GASTRON GIR-3000 User manual

GIR-3000
Instruction Manual
Read in detail for correct use.

Gas & Flame
Detection System
GIR-3000
Instruction Manual
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.
* KOSHA GUIDE : P-135-2013
Calibration should be executed at the periods required by the manufacturer, and should be executed
every quarter unless there are separate calibration periods.
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02_03
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.
( * See No. 13 of KOSHA GUIDE : P-135-2013 / 8.3 paragraph on qualification and calibration)
■ 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.
Greetings

Contents
GIR-3000
Instruction Manual
1. Overview ·························································································· 6
2. Structure ·························································································· 6
3. Specification ······················································································· 7
3.1. Basic 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
4.2. Components of infrared sensor ····························································· 11
5. Installation ························································································· 12
5.1. Separation of Housing Cover······························································· 12
5.2. Configuration of Main PCB ·································································· 12
5.3. Configuration of power supply and 4-20mA terminal ······································· 14
5.3.1. Wire connection diagram of driving method for 4~20mA Source ··················· 14
5.3.2. Wire connection diagram of driving method for 4~20mA Sink ······················ 14
5.3.3. Wire connection diagram of driving method for 4~20mA 3Wire Sink ················ 16
5.4. Configuration of Relay terminal and communication terminal ······························· 16
5.4.1. Configuration of terminal ···························································· 16
5.4.2. Setting for Relay mode ······························································ 17
5.4.3. Setting for RS485 MODBUS ························································· 17
5.5. Configuration of sensor connecting terminal ··············································· 18
5.6. Configuration of Remote Type connection ················································· 19
5.7. Length of installed cable ···································································· 20
6. Operation Flow for sensor ········································································ 21
6.1. Initial operation state (Power On) ··························································· 21
6.2. Gas measuring state (Measuring Mode) ····················································· 21

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Contents
6.3. Operation Flow ············································································· 22
6.4. Menu Configuration Table ·································································· 23
7. System Mode ······················································································ 25
7.1. PROGRAM MODE ············································································· 25
7.2. CALIBRATION MODE ·········································································· 26
7.2.1. Zero Calibration ····································································· 26
7.2.2. Span Calibration ···································································· 27
7.3. ALARM MODE ················································································ 28
8. Troubleshooting ··················································································· 30
8.1. Fault List ···················································································· 30
8.2. Recovery List ··············································································· 31
9. Interface configuration ············································································· 32
9.1. MODBUS RS485 ·············································································· 32
9.1.1. Interface setting····································································· 32
9.1.2. MODBUS RS485 Register map ························································· 32
10. Outline drawing and Dimensions ··································································· 33
10.1. Standard Type ··············································································· 33
10.2. Upon coupling of warning light ····························································· 34
10.3. Upon coupling of Raincover ································································ 35
10.4. GIR-3000 Remote Type ····································································· 36
11. Notes before installation ··········································································· 37
11.1. Selection of installation place(Data from occupational safety and health regulations) ······· 37
11.2.
Selection of installation place (Data from safety management regulations for high-pressure gas) ····· 37
11.3. Notes upon installation······································································ 38
12. Revision record ···················································································· 39

The GIR-3000 infrared Gas detector has been developed to prevent accidents beforehand by detecting various
leaked gases generated in industry fields such as plants producing or using combustible gas, carbon monoxide,
carbon dioxide, gas storage place, manufacturing processes, etc.
The GIR-3000 infrared Gas detector is installed in areas with a risk of gas leakage to display measured values
with LCD, OLED installed in the detector by continuous detection of gas leakage, providing DC 4~20mA standard
output, Isolation RS-485 communication signal, HART communication, and Relay contact signal of gas Alarm. Also,
DC 4~20mA standard output can connect up to the maximum of 500m (upon using CVVS or CVVSB 1.5sq↑ Shield
Cable) in transmission distance of output signals of Gas detector and receiving unit while RS-485 communication
signal can be transmitted up to1,000m (upon using RS-485 exclusive line).
The GIR-3000’s body is made of aluminum alloy material in a structure of complete pressure-resistant explosion-
proof type(Ex d IIC T6), can be installed in the areas with a risk of leakage and explosion of all combustible gases,
displaying leakage situation of gas at the installed field by embedding LCD, OLED in the Gas detector. Inside structure
is comprised of liquid crystal unit displaying measured values, connector unit outputting measured values (DC
4~20mA) or Isolation RS-485 communication (Option) Signal, HART
communication signal, and Alarm Signal to outside, and 2 PCB Boards. Outside structure is comprised of Sensor
unit for detection of gas leakage and Cable lead-in unit (2ea). Calibration operation can be conducted outside of Gas
detector body by using Magnet-bar, making maintenance and repair operation convenient.
[Figure 1. GIR-3000 Overview]
Infrared Gas
Sensor Module
(GSA920)
Main Board
(Transmitter)
+24V DC
4-20mA Analog
Signal Output
Display Board
(User Interface)
Transmitter enclosure
Safety Power Supply Unit
(24VDC)
Safety Controller
(PLC or DCS)
GIR-3000 Gas Detector
Hazardous Area (Filed) Safe Area
2. Structure
1. Overview
GIR-3000
Instruction Manual

