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Microprocessor control
Addressing system up to 10
points
IP55 enclosure protection
Duplicated address detection
3 configurable output relays
External alarms control
Reference Norms:
EN 50270
EN 60079291
Application
NRG Tech Srl is recognized within the gas industry for providing a comprehensive range of highreliability
gas detection for many applications. We have installed and commissioned natural gas and carbon monoxide
sensors in applications such as boiler rooms, kitchens, car parks, aircraft hangers, factories and shopping
centers. The GCU410 is the control unit for the complete range of addressable gas sensors. This unit is part
of the GCU series and is able to address up to 10 devices in complex gas detection systems. Every NRG
Tech Srl product is manufactured to meet relevant European Norms and proposals for explosive and toxic
gases.
Operation
The GCU410 can detect both explosive and toxic gases. When the remote device detects the presence of
the target gas a digital bus signal is sent to the gas detection controller. The signal information is the
measuring unit, the gas concentration, the address of the connected unit and the general status. The
GCU410 can operate a siren relay used for remote sirens or visual indicators, electro valves and others
peripherals. In the case of explosive gases, when the gas reaches a preset level, the main alarm relay is
activated to break the electrical supply to the gas safety shutoff valve. The GCU410 also has a separate
voltfree fault relay that actuates if the controller looses partially or completely the functionality. This
controller can be interlinked with a fire alarm so that in the event of a fire, it would shut down the gas
supply.
Features
The GCU410 is a wall mount microprocessor based gas detector control unit. It can be configured to meet
customer requirements. The following parameters can be changed using the onboard menu:
Three alarm levels for each sensor
Alarm relay action (latching or autoreset)
The GCU410 has dedicated terminal blocks for the following:
The fault, siren, prealarm and alarm circuit wiring
The alarm output circuit wiring (eg. to BMS)
The input for external alarms (eg. from fire panel)
The front panel has an LCD display with resistive touch screen showing date, time, current sensor levels,
active alarms and much more.
Important notes
Carefully read the following instructions prior to installation of this device. Always keep this pamphlet for
future reference.
Ensure that the gas detection system is wired correctly and is only used for the purpose for which it is
intended.
Devices to be connected
ATEX No No No Exd
Front panel layout
"Power". Lights when the supply voltage is applied. This light flashes during selfdiagnostics start up.
"Fault". Indicates a loss of signal, incorrect connection, address conflict of a device connected to the bus.
When the fault led is blinking, the fault relay switches the contacts and the display will show the type of
fault detected. When the fault led is constant, a full fault status is reached and the fault relay switches the
contacts. To reactivate the device, the damaged part must be repaired or disabled using the setting
program, and then the RESET button must be pressed.
"Alarm". Lights when the main alarm gas threshold has been reached.
"Comm". Lights if the communication bus is working.
GCU410 bar. The cursor bar continuously moves to signal the gas control panel activity.
Menu button. When pressed let the user get access to the main menu window. A password is requested.
Reset button. When pressed it resets all internal volatile memory. If pressed in presence of a
misconnected slave device or in the case of an address conflict fault, it restarts the controller.
About button. Gives gas control panel information if pressed.
2/16
Connections layout
Symbol Function
P Phase terminal 230VAC
i Ground terminal. Used for internal protection circuitry and for the bus shield
N Neutral terminal 230VAC
BATTERY Negative terminal of secondary 24V supply (or rechargeable battery)
BATTERY + Positive terminal of secondary 24V supply (or rechargeable battery)
RS485 0 Common signal terminal for addressable system bus
RS485 A+ Positive signal terminal for addressable system bus
RS485 B Negative signal terminal for addressable system bus
R1 NO Alarm Relay n. 1. Normally open terminal clean contact
R1 C Alarm Relay n. 1. Common terminal clean contact
R1 NC Alarm Relay n. 1. Normally close terminal clean contact
R2 NO Alarm Relay n. 2. Normally open terminal clean contact
R2 C Alarm Relay n. 2. Common terminal clean contact
R2 NC Alarm Relay n. 2. Normally close terminal clean contact
R3 NO Alarm Relay n. 3. Normally open terminal clean contact
R3 C Alarm Relay n. 3. Common terminal clean contact
R3 NC Alarm Relay n. 3. Normally close terminal clean contact
AL IN 1 Input from external pushbutton, fire controller, BMS or similar device. The
AL IN 1 external device should have a normally open free of voltage contact as interface.
