GASTRON GTD-1000Ex User manual

GTD-1000Ex
Instruction Manual
Headquarters / Engineering research laboratory :
23 Gunpo Advance d Industry 1-ro(Bugok-dong), Gunpo-si, Gyeonggi-do
Tel [phone] Fax [phone]
Yeongnam business office / Plant :
55 Gonghangap-gil 85beon-gil, Gangseogu, Busan Metropolitan City
Tel [phone] Fax [phone]
E-mail : [email protected]
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Read in detail for correct use.

* KOSHA GUIDE : P-135/6-2018
Calibration must be performed at a frequency requested by the manufacturer and shall be performed quarterly
when the calibration period is not specified.
Gas & Flame
Detection System
GTD-1000Ex
Instruction Manual
www.gastron.com
02_03
Greetings
When abnormalities occur after purchasing the product,
please contact the following address.
· Address : 23 Gunpo Advanced Industry 1-ro,
Gunpo-si, Gyeonggi-do
· Tel : [phone]
· Fax : [phone]
· URL : www.gastron.com
· e-mail : [email protected]
We sincerely thank you for purchasing the product of Gastron Co. Ltd.
Our Gastron Co.Ltd. is a company specialized in Gas detector and Gas Monitoring System, being recognized
by many consumers due to the best quality and use convenience. We always enable you consumers to find
desired products nearby and are ceaselessly studying and striving for development of Gas detectors satisfying
customers. From now on, solve all anguishes concerning Gas detector with the products of Gastron Co. Ltd,
We Gastron Co. will take a responsibility and give you satisfaction.
In the present instruction manual, operation method for Gas detector as well as simple methods for
maintenance and repair, etc. are recorded If you read it in detail and keep it well, for reference when you
have questions, then it will give you much help.
The present product and the product manual can be changed without advance notice for performance improvement
and use convenience of the product.
■ForaccurateoperationofGasdetector,checkupandcalibrateformorethanonceinevery6months.
( * In reference to KOSHA GUIDE: P-135/6-2018 / 7.2 In-house inspection, section 2 )
■ForaccurateoperationofGasdetector,checkupandcalibrationwithcalibrationgasbefore
measurement is recommended.
■Whennotcalibrated,itmaycausemalfunctionoftheequipmentduetoproblemsresultingfrom
Sensor aging.
■Whenthepresentinstrumentshouldbedismantled,thosewithprofessionalskillsforGasdetector
should conduct the operation.
■Forpowersupplycable,wirespecificationsshouldbedeterminedbyreferringtotheitemof"Lengthof
 installedcable".
■ForthecontentsoncheckupandcalibrationofGasdetector,pleaseuseourcompany'sengineering
department , e-mail, or web site.

www.gastron.com
04_05
ContentsContents
GTD-1000Ex
Instruction Manual
8.2. Selecting a Site for Installation (High-Pressure Gas Safety Control Act Data) ················································· 21
8.3. Precautions during Installation·························································································································· 21
9. Revision History··························································································································································· 23
1. Overview ······································································································································································ 6
2. Configuration······························································································································································ 6
3. Specification ································································································································································ 7
3.1. Specifications ····················································································································································· 7
3.2. Mechanical Specifications ································································································································· 7
3.3. Electrical Specifications (Standard Type)··········································································································· 8
3.4. Environmental Specifications ···························································································································· 8
4. Name and Description of Each Part························································································································ 9
4.1. Components ······················································································································································ 9
5. Installation ····························································································································································· 11
5.1. Detachment of Housing Cover·························································································································· 11
5.2. Main PCB Configuration···································································································································· 12
5.3. Power and Signal Terminal Configuration ······································································································· 13
5.4. Method to Connect to External Control Unit ··································································································· 14
5.5. Installation Cable Length ··································································································································· 15
6. Calibration and Maintenance ·································································································································· 16
6.1. 4-20mA Output Diagnosis ································································································································ 16
6.2. Gas Sensor Status Diagnosis ····························································································································· 16
6.3. 4mA Adjustment (ZERO Calibration)················································································································ 17
6.4. SPAN Calibration················································································································································ 18
6.5. Gas Detector Calibration Method using Methane(CH4) Standard Gas ·························································· 19
7. Drawings and Dimensions········································································································································ 20
8. Precautions before Installation ································································································································ 21
8.1. Selecting a Place for Installation (Occupational Health & Safety Act Data) ····················································· 21