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06_07
3. Specications
3.1. Basic Specifications
3.2. Mechanical Specifications
ITEMS SPECIFICATION
Measuring Type Diffusion type
Measuring Value Display Local Digital LCD or OLED Display
Measuring Method Non-Dispersive Infrared(NDIR)
Detectible Gas
Combustible Gas
Carbon dioxide (CO2)
Carbon monoxide(CO)
Measuring Range Combustible:
0~9,999ppm / 0~100% LEL /
0~100% VOL
CO₂: 1.0% ~ 100% VOL
CO: 5% ~ 100% VOL
Accuracy ≤ ±3% / Full Range
Zero Drift ≤2% / Full Range
Response Time 90% of full scale in less than 10 sec
Approvals Classification
KCs: Ex d llC T6,T4, IP65
ATEX/IECEX: II 2 G Ex d IIC Gb T4,T6
SIL2, MED, ABS, DNV
Basic Interface Analog 4-20mA current interface
HART Interface HART REV7(Option)
Option
HART Board
MODBUS RS485 Board
GTL-100 warning light
Rain Cover
Warranty Body (Transmitter) 2Year
Sensor 1Year
ITEMS SPECIFICATION
Explosion Proof type Pressure-resistant, explosion-proof enclosure
Dimension 156(W) × 322(H) × 110(D) mm
Weight including Sensor App. 3kg
Mounting type Wall mount
Mounting Holes Ø 7 ±0.1
Cable inlet 3/4" PF ( 1/2"or 3/4" NPT )
Body material Body (Transmitter)
aluminum alloy
Sensor Stainless Steel (STS316)

3.3. 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:
9.6W @+24 VDC
400mA @+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
22mA
3mA
Analog output current ripple & noise max ±20uA
Relay contact Alarm1, Alarm2, Fault Relay
Rated 1.0 A @ 30VDC or 0.5 A @ 125 VAC
Wiring requirement
Power CVVS or CVVSB with shield
Analog CVVS or CVVSB with shield
RS485 STP(Shielded Twisted Pair)
Signal transmission distance
(Cable Connection Length)
Analog 2500m
RS485 1000m
EMC Protection: Complies with EN50270
3.4. Environmental Specifications
ITEMS SPECIFICATION
Operation Temperature Transmitter -40 to 80 ℃
Sensor -40 to 80 ℃
Storage Temperature Transmitter -40 to 80 ℃
Sensor -40 to 80 ℃
Operation Humidity Transmitter 5 to 99% RH (Non-condensing)
Sensor 5 to 99% RH (Non-condensing)
Pressure Range 90 to 110KPa
Max. air velocity 6m/s
3. Specications
GIR-3000
Instruction Manual

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08_09
4. Name and description of each part
4.1. Components of transmitter
No ITEMS SPECIFICATION
1Housing Protect PCB Board embedded inside Sensor and Housing from change of
outside environments and impact.
2Main PCB
Amplify output signals produced by Sensor, and convert to standard output of DC 4~20mA for
transmission, and output Isolation RS- 485 communication Signal and Alarm relay contact signal.
Also, send Data to be displayed in Display unit.
3Display PCB Display Data received from MAIN PCB in LCD or OLED, and
display the current Event situations by Power lamp, Alarm lamp, Trouble lamp
4Power/Signal
Terminal
CN12 is comprised of power supply of DC18-31V and DC 4~20mA standard output Connection
terminal (VISO, +V, mA, -V, ETH).
5Alarm signal
Terminal
CN8 is Alarm signal connection terminal, as a terminal where Trouble, Alarm1, Alarm2 Relay
contact are outputted.
6RS-485 signal CN3 is Isolation RS-485 communication signal connection terminal(A, B).
7Sensor terminal CN10 is Sensor connection terminal. (RD, WH, BK, BE)
8Program Downloading
Connector Connector that allows downloading of product program.
[Figure 2. Components of GIR-3000]

