Operation & Maintenance Manual. GASMAX IIx Wireless Toxic / Oxygen / Combustible Gas Monitor with Smart Sensor Interface

Transcription

1 Operation & Maintenance Manual GASMAX IIx Wireless Toxic / Oxygen / Combustible Gas Monitor with Smart Sensor Interface Important: Read and understand contents of this instruction manual prior to use. Improper use of equipment could result in instrument malfunction or serious injury. GDS Corp Hwy 646 Santa Fe, Texas (409) (409) (FAX) tech@gdscorp.com

2 Table of Contents SECTION 1 SAFETY INFORMATION Safety Information Read Before Installation & Applying Power Contacting GDS Corp... 1 SECTION 2 GENERAL DESCRIPTION Introduction Description of GASMAX IIx & Client / Server Wireless Networks GASMAX IIX Radio Status (RS) Icons - Zzz s,,,, RF Comm Cycle and Power Consumption... 4 SECTION 3 INSTALLATION INSTRUCTIONS Ratings and Certifications Sensor Location Mounting the Enclosure Magnetic Mount Option Specifications Antenna Transmission Range Antenna Selection & Location Smart / Simple Sensors I/O Board Wiring Installation GASMAX IIx 900MHZ / 2.4GHZ RF MODULES SECTION 4 INITIAL START-UP Xmitter Config Configuration Menu Initial Bridge Sensor Monitor Start-Up Initial Bridge Sensor Monitor Sensor Volts Check Initial Bridge Sensor Monitor Balance Check Initial Bridge Sensor Monitor Span Check Initial Toxic / Oxygen Monitor Start-Up Initial Toxic / Oxygen Monitor Span Check SECTION 5 ROUTINE OPERATING INSTRUCTIONS CAL MODE - Routine Sensor Calibrations ALARM OPERATION ALARM 3 UNDERSTANDING FAULT / LEVEL OPERATION SECTION 6 SETUP MENU CONFIGURATION Menus Database Configuration Configuration Using the Magnetic Wand: System Configuration Menus: User Info Eunits Zero Span Decimal Points Cal Span Value Readout Deadband Track Negative Backup Config Restore Config Upload Sensor Data Alarm Settings: Set Point Dead-Band ON Delay OFF Delay Low Trip Latching Sensor Information: Clock / Warm-Up & Cal Purge Delays SETUP:

3 6.7 COMMUNICATIONS SETUP: Hop Channel Remote ID System ID *TX Multiples *TX Mode *TX Power TX Verbose Radio Status GASMAX IIx Operation with C1 Protector Controllers GASMAX IIx Operation with C2 Quad Protector Controllers SYSTEM SECURITY: LCD Contrast Adj: SECTION 7 TECHNICIANS ONLY MENUS Introduction: Set Balance / Set Sensor Voltage (Technicians only!): Set Gain to Unity (Technicians only!): PreAmp Gain Adjust (Technicians only!): Simple Sensor Input Type (Technicians only!): Zero Cal Value (Technicians only!): Raw Min / Max Counts (Technicians only!):

4 SECTION 1 SAFETY INFORMATION 1.1 Safety Information Read Before Installation & Applying Power IMPORTANT Users should have a detailed understanding of GASMAX IIx operating and maintenance procedures. Use the GASMAX IIx 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 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. Do not paint the sensor assembly or the Transmitter. Do not use the GASMAX IIx if its enclosure is damaged or cracked or has missing components. Make sure the cover, internal PCB s and antenna connections are securely in place before operation. Use only a sensor assembly compatible with the GASMAX IIx and approved by GDS Corp. Periodically test for correct operation of the system s alarm events by exposing the monitor to a targeted gas concentration above the High Alarm setpoint. Do not expose the GASMAX IIx to electrical shock or continuous severe mechanical shock. Protect the GASMAX IIx from dripping liquids and high power sprays. Use only for applications described within this manual. 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. 1.2 Contacting GDS Corp. GDS Corp technical support is available between the hours of 7:30am and 5:00pm Monday through Thursday and 7:30am until Noon on Friday Central Standard Time. Please call or FAX Our address is info@gdscorp.com and our website is Our shipping address is 2513 Hwy 646, Santa Fe, TX

5 SECTION 2 GENERAL DESCRIPTION 2.1 Introduction This manual describes the externally powered GASMAX IIx Gas Monitor equipped with RF Wireless Interface and RF firmware. The GASMAX IIx gas monitor is capable of accepting either electrochemical sensors or bridge-type combustible or VOC sensors and requires an external 10-30VDC power source. A separate manual is available for the GASMAX ECx battery powered device which requires no external power or signal wiring but is limited to toxic and oxygen measurements. Both units are single channel, fixed-point monitors designed to provide continuous monitoring of gases in the workplace. Gas values are displayed in their engineering units, graphically as bar graphs or 30-minute trends (Figure 2-1) and transmitted wirelessly to a remote controller for alarm or data recording. Flashing front panel LED s notify personnel when alarm levels have been reached. IMPORTANT: Periodic calibration checks are needed to assure dependable performance. The GASMAX IIx gas monitor broadcasts on a license-free frequency of 900MHZ (specify GASMAX IIx RF900) or 2.4GHZ (specify GASMAX IIx RF2400) to GDS Corp C1 Protector eight or sixteen channel controllers or C2 Quad Protector Four Channel Controllers equipped with a matching RF wireless modem and appropriate antenna. Each C1 Protector controller can support up to sixteen remote wireless units; networks with more than sixteen detectors can easily operate with multiple controllers. Advanced microcontroller electronics and superior graphic LCD operator interface offers enhanced diagnostics and fault analysis not possible in competing products. Non-volatile memory retains all configuration data during power interruptions. The magnetic keypad allows non-intrusive calibrations be performed by one person without opening the enclosure. A real time clock & calendar feature allows logging of calibrations, alarm trips, communication faults and other events for review on the LCD readout. Compatible sensors provide an 8-wire Smart Sensor interface capable of uploading configuration data to the GM IIx monitor. For remote sensor applications, simple sensors are also supported. A separate PC compatible USB Interface device (part # ) allows Smart Sensors to be loaded with configuration variables via a PC and, when connected to a GASMAX IIx local sensor head, upload this data to the GASMAX IIx. This configuration data includes alarm set points, range, target gas, calibration constants and other variables required for a specific application. For Simple sensors without the smart interface, the USB device allows direct GASMAX IIx configuration from a PC. Additional features include: On screen radio status icons indicate Server In Range, Server Out of Range, Server Previously Out of Range and Low Battery conditions. No potentiometer or jumper settings required. All setup is with menus accessed via the LCD / magnetic keypad operator interface without opening the enclosure. Backlit LCD (remains illuminated for 10 seconds after any keystroke). Field adjustable alarm levels flash front panel LED indicators for HIGH, WARN, FAIL conditions. Alarm relays are not available with this low power model. CAL MODE provides on-screen prompts when to apply cal gas during calibrations. Sensor life bar-graph updates after each SPAN calibration indicating when to replace old sensors. Half hour trend screen shows rate of change of gas exposures. Modular design affords efficient installation and plug in sensors allow changing target gases even after installation. New smart sensors are recognized by the GASMAX IIx and prompts users to either upload new configuration data or continue with data from the previous smart sensor. 2

