GDS GDS-68XP User manual

GDS Corp
1245 Butler Road League City, TX 77573
409-927-2980 409-927-4180 (Fax) www.gdscorp.com
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Operation and Maintenance
Manual
GDS-68XP Process Monitor for Low O2Applications

GDS-68XP Operation & Maintenance Manual, Revision 3.5
Page 2
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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 3.0 6/5/13 Initial rewrite for version 3.0
Revision 3.1 11/1/13 Update for GASMAX CX
Revision 3.2 12/15/13 Update for v2.3 sequencer firmware
Revision 3.4 1/30/14 Update for v2.4x sequencer firmware
Revision 3.5 11/10/14 Errata, updated filter information
Copyright © 2014 GDS Corp. All Rights Reserved
P/N 1200-0732-05

GDS-68XP Operation & Maintenance Manual, Revision 3.5
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Page 3
CONTENTS
1SAFETYINFORMATION_______________________________________________8
2GENERALINFORMATION______________________________________________9
Introduction_________________________________________________________________9
ExplosionProofInstallation____________________________________________________9
IntrinsicallySafeInstallation____________________________________________________9
3SPECIFICATIONS____________________________________________________10
4OPERATION_______________________________________________________12
Overview__________________________________________________________________12
SampleDrawConfiguration___________________________________________________14
SensorConsiderations________________________________________________________14
5INSTALLATION_____________________________________________________15
SelectingaLocation__________________________________________________________15
Power&SignalConnections___________________________________________________16
On‐DemandSequenceInput___________________________________________________16
EthernetConnection_________________________________________________________16
RelayConnections(Optional)__________________________________________________17
MODBUSConnections(Optional)_______________________________________________17
ACHeater(Optional)_________________________________________________________19
PurgeAirInlet______________________________________________________________19
SampleInlet________________________________________________________________20
FilterDrain&FilterBypass____________________________________________________21
SampleExhaust_____________________________________________________________22
InstallationSummary:Do’sandDon’ts__________________________________________23

GDS-68XP Operation & Maintenance Manual, Revision 3.5
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6INITIALSETUP_____________________________________________________24
Overview__________________________________________________________________24
SequencerControlsandIndicators______________________________________________24
SEQUENCE_______________________________________________________________________24
Bypass__________________________________________________________________________25
Run____________________________________________________________________________25
L1andL2________________________________________________________________________25
GASMAXControlsandDIsplay_________________________________________________26
RAWSENSOR____________________________________________________________________26
PPMOUTPUT____________________________________________________________________26
DUALDISPLAY____________________________________________________________________26
GDS‐68XPSTARTUPPROCEDURE_______________________________________________27
7CALIBRATION______________________________________________________28
CalibrationOverview_________________________________________________________28
CalibrationProcedure(CALPORTSAMPLE)_______________________________________29
CalibrationProcedure(INLETPORTSAMPLE)_____________________________________30
CalibrationProcedure(STREAMSAMPLE)________________________________________31
8OPERATIONandMAINTENANCE_______________________________________32
NormalOperation___________________________________________________________32
ColdWeatherOperation______________________________________________________32
NormalMaintenance________________________________________________________32
FaultandoverrangeConditions________________________________________________33
PowerUp_______________________________________________________________________33
InputOverrangeFAULT____________________________________________________________33
SensorRecoveryFAULT____________________________________________________________33
PeakAlgorithmfault_______________________________________________________________33
SampleorPurgeAirFlowfault_______________________________________________________33
Calibrationfault__________________________________________________________________33
SensorFailfault__________________________________________________________________33

