GDS Corp GASMAX CX User manual

GDS Corp.
1245 Butler Road League City, TX 77573
409-927-2980 409-927-4180 (Fax) ww.gdscorp.com
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Operation and Maintenance
Manual
GASMAX CX + GDS-IR
GASMAX CX Gas Monitor with GDS-IR Infrared Sensor for
Combustibles and Carbon Dioxide

GASMAX CX + GDS-IR Operation & Maintenance Manual, Revision 1.0
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CAUTION: FOR SAFETY REASONS THIS EQUIPMENT MUST BE OPERATED AND
SERVICED BY QUALIFIED PERSONNEL ONLY. READ AND UNDERSTAND
INSTRUCTION MANUAL COMPLETELY BEFORE OPERATING OR SERVICING.
ATTENTION: POUR DES RAISONS DE SÉCURITÉ, CET ÉQUIPEMENT DOIT
ÊTRE UTILISÉ, ENTRETENU ET RÉPARÉ UNIQUEMENT PAR UN PERSONNEL
QUALIFIÉ. ÉTUDIER LE MANUE D’INSTRUCTIONS EN ENTIER AVANT
D’UTILISER, D’ENTRETENIR OU DE RÉPARER L’ÉQUIPEMENT.
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REVISION HISTORY
Revision 1.0 2/15/17 Initial Release
Copyright © 2017 GDS Corp. All Rights Reserved
P/N 1200-0934-01

GASMAX CX + GDS-IR Operation & Maintenance Manual, Revision 1.0
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Page 3
CONTENTS
1SAFETYINFORMATION_______________________________________________5
2OVERVIEW_________________________________________________________6
3INSTALLATION______________________________________________________7
4INITIALSTARTUP___________________________________________________12
5CALIBRATION______________________________________________________16
6MAINTENANCE_____________________________________________________19
7TROUBLESHOOTING_________________________________________________21
8SPECIFICATIONS____________________________________________________23
9SPAREPARTS______________________________________________________24
10DRAWINGSANDDIMENSIONS______________________________________25
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GASMAX CX + GDS-IR Operation & Maintenance Manual, Revision 1.0
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TABLEOFFIGURES
FIGURE2‐1:GASMAXCX+GDS‐IRLOCALSENSOR........................................................................................6
FIGURE2‐2:GASMAXCX+GDS‐IRREMOTESENSOR.....................................................................................6
FIGURE3‐1:GASMAXCXI/OPOWER&SIGNALWIRING...............................................................................8
FIGURE3‐2:GASMAXCXETHERNETINTERFACE............................................................................................9
FIGURE3‐3GASMAXCXOPTIONALRELAY/MODBUSINTERFACE................................................................9
FIGURE3‐4:GASMAXCX+GDS‐IRLOCALSENSORWIRINGDIAGRAM........................................................10
FIGURE3‐5:GASMAXCX+GDS‐IRREMOTESENSORWIRINGDIAGRAM....................................................10
FIGURE3‐6:MODBUSWIRINGJUNCTIONBOX............................................................................................11
FIGURE3‐7:MODBUSJBOXLOCATIONOPTIONS........................................................................................11
FIGURE4‐1:GASMAXSINGLECHANNELDISPLAY........................................................................................12
FIGURE4‐2:GASMAXDUALCHANNELDISPLAY...........................................................................................12
FIGURE4‐3:USERMENUSCREEN.................................................................................................................13
FIGURE4‐4:ACCESSINGCALMODE.............................................................................................................13
FIGURE4‐5:GASMAXDATADISPLAY...........................................................................................................14
FIGURE4‐6:GASMAXTRENDDISPLAY.........................................................................................................14
FIGURE5‐1:CALIBRATIONFLOWCHART......................................................................................................16
FIGURE5‐2:CALIBRATIONSETUP.................................................................................................................17
FIGURE5‐3:IRZEROFORLOCALSENSORS...................................................................................................18
FIGURE5‐4:IRZEROFORREMOTESENSORS...............................................................................................18
FIGURE6‐1:GDS‐IRDISASSEMBLY...............................................................................................................20
FIGURE9‐1:GASMAXCX+GDS‐IRLOCALSENSORSPAREPARTS................................................................24
FIGURE10‐1GASMAXCX+GDS‐IRDIMENSIONS(VERTICAL)......................................................................25
FIGURE10‐2GASMAXCX+GDS‐IRDIMENSIONS(HORIZONTAL)................................................................26