6 Missing sensors trip the FAIL alarm. Compatible sensors are industry proven for fast response and long life. Figure 2-1: Data Displays 2.2 Description of GASMAX IIx & Client / Server Wireless Networks All GDS Corp wireless transceivers utilize a FHSS (Frequency Hopping Spread Spectrum) Server-Client network where multiple Clients synchronize their frequency hopping to a single Server. The Server transmits a beacon at the beginning of every frequency hop (50 times per second). Client transceivers listen for this beacon and upon receiving it synchronize their hopping with the Server. GASMAX IIx monitors are often powered by solar arrays, so care is taken to reduce power consuming RF transmissions to a minimum. GASMAX IIx monitors are never used for Server operation and are always Clients. Each GASMAX IIx wireless broadcast includes gas value, battery voltage and monitor status. This wireless protocol interface operates only with GDS Corp C1 Protector or C2 Quad Protector Controllers. Both controllers are capable of functioning as Clients or Servers but only one Server is allowed per wireless network. Multiple C1 Protector or C2 Quad Protector Controllers may receive the same transmissions from GASMAX IIx monitors. Each transceiver on a wireless network must have its RADIO SETUP menus configured to share the same Hop Channel and System ID to communicate (see section 6.7). There should never be two servers with the same Hop Channel / System ID settings in the same coverage area as the interference between the two servers will severely hinder RF communications. The Server must be in a powered location and should be centrally located since all Clients must receive the server s beacon signal to communicate successfully. Correct planning and design of wireless systems are important for ensuring a successful installation. It is highly recommended that a site drawing indicating location of monitors and base station, line of site obstructions, and sources of RF interference be submitted when requesting a quotation GASMAX IIx Radio Status (RS) Icons - Zzz s,,,, Figure 2-1 shows the GASMAX IIx data displays and identifies radio status (RS) icons which appear on the LCD. RS icons, along with the TXD led (see Figure 2-1), are useful diagnostic tools for evaluating RF communication. Status conditions indicated by the RS icon are Sleep Mode - Zzz s, Server In Range - (server s beacon received at most recent attempt), Server Out of Range - (server s beacon not received at most recent attempt), Server Previously Out of Range - and Low Battery -. The Server Previously Out of Range icon is useful in determining if intermittent communication failures are a result of this monitor having problems 3

7 receiving the Server s beacon. The duration and frequency of out of range conditions are stored in the Event Log table described in Section 6.4. Low Battery conditions also flash the FAIL led. It is important to understand RS icons only update as the TXD LED flashes indicating an RF transmission has occurred. RF transmissions are typically each 5-minutes, but increase to each 6-seconds during alarm conditions RF Communications Cycle and Power Consumption Wireless systems are often battery or solar powered and therefore power consumption must be kept low. The majority of power is consumed when the radio communicates to the wireless network. Each Communications cycle consists of the following operations: 1) wake the radio in receive mode; 2) listen for the Server s beacon; 3) synchronize to the Server s hopping frequency to become In Range ; 4) transmit data packet out the antenna and return to sleep mode. This sequence takes from.25 to 1 second to complete. If the radio fails to synchronize upon the initial attempt it waits 6 seconds and tries again, then waits 6 seconds and tries once more. If the third attempt fails the Out of Range icon appears and the GASMAX IIx returns to its Communications cycle. Out of range will also be logged into the Event Log (see section 6.4). Every 6 seconds, the monitor performs a sniff test to detect the level of target gas present at the sensor. At each sniff test, the Zzz s Sleep Mode icon is briefly replaced by an RS icon as described above in section At this time the readout updates to indicate gas value measured at the sniff test. The radio stays OFF if the gas value does not trip A1 or A2 alarms. Except upon the 50 th consecutive sniff test (every 5-minutes) the radio turns on, receives the Server s beacon, and transmits its data. These 5-minute transmissions allow C2 Quad Protector or C1 Protector Controllers to confirm a good wireless link even when no alarms exist. If A1 or A2 alarms do exist during the sniff test, the radio wakes, receives the Server s beacon, and transmits its data immediately. The following list identifies each of the conditions that cause the radio to transmit: Broadcast every 5 minutes when there is no A1 or A2 alarm. This allows the receiving controller to monitor the link and report Communications (Comm) Error if the monitor does not reply for periods of greater than 18-minutes. Broadcast every 6 seconds if there is an A1 or A2 level alarm. Broadcast upon entry into CAL MODE. When entering CAL MODE, the GASMAX IIx sends a digital value of 75 counts (-15.6% FS). Controllers receiving this value indicate IN CAL reading. Broadcast upon ENTRY into CAL PURGE. When entering CAL PURGE, the GASMAX IIx sends a digital value of 200 counts (0% FS). NOTE: To prevent A1 & A2 low trip alarms, GASMAX IIx units configured for OXYGEN transmit a reading of 20.9% upon entry into CAL PURGE. Holding the magnet to the UP key for >8 seconds forces a transmission of the current reading value. 4

