MSA 610A User manual

Model 610A
Four Channel Control Module
Combustible Gas Applications
The inf ormation and technical data disclosed in
this document may be used and disseminated
only for the purposes and to the extent
specifically authorized in writing by General
Monitors.
Instruction Manual 07-21
General Monitors reserves the right to change
published specifications and designs without
prior notice.
Part No MAN610A
Revision H07-21
CR 800000051894

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Table of Contents
MODEL 610A........................................................................................................................... I
FOUR CHANNEL CONTROL MODULE................................................................................... I
COMBUSTIBLE GAS APPLICATIONS.................................................................................... I
ILLUSTRATIONS...................................................................................................................VI
LIST OF TABLES................................................................................................................. VII
INTRODUCTION..................................................................................................................... 1
Protection for Life..................................................................................................................1
Sp ec ial Warning....................................................................................................................1
Customer Support......................................................................................................2
1.0 BEFORE INSTALLATION................................................................................................. 3
1.1 Differences Between Models 610A and 610...................................................................3
1.2 General Product Description........................................................................................3
1.3 Controller..................................................................................................................4
1.4 S e nso r A ss emb ly .......................................................................................................5
2.0 INSTALLATION................................................................................................................ 6
2.1 Location of the Controller............................................................................................6
2.2 Power Connections ....................................................................................................6
2.3 Battery Backup..........................................................................................................7
2.4 Analog Output Connection ........................................................................................11
2.5 Remote Reset Connection ........................................................................................11
2.6 Choosing Sensor Locations.......................................................................................11
2.6.1 V apo r D ens it y ..............................................................................................11
2.6.2 Air Currents .................................................................................................11
2.6.3 Likely Sources of Gas Emission......................................................................11
2.6.4 Environmental Factors...................................................................................12
2.6.5 Catalytic Poisons..........................................................................................12
2.7 Sensor Installation ...................................................................................................12
2.8 Alarm Wiri ng Co nnec tio ns .........................................................................................15
2.9 Special Voting Option...............................................................................................16
3.0 START-UP AND OPERATION........................................................................................ 18
3.1 Types of User Interf aces ...........................................................................................18
3.2 Initial Application of Power ........................................................................................19
3.3 Resetting Latched Alarms .........................................................................................19
3.4 Analog Output .........................................................................................................19
3.5 Calibration Check Mode............................................................................................20
3.6 Calibration Mode......................................................................................................21

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3.6.1 Aborting Calibration ......................................................................................21
3.7 S e t up and S et up Check Mod es ..................................................................................22
3.7.1 Entering the Password ..................................................................................23
3.7.2 Hi g h Al arm Opt io ns .......................................................................................23
3.7.3 Low Alarm Options .......................................................................................23
3.7.4 Calib ration Level Option.................................................................................24
3.7.5 Password Enabled/Disabl ed Opt io n.................................................................24
3.7.6 LED Test.....................................................................................................24
3.8 Setup Mode Selection Table......................................................................................25
3.9 Check Points for Calibration and Operation..................................................................26
3.9.1 Frequency of Calibration................................................................................26
3.9.2 Background of Combustible Gases..................................................................26
3.9.3 Rep l ac i ng a S enso r.......................................................................................26
3.10 Special Options.......................................................................................................26
3.10.1 Optional Model 610A Controller for Zone Control (Voting)...................................26
3.10.2 Set Up Options.............................................................................................27
4.0 MAINTENANCE.............................................................................................................. 28
4.1 General Maintenance...............................................................................................28
4.2 P eriod ic Sys tem Verificat io n ......................................................................................28
5.0 TROUBLESHOOTING .................................................................................................... 29
5.1 General..................................................................................................................29
5.2 Troubleshooting Table..............................................................................................29
5.3 Fault Codes ............................................................................................................30
6.0 CUSTOMER SUPPORT .................................................................................................. 31
6.1 General Monitors’ Offices..........................................................................................31
6.2 Other Sources of Help ..............................................................................................31
7.0 APPENDIX...................................................................................................................... 32
7.1 Warranty ................................................................................................................32
7.2 S e nso r Op erat i ng P rinc iple........................................................................................32
7.3 General Specifications - Controller..............................................................................34
7.3.1 Mechanical Specifications..............................................................................34
7.3.2 Environmental Specific atio ns..........................................................................34
7.3.3 E lec tric al Specif ic at io ns .................................................................................34
7.3.4 S yst em Sp ecif icatio ns ...................................................................................34
7.4 General Specifications - Sensor.................................................................................34
7.4.1 System Specif icat io ns ...................................................................................34
7.4.2 Environmental Specifications..........................................................................34
7.5 Cable Requirements.................................................................................................35
7.6 S enso rs..................................................................................................................35
7.7 Accessories ............................................................................................................36
7.7.1 Calibration Equipment ...................................................................................36
7.7.2 Sensor Covers .............................................................................................36
7.8 Recommended Spare Parts.......................................................................................37
7.9 Sample Calibration Schedule and Checklist .................................................................38
7.10 Engineering Documentation.......................................................................................40