4.1. Components of transmitter
No ITEMS SPECIFICATION
9Power lamp Lamp is lighted when .power switch is turned On
10 Trouble lamp Lighted when abnormality occurs in circuit or sensor sensitivity, etc.
11 Alarm1 lamp Lighted when gas is leaked to become higher than Alarm1 level
12 Alarm2 lamp Lighted when gas is leaked to become higher than Alarm2 level
13 Function key
When contact is made for more than 2sec by using Magnet-bar upon parameter setting, it is
converted to Program mode. (Program mode, Calibration mode, Test mode, etc.) Also, it is
used when Data is inputted for setting.
14 Reset key
Converted when cancelled during parameter setting or touched for more than once by using
Magnet bar to return to the previous state. (Converted to the previous mode by one stage at
a time upon every touch.
15 ↑(Up) key Converted or transformed by one stage at a time when touched once by using Magnet-bar
upon mode conversion or figure transformation (transformed to the higher stage)
16 ↓(Down) key Converted or transformed by one stage at a time when touched once by using Magnet-bar
upon mode conversion or figure transformation(transformed to the lower stage)
17 External earth - Outside grounding for protection from outside noise or strong electric field
- For grounding cable, use conductor larger than 4mm upon coupling connection
18 Mount hole Hole to mount Gas Detector onto outer wall and other installation place.
19 Cover fixed screw(M4) Fix with a hexagonal lens bolt to prevent drop-off due to outside impacts after assembly of
Detector Housing Body and Detector Housing Cover
20 Sensor thread Mounting port for mounting of infrared gas sensor (Detector)
21 Cable inlet Basically PF 3/4" is provided for power supply to Gas detector and lead-in of measurement
output signals upon installation operation.
22 Internal earth - Inside grounding of Detector for protection from outside nose or strong electric field
- For grounding cable, use conductor larger than 4mm upon coupling connection.
23 RS-485 Module /
HART Module
Connector to connect Isolation Type RS-485 communication Module for communication with
PC or PLC and HART communication Module. For RS-485 communication, communication
Address should be set, and the basic value is set for No.1. For HART communication,
Polling-Address and Tag No. etc. should be set. (Optional specifications)
24 Relay Contact
Type Selection
Configured so as to allow selection of A, B contact. If not in ENERGIZER MODE, it operates
as contact A (Normal Open) when Jumper is connected to the part displayed as silk A, while
it operates as contact B (Normal Close) when Jumper is connected to the part displayed as
silk B. On the contrary, if in ENERGIZER MODE, it operates as contact B when Jumper is
connected to A, while it operates as contact A when Jumper is connected to B.
25 Warning Light
Connector Connecting connector when the warning light is used(Optional)
[Table 1. Description on components of GIR-3000 transmitter]
4. Name and description of each part
GIR-3000
Instruction Manual

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4. Name and description of each part
No ITEMS SPECIFICATION
1Power & Signal cable
Comprised of power supply input, 4-20mA analog signal, and transmitter communication cable.
2Detector fixed screw Screw processing part for mounting of transmitter
3Earth Ground Outside grounding for protection from outside noise or strong electric field
4Housing Protect PCB Board embedded inside from change in outside environment or impact
5IR Sensor Sensor device for transformation of IR wavelength to electric signals
6IR Tube Lock Screw for fixing of IR tube
7IR Tube Optical path passing infrared wavelength generated in IR lamp
8Filter Filter device for protection of inside optical paths from outside contaminants
9IR Source Lamp for generation of infrared signals
10 Calibration port Inlet for calibration gas upon gas calibration
11 Filter fixing screw Screw for fixing of filter
4.2. Components of infrared sensor

5. Installation
GIR-3000
Instruction Manual
5.1. Separation of Housing Cover
■ When Cover is separated, separate Display Parts in the
following order.
① Simultaneously push inward the fixing chains on
left side and right side on the front face of LCD unit.
② Separate from Gas detector body by pulling Display
Parts forward in the pushed state.
③ Main PCB is installed below Detector Body after
separation of Display Parts .
Absolutely no one other the approved users or those of the headquarters in charge of installation and repair should
be allowed to install in the field, open or operate Cover of the installed gas leakage detector. Otherwise serious
damages to life and property may be inflicted. Also, make sure to shut off the power supply and conduct operation
after checking whether explosive GAS remains or flammable substances are present in the surroundings.
■ <Warning - Do not open during current supply.>
■ Cover can be separated when the cover for gas
leakage detector is turned counterclockwise after
slotted set
■ screw for fixing of body's cover (M4 x 1ea) is turned
3~4 turns clockwise by using a hexagonal wrench (M2).
When Cover is separated, LCD unit is displayed.
Slotted set
screw (M4)
Figure when infrared
Sensor(Detector) is mounted
[Figure 4. Separation method for Display Part]
[Figure 3. Slotted set screw]