8 SECTION 3 INSTALLATION INSTRUCTIONS 3.1 Ratings and Certifications The enclosure is NRTL certified for Division 1 hazardous area installations for explosion-proof Class 1 Groups B,C,D (see Figure 3-1). The GASMAX IIx is designed to meet ISA Part 1 for Toxic Monitors. The antenna fitting has an RP-SMA connector and is suitable for Division 2 classified areas. An optional antenna is also available for Division 1 classified areas. Figure 3-3 shows both antenna styles. 3.2 Sensor Location Factors such as air movement, gas density in relation to air, emission sources and environmental variables affect correct sensor location. Air movement by fans, prevailing winds and convection should be carefully evaluated to determine if a leak is more likely to raise gas levels in certain areas within the facility. Vapor density of a gas determines if it will rise or fall in air when there are no significant currents. Lighter than air gases should have the monitors mounted inches (30 45 centimeters) above the potential gas leak and heavier than air gases should be this distance below. Even though the GASMAX IIx is designed for rugged service, sensors should be protected from environmental damage from water, snow, shock, vibration and dirt. 3.3 Mounting the Enclosure The GASMAX IIx standard enclosure is a cast aluminum explosion-proof (NEMA 7) enclosure shown in Figure 3-1. Modular design simplifies the installation of the GASMAX IIx (Figure 3-2). The GASMAX IIx antenna should typically be mounted with line of sight access to the controller s base station antenna. If a good line of sight angle is not possible the GASMAX IIx monitor will usually still function properly at ranges up to 1500 feet but obstructions should be kept to a minimum. WARNING: Qualified personnel should perform the installation according to applicable electrical codes, regulations and safety standards. Ensure correct cabling and sealing fitting practices are implemented. Install the GASMAX IIx to a wall or bracket using the predrilled mounting flanges with I.D on 5.0 inch centers (Figure 3-1). CAUTION: Optional Sensor heads should never be installed pointing upwards Magnetic Mount Option GDS Corp offers square aluminum plate, with a magnet on each corner, to bolt to the back of the GASMAX IIx instrument enclosure. The Magnetic Mount securely attaches the assembly to solid steel structure that is at least 6 inches wide. 5

9 Figure 3-1: GASMAX IIx Explosion-Proof Housing 6

10 Figure 3-2: Outline Drawing 3.4 Specifications Power Supply: VDC applied to TB2 on I/O PCB. Power Consumption: <20mA during sleep mode, 60mA during receive beacon mode, up to 1 amp during 1 watt transmit mode. Transmit power may be set from 10mW to 1 watt (see Section 6-7) RF900 Transmit (TX) Power 30dBm at highest 1W power setting. 900MHZ Transmit Power may be set from 10mW to 1 watt (see Section 6-7) RF2400 Transmit (TX) Power 2.4GHZ model Transmit Power is fixed at 50mW. Receive (RX) Sensitivity -100 dbm (RF900); -90 dbm (RF2400) Radio Frequency RF900 model hopping occurs between MHZ. RF2400 between 2.4 & 2.5GHZ. Memory: Non-volatile E2 memory retains configuration values in the event of power outages. 3.5 Antenna Transmission Range The distance radio signals can travel is dependent upon several factors including antenna design, transmitter power and Freespace losses. In order for a wireless link to work, the available system operating margin (TX power - RX Sensitivity + Antenna gains) must exceed the Freespace 7

11 loss and all other losses in the system. For best RF line-of-site, the combined height of both antennas must exceed the Fresnel zone diameter (see below). Dist. between ant's Fresnel zone diameter Freespace loss (db) 1000 ft (300 m) 16 ft (4.9 m) 81 1 Mile (1.6 km) 32 ft (9.7 m) 96 5 miles (8 km) 68 ft (20.7 m) miles (16 km) 95 ft (29 m) 116 Example: The RF MHZ radio modem has the following parameters: Maximum RF TX power setting = 30 dbm (1 Watt) RF RX sensitivity = -100 dbm (this is a constant) Antenna gain (standard equipped dipole) = 2.1dBi x 2 = 4.2dBi So the system operating margin is 30 - (-100) = dbm. This is enough to transmit 10 miles if freespace was the only loss in the system. For this to be the case, the antennas must be mounted with a combined height greater than 95ft above all obstructions (including the ground) to keep the fresnel zone clear. In practice however, there are many losses in the system besides just freespace and it is recommended there be at least 20dB extra system operating margin. RF Rules of Thumb Doubling the range with good RF Line of Site (LOS) requires an increase of 6 db. Doubling the range without good RF LOS requires an increase of 12 db Antenna Selection & Location A site survey using an RF spectrum analyzer and test radios is highly recommended. The location of the antenna is very important. Ensure the area surrounding the proposed location is clear of objects such as other antennas, trees or power lines which may affect the antenna s performance and efficiency. It is also vital that you ensure the support structure and mounting arrangement is adequate to support the antenna under all anticipated environmental conditions. The choice of appropriate mounting hardware is also important for both minimizing corrosion and maintaining site performance. Most installations utilize locally mounted dipole antennas as shown in Figure 3-3. An option is available for a 6 foot riser to increase the height of the antenna 6 feet above the ST-48EC/RF monitor. Extreme cases may require special order of directional antennas mounted in such a way to allow aiming towards the base station antenna. Minimize obstructions between the ST- 48EC/RF and the base station antenna Water Proofing Antenna Connections Waterproof all outdoor coax connectors using a three layer sealing process of initial layer of adhesive PVC tape, followed by a second layer of self-vulcanizing weatherproofing tape such as 3M 23 (order # ), with a final layer of adhesive PVC tape (see Figure 3-4). 8