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06_07
3. Specication
GTD-1000Ex toxic gas detector has been developed to detect gas leaked from industrial sites and various toxic gases
generated from factories, gas storages, and manufacturing processes that produce or use toxic gases and to prevent
accidents in advance.
GTD-1000Ex toxic gas detector is installed in areas with gas leak hazards and continuously monitors gas leak. It displays
measurements on LCD of the detector, converts and transmits data in DC 4~20 mA standard output signal. Also, for DC
4~20 mA standard output, output signal transmission length between detector and receiver can be connected up to 2,000
m. (When Cable CVVS or CVVSB 1.5sq and above is used.)
3.1. Basic Specifications
3.2. Mechanical Specifications
ITEMS SPECIFICATION
Measuring Type Diffusion
Measuring Method
- Catalytic Cell)
- Thermal Conductivity Cell
- Heated-semiconductor Cell
Detectible Gas Combustible Gas
Measuring Range 0~100% LEL
Accuracy ≤±3%/FullRange
Zero Drift ≤2%/FullRange
Response Time 90% of full Scale in less than 15 sec
Approvals Classification KCs: Ex d llC T6
Basic Interface Analog 4-20mA current interface
Option Rain Cover
Warranty Transmitter 2Year
Sensor 1Year
ITEMS SPECIFICATION
Explosion Proof type Explosion-proof enclosure
Dimension 136(W) × 166(H) × 95 (D) mm
Weight including Sensor App. 1.5kg
Mounting type Wall mount
Mounting Holes Ø7±0.1
Cable inlet 3/4"PF(1/2”or3/4”NPT)
Body material Transmitter aluminum alloy
Sensor Stainless Steel (STS316)
2. Conguration
1. Overview
GTD-1000Ex
Instruction Manual
Body of GTD-1000Ex is made of Aluminum alloy and the gas sensor module is made of stainless steel. It consists of
a complete explosion-proof enclosure (Ex d IIC T6). This product can be installed in areas with potential combustible
gas leak and explosion hazards and internal structure consists of 1 PCB board with display part for measurements and
terminal part that outputs measurements (DC 4 - 20 mA) externally. External configuration consists of detector part that
monitors gas leak and cable inlets.
[Figure 1. GTD-1000Ex Overview]
Gas
Sensor Module
(GSA860EX)
Main Board
(Transmitter)
+24V DC
4-20mA Analog
Signal Output
Transmitter enclosure
Safety Power Supply Unit
(24VDC)
Safety Controller
(PLC or DCS)
GTD-1000Ex Gas Detector
Hazardous Area (Filed) Safe Area
제어Signal
External Interface
Power Line
Legend