GDS-68XP Operation & Maintenance Manual, Revision 3.5
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SensorReplacement_________________________________________________________34
9USERMENUS______________________________________________________35
AlarmOUTPUTSMenu_______________________________________________________36
ChannelSettingsMenu_______________________________________________________37
CommSettingsMenu________________________________________________________39
SystemSettingsMenu________________________________________________________40
DiagnosticsMenu___________________________________________________________41
10MODBUSREGISTERS______________________________________________42
ListofGDS‐68XPMODBUSvariables____________________________________________42
11TROUBLESHOOTINGGUIDELINES____________________________________50
FaultIndicationonOUTPUTChannel(CH2)_______________________________________50
FaultIndicationonrawSensorChannel(CH1)____________________________________50
SensorFailsCalibration_______________________________________________________50
GDS‐68XPandReceivingDeviceDisplayedValuesDon’tMatch______________________50
ControllerMODBUSDataIncorrect_____________________________________________51
ControllerShowingMODBUSCOMMERROR_____________________________________51
GDS‐68XPDisplayBlank______________________________________________________51
12SPAREPARTS____________________________________________________52
13DRAWINGSANDDIMENSIONS______________________________________57
14WIRINGDIAGRAMS_______________________________________________58
15GASMAXCXGDS‐68XPFACTORYDEFAULTSETUP_______________________59
16SEQUENCERSETTINGS(DIPSWITCHVERSIONS)_________________________65
17KNOWNERRATA__________________________________________________66
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GDS-68XP Operation & Maintenance Manual, Revision 3.5
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TABLEOFFIGURES
FIGURE3‐1:TOXICSENSORCHARACTERISTICS............................................................................................11
FIGURE3‐2:SEQUENCETIMING...................................................................................................................11
FIGURE3‐3:RECOMMENDEDMINIMUMSEQUENCETIMES.......................................................................11
FIGURE4‐1:GDS‐68XPFLOWDIAGRAM(PRESSURE)..................................................................................12
FIGURE4‐2:GDS‐68XPSAMPLETIMING......................................................................................................13
FIGURE4‐3:GDS‐68XPMAXIMUMTIMINGVALUES....................................................................................13
FIGURE4‐4:GDS‐68XPFLOWDIAGRAM(SAMPLEDRAW)..........................................................................14
FIGURE5‐1:GDS‐68XP(HIGHPRESSURE,STANDARDFILTER).....................................................................15
FIGURE5‐2:GDS‐68XPPOWERANDSIGNALWIRING..................................................................................16
FIGURE5‐3:RELAY/MODBUSCONNECTIONS.............................................................................................17
FIGURE5‐4:MODBUSWIRINGJUNCTIONBOX............................................................................................18
FIGURE5‐5:200WACHEATERWIRING........................................................................................................19
FIGURE5‐6:INLETTUBINGRECOMMENDATIONS.......................................................................................20
FIGURE5‐7:FILTERDRAIN&EXHAUSTTUBINGRECOMMENDATIONS.......................................................21
FIGURE5‐8:GDS‐68XPEXHAUSTTUBING....................................................................................................22
FIGURE6‐1:GDS‐68XPUSERINTERFACE......................................................................................................24
FIGURE6‐2:SEQUENCETIMING...................................................................................................................25
FIGURE6‐3:L1/L2INDICATOROPERATION................................................................................................25
FIGURE6‐4:GDS‐68XPGASMAXDISPLAYSEQUENCE..................................................................................26
FIGURE7‐1:CALIBRATIONPROCEDURE(CALPORT)....................................................................................29
FIGURE7‐2:CALIBRATIONPROCEDURE(INLETPORT).................................................................................30
FIGURE7‐3:CALIBRATIONPROCEDURE(SAMPLESTREAM)........................................................................31
FIGURE8‐1:FAULTCONDITIONS..................................................................................................................33
FIGURE9‐1:MAINMENUTREE....................................................................................................................35
FIGURE9‐2:ALARMOUTPUTSMENUTREE.................................................................................................36
FIGURE9‐3:CHANNELSETTINGSMENUTREE(1)........................................................................................37
FIGURE9‐4:CHANNELSETTINGSMENUTREE(2)........................................................................................38
FIGURE9‐5:COMMSETTINGSMENU..........................................................................................................39
FIGURE9‐6:SYSTEMSETTINGSMENUTREE................................................................................................40
FIGURE9‐7:DIAGNOSTICSMENUTREE.......................................................................................................41
FIGURE12‐1:GDS‐68XPSAMPLEDRAWCOALESCINGFILTER(SPAREPARTS).............................................52
FIGURE12‐2:GDS‐68XPLOWPRESSURECOALESCINGFILTER(SPAREPARTS)............................................53
FIGURE12‐3:GDS‐68XPHIGHPRESSURECOALESCINGFILTER(SPAREPARTS)...........................................54