12 Figure 3-4: Water Proofing Antenna Connections System Grounding Direct grounding of the ST-48 enclosure via a good electrical connection to a well designed grounding system is essential. This will protect your system, reduce the damage that can occur during lightning strikes and reduce noise. Figure 3-3: Local Antennas (900MHZ Shown) 3.6 Smart / Simple Sensors Sensors used with the smart sensor head (see Figure 3-5) are considered smart since they include a memory device that uploads sensor information to the GASMAX IIx anytime a new sensor is installed. The GASMAX IIx may also accommodate other industry standard simple electrochemical toxic / oxygen sensors, without the memory device, by accepting their wiring into TB2 of the Display Assembly (see Figure 3-4). Sensor heads with the 8-wire Smart Sensor cable connects to S2 of the Radio Assembly (see Figure 3-4). This unique Smart Sensor Interface may be used to configure smart sensors and / or GASMAX IIx s from a PC rather than entering all variables via the magnetic keypad. 9

13 GASMAX IIx BRIDGE/RF Sensor Transmitters may accept either electrochemical sensors or bridge sensors but wiring terminates differently for each. Smart & simple electrochemical sensor wiring connects to the back of the Display assembly as shown in Figure 3-4. Smart & simple bridge sensor wiring connects to the I/O board as shown in Figure 2-2. Figure 3-4: Display Assembly with RF PCB Figure 3-5: Smart Sensor Head Assembly 10

14 Smart Sensors are automatically recognized by the GASMAX IIx. The Smart Sensor identification screen in Figure 3-6 is shown after power-up, upon installation of a new smart sensor or by viewing INPUT type in the SENSOR SETTINGS / INFO menu (section 5-5). SMART SENSOR Type: Cat-Bead Span: 100 Zero: 0 SN: xxxxxx Born On: 01/28/04 Last Cal: 04/05/04 ANY key to Exit ERROR CODE 01 Incorrect Sensor installed. Install correct sensor or update transmitter. SEE MANUAL EDIT key to update. Any other to abort. If installed sensor type does not match transmitter database Figure 3-6: Smart Sensor Info / ERROR Screens 3.7 I/O Board Wiring Installation Connect VDC between terminals 1 & 4 of TB2 (+ wire on 1 and 0V wire on 4) as shown in Figure 3-7. Wireless models also transmit a sourcing 4-20mA output (electrochemical sensor output on TB2-2 and bridge sensor outputs on TB2-3). Instructions: Unscrew the cover on the GASMAX IIx explosion-proof enclosure. Loosen the 2 thumbscrews holding the display assembly and remove it. A small ribbon cable is attached with sufficient length to allow access to the I/O PCB mounted in the bottom of the enclosure (Figure 3-7). Power and signal connections are to TB2 where 24 VDC, Signal and Common wires must be connected. A blocking diode protects the GASMAX IIx if polarity of the power supply is reversed but it will not operate. Reassemble the GASMAX IIx. Follow the procedures and recommendations in the receiver and power supply manuals to complete the installation. Be sure the GASMAX IIx enclosure and conduit are properly grounded. Apply power and the GASMAX IIx should function. Proceed to section-4. Figure 3-7: I/O Power Supply / 3-Wire 4-20mA Assembly 11

15 3.8 GASMAX IIx 900MHZ / 2.4GHZ RF MODULES The GASMAX IIx monitor radio module mounts piggy back to the back of the Display assembly as shown in Figure 3-8. The module s MMCX RF connector connects to the antenna fitting s pigtail coax cable. GASMAX IIx Bridge models have a ribbon cable connecting to the I/O PCB. Figure 3-8: MHZ / GHZ RF Modules 12

16 SECTION 4 INITIAL START-UP 4.1 Xmitter Config Configuration Menu Figure 4-1shows how to access the menu for setting the input type (if necessary). To access from any data display, press and hold the NEXT key for 5-seconds until the screen appears requesting a special key sequence (4-UP keystrokes). Input should be set for Bridge when connecting bridge sensors such as catalytic bead, infrared and PID, and should be set to O2/TOXIC if using oxygen or toxic electrochemical sensors. Under normal conditions this setting should remain at factory default. Figure 4-1: Transmitter Configuration Menu 4.2 Initial Bridge Sensor Monitor Start-Up GASMAX IIx Monitors that are factory equipped with a local Simple or Smart Bridge Sensor rarely require adjustments, other than routine calibrations, to provide accurate readings. However, after installation the following checks should be performed to insure proper operation. In addition, alarm levels, Measurement Name ASCII fields and other variables may require configuration by users in order to best serve their application Initial Bridge Sensor Monitor Sensor Volts Check CAUTION: Sensor Volts in excess of the rated values may destroy the sensors. Section 7.2 describes reading and setting sensor volts using the GASMAX IIx LCD. The voltage displayed on the LCD is monitored across TB1-REF and TB1-ACT on the GASMAX IIx I/O board (Figure 2.2) and may be confirmed with a voltmeter. This TB-1 value is correct for locally mounted sensors only. Sensors mounted more than a few feet away from the GASMAX IIx may receive a lower voltage due to the inherent voltage drop across sensor wiring. Remote mounted sensors must have their sensor voltage (across ACTIVE and REFERENCE beads) measured AT THE SENSOR end of the cable. The GASMAX IIx setting will require a higher value in order to achieve the correct voltage at the sensor. Correct sensor voltage should be confirmed after startup for locally and remotely mounted bridge sensors Initial Bridge Sensor Monitor Balance Check Bridge sensors may require a balance adjustment after installation especially when the sensor is remote mounted from the GASMAX IIx. Section 7.2 describes using the LCD to read and adjust BALANCE settings. Correct BALANCE setting should be confirmed after start-up for locally and remotely mounted bridge sensors Initial Bridge Sensor Monitor Span Check Prior to the initial Routine Sensor Calibration described in section 4.1, a coarse SPAN gas reading verification should be performed after installation. After correct Sensor Volts and 13

