet-bar for 2
seconds or more(Program mode, Calibration mode and Test mode are
also provided). The switch is also used to input and set data.
14. Reset switch
Reset switch can be used to cancel setting parameter or return back to
previous state by touching it once with magnet bar. (Each time it is
touched with magnet bar, the mode will be switched back to the
immediate previous mode)
15. ↑(Up) switch
This switch is used to transit mode or adjust number by touching it with
magnet bar. The mode will be switched in a forward direction and the
number in an increasing direction.

GIR-3000 Instruction Manual
PAGE 10 of 44 Rev 2.0, 2012.8.21
No. Name of component Description
16. ↓(Down) switch
This
switch is used to transit mode or adjust number by touching it with
magnet bar. The mode will be switched in a backward direction and the
number in a decreasing direction.
17. External earth The gas detector must be connected to ground via the external earth
point to protect it against external noises or high voltage.
18. Mount hole(ø7×2ea) These holes are used to fix the gas detector on wall or other installed
places.
19.
Cover fixed
screw(M4)
The gas detector’s housing body and housing cover must be fixed with
hex sockethead cap screw after they are assembled in order to prevent
separation which might be caused by external shocks.
20. Sensor thread Attachment places where IR gas Sensor(Detector) is attached.
21. Cable inlet
These cable inlets are used to supply power and input & output
measured data signal during installation. PF 3/4" is basically provided.
22. Internal earth
The gas detector must be connected to ground via the internal earth
point to protect it against external noises or high voltage.
23.
RS-485 Module /
HART Module
(Optional)
This is a connector which enables the detector to communicate with PC
or PLC through isolation-type RS-485 communication protocol or HART.
To activate RS-485
communication, communication address must be
assigned to the detector properly.(the value is set to be 1 by default)
For using HART, polling-address and tag no. must be set appropriately.
24.
Relay Contact
Type Selection
It enables the user to select relay contact between A and B.
When the detector is not ENERGIZER MODE, i
t will operate with A
contact(Normal Open) if the spot marked by A silk is connected by
jumper wire. It will operate with B contact(Normal Close) if the spot
marked by B silk is connected by jumper.
The other way, when the detector is ENERGIZER MODE, it will operate
with B contact if the spot marked by A silk is connected by jumper wire.
It will operate with A contact(Normal Close) if the spot marked by B silk
is connected by jumper.
25.
Warning Light
Connector
(Optional)
This connector will be connected only if LED needs to be used.
26. Program Downloading
Connector The connector enables the user to download program to the product.
[Table 3. Detailed Description about components of the GIR-3000]

GIR-3000 Instruction Manual
PAGE 11 of 44 Rev 2.0, 2012.8.21
5. Terminal wiring diagram
Warning Never install, uncover, or manipulate the Detector other than authorized
personnel or installation/repair service person from Gastron, or serious loss of life and property
damage such as fire or explosion may occur. In addition, check around for explosive Gas or
flammable substances, followed by turning OFF before any work.
5.1. Separation of Detector Body and Cover
The Gas Detector Cover can be removed by turning the Cover fastening Slotted Set Screw (M4 x 1ea)
three to four rotations anti-clockwise using hex wrench (M2), followed by turning the Cover
counterclockwise by hand. After the separation of Cover, the LCD indicator appears.
[Figure 2. Slotted Set Screw]
After the Cover removal, remove the Display Part as follows.
.
[Figure 3. Display Parts removal ]
1
2
1
①Click the left and right retainer rings on
the front of the LCD display inwards at
the same time.
②While holding, pull the Display Part
forward to separate from the Gas
detector Body.
③
With the Display Part removed, the
Main PCB is shown under the Detector
Body.

GIR-3000 Instruction Manual
PAGE 12 of 44 Rev 2.0, 2012.8.21
5.2. Main PCB configuration
5.2.1. Main PCB configuration
With the Display Part removed, the Main PCB terminal arrangement is shown as the following Figure.
[Figure 4. Main PCB terminal arrangement ]
No Name Description
1 CN12 Power & Output Signal Terminal
2 J4 4~20mA Source / Sink selection jumper
( ON: Source Type, OFF: Sink Type )
3 CN11 Display LCD Connector
4 CN10 Sensor Connector
5 CN6 Program download Connector
6 D1 Status LED ( blinks every second in normal operation )
7 CN1,CN2,CN4 HART Option Board Connector
8 CN5 Warning Light(GTL-100) Interface Connector
[Table 4. Main PCB main Parts Description]

GIR-3000 Instruction Manual
PAGE 13 of 44 Rev 2.0, 2012.8.21
5.2.2. HART Board configuration
HART Board consists of Option Board, and is connected using CN5, CN6, CN7 terminals of Main PCB
and the HART Board Screw at the top left.
[Figure 5. HART Board constituting Main PCB]
No Name Description
1 HART Board Screw Constructed using 3Ø Screw
2 Blank Hole Reserve Hole
3 HART Board Option Board for HART Interface
[Table 5. HART Board main Parts description ]