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08_09
4. Name and Description of Each Part
4.1. Components3.3. Electrical Specifications (Standard Type)
ITEMS SPECIFICATION
Input Voltage(Standard)
※CustomersuppliedPSUmustmeet
requirements IEC1010-1 and CE
Marking requirements.
Absolute min:
Nominal:
Absolute max:
Ripple maximum allowed:
18V
24V
31V
1V pk-pk
Wattage Max. wattage:
Max. current:
4.8W @+24 VDC
200mA @+24 VDC
Analog output Current
0-20mA(500 ohms max load)
Allreadings±0.2mA
Measured-value signal:
4mA(Zero) to 20mA(Full Scale)
Fault:
0-100% LEL:
100-109%LEL:
Over 110% LEL:
Maintenance:
0mA
4mA - 20mA
21.6mA
20mA - 21.4mA
3mA
Analog output current ripple & noise max ±20uA
Wiring requirement Power CVVS or CVVSB with shield
Analog CVVS or CVVSB with shield
Signal Transmission Distance
(Cable Connection Length) Analog 2500m
EMC Protection: Complies with EN50270
3.4. Environmental Specifications
ITEMS SPECIFICATION
Operation Temperature Transmitter -20to50℃
Sensor Refer to Sensor Specification
Storage Temperature Transmitter -20to50℃
Sensor Refer to Sensor Specification
Operation Humidity Transmitter 5 to 99% RH (Non-condensing)
Sensor Refer to Sensor Specification
Pressure Range 90 to 110KPa
Max. air velocity 6m/s
3. Specication
GTD-1000Ex
Instruction Manual
NO NAME DESCRIPTIONS
1Detector housing body Protects PCB Board built in Sensor and Housing from external environmental change and shock.
2Detector housing cover It is assembled with detector housing body and protects PCB Board built in Sensor and Housing from
external environmental change and shock
3Sensor head It is a site that detects actual gas leak. It converts the amount of gas leak into electrical signal and
transmits to the Amp PCB.
4Internal grand
(2sq↑cable) It must be grounded to inside of detector for protection from external noise or strong electric field
5External ground
(2sq↑cable) It must be grounded to outside of detector for protection from external noise or strong electric field.
6Conduit connection It is supplied for inlet of power supply and measurement output signal for the detector during
installation.Forcableinlet,PForNPT1/2",3/4"areprepared.(DefaultspecificationisPF3/4".)
7Mount holes(2-Ø7) Hole to fix the gas detector on external wall or other installation sites.
8Amp(main) PCB Amplifies fine outputs generated from Sensor Element to transmit a converted output in 4~20 mA
DC standard. It sends data to display part.
[Figure 2. GTD-1000Ex Components]

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10_11
4.1. Components
No ITEMS SPECIFICATION
9Power/mA terminal CN1 consists of power input of DC 18~31 V and connection terminal (+, mA, -, ET) for signal
output.
10 Sensor terminal CN2 is Sensor Connection Terminal.
11 Model name plate Model name, measuring gas, serial number, etc. are labeled.
12 Set screw(M4-L6) It is a set screw that prevents cover opening from the detector housing body.
[Table 1. GTD-1000Ex Components Description]
4. Name and Description of Each Part
GTD-1000Ex
Instruction Manual
[Figure 3. Slotted Set Screw]
5. Installation
■Itisprohibitedforanindividual,otherthananapproveduseroratechnicianresponsibleforinstallationand
repair from the head office, to install a gas leak sensor on site or open the cover of the installed gas leak detector
and manipulate it. This may cause serious loss of life and property from fire, explosion, and etc. In addition,
please check whether there is any remaining explosive gas or combustible material in the surroundings. Power
must be turned off before performing work.
5.1. Detachment of Housing Cover
■Turntheslottedsetscrew(M4x1ea)fixingthecoverpartofmainbody3~4tunscounterclockwise(ccw)using
a hex wrench (M2) then turn the cover of gas leak detector ccw to detach the cover.

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5. Installation5. Installation
GTD-1000Ex
Instruction Manual
Figure 4. Main PCB Key Layout
5.2. Main PCB Configuration
■Afterdetachingthecover,theMainPCBterminallayoutappearsasshowninthefigurebelow.
Table 2. Main PCB Key Part Description
No NAME DESCRIPTION
1CN3 Program download Connector
2SW5 Zero Calibration Switch
3SW6 Span Calibration Switch
4CN1 Sensor Connector
5VR3 Potentiometer for SPAN Output Adjustment
6VR2 Potentiometer for ZERO Output Adjustment
7CN5 Power & Output Signal Terminal
8SW1 Mode Control DIP Switch
9FND1, 2 FND for Internal Status Display
5.3. Power and Signal Terminal Configuration
■Afterdisassemblingdisplayparts,thereisaterminalblockintheMainPCBasshowninthefigurebelow.
Holding it with hands and pulling towards ceiling detaches it from the Main PCB.
■Loosen5terminalfixingscrewslocatedattoppartofdetachedterminalblockCN8(VIS,+,mA,-,ETH)
 Connectorbyturningcounter-clockwiseusingaΘdriver.ConnectDC18~24Vpowerto+,and-thenconnect
signal cable to mA. Tighten 5 terminal fixing screws clockwise so that terminal does not leave the track then insert
Main PCB as the same condition before disassembly.
[Figure 5. CN1 Terminal Configuration]
■UseCVVSorCVVSB2.0sq↑ShieldCableforterminalconfiguration.
[Table 3. CN1 Terminal Detailed Description]
NO PIN NAME DESCRIPTION
1 + +24V / POWER (+)
2mA 4~20mA Source Out
3 - GND / POWER (-)
4ET EARTH
Terminal Set Screw

