GDS Corp GDS-68XP Manuel utilisateur
GDS Corp.
2513 Hwy 646 Santa Fe, Texas 77510
409-927-2980 409-927-4180 (Fax) ww.gdscorp.com
Operation and Maintenance
Manual
GDS-68XP Process Monitor for Low O
2
Applications
GDS-68XP Operation & Maintenance Manual, Revision 3.4
Page 2
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.
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
Copyright © 2014 GDS Corp. All Rights Reserved
P/N 1200-0732-05
GDS-68XP Operation & Maintenance Manual, Revision 3.4
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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
Sa ple Draw Configuration ___________________________________________________ 14
Sensor Considerations _______________________________________________________ 14
5 INSTALLATION _____________________________________________________ 15
Selecting a Location _________________________________________________________ 15
Power & Signal Connections __________________________________________________ 16
On-De and Sequence Input __________________________________________________ 16
Ethernet Connection ________________________________________________________ 16
Relay Connections (Optional) _________________________________________________ 17
MODBUS Connections (Optional) ______________________________________________ 17
AC Heater (Optional) ________________________________________________________ 19
Purge Air Inlet______________________________________________________________ 19
Sa ple Inlet _______________________________________________________________ 20
Filter Drain & Filter Bypass ___________________________________________________ 21
Sa ple Exhaust ____________________________________________________________ 22
Installation Su ary: Do’s and Don’ts __________________________________________ 23
GDS-68XP Operation & Maintenance Manual, Revision 3.4
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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 DISPLA ___________________________________________________________________ 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 an MAINTENANCE _______________________________________ 32
Nor al Operation __________________________________________________________ 32
Cold Weather Operation _____________________________________________________ 32
Nor al 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 3.4
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Sensor Replace ent ________________________________________________________ 34
9 USER MENUS ______________________________________________________ 35
Alar OUTPUTS Menu _______________________________________________________ 36
Channel Settings Menu ______________________________________________________ 37
Co Settings Menu ________________________________________________________ 39
Syste 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
GDS-68XP Operation & Maintenance Manual, Revision 3.4
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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: RELA / 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 DISPLA 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: S STEM 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
FIGURE 12-4: GDS-68XP HIGH PRESSURE B PASS FILTER (SPARE PARTS) .................................................. 55
GDS-68XP Operation & Maintenance Manual, Revision 3.4
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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
GDS-68XP Operation & Maintenance Manual, Revision 3.4
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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.
GDS-68XP Operation & Maintenance Manual, Revision 3.4
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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.
GDS-68XP Operation & Maintenance Manual, Revision 3.4
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3SPECIFICATIONS
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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