GASMAX CX + GDS-IR Operation & Maintenance Manual, Revision 1.0
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Page 5
1SAFETYINFORMATION
Important–ReadBeforeInstallation
UsersshouldhaveadetailedunderstandingofGASMAXCXoperatingandmaintenanceinstructions.Use
theGASMAXCXonlyasspecifiedinthismanualordetectionofgasesandtheresultingprotection
providedmaybeimpaired.ReadthefollowingWARNINGSpriortouse.
WARNINGS
CAUTION:KEEPEXPLOSIONPROOFCOVERTIGHTWHILECIRCUITSAREALIVE
MISEENGARDE:GARDEREXPLOSIONCOUVERTUREPREUVETIGHTCIRCUITSPENDANTQUESONT
ALIVE
Unitmustbeinstalled,operatedandmaintainedinaccordancewithinformationcontainedherein.
Installationinanyhazardousareamustcomplywithallapplicablerestrictions,requirementsand
guidelinesforsaidhazardousareas.Itistheendusercustomer’sfinaldecisiontoensurethatthe
GASMAXCXissuitablefortheintendeduse.
TheGASMAXCX+GDS‐IRisdesignedandconstructedtomeasurethelevelofcertaingasesin
ambientair.Accuracyinatmospherescontainingsteamorinertgasescannotbeguaranteed.
TheGDS‐IRinfraredsensormaybemountedverticallyorhorizontally.DonotmounttheGDS‐IR
upsidedown.IfusingtheGDSRainShield[IRRS],thesensormustbemountedhorizontally.
Donotpainttransmitterorsensorassembly.
DonotoperatetheGASMAXCX+GDS‐IRiftheenclosureisdamagedorcrackedorhasmissing
components.Makesurethecover,internalPCB’sandfieldwiringaresecurelyinplacebefore
applyingpower.
DonotexposetheGASMAXCX+GDS‐IRtoelectricalshockorcontinuousseveremechanicalshock.
ProtecttheGASMAXCX+GDS‐IRandrelatedsensorassembliesfromdrippingliquidsandhighpower
sprays.
Calibratewithknowntargetgasatstart‐upandcheckonaregularschedule,atleastevery90days.
Morefrequentinspectionsareencouragedtospotproblemssuchasdirt,oil,paint,greaseorother
foreignmaterialsonthesensorhead.
Periodicallytestforcorrectoperationofthesystem’salarmeventsbyexposingthemonitortoa
targetedgasconcentrationabovetheHighAlarmsetpoint.
Useonlyforapplicationsdescribedwithinthismanual

GASMAX CX + GDS-IR Operation & Maintenance Manual, Revision 1.0
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2OVERVIEW
TheGASMAXCXisanext‐generationsingleordualchannelfixed‐pointgasmonitordesignedtoprovide
continuousmonitoringoftoxicorcombustiblegasesinhazardousareas.Gasvaluesaredisplayedin
calibratedengineeringunitsonahighlyvisiblecolorLCDdisplay.TheGDS‐IRisahighperformancegas
sensorthatusesinfraredtechnologytodetectthepresenceofcombustiblehydrocarbongases.
TheGASMAXCX+GDS‐IRcombinationisavailableinbothLocalSensorandRemoteSensorconfigurations
asshownbelow:
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Figure 2-1: GASMAX CX + GDS-IR Local Sensor
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Figure 2-2: GASMAX CX + GDS-IR Remote Sensor
TheGASMAXCXisenclosedinaCSA/FM/IECExcertifiedanodizedaluminumexplosionproofyellow
enclosuredesignedtoprotecttheelectronicsandmakeiteasyforworkerstoidentifyinindustrial
environments.Thescrew‐onfrontcoveriseasilyremovedforinstallationandmaintenance;however,
built‐inuserinterfacemagneticswitchesallowoperatorsandtechnicianstoadjust,calibrateor
troubleshoottheGASMAXCXwithoutdeclassifyingthearea.
SeetheGASMAXCXUser’sManualformoreinformationontheGASMAXCXgasmonitor.
GDS‐IRRainShield
Vertical
Configuration
Horizontal
Configuration
GASMAXCX
GasMonitor
LocalGDS‐IR
InfraredSensor
GASMAXCX
GasMonitorRemoteGDS‐IR
InfraredSensor
RemoteGDS‐IR
InfraredSensor
withRainShield