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GTD-1000Ex
Instruction Manual 5. Installation5. Installation
5.4. Method to Connect to External Control Unit 5.5. Installation Cable Length
■Connect18V~31VDCoperationpowertoCN1(+,mA,-,ET)ConnectionTerminalofthegasdetectorthen
connect a device that can receive 4~20 mA signals to mA.
■ThemaximumlengthbetweenGTD-1000Exandpowersupplyisdecidedbywirespecification.
■Max.InstallationLength=VMAXDROP÷IMAX÷WIRER/m÷2
 ·VMAXDROP:MaximumPowerLoopVoltageDrop(=PowerSupplyvoltage
- min operating voltage)
 ·IMAX:Max.CurrentofGTD-1000Ex
 ·WIRER/m:Theresistanceofthewire(ohms/metervalueavailableinwiremanufacturer'sspecificationdatasheet)
■Exampleofinstallationlengthsusing24Vpowersupplyand16AWGisasfollows.
 ·GTD-1000Exminimumoperatingvoltage=18Vdc
 ·VMAXDROP=24-18=6V
 ·IMAX=0.2A(200mA)
 ·6÷0.2÷0.01318÷2=1138.088m≒1138m
[Figure 6. External Control Unit Connection Method]
[Figure 7. Calculation of GTD-1000Ex Installation Cable Length]
■Powercableinstallationforeachcabletypeisasshowninthetablebelow.
[Table 4. GTD- 1000Ex Power Cable Installation Length]
AWG mm2 COPPER RESISTANCE(ohms/m) METERS
12 3.31 0.00521 2879
14 2.08 0.00828 1811
16 1.31 0.01318 1138
18 0.82 0.02095 715
20 0.518 0.0333 450

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GTD-1000Ex
Instruction Manual
■Stabilizationtimeof30minfromtheinitialsupplyofoperationpowertothesensorforthestabilizationofthesensor.
Calibration and test must be performed approx. 30 min after when the sensor has been stabilized.
6.1. 4-20mA Output Diagnosis
■Itsuppliesvoltageof18~31Vandcurrentof200mAtothesensor.Whenthevoltageismeasuredbyconnectinga
multimeter to TP5 (+mA) and TP6 (-mA) of AMP PCB, current of 4~20 mA can be confirmed.
6.3. 4mA Adjustment (ZERO Calibration)
■Checkvoltageof18~31VDCatboth(+24V)and(GND)ofterminalblock'N5'.
■Checkwhether(mA)terminalofterminalblock'CN5'isconnectedtothereceiver.
■ChangeDMMtocurrentmeasuringmode,thenconnect(+)and(-)terminalsorDMMtoTP5(+mA)andTP6(-mA)
of AMP PCB, respectively.
■Whenzeroswitch(SW5)ispressedfor3sec,amessage"[ZE][RO]"flashes3timesonFND1andFND2anditenters
zero calibration mode.
■Whencleanairor99.9%nitrogen(N2)isinjectedtocellpart,4mAoutputisobserved.Iftheoutputisnot4mA,
 adjustthepotentiometer'VR2(ZERO)'leftandrighttoset4mA.
■Adjust'ZERO'potentiometertoobtainacurrentof4.00mAtobedisplayedonFND1andFND2.
■Whenzeroswitch(SW5)ispressedfor3secafteroutputissetto4mA,resultfromzerocalibrationisdisplayedon
 FND1andFND2."[PA][SS]"meansthatthecalibrationhasperformedsuccessfully."[FA][IL]"meansthatthecalibration
has not met the condition and failed. In this case, sensor and power must be reconfirmed then calibration shall be
performed again.
6.2. Gas Sensor Status Diagnosis
■ Aftersupplyingavoltageof18~31Vtothesensor,itisnormalifavoltageof2.5V~2.6Vismeasuredbyconnecting
multimeter to TP3 (GND) and TP4 (SPWR) of AMP PCB.
[Figure 8. 4-20mA Output Test Terminal]
[Figure 9. Sensor Power Test Terminal]
[Figure 10. ZERO Calibration related Parts]
6. Calibration and Maintenance6. Calibration and Maintenance