GIR-3000 Instruction Manual
PAGE 14 of 44 Rev 2.0, 2012.8.21
5.3. Main PCB terminal description and wiring method
If you remove the Display Part, there is the Terminal Block under the Main PCB as shown in the
following Figure 6. The Terminal Block can be removed from Main PCB by holding and pulling upward
by hand. Unscrew the 5 terminal set screws above the separated Terminal Block CN12 (VIS, +, mA, -,
ETH) Connector counter-clockwise with a Θ screwdriver; connect DC18-24V power to +, -; connect
Signal Cable to mA; tighten the terminal set screws clockwise to keep the terminals in place; and insert
it like before the removal.
[Figure 6. CN12 Terminal structure]
No PCB Silk Pin Name
Description
4~20mA Source Drive
(J1 Jumper ON)
4~20mA Sink Drive
(J1 Jumper OFF)
1 VISO VIS N.C 4~20mA Sink In(+)
2 +24V + +24V / POWER (+)
3 mA mA 4~20mA Source Out 4~20mA Sink Out(-)
4 GND - GND / POWER (-)
5 ETH ET EARTH
[Table 6. CN12 connector description ]
Note 1) Be sure to use CVVS or CVVSB 2.0sq↑Shield Cable before Terminal construction.
Note 2) Fasten Terminals based on +24V of 2Pin to connect the 4Pin Terminal of existing
conventional GIR3000.

GIR-3000 Instruction Manual
PAGE 15 of 44 Rev 2.0, 2012.8.21
5.3.1. Relay drive type wiring method
The Relay drive type of GIR-3000 can be operated by two ways.
There is De-Energized Mode and Energized Mode.
Main PCB is marked A, B silk to set Relay drive type and connect using Jumper as you want
Relay drive type.
[Figure 7. Main PCB Relay part Configuration]
Drive type A Contact B Contact
De-Energized Connect Jumper to (A-C) Connect Jumper to (B-C)
Energized Connect Jumper to (B-C) Connect Jumper to (A-C)
[Table 7. Relay drive type description]
Note 1) Be sure to use the same J1, J2, J3.
Note 2) Conventional GIR-3000 can be operated DE-Energized Mode.

GIR-3000 Instruction Manual
PAGE 16 of 44 Rev 2.0, 2012.8.21
5.3.2. 4~20mA Source drive type wiring method
Connect 4-20mA Signal Terminal of PLC to ‘mA’ of GIR3000. GND Terminal is used in common with the
power. Turn J4 Jumper ON.
※HART Communicator can be used only in models utilizing HART Option Board.
[Figure 8. Analog 4~20mA Source Configuration]

GIR-3000 Instruction Manual
PAGE 17 of 44 Rev 2.0, 2012.8.21
5.3.3. 4~20mA Sink drive type wiring method
Connect 4-20mA Sink Output (+) Terminal of PLC to VISO Terminal; and (-) Terminal to ‘mA’ Terminal.
Turn J4 Jumper OFF.
※HART Communicator can be used only in models utilizing HART Option Board.
[Figure 9. Analog 4~20mA Sink Configuration ]

GIR-3000 Instruction Manual
PAGE 18 of 44 Rev 2.0, 2012.8.21
5.3.1. Connection method with our main Control Unit
Connect CN12 (VISO,+, mA, -, ET) Connection Terminal of the Gas Detector and the Control Unit with
reference to the Figure below. (See product manual for each Control Unit.)
11
10
9
mA
24V
감지기
(SENSOR)
-
CONTROL UNIT
GAS DETECTOR
-
+
ET
mA
SHIELD
EARTH
POWER
/mA
VISO
(GTC-100A Series Control unit)
-
mA
CONTROL UNIT
SENSOR
(탐지기)
17
16
15
+
GAS DETECTOR
-
+
ET
mA
SHIELD
EARTH
POWER
/mA
VISO
(GTC-200A/210A Series Control unit)
POWER
/mA
GAS DETECTOR
-
+
ET
mA
S-IN(mA)
GND
+24V
CN2
CONTROL UNIT
SHIELD
EARTH
VISO
(GTC-510A/520A Series Control unit)

GIR-3000 Instruction Manual
PAGE 19 of 44 Rev 2.0, 2012.8.21
6. Standard Type outside view and Dimensions
[Figure 10. GIR3000 outside view]

GIR-3000 Instruction Manual
PAGE 20 of 44 Rev 2.0, 2012.8.21
7. Warning light type: Outside view and Dimensions
56 54
110
35
146
<322> <GSA920A Sensor(Detector) 취부시>
140
156
2-Ø7
TRANSMITTER
GASTRON
방 폭 형 식:
규격 및 형식:
12-KB2BO-XXXX
II 2G Ex dIIC T6 Gb IP65
GTL-100
한국산업기술시험원 인증필
인 증 번 호:
사 용 온 도: -30°C ~ +70°C
사 용 전 원: 24VDC / 80mA Max.
84.5
198.8
[Figure 11. GIR3000 Warning Light type outside view]