GASMAX CX + GDS-IR Operation & Maintenance Manual, Revision 1.0
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3INSTALLATION
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SELECTINGALOCATION
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Factorssuchasprevailingwinds,targetgasdensity,potentialleaksources,airmovementmachineryand
similarenvironmentalvariablesareimportantwhenselectingalocationfortheGASMAXCX+GDS‐IRgas
monitororgassensor.EventhoughtheGASMAXCX+GDS‐IRisdesignedforruggedservice,sensorsand
electronicsshouldbeprotectedfromenvironmentaldamageduetowater,snow,shock,vibrationand
dirt.Inaddition,thesensorand/ordisplayshouldbelocatedsuchthatregularmaintenanceandperiodic
sensorreplacementcanbereadilyaccomplished.Whiletherearenoindustrystandardsforgasdetector
placement,professionaltoolsexistthatcansimulateleaksorspillsandprovideexcellentguidancefor
locatinggasdetectorsthroughoutafacility.
INSTALLATION
GASMAXCXmonitorswithGDS‐IRsensorsarecertifiedforuseinClass1Division1hazardousareas.
Installationintheseareasshouldfollowbestindustrystandardpracticesandallappropriateelectrical
codes.Generally,thesecodesrequirerigidmetalconduit,pouredsealsandotherinstallationelements
necessarytoensuresafety.
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FormaximumprotectionagainstRFinterferenceorelectricalsurge,theGASMAXCXenclosure,allremote
sensorsandinterconnectingconduitmustbeproperlygrounded.
INTRINSICALLYSAFEINSTALLATION
TheGASMAXCXisnotcertifiedforuseasanIntrinsicallySafedevice.
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MOUNTINGTHEGASMAXCXINSTRUMENTENCLOSURE
TheGASMAXCXstandardenclosureisacastaluminumexplosion‐proof(NEMA7)enclosure.Twochannel
GASMAXCXunitswithduallocalsensorheadsincludea“Y”adapter.TheGASMAXCXorremotesensor
shouldalwaysbemountedwiththesensorheadopeningfacingdown.
WheninstallingtheGASMAXCX+GDS‐IR,leaveaminimum
of12inchesofclearancebelowthesensorforvertical
configurationsand12”belowand12”totherightof
horizontalconfigurationstoallowforgasflowandremoval
ofthestainlesssteelbarrelformaintenanceandcleaning.
12”MIN
12”MIN
12”MIN

GASMAX CX + GDS-IR Operation & Maintenance Manual, Revision 1.0
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CONNECTINGDCPOWER&OUTPUTSIGNALWIRING
ToaccesstheGASMAXsignalandpowerconnections,removethecoverontheGASMAXCXexplosion‐
proofenclosure,loosenthe2thumbscrewsholdingthedisplayassemblyandremoveit.Thedisplaywill
remainconnectedtotheIO/PowerSupplyPCBmountedinthebackoftheenclosurebyashortribbon
cable.
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Figure 3-1: GASMAX CX I/O Power & Signal Wiring
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Routethepowerandsignalwiresthroughtheconduitentryandconnecttoterminalblock“TB1”.
Plus24VDCconnectstoTB1‐1.DCGroundconnectstoTB1‐4.ChannelOne4‐20mAoutputisavailableon
TB1‐2andChannelTwo4‐20mAoutputisavailableonTB1‐3.
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GDSCorpalwaysrecommendsusingshieldedwireforsignalandpowercable.
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CONNECTINGTOANETHERNETNETWORK
TheGASMAXCXprovidesastandard10/100EthernetnetworkinterfaceonthePowerI/Oboardas
showninFig.4‐2.BothDHCPandfixedIPaddressmodesareprovided.TheEthernetinterfaceprovides
accesstotheMODBUSdatabaseviaMODBUS/TCPaswellasremoteaccessandsetupviaabuilt‐inweb
server.




COM
420OUT2
420OUT1
PWR
R/PWR
C/420IN1
A/COM
420IN2
CH1CH2
E‐NET
LOCAL
SENSOR
TO DISPLAY
TB1
–
1:+12‐30VDCInput
TB1–2:Channel14‐20mAOut
TB1–3:Channel24‐20mAOut
TB1–4:Power/SignalCommon
NOTE:THEMAXIMUMDISTANCE4‐20MASIGNALSCANTRAVELISDEPENDENTUPONCABLE
GAUGE,DCPOWERSUPPLYVOLTAGELEVELANDINPUTIMPEDANCEOFTHERECEIVINGDEVICE.
ASSUMINGANOMINAL24VDCPOWERSUPPLY,100OHMLOADANDMAXIMUMTOTALLOOP
RESISTANCEOF750OHMS:
#18GA,0.0064OHM/FT=>9.6MILES/15.5KM
#24GA,0.026OHMS/FT=>2.3MILES/3.7KM
Note:
LocalGDS‐IRoutputisonChannel2
RemoteGDS‐IRoutputcanbeconfigured
foreitherchannel.