AL IN 2 Input from external pushbutton, fire controller, BMS or similar device. The
AL IN 2 external device should have a normally open free of voltage contact as interface.
FAULT NO Fault relay. Normally open terminal clean contact
FAULT C Fault relay. Common terminal clean contact
FAULT NC Fault relay. Normally close terminal clean contact
AL OUT 1 NO Auxiliary signal output relay n. 1. Normally open terminal clean contact
AL OUT 1 C Auxiliary signal output relay n. 1. Common terminal clean contact
AL OUT 1 NC Auxiliary signal output relay n. 1. Normally close terminal clean contact
AL OUT 2 NO Auxiliary signal output relay n. 2. Normally open terminal clean contact
AL OUT 2 C Auxiliary signal output relay n. 2. Common terminal clean contact
AL OUT 2 NC Auxiliary signal output relay n. 2. Normally close terminal clean contact
3/16
Typical wiring schematic
(1) For distances of sensorcentral wiring less than 100 meters, it is possible to use a single cable with 4
wires to bring both the power supply and the signal to the sensors. See the paragraph of the technical
specifications for the cable sections.
(2) It is a reference scheme, the connections to the peripheral devices may vary depending on the type of
device connected and the type of use. Carefully check the connection diagram on the peripheral data sheet.
All relays are free of voltage.
4/16
Electrical installation
The GCU410 is a safety device designed to give audible alarms and automatically provide latched electrical
isolation of associated gas safety shut off valves in the event of a gas leak or buildup of toxic gases. The
addressable sensors and the controllers can be located up to 1000m from the gas control panel. Signals
cable for the bus should be Belden 3106A or equivalent. Is essential to use screened cable for the bus
connection to the others devices. The wiring should be performed by a qualified person in accordance with
current regulations. Do not mount close to any heat source or in an area where moisture is likely to effect
operation. Sensors should be positioned as shown below.
Installing a sensor
The sensors must be mounted as shown below with the sensor head pointing vertically down. When
replacing sensors never separate a sensing head from its PCB. The sensor will have been calibrated using
this particular board and therefore will not function correctly with any other.
Important notes
Always check the wiring before powering up the system. Do not test this sensor with anything other than
certified test gas (see 'GCU410 Operation' section for further information). Concentrations above this will
damage the sensor and shorten sensor life. The installation of this gas detector does not release the user
from observing all the regulations concerning the characteristics, installation and the use of gas appliances;
the ventilation of the environment and the elimination of combustion products in accordance with the local
recommendations, regulations, and bylaws. For any damage caused to people, property or animals resulting
from the incorrect connection, installation or application of this gas detector NRG Tech will not be held
responsible or liable.
5/16
Powering up
After ensuring correct installation of the gas control panel GCU410, the unit can be switched on. A led test
is performed and the initialization procedure begins to scan for all the 256 available addresses (from 0 to
255 included). When the percentage reaches 100% all connected devices (also called "nodes") are stored in
the internal memory. The "Initialize..." window disappears showing the nodes addresses, the type of node
and the status.
Main screen
The normal screen will show the status of firsts 10 devices connected to the system bus. On the upperleft
corner, date and time are updated continuously (to adjust it, Menu>Time Set). On the upper side there is
the virtual LED's panel and on the upperright corner, there is an "alive bar" that cycles to confirm the user
about the efficiency of the controller. The address field is composed of the nodes primary address and
secondary address. The first 3 digits are for the primary address (from 0 to 255) that is the number set at
the device side (see the datasheet of the connected item for details), the following 3 digits are for the
secondary address. The secondary address is automatically generated from the controller and is related to
the physical port in which the detector/sensor is connected. For example, in the figure above at the first
row, there is a gas sensor connected to the port 1 of a device (can be a controller or a port expander) that
has the address set to 002. The arrows up and down on the right side of the nodes list allow to scroll up
and down the listed 10 items each time is pressed.