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18_19
GTD-1000Ex
Instruction Manual
6.4. SPAN Calibration
■Checkvoltageof18~31VDCatboth(+24V)and(GND)ofterminalblock‘CN5’.
■Checkwhether(mA)terminalofterminalblock‘CN5’isconnectedtothereceiver.
■ChangeDMMtocurrentmeasuringmode,thenconnect(+)and(-)terminalsorDMMtoTP5(+mA)and
TP6(-mA) of AMP PCB, respectively.
■Whenspanswitch(SW6)ispressedfor3sec,amessage"[SP][AN]"flashes3timesonFND1andFND2and
it enters span calibration mode.
■Whenthestandardcalibrationgasisinjectedintocellpart,12mAoutputisobserved.Iftheoutputisnot12mA,
 adjustthepotentiometer'VR3(SPAN)'leftandrighttoset12mA.
■Adjust'SPAN'potentiometertoobtainthecorrectcurrentoutputforthestandardgastobedisplayedonFND1
and FND2.
■WhenSPANswitch(SW6)ispressedfor4secafteritissettoadesiredoutput,resultfromspancalibrationis
 displayedonFND1andFND2."[PA][SS]"meansthatthecalibrationhasperformedsuccessfully."[FA][IL]"means
that the calibration has not met the condition and failed. In this case, sensor and power must be reconfirmed
then calibration shall be performed again.
6.5. Gas Detector Calibration Method using Methane(CH4) Standard Gas
■Combustiblegassensorusedfordevicecanmeasurevarioustypesofcombustiblegas.However,eachcombustible
gas has different properties including explosion range, heat generation rate, specific gravity, etc., therefore, it is
impossible to perform calibration with every standard gas.
■Thus,thisproductusesmethanegasasareferenceandappliescomparativepropertiesofeachcombustiblegas
analyzed as shown in the table below.
■CH450%LELcalibrationoutputcalculationisasfollows.
Range : 0-100#LEL
Output signal : 4-20mA
Calibration Gas: CH4 50% LEL /N2
balance Test point signal ( TP5, TP6 )
(200 - 40) × 50%LEL (Standard Gas) +40=120=12.0mA
100%LEL( Full Range)
■Wheniso-Butanesensoriscalibratedwith2.5%methanestandardgas,calculateasshownbelow.
(Explosion range of iso-butane is 1.8% and methane is 5%.)
■Insensor,itbecomes:(100%LEL÷80%LEL)×(2.5%÷5%)×100%LEL=62.5%LEL
■Atthistime,outputfromthesensorbecomes:20mA-4mA)X0.625+4mA=14mA
Gas Type Explosion Range (VOL%) Relative Span LEL%(CH4)
Methane CH4 5.0 100
Propane C3H8 2.2 80
iso-Butane C4H10 1.8 80
n-Pentan C5H12 1.4 80
n-Hexane C6H14 1.2 75
n-Heptane C7H16 1.05 65
iso-Octane C8H18 0.95 60
Methanol CH3OH 6.7 130
Ethanol C2H5OH 3.3 95
iso-Propanol C3H7OH 2.2 80
Acetone (CH3)2OH 2.6 85
Toluene C6H5CH3 1.2 70
Ethyl Acetate CH3COOC2H5 2.2 75
Hydrogen H2 4.0 125
Ammonia NH3 15 150
Cyclohexane C6H12 1.3 75
Acetylene C2H2 2.5 35
Ethylene C2H4 2.7 95
6. Calibration and Maintenance6. Calibration and Maintenance
[Figure 11. SPAN Calibration related Parts]