[Table 3.Description on major parts of Main PCB]
[Figure 5.Layout diagram for Main PCB terminals]
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5. Installation
5.2. Configuration of Main PCB
■ When Display Parts are separated, the layout diagram for Main PCB terminal as follows can be seen.
■ By using OC1, OC2, OC3 of the above layout diagram, HART Option or RS485 MODBUS board can be mounted,
and is fixed by using 3 Ø Screw hoe on the to[ left side of Option board.
No NAME DESCRIPTION
1CN12 Power & Output Signal Terminal
2J4 4~20mA Source / Sink selection jumper (ON: Source Type, OFF: Sink Type)
3CN11 Display LCD Connector
4CN10 Sensor Connector
5CN6 Program download Connector
6D1 Status LED (Blinks by the unit of 11 sec in the case of normal operation)
7OC1, OC2, OC3 HART Option Board Connector
8CN5 Warning light (GTL-100) Interface Connector

5.3. Configuration of power supply and 4-20mA terminal
■ <Warning - Conduct operation after shutting off the power supply upon connection of power supply terminal.>
■ When Display Parts are separated, Terminal Block in Main PCB can be seen as show in the following figure,
which is separated from Main PCB when held by hand and pulled up.
■ Loosen by turning counterclockwise the terminal-fixing screws at 5 places in the upper part of the separated
Terminal Block CN12 (VISO, +V, mA, -V, ETH) Connector by using Θ driver, connect DC18-31V power supply
to +, - , and Signal Cable to mA , followed by locking terminal-fixing screws at 5 places clockwise to prevent
terminal from breaking away, and fit it in Main PCB as before separation.
5. Installation
GIR-3000
Instruction Manual
No PCB Silk PIN NAME DESCRIPTION
4~20mA Source Drive (J1 Jumper ON) 4~20mA Sink Drive (J1 Jumper OFF)
1VISO VIS N.C 4~20mA Sink In(+)
2+V ++24V / POWER (+)
3mA mA 4~20mA Source Out 4~20mA Sink Out(-)
4-V -GND / POWER (-)
5ETH ET EARTH
[Table 4. Detailed description on CN12 terminal]
[Figure 6. Configuration of CN12 terminal]
■ Upon configuring the Terminal, use CVVS or CVVSB 2.0sq↑ Shield Cable.
■ To connect 4Pin Terminal of the existing old-style GIR-3000, fasten the terminal based on +24V as No.2 plate.
<Terminal-fixing Screw>

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5. Installation
5.3.1. Wire connection diagram of driving method
for 4~20mA Source
5.3.2. Wire connection diagram of driving method for
4~20mA Sink
[Figure 7.Configuration of 4-20mA Source]
[Figure 8. Configuration of 4-20mA Sink]
■ Connect 4-20mA Signal terminal on PLC side to
GIR-3000의 'mA', while GND terminal is used in
common with the power supply. And then turn
the J1 Jumper ON.
■ HART Communicator can be used only in the model
using HART Option board
■ Connect 4-20mA Sink output (+) terminal on PLC
side to VISO terminal, and (-) terminal to 'mA'
terminal. And then turn the J1 Jumper OFF.
■ HART Communicator can be used only in the model
using HART Option board.

5. Installation
GIR-3000
Instruction Manual
[Figure 9. Configuration of 4-20mA 3Wire Sink]
■ Connect 4-20mA Sink output (+) terminal on PLC
side to VISO terminal, and (-) terminal to (24V DC)
(-) terminal. Connect 'mA' terminal of GIR-3000 to
'GND' terminal. Then connectturn the J1 Jumper
OFF.
5.4.1. Configuration of terminal
5.3.3. Wire connection diagram of driving method for
4~20mA 3Wire Sink
5.4. Configuration of Relay terminal and communication terminal
TER. NO. PIN NO. TERMINAL NAME DESCRIPTION
CN8
1TRB OUT
Output mode is determined by TROUBLE RELAY OUTPUT terminal and J3 Jumper setting
2TRB COM TROUBLE RELAY COMMON terminal
3AL1 OUT Output mode is determined by ALARM1 RELAY OUTPUT terminal, J2 Jumper setting.
4AL1 COM ALARM1 RELAY COMMON terminal
5AL2 OUT
Output mode is determined by ALARM2 RELAY OUTPUT terminal and J1 Jumper setting.
6AL2 COM ALARM2 RELAY COMMON terminal
CN3 7RS485 A RS485 A terminal
8RS485 B RS485 B terminal
[Figure 10. Relay and RS485 Terminal]
[Table 5. Description on Relay and RS485 terminal]