6/16
Alarm state
The alarm condition will be activated according to the settings for each and every input. When an alarm
from a node is detected, the interesting device is highlighted in red, the primary and secondary address is
written above the red alarm led and a vertical bar on the left side of the nodes list appears to indicate the
entire node involved. If the alarm detected is not originated by a secondary address but is from the node
itself, only the vertical bar and the writing above the red alarm led will appear.
When the alarm cause is removed the GCU410 controller leaves the red alarm led constantly on until the
reset button on the screen is pressed. Also, the alarm relays (if the latch feature is enabled in Menu
>Relays Set) remain activated until the reset is pressed. The "R3" relay is in the failsafe configuration if
the controller looses the power supply (also from batteries), the relay switches its position.
Fault state
The fault condition is activated when an internal GCU410 fault is detected or for bus errors (node absence
or node conflict). If a device connected to the bus is in a fault state, the GCU410 will signal this event but
doesn't act the fault built in relay. At the contrary, the relay will activate if:
is missing a node that was present in the list created by an initial turn on or a remapping.
two or more nodes on the bus have the same address.
an internal error occurs.
The fault relay is in the failsafe configuration if the controller looses the power supply (also from batteries),
the relay switches its position.
7/16
Initial setup
To get access to the controller configuration press the Menu button. Once pressed a 4 key password should
be inserted ("1","2","3","4" by default). For the next five minutes, the user has free access to the menus
without reinsert the password.
Controller settings menu
From this menu, you can select to change the internal calendar and clock (Time Set), modify the sensors
alarm thresholds (Sensors Set), change the relay behavior (Relays Set) and remap the entire system
(Remap Net).
8/16
Time settings
Using the arrow buttons the user can change the fields present in this menu. From the left to the right there
is the field "day" (from 1 to 31), "month" (from 1 to 12), "year" (from 2000 to 2099), "hour" (from 0 to 23)
and "min" (from 0 to 59). Meanwhile, the changes are in progress also the date and time on the upperleft
corner of the screen will change. Once the date and time are updated, close the menu pressing the "X"
symbol on the upperright corner.
Sensors settings
In this menu, the user can change the thresholds for the alarms for each sensor in the system. With the up
and down arrows on the left of the menu, the user chooses the primary and secondary address of the target
sensor. Once selected the right sensor, push the relay button (can be "R1", "R2", "R3") and change the
threshold linked to the relay button highlighted. For each sensor, the user can have up to three threshold
levels. The threshold of relay "R3" should be greater or equal than the threshold of relay "R2" and the
threshold of relay "R2" should be greater or equal than the threshold of relay "R1". The control panel
software will guide the user to respect the relays priority.
9/16
Relays settings
From this menu, the user can select if the control panel relays will have the latching feature or not. Pushing
the Latch button of the relevant relay you can toggle on or off this function. When the button is colored the
latching function is active and the relay associated will remain in alarm position also after the event is
terminated.
Remapping
If a device on the bus is lost for a misconnection, when reconnected an automatic remap of the entire
system will be started. Also manual remap can be done by pushing the Remap Net button on the main
menu screen. The remap function can take time depending on the connected devices to the bus.
10/16
Duplicate node address detection
Up to 10 duplicate nodes can be detected by this controller. A fault is raised when a conflict is detected. The
detection procedure can be long (up to several minutes if the net is composed of hundreds of sensors)
because is based on many slave replies to avoid false alarms. Once the conflict is detected, the GCU410 will
show the involved address like in the following picture.
GCU410 operation
Before powering up the control unit once again check that all electrical connections are correct.
1. Apply 230V supply to the P and N terminals. Ensure that the correct fuse is installed in the supply line.
2. The display and all lights on the display will light up in turn. This will take approximately 10 seconds. This
checks the function of all the LEDs.
3. The "Power" LED will remain flashing for about 90 seconds and the "initialize" window gives the
completion percentage. This is the sensor warmup period and the net nodes detection. The gas sensors will
not provide gas detection during this period. When the power light becomes constant and the "initialize"
window disappears the controller is in operation.
4. Set all options using the touch screen and following the instructions present in the previous pages of this
manual.
5. Simulate a gas leakage with the use of calibrated test gas.
6. To simulate a sensor fault situation disconnect the node device from the bus. The controller will go into a
fault state and the fault relay will be actuated.
Maintenance procedure
The detectors connected to this control panel must be function checked as described above using calibrated
test gas every 6 months.