GDS-68XP Operation & Maintenance Manual, Revision 3.5
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FIGURE12‐4:GDS‐68XPHIGHPRESSUREBYPASSFILTER(SPAREPARTS)....................................................55
FIGURE12‐5:GDS‐68XPSENSORHEADEXPLODEDVIEW............................................................................56
FIGURE13‐1:GDS‐68XPDIMENSIONS(NEMA4XENCLOSURE)...................................................................57
FIGURE14‐1:GDS‐68XPWIRINGDIAGRAM.................................................................................................58
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GDS-68XP Operation & Maintenance Manual, Revision 3.5
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1SAFETYINFORMATION
Important–ReadBeforeInstallation
UsersshouldhaveadetailedunderstandingofGDS‐68XPoperatingandmaintenanceinstructions.Use
theGDS‐68XP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
TheGDS‐68XPprocessmonitordescribedinthismanual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GDS‐68XPissuitableforthe
intendeduse.
TheGDS‐68XPisdesignedandconstructedtomeasurethelevelofcertaingasesinbackgrounds
thatcontainlowamountsoffreeoxygen.Accuracyinatmospherescontainingsteamorinert
gasescannotbeguaranteed.
Donotpaintenclosure,transmitterorsensorassembly.
DonotoperatetheGDS‐68XPifits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GDS‐68XPtoelectricalshockorcontinuousseveremechanicalshock.Protect
theGDS‐68XP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inthesampletubingorinthesensorhead.
Periodicallytestforcorrectoperationofthesystem’salarmeventsbyexposingthesample
extractionpointtoacalibrationgasconcentrationabovetheHighAlarmsetpoint.
Useonlyforapplicationsdescribedwithinthismanual.
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GDS-68XP Operation & Maintenance Manual, Revision 3.5
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2GENERALINFORMATION
INTRODUCTION
TheGDS‐68XPprovidesasafeandreliablewaytomeasurethelevelofhydrogensulfide,mercaptan,THT
andothergasesinaprocessstreamthatcontainslowlevelsofoxygen.TheGDS‐68XPusesaprogrammed
sequencertoalternativelyapplysampleandpurgeairtoahighlysensitiveandreliableelectrochemical
sensor.Applyingpurgeairperiodicallyrefreshesthesensor’schemistry,significantlyextendsthelifeof
thesensorandreducesthetotalamountofsamplegas
releasedintotheatmosphere.
TheGDS‐68XPcanbeconfiguredtodrawsamplesfrom
non‐pressurized(ambient)sourcesortoacceptpositive
pressuresamples,from+5psigto+1500psig.Multiple
filteroptionsareavailableandtheunitfeaturesalow‐flow
warningswitchandlonglifebrushlessDCpumpforsample
andpurgeair.
TheGDS‐68XPfeaturesthenewdual‐channelGASMAXCX
networkedgasmonitor.Inadditiontoanewhighvisibility
colordisplay,theGASMAXCXincludesanEthernetportwithbuilt‐inMODBUS/TCPinterfaceandweb
serverforcompleteintegrationintousernetworks.GDSCorpsoftwarecanbeusedtoremotelymonitor
thestatusandperformanceofGDS‐68XPsystemsifanetworkconnectionisavailable.
EXPLOSIONPROOFINSTALLATION
TheGDS‐68XPisdesigned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.For
maximumprotectionagainstRFinterferenceorelectricalsurge,theGDS‐68XPenclosureand
interconnectingconduitmustbeproperlygrounded.
INTRINSICALLYSAFEINSTALLATION
TheGDS‐68XPisnotdesignedorcertifiedforuseasanIntrinsicallySafedevice.
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3SPECIFICATIONS
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ModelGDS‐68XPProcessMonitorforLowOxygenApplications
PowerInput24VDC±5%at<12watts
DisplayHighresolutioncolorLCDwithengineeringunits,bargraphand30‐minutetrend
SensorTypesElectrochemicalsensorsfortoxicgases
InletPressure
Requirements
Sampledraw:Ambientto+5inchesofwatercolumn
Lowpressure/noregulator:+5incheswatercolumnto+25psig(±10%max)
Highpressure/standardfilter:+10psigto+1500psig
Highpressure/combinationfilter:+10psigto+1500psig
DrawDistanceDemonstratedupto100feetof¼”ODtubing
Accuracy+/‐5%offullscale(typical)
Standard
Output
Three‐wire4‐20mAcurrentsourceoutputswithfaultandoverrangeindication.
Maximumloopresistanceis750ohmswithstandard24VDCsupply.
EthernetRJ‐45withbuilt‐inMODBUS/TCPinterfaceandwebserver
OptionalRelay/MODBUSinterfacewith3x5ASPDTprogrammablealarmrelays.
Temperature
(operating)
0°Cto+50°Cstandard(noenclosure)
Note:Ambienttemperaturebelow0°Cmaykeeppurgeairpumpfromstarting
‐20°Cto+50°CwithNEMA4Xenclosureandoptional200WACheater.Heater
thermostatissetto50°Fandisnotuser‐adjustable.
Temperature
(inert)
‐20°Cto+55°C
Incoldweather,GDSCorprecommendsturningontheACheater(ifinstalled)for
severalhoursbeforeapplyingDCpower
MemoryOn‐boardnon‐volatilememoryretainsallusersettings
MaterialsInstrumenthousings:Aluminum
Tubing&fittings316stainlesssteel
DimensionsPaintedsteelplate:21”x21”x8”,
NEMA4xnon‐metallicenclosure,24”x24”x8”
ApprovalsGASMAXCXGasMonitorCSACertifiedClassI,Div1&2GroupsB,C,D.
SequencerenclosureCSAcertifiedforuseinClassIDiv1areas.
FlamearrestorsULcertifiedforuseinClass1Div1areas.
WarrantyTwoyearsonelectronics
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