17 BALANCE have been verified, apply an upscale gas value such as 50% LEL to the sensor. The indicated value should read between 35 and 65% LEL with 50% LEL gas applied. Larger errors may indicate incorrect sensor wiring or defective sensor. Remember that this is only a coarse check and precision calibrations are performed in Routine Sensor Calibrations described in the following section 4.1. Section 6.4 describes PREAMP GAIN adjustments that may be required if full-scale ranges are changed. 4.3 Initial Toxic / Oxygen Monitor Start-Up GASMAX IIx Monitors that are factory equipped with a local Simple or Smart electrochemical sensor, rarely require adjustments (other than routine calibrations) to provide accurate readings. However, after installation the following checks should be performed to ensure proper operation. In addition, alarm levels, Measurement Name ASCII fields and other variables may require attention by users in order to best serve their application Initial Toxic / Oxygen Monitor Span Check Prior to the initial Routine Sensor Calibration described in section 5.1, a coarse SPAN gas reading verification should be performed after installation. Apply an upscale gas value of at least 25% of full scale to the sensor. For example, if 0-100ppm H2S is the measurement range, apply at least 25ppm but not more than 100ppm. The indicated value should read within 15% of full scale of the applied gas value. Remember, this is only a coarse check and precision calibrations are performed in Routine Sensor Calibrations described in the following section 5.1. Section 7.3 describes PREAMP GAIN adjustments that may be required if full-scale ranges are changed. SECTION 5 ROUTINE OPERATING INSTRUCTIONS 5.1 CAL MODE - Routine Sensor Calibrations Calibration is the most important function for ensuring correct gas readings. The CAL MODE (flow chart shown in Figure 5-2) is designed to make calibration quick, easy and error free. A successful ZERO and SPAN calibration requires only four keystrokes. CAL MODE is always followed by an adjustable CAL PURGE time period (see section xxx). CAL PURGE holds the output value at a level to prevent alarms being tripped by the upscale span gas. The GASMAX IIx s wireless 10-bit output range is 200 to 1000 counts for 0 to 100% of full scale. It indicates CAL MODE by transmitting 75 counts (-15.6% FS) to receivers on the network. Toxic gas ranges transmits 200 counts (0% FS) during the subsequent CAL PURGE delay to prevent external alarms during calibration. NOTE: To prevent activating A1 & A2 low trip alarms at the controller, oxygen ranges transmit 884 counts (20.9% oxygen reading) upon entry into CAL PURGE. CAL MODE automatically exits if no keystrokes are detected after 5 minutes. Follow these GASMAX IIx calibration guidelines: Calibration accuracy is only as good as the calibration gas accuracy. R. C. Systems recommends calibration gases with NIST (National Institute of Standards and Technology) traceable accuracy to increase the validity of the calibration. Do not use a gas cylinder beyond its expiration date. Calibrate a new sensor before use. Allow the sensor to stabilize before starting calibration (approximately 5 minutes). Calibrate on a regular schedule. (R. C. Systems recommends once every 3 months, depending on use and sensor exposure to poisons and contaminants.) Calibrate only in a clean atmosphere, which is free of background gas. 14

18 Figure 5-1: Calibration Gas Input Use the following step-by-step procedure to perform ZERO and SPAN calibrations. 1. To enter the CAL MODE from the data displays, press the DOWN / CAL key and within 5 seconds press the EDIT key. Note: During CAL MODE, 75 counts (-15.6% FS ) is transmitted to listening receivers and signifies CAL MODE. This special value is used to inhibit alarm trips at the receiver. 2. Using the Cal-Cup, apply a clean ZERO gas or be sure there is no background target gas in the monitored area. After the reading is stable, (approximately 1 minute) press the EDIT key to perform a ZERO calibration. 3. If the ZERO calibration is successful, press the NEXT key to proceed to the SPAN check. 4. Apply the correct SPAN gas at.5 liters/min. After the reading is stable, (approximately 1 minute) press the EDIT key to perform a SPAN calibration. WARNING: The SPAN gas used must match the value specified since this is what the GASMAX IIx will indicate after a successful SPAN calibration. The Cal Span Value may be edited if it becomes necessary to apply a different gas concentration (see Cal Span Value in section 6.3). 5. If the SPAN calibration is successful, the display flashes REMOVE CAL GAS and starts the CAL PURGE delay (see section 6.6). Note: During CAL PURGE, toxic monitors transmit 0% FS to listening receivers to prevent alarms by residual upscale SPAN values. Oxygen monitors transmit a 20.9% oxygen reading during CAL PURGE because 0% FS would trip low oxygen alarms. 6. CAL MODE is complete after the end of the CAL PURGE delay. The flow chart in Figure 5-2 illustrates the above procedure from left to right. UP, CAL, NEXT & EDIT labels indicate keystrokes using the magnetic wand. The CAL MODE information screen 15