In case of alarm
Extinguish any naked flames.
Do not switch lights or electrical devices on or off.
Open all windows and doors to increase ventilation.
If the red highlighted row indication is not present the levels of gas have dropped. A responsible, qualified
person is now safe to find the cause of the alarm.
If the alarm sound remains constant, and the cause is not evident or possible to eliminate turn off the
emergency isolation valves to the area and contact your gas provider emergency line. They will advise
accordingly.
11/16
Troubleshooting
The problem The solution
No lights are illuminated on the fascia of the detector Check that the electrical supply is reaching the
device and that the plug in terminal rail is pushed
into place.
The fault light is flashing and the status of one or The node address is duplicated at slave side or a
more nodes is marked "CONFLICT". very poor shielding is provided. Verify locally at the
address highlighted. If two devices have the same
address, change one of it. If the addresses are
correct verify the shield cable or electromagnetic
disturbances near the device. The shield of the
cable must be connected to ground only at the side
of the master unit. Press the RESET key to reboot
the master device once the problem is solved.
The fault light is flashing and the status of one or Check if there is a disconnected bus cable at the
more nodes is marked "". address highlighted. When reconnected the master,
the unit will do a "Remapping" of the system.
Sensor fault light is constant Check if there is a visible damage to the controller
components. Press the reset button and check all
the device settings.
The controller is subject to repeated alarms Ensure that there is not an occasional gas leak.
This
could be due to a valve or joint which leaks under
pressure.
The controller is in a main alarm condition and the Check that the connections are correct and that
main gas valve is not closing power is supplied to the valve i.e. the valve is not
stuck in the open position. The function of the
alarm relays can be checked by doing a test with
calibrated gas bottles. Check that the main alarm
action is configured for a latching alarm (see the
setting on the internal menu).
12/16
Overall dimensions
Top view
Side view
13/16
Technical specification
Mains power ................................................................................................. 230VAC 50/60Hz ±10%
Secondary power through battery .................................................................................. 24VDC ±10%
Recommended battery (optional) ......................................................................... 24V 2.3Ah lead AGM
Maximum power consumption (mains power) ................................................................................. 5W
Maximum power consumption (secondary DC power) ................................................................... 4.5W
Relay contact range (except alarm out signal) ......................... 10A 250VAC resistive 5A 30VDC resistive
Alarm out relay contact range .............................................. 0.5A 250VAC resistive 2A 30VDC resistive
Number of sensors that can be connected ................................................................. 10 directly on bus
Slave transmission time ............................................................................................... 160ms typical
Sensor fault ............................................................................ Open/short circuit, sensor deterioration
Sensor input signal .................................................................................................... Proprietary bus
Device precision .................................................................................................................... 1% FS
Working temperature ................................................................................................ 10°C to +40°C
Working humidity ..................................................................................... 080% RH (non condensed)
Warmup time ................................................................................................................ 90 seconds
Stabilization time .......................................................................................................... < 3 seconds
Distance from "slave" unit (1) ............................................................................................. <1000 m
Distance from "slave" unit with supply on cable (2) .................................................................... <100 m
Dimensions ............................................................................................. 406mm x 306mm x 200mm
Protecting rating for the "W" version............................................................................................ IP55
(1) Cable Belden 3106A or equivalent.
(2) Four wire shielded cable with 0,5mm2 minimum size for supply pair, twisted AWG22 for data pair.
14/16
Notes
15/16
Warranty
The warranty term is 2 years from manufacturing date, in NRG Tech S.r.l.
agreement with the following conditions. The components Via Primo Maggio, 23
acknowledged as faulty will be replaced free of charge, 35030 Bastia di Rovolon (PD)
excluding the replacement of plastic or aluminium cases, ITALY
bags, packing, batteries and technical reports. The device Email: info@nrgtech.it
must arrive free of shipment charges to the NRG Tech Web: http:// www.nrgtech.it
company. Defects caused by unauthorized personnel's
tampering, incorrect installation and negligence resulting
from phenomena outside normal functioning shall be
excluded from the warranty.
The NRG Tech company is not liable for possible damage,
direct or indirect, to people, animals or things, from product
faults and from its enforced suspension of use.
DSHEN2616r6