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20_21
GTD-1000Ex
Instruction Manual 8. Precautions before Installation7. Drawings and Dimensions
[Figure 12. GTD-1000Ex Drawing]
8.1. Selecting a Place for Installation (Occupational Health & Safety Data)
A gas leak detector alarm shall be installed in the following places.
■Aroundchemicalequipmentandaccessoriesthathaveconcernsofgasleak.Thisincludescompressors,valves,
reactors, pipe joints, etc. installed inside and outside of a building that handle combustible and toxic materials.
■Placesthatareeasierforgasestostaysuchasareasaroundmanufacturingfacilitieswithignitionsourceslike
heating furnace, etc,
■Areasaroundequipmentforfillingcombustibleandtoxicmaterials.
■Substations,panelrooms,controlrooms,andetc.locatedwithinexplosivearea.
■Otherareasthatareeasierforgasestostay.
8.2. Selecting a Site for Installation (High-Pressure Gas Safety Act Data)
Gas detector of gas leak detector alarm must be installed as close to the areas with concerns of gas leakage as possible.
However, for areas where direct gas leakage is not expected but are easier for leaked gas to stay, the detector must be
installed at the point 1 of the following.
■Gasleakdetectoralarminstalledoutsideabuildingshallbeinstalledatpointswheregasislikelytostayin 
consideration to wind direction, wind speed, specific gravity of gas, etc.
■Gasleakdetectoralarminstalledinsideabuildingshallbeinstallednearthefloorwhenthespecificgravityofgasis
heavier than air and near ventilation of ceiling when it is lighter than air.
■Alarmforgasleakdetectoralarmmustbeinstalledatsiteswherethegasdetectorisinstalledandworkersare
present.
8.3. Precautions during Installation
Avoid areas with electrical barriers such as rain water, etc. It is recommended to be installed in areas that are easier to
work in since regular maintenance is needed. Avoid areas with vibration or shock since they can affect output values.
Sensor part must be installed towards the direction of gravity.
■Thisequipmenthasexplosion-proofconstructionforinternalpressureandbelongstoGROUPIIforgasandvaporin
general work sites and chemical plants. It can be used in ZONE 1 (ONE) and ZONE 2 (TWO) hazardous sites.
■Allowabletemperatureis85Corbelow,whichcorrespondstoT6.

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22_23
9. Revision History8. Precautions before Installation
GTD-1000Ex
Instruction Manual
■Usewithsurroundingtemperatureinarangeof-20C~50C.
■InstallationHeight:1,000Mbelowsealevel
■RelativeHumidity:5%~99%
■InstallationSite:IndoorandOutdoor
■ExplosionIgnitionGradefortheGasorVapor:ExdIICT6
■Duringwiringwork,useexplosion-proofcableglandatcableinletortightlysealcableconduitduringmetal 
cable wiring construction to prevent spread of flames in case of explosion or movement of gas, etc. through
the cable conduit within 50 mm. All materials including materials used for sealing of unused inlets must have
safety certificates!
■Whenconnectingtheequipmentwithcable,screwthreadmustbetightened5threadsormore.
■Workinconditionssatisfyingother[StandardsforSelection,Installation,andMaintenance,etc.ofExplosion-
proof Electric Machine and Equipment Wiring, etc. at Work Site]
■Allmaterialsusedforcableinletsuchascableglandandsealingfitting,etc.andusedassealingunusedinlets
must pass the verification!
VERSION CONTENTS DATE
0.0 * Manual Initial Revision 2013.06.10
1.0 * Drawing and Function Added. 2015.06.29
1.1 * Changed Font 2016.05.19
2.0 * Separated Factory mode manual 2016.09.27
3.0 *ChangedExplosion-proofEquipmentCableEntryInstallationRegulation45cm→50mm 2017.01.20
[Figure 13. High-Pressure Packing Type] [Figure 14. Y Sealing Compound]
Cable Cable
Inside Inside
Outside Outside
Lead-in unit connector
Lead-in unit connector
Charging compound
Cable-fixing device
Pipe for piping
Cable-fixing device
Sealing ring
Sealing
ring
Connector
Pipe for piping
Compressed
element
Connector for fixing
compressed element