19 (top of the chart) is available for advanced users to see Offset / Gain calibration constants and live analog to digital converter (A/D) counts. Span Gas calibration values may also be edited from this screen. Holding the UP key, for 5 seconds during CAL MODE, displays this screen. Calibration history records are logged and may be viewed in the Sensor Information menu (see section 6-5). DATA DISPLAY 2 % LEL Measurement Name REPEAT CAL ZERO FAIL live reading/eunits EDIT to Set ZERO NEXT=SPAN CAL Mode NEXT KEY EDIT (If ZERO Cal Fails) (If ZERO Cal OK) ERROR CODE 4 Hold UP key 5 sec. CAL, then EDIT Apply ZVAL Eunits show for 5 seconds ZERO CAL Successful live reading/eunits Counts = xxxxxx Cal Span Value=xxxxxx EDIT=Set Span Value Offset = xxxx Gain = xxxx PGA = xxxx% NEXT = Return to Cal CAL MODE info screen (use to change SPAN GAS value and to see Offset / Gain constants) Hold UP key 5 sec. (If SPAN Cal Fails) REPEAT CAL SPAN FAIL ERROR CODE 5 Apply SVAL Eunits live reading/eunits EDIT to Set ZERO NEXT=EXIT CAL Mode show for 5 seconds NEXT EDIT (If SPAN Cal OK) SPAN CAL Successful Sensor Life Figure 5-2: Cal-Mode Flow Chart and Menus REMOVE CAL GAS Back to DATA DISPLAY 0 % LEL Measurement Name 5.2 ALARM OPERATION GASMAX IIx monitors have front panel LED indicators for Alarm 1, Alarm 2 and FAIL. Alarm LED s only flash during alarm events to conserve battery life. Low Battery is indicated by an icon on the LCD and by flashing the FAIL led. ALL ALARM CONDITIONS EXCEPT FOR LOW BATTERY AND FAULT INCREASE WIRELESS TRANSMISSIONS TO EVERY 6- SECONDS! ALARM 3 UNDERSTANDING FAULT / LEVEL OPERATION The A3 alarm is typically dedicated to FAIL conditions indicating sensor failures or out of measurement range conditions. However, some applications require a third level alarm. The A3 menu is identical to A1 & A2 and may be set to trip at an upscale level value. A3 WILL ALSO TRIP WITH MISSING OR FAILED SENSORS REGARDLESS OF THE LEVEL VALUE! CAUTION: Missing or failed sensors always trip the FAIL alarm. A3 and FAIL alarm conditions DO NOT cause the radio transmission rate to increase to 6-seconds. SECTION 6 SETUP MENU CONFIGURATION 6.1 Menus Database Configuration All GASMAX IIx configuration variables are stored in its non-volatile menu database. Upon installation, many menu items will contain default values from the factory and require changes to better match a user s particular application. GASMAX IIx menus may be configured from the magnetic keypad in just a few minutes per transmitter. For installations consisting of many points, a USB Interface device is offered to allow Smart Sensors, or the GASMAX IIx monitor to be configured from a PC s USB port. This is useful when GASMAX IIx units have not yet been installed or if a portable computer may be carried to each unit. The GASMAX IIx configuration menus tree is shown in Figure

20 Figure 6-1: Configuration Menu Tree 6.2 Configuration Using the Magnetic Wand: Passing the magnetic wand over the EDIT key, from either data display, displays EC INPUT PAGE 1 setup screen as shown in Figure 6-2. The UP / DOWN keys maneuver the pointer while EDIT enters sub-levels of menu items. All SETUP menu items have at least one page of submenus. Items with sub-menus are indicated by the > symbol (right hand pointing arrow) at the end of each line. Edit menu items by pointing to them, press the EDIT key to display the cursor, press UP / DOWN to change that character, press NEXT to move the cursor, then press EDIT again to load the new item and remove the cursor. Press NEXT to reverse out of the sub-menu. To view EC INPUT PAGE 2, press the DOWN key with the pointer aimed at the bottom item on PAGE 1. Figure 6-2: Setup Menu Entry 17

21 6.3 System Configuration Menus: The System Config. group consists of two pages of menus as shown in Figure 6-3. Each menu item s description follows in this section. Figure 6-3: System Config. Menus User Info may be edited to contain virtually any 16-character ASCII field. It is typically used to describe the monitored point by user tag # or other familiar terminology. Eunits (engineering units) may have up to a 10 character ASCII field. Many common gases have pre-configured Eunits based upon the sensor type and each may be edited in this menu as described in Configuration Using the Magnetic Wand section 5-2. Zero (0%) defines the reading to be displayed when 4mA (0%) is the GASMAX IIx output. Span (100%) defines the reading to be displayed when 20mA (100%) is the GASMAX IIx output. The highest reading allowed is 9999 includes negative polarity sign and one decimal point. Polarity is only indicated for negative readings. Decimal Points sets the resolution of the LCD readings and may be for 0, 1 or 2. Example: ZERO readings for 0, 1 & 2 DP s respectively are 0, 0.0 & Cal Span Value sets what upscale value must be applied when performing Span calibrations. Readout Deadband allows forcing low values to continue to read zero. This is useful when there are small amounts of background gases that cause fluctuating readouts above zero. The highest amount of deadband allowed is 5%. Track Negative, set to NO, causes negative values to read the Zero (0%) value in data displays. The CAL MODE readout displays negative values regardless of this setting and negative values below the Fault set point will still cause the Fault alarm to trip. The gas value s counts output always locks at 200 counts when the reading is negative. Backup Config. allows users to store the entire current GASMAX IIx menu database into non-volatile memory for restoration later if incorrect values are accidentally entered or uploaded. Restore Config. restores the GASMAX IIx menu database to the values from the most recent Backup Config. This menu item is only available if a smart sensor is not installed. The special keystroke sequence of 4 consecutive UP keys is also required to perform backup and restore operations. Upload Sensor Data allows manually uploading the entire smart sensor database to the GASMAX IIx from the smart sensor. This menu item only appears if a smart sensor is connected. 18