5.4.2. Setting for Relay mode
5.4.3. Setting for RS485 MODBUS
■ MODBUS of GIR-3000 product is an Optional item, and is connected to the receiver unit by the following method.
■ For driving of Relay of GIR-3000 product, 2 types of Normal open and Normal close are operated. To allow
setting of Main PCB에 Relay driving method, Jumper is configured with operation setting as follows.
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5. Installation
TER. NO. PIN NO. TERMINAL NAME MODE 설정
CN8
1TRB OUT J3 A-C connection : Contact A ( Normal Open )
J3 B-C connection : Contact B ( Normal Close )
2TRB COM
3AL1 OUT J2 A-C connection : Contact A ( Normal Open )
J2 B-C connection : Contact B( Normal Close )
4AL1 COM
5AL2 OUT J1 A-C connection : Contact A ( Normal Open )
J1 B-C connection : Contact B ( Normal Close )
6AL2 COM
TER. NO. PIN NO. TERMINAL NAME RECEIVER TERMINAL NAME NOTE
CN3 7485A 'TRXD+' or 'A' or 'P'
8485B 'TRXD-' or 'B' or 'N'
[Table 6. Setting for Relay Mode]
[Table 7. Description on RS485 terminal]
[Figure 11.Setting for Relay Mode]
■ When power is supplied to the power supply terminal on MAIN PCB board after wiring, the following contents can
be checked in LCD unit. After the initial operation power is supplied, stabilization time of about 30 minutes is required,
and normal operation occurs from the time of sufficient stabilization.

5. Installation
GIR-3000
Instruction Manual
5.5. Configuration of sensor-connecting terminal
■ IR sensor module (to be referred to as GSA920A hereafter) is connected to the transmitter by using CN No.10
terminal.
TER. NO. PIN NO. TERMINAL NAME COLOR OF SENSOR CABLE REMARKS
CN10
1TRB OUT TROUBLE RELAY OUT is determined +24V sensor power supply
2TRB COM TROUBLE RELAY COMMON terminal Sensor communication with transmitter
3RS485 A RS485 A terminal
Sensor power supply GROUND
4RS485 B RS485 B terminal EARTH
[Table 8. Description on sensor-connecting terminal]
[Figure 13. Configuration of connection for GSA920A]
■ Configuration of the cable with wire connection to
GSA920A is as follows.
- GSA920A module allows configuration of
extension cable, and is connected by using
CN10 terminal of transmitter.
- GSA920A Option1 is an exclusive output of
4-20mA, while the relevant option is used
upon sole installation of GSA920A
- GSA920A Option2 is an exclusive Zero port,
while the relevant option is used upon sole
installation of GSA920A.
[Figure 12. Sensor-connecting terminal]

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5. Installation
■ To remotely configure GSA920A, the sensor is installed by using Junction Box(GDH-1010) of the following form,
and connection is made to GIR-3000 transmitter by using component terminal inside Junction Box.
5.6. Configuration of Remote Type connection
[Figure 14. Configuration for GSA-920A Remote Type]
Wire connection
diagram for Cable
(GSA-920A)
Wire connection
diagram for Cable
(Receive Unit)

5. Installation
GIR-3000
Instruction Manual
5.7. Length of installed cable
[Table 9. Installation length for GIR-3000 power supply cable]
PIN NO. mm
2
COPPER RESISTANCE(ohms/m) METERS
12 3.31 0.00521 1439
14 2.08 0.00828
905
16 1.31 0.01318 569
18 0.82 0.02095 357
20 0.518 0.0333 225
[Figure 15. Calculation of length for GIR-3000 installation cable]
■ The maximum length between GIR-3000 and power supply is determined by the wire specifications.
■ Maximum installation length= VMAXDROP ÷ IMAX ÷ WIRER/m ÷ 2
■ VMAXDROP: Maximum Power Loop Voltage Drop (=Power Supply voltage - min operating voltage)
■ IMAX: Maximum current value of GIR-3000
■ WIRER/m: The resistance of the wire (ohms/meter value available in wire manufacturer's
specification data sheet),
■ An example for installation length using 24V power supply and 16AWG is as follows.
■ GIR-3000 minimum operating voltage = 18 Vdc
■ VMAXDROP = 24 - 18 = 6V
■ IMAX = 0.4A(400mA)
■ 6÷ 0.4÷0.01318÷ 2 = 569.044m ≒ 569m