GASMAX CX + GDS-IR Operation & Maintenance Manual, Revision 1.0
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Page 9
CONNECTINGETHERNETSIGNALWIRING
TheGASMAXCXprovidesastandardRJ‐45EthernetconnectoronthecenteroftheIO/PowerSupplyPCB.
DatacanbeaccessedusingtheMODBUS/TCPdataprotocolorviathebuilt‐inwebpage.SeeGASMAXCX
manualformoredetails.

Figure 3-2: GASMAX CX Ethernet Interface

OPTIONALRELAY/MODBUSINTERFACE
TheoptionalRelay/Modbusboardisconnected“piggyback”tothebackoftheGASMAXCXDisplay
Assemblyandprovidesthreelevelalarmrelays,aFAULTrelay(“K3”),twoRS‐485ModbusRTUserialports
andaccesstotheDigitalInput/RemoteACKport.


Figure 3-3 GASMAX CX Optional Relay / MODBUS Interface

NOTE:THEFAULTRELAYISPROGRAMMEDTOOPERATEINFAILSAFEMODEONLY;THERELAYISACTIVE
WHENNOFAULTEXISTS(C‐>NO),ANDBECOMESINACTIVEIFAFAULTISPRESENT(C‐>NC).

COM
420OUT2
420OUT1
PWR
R/PWR
C/420IN1
A/COM
420IN2
CH1CH2
E‐NET
LOCAL
SENSOR
TO DISPLAY
2
3
4
1
TB1
5
B
S
A
A
B
TB2
RelayWiring:
1Fault1NC
2Fault1Common
3Fault1NO
4Relay3NC
5Relay3Common
6Relay3NO
7Relay2NC
8Relay2Common
9Relay2NO
10 Relay1NC
11 Relay1Common
12 Rela
y
1NO
MODBUSinterface
ModbusWiring:
1Modbus1A
2Modbus1B
3ShieldTiePoint
4Modbus2A
5Modbus2B
RemoteAlarmAcknowledge
S1
–
Ethernet
RJ‐45Connector
NOTE:USERMENUCHANGESTO
NETWORKSETUPPARAMETERS
REQUIRESADEVICEREBOOT.
NOTE:STANDARDETHERNET
CABLESWITHMOLDEDSTRAIN
RELIEFFITTINGSARENOT
RECOMMENDEDDUETOSPACE
CONSTRAINTS.

GASMAX CX + GDS-IR Operation & Maintenance Manual, Revision 1.0
Page 10
LOCALGDS‐IRSENSORWIRING
AGASMAXCXwithlocalGDS‐IRsensorispre‐wiredatthefactoryasshownbelow.TheGASMAXCX
includesasensorpersonalityboardthatadaptstheGDS‐IRwiringtotheGASMAXCXinputsandprovides
amagneticswitchthatallowstheusertoperformthe“IRZero”functionwithoutopeningtheenclosure.


Figure 3-4: GASMAX CX + GDS-IR Local Sensor Wiring Diagram

REMOTEGDS‐IRSENSORWIRING
WiringbetweentheGASMAXCXandaremoteGDS‐IRsensorisprovidedbythecustomer.Theinterface
requiresafour‐conductorshieldedcableasshownbelow.Theremotejunctionboxprovidesbotha
magneticswitchandlocalpushbuttonforthe“IRZero”function.


Figure 3-5: GASMAX CX + GDS-IR Remote Sensor Wiring Diagram

COM
420OUT2
420OUT1
PWR
R/PWR
C/420IN1
A/COM
420IN2
CH1CH2
E‐NET
LOCAL
SENSOR
TODISPLAY
BlackWire–CommonGround
BlueWire–Sensor4‐20mAOutput
WhiteWire‐IRZeroInput
RedWire‐+18to+30VDCInput
Important–RemoveDCpowerbeforeconnectingor
disconnectinganywiringto/fromtheGDS‐IR
Sensor
Personality
Board
Sensor
Personality
Board
Remote
GDS‐IR
Sensor
Remote
Sensor
Junction
Box