22 6.4 Alarm Settings: The Alarm Settings page has the Alarm 1, 2, 3 Setups and Event Log submenus shown in Figure 6-4. Alarm 1, Alarm 2 and Alarm 3/Fail menus are identical and therefore described only once in this section. Alarm conditions are indicated by A1, A2, A3 LCD icons and by flashing the A1, A2 and FAIL led s. The Event Log time and date stamps significant events such as power applied, alarm trips sensor faults and wireless INRange / Out of Range conditions. The wireless range icon changes to after an Out of Range and subsequent return to InRange event. It may be reset to normal with the Reset Range Icon menu. Figure 6-4: Alarm Settings Menus Set Point enters the engineering unit value where the alarm trips. It may be negative and trip when monitored values fall out of range in this direction. A3 has a default negative 5% of range Set Point with Low Trip set for YES. This makes it function as a FAULT alarm and trip when the monitored value is more than 5% out of range. Dead-Band has a minimum value of 1% and a maximum value of 10%. It is useful for preventing alarm cycling when the monitored value is hovering around the set point. EXAMPLE: With a range of ppm, if Dead-Band equals 5% and the set point is 20 ppm, after tripping at 20 ppm the value must drop below 15 ppm to reset. ON Delay allows entering a maximum 10 second delay before this alarm becomes active. This is useful for preventing nuisance alarms caused by brief spikes beyond the set point. OFF Delay allows entering a maximum 120 minute delay before clearing an alarm after the alarm condition is gone. This is useful for continuing an alarm function, such as operation of an exhaust fan, for a period of time after the alarm condition clears. Low Trip set to YES causes the alarm to trip as the value falls below the set point. Latching set to YES causes the alarm to remain active even after the condition is gone and only reset when the UP / RESET key is pressed from a data display. 19

23 6.5 Sensor Information: Sensor Information has the SENSOR SETUP/INFO menus shown in Figure 6-5 SENSOR SETTINGS/INFO Install Sensor > Recall Cal History > Input Type SMART > New Sensor 01/28/04 Recent Cal 04/05/04 Sensor Life EDIT INSTALL NEW SENSOR EDIT to install New Sensor. Any other key to Exit. EDIT INSTALL NEW SENSOR Historical CAL data Will be Deleted. EDIT to Accept NEXT to Abort CALIBRATION DATES Record 22 of 22 CAL Date: 04/05/04 UP/DOWN NEXT to to scroll EXIT. SMART SENSOR Type: Cat-Bead Span: 100 Zero: 0 SN: xxxxxx Born On: 01/28/04 Last Cal: 04/05/04 ANY key to Exit Figure 6-5: Sensor Information Menus Install New Sensor should always be performed when a new simple sensor is installed. This deletes historical CAL data and sets sensor life to 100% after initial calibration of the new simple sensor. The GASMAX IIx Smart sensor interface will automatically detect new smart sensors and this menu is therefore not available with a smart sensor connected. Recall Cal History recalls each successful calibration. These dates may be reviewed by scrolling with the UP / DOWN keys. Input Type indicates what kind of input or sensor the GASMAX IIx is configured to accept and is typically pre-configured at the factory. There are three Input Type possibilities consisting of simple EC negative, simple EC positive and Smart. Smart sensors upload sensor type and other data to the GASMAX IIx and may be viewed on the SMART SENSOR information screen. New Sensor displays the date when a new sensor was last installed. Recent Cal displays the most recent calibration date. 6.6 Clock / Warm-Up & Cal Purge Delays SETUP: Since the GASMAX IIx is equipped with a Real Time Clock & Calendar Time and Date must be set to correctly match its location. They are set at the factory in a 24 hour format but may require adjustment to match the location s time & date after shipment. Follow the procedure in Configuration Using the Magnetic Wand in section 6.2. Warm Up and Cal Purge time delays are also available to prevent unwanted alarm trips. Figure 6-6 shows the menu for these items. 20

24 CLOCK/DELAY SETUP Time 12:35:42 Date 04/22/04 Warm Up Sec 120 Cal Purge Sec 100 Figure 6-6: Clock & Calendar / Delay Timer Menu 6.7 COMMUNICATIONS SETUP: The Communications menu provides access to RADIO SETUP menus described below. Hop Channel and System ID settings must match these settings in the Server. Remote ID must be unique to each GASMAX IIx. Items tagged with an asterisk affect power consumption and may have significant affects upon battery life. Figure 6-7: Radio Setup Menu Hop Channel may be set from 1-32 and assigns the pseudo-random radio frequency hopping pattern. A transceiver will not go In Range of or communicate with a transceiver operating on a different Hop Channel. Different hop channels can be used to prevent radios in one network from listening to transmissions of another. Installations having more than one Server network should also have different hop channels for each network. 2.4GHZ variation: Hop channels on 2.4 GHZ models may be set between 0 and 39. Hop channels 0-19 includes EU low band frequencies MHZ. Hop channels includes EU high band frequencies MHZ. IMPORTANT!! EXPLORE WHAT FREQUENCIES ARE APPROPRIATE FOR THE FINAL LOCATION OF ANY WIRELESS SYSTEM. Remote ID may be set from and acts as the RTU address for this particular GASMAX IIx. Controller channels receiving this monitor s data must also be configured with this matching Remote ID address. System ID may be set from and is similar to a password character or network number and makes network eavesdropping more difficult. A transceiver will not go In Range of or communicate with a transceiver operating on a different System ID. *TX Multiples allows up to 5 consecutive repeats of EVERY transmission. The default setting of 1 should only be increased if there is no other way to improve communications success. Power consumption increases with radio transmissions and battery life will be affected by raising the TX Multiples setting. *TX Mode affects the way RF transmissions are made by the GASMAX IIx. This menu may be set for BROADCAST (default) or AUTO DESTINATION. AUTO DESTINATION should be used only when transmitting to a single receiving server. Since AUTO DESTINATION creates an acknowledge hand shake returned from the receiver, only one receiver is allowed to avoid data collisions of the acknowledge signal. If an acknowledge is not received by the GASMAX IIx it transmits repeatedly up to 16 times. BROADCAST may be used for any application but is required when transmitting to a 21

25 Server and other Client radios. BROADCAST always transmits the packet 4 times and does not require any acknowledge returned by the receivers. *TX Power (900MHZ models only) may be set for 10mW, 200mW, 400mW and 1 watt. If the GASMAX IIx monitor is battery or solar powered, the TX Power setting should be set as low as possible to sustain reliable communication. The maximum TX Power setting is 30db (1 watt). Each time TX power is reduced by half, antenna transmit power is reduced by 3dB. 2.4GHZ variation: The TX Power menu is not available in 2.4GHZ models and the power level is fixed at 50mW. TX Verbose should be set to NO for normal operation. YES entries cause the GASMAX IIx to transmit additional information that may be used in future products. Radio Status opens a page indicating if the GASMAX IIx is In-Range of the Server. A reading on this page displays the internal 3.3V power supply value. * TX Multiples, TX Mode and TX Power menu settings are available to improve communications reliability by increasing the quantity and power of wireless transmissions. IMPORTANT! Ensure proper selection and location of antennas before increasing TX Multiples and TX Power settings! Battery life will be reduced by increasing these settings. Proper selection and location of antennas contributes much more to successful communications, without sacrificing battery life, than these settings GASMAX IIx Operation with C1 Protector Controllers Figure 6-8 shows correct settings for the C1 Protector base station s Data From menu to receive data from GASMAX IIx monitors.. Each C1 channel s Remote ID must match the GASMAX IIx Remote ID setting (see section 6.7) in order for its VALUE to appear on the desired C1 channel. During normal operation, the GASMAX IIx digital output value equals 75 counts, or minus 15.6%, during CAL MODE. Enabling the C1 Protector s INPUT MARKER menu as shown on the right menu in Figure 6-8 causes the C1 to indicate IN CAL when the GASMAX IIx CAL MODE activated. When Input Req is set for VALUE, this C1 channel reads the GASMAX IIx monitored gas value. If Input Req is set for BATT, the C1 channel reads the battery voltage from the GASMAX IIx with the same Remote ID. To properly display the GASMAX IIx battery voltage, the C1 s engineering unit range should be set to VDC. Even if this channel reads VALUE from the GASMAX IIx, the battery voltage is displayed at the bottom of this C1 menu as shown in Figure 6-8. Figure 6-8: C1 Protector Base Station Data From Menu 22

26 6.7.2 GASMAX IIx Operation with C2 Quad Protector Controllers FIGURES 6-9 and 6-10 show correct settings for a C2 Quad Controller to receive data from GASMAX IIx monitors. Figure 6-9 C2 Quad controllers must have their Communications menus set for Wireless Receiver mode as shown in Figure 6-9. In Receiver mode the C2 Quad may have 1-4 channels configured to receive input data from 1-4 GASMAX IIx sensor transmitters. Channel input type is configured in the ANALOG SETUP menu located within the Input/Output Setup menus as shown in Figure GASMAX IIx monitors transmit 200 counts for 0% and 1000 counts for 100% full scale readings, so Input Min/Max menu values should be set for 200 & The Remote Xmitter ID menu entry must match the Remote ID address setting in the GASMAX IIx providing data to this C2 Quad Controller channel. The voltage level of the 3.6 volt lithium battery and the most recent A/D Counts value are displayed at bottom of the screen. Figure SYSTEM SECURITY: The SYSTEM SECURITY menu in Figure 6-11 offers two levels of protection. A LOW level allows CAL MODE sensor calibrations but requires the 4-digit Pass Code prior to altering menus. HIGH level locks the entire menu database and CAL Mode until the correct Pass Code is entered. LOW and HIGH security levels always allow viewing of configuration menus but they may not be changed. Contact Name is a 12 character ASCII field available for displaying a phone # or name of personal who know the Pass Code. Lost Pass Codes may be recovered by entering the locked security menu and holding the UP key for 5 seconds. The 4-digit code appears near the bottom of the screen. SYSTEM SECURITY Contact Name Secure Level LOW Pass Code Unlocked Figure 6-11: System Security Menu 23

27 6.9 LCD Contrast Adj: LCD Contrast Adj. may be set for optimum viewing using the menu shown in Figure CONTRAST UP/DOWN to change NEXT to EXIT Figure 6-12: LCD Contrast Adjust Menu 24

28 SECTION 7 TECHNICIANS ONLY MENUS 7.1 Introduction: WARNING! Users of these menus must have a detailed understanding of their functions. Monitoring of target gases, processing of alarms, wireless communications should not be relied upon while editing these menus! Back-up the current configuration prior to altering any Technical menus in case Restore is required later (see section 6.3). The TECHNICIAN ONLY menu group in Figure 7-1 contains items that are factory configured depending upon the type sensor input connected to the GASMAX IIx BRIDGE/RF. They should not be tampered with after installation. If configured incorrectly, some items will prevent monitoring of target gases. Access requires a special key sequence of four consecutive UP keystrokes to prevent accidental modification of critical items. Figure 7-1: Technicians Menu Tree 7.2 Set Balance / Set Sensor Voltage (Technicians only!): Set Balance and Set Sensor Voltage are used when Input Type is for Bridge sensors. They are factory configured and only require field adjustment if the bridge sensor is mounted remote from the GASMAX IIx or if a new sensor is installed. Other input type entries draw a line through these menus and they are inactive. Sensors mounted a long distance away may require the voltage at the GASMAX IIx be higher than the sensor s rated voltage to compensate for losses in field wiring. Be careful not to exceed the rated voltage at the sensor s A and R terminals. Set Balance allows balancing of the bridge sensor and must only be performed with ZERO gas on the sensor (Figure 7-2). Balance is similar to a very coarse ZERO calibration and does not need to be precise since subsequent calibrations will correct for small errors. ZERO gas applied to the sensor should provide a Reading of 3 to +3 on the SENSOR BALANCE menu. 25