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7.10.1 Panel Assembly, Panel Mount – 98, Ref: 10199C..............................................40
7.10.2 Interconnec tion Drawing Zone Control Model 610A Controller .............................41

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Il l us t rat io nsFigure 1: Model 610A Controller ..............................................................................4
Figure 2: Sc hem at ic B at t ery B ack up Sy st em .............................................................................7
Figure 3: Outline Drawing & Rear Terminal Connections (REF: 20659) .........................................8
Figure 4: Rear Terminal Common Relay Configuration................................................................9
Figure 5: Rear Terminal Discrete Relay Configuration...............................................................10
Figure 6: Junc tion Box Assembly – S enso r .............................................................................14
Figure 7: Protection Circuit for Relay Contacts.........................................................................16
Figure 8: F ro nt P anel D isp lay ................................................................................................18
Figure 9: Portable Purge Calibrator........................................................................................20
Figure 10: Panel Assembly, Panel Mount –98, Ref: 10199C ......................................................41
Figure 11: Interconnection Drawing Zone Control Model 610A Controller.....................................41

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List of Tables
Table 1: Model 610A Mounting Parts........................................................................................6
Tab le 2: Terminal Colors ......................................................................................................13
Table 3: Maximum Cable Run Distance..................................................................................13
Table 4: Sensor Guards .......................................................................................................15
Table 5: De-Energized Alarm Relay Contacts ..........................................................................15
Table 6: Energized Alarm Relay Terminations .........................................................................15
Table 7: S et up D isp lay Opt io ns .............................................................................................25
Table 8: Relay Alarm Options................................................................................................27
Tab le 9: Tro ub les hoo ting Tab l e .............................................................................................30
Tab le 10: Max im um Cab l e Leng t hs ........................................................................................35
Table 11: GMI Sensors Available for 610A System...................................................................35
Table 12: Recommended Spare Parts....................................................................................37
Table 13: Prod uct Configuration Tables ......................................... Error! Bookmark not defined.

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Introduction
Protection for Life
General Monitors’ mission is to benefit society by providing solutions through industry
leading saf ety products, services, and systems that save lives and protect capital
resources from the dangers of hazardous flames, gases, and vapors.
This manual provides instruction for installing and operating the General Monitors Model
610A Four Channel Control Module for Combustible Gas Applications. While t he 610A
system is easy to install and operate, this manual should be read in f ull and the
inf ormation contained herein understood bef ore attempting to place the system in
service.
The saf ety products you have purchased should be handled carefully and installed,
calibrated, and maintained in accordance with the respective product instruction manual.
Remember these products are f or your safety.
Special Warning
Through engineering design, testing, manufacturing techniques, and rigid quality control,
General Monitors (GMI) supplies the finest gas detection system s av ail abl e. The us er
must recognize his responsibility for maintaining the gas detection system in operational
condition.
The Model 610A Four Channel Combustible Gas Monitor contains com ponent s, which
can be damaged by static electricity. Special care must be taken when wiring the system,
to ensure that only the connection points are touched.
Only catalytic bead sensors designed by General Monitors will work with the Model 610A
Controller. Any attempt to use a sensor that has not been approved by General Monitors,
will void the warranty.
General Monitors cautions, as with all equipment of this type, that high levels or long
exposure to certain atmospheres will “poison” the sensor catalyst and eventually affect
sensitivity. Please see Section 2.6.5 for specific information. Use in s uch at mos pheres
requires calibration checks on a more frequent schedule than normal. General Moni tors
should be consulted for an application feasibility determination, before installing a system
in such atmospheres.
General Monitors’ sensors and sensor housings are designed and tested f or use in
certain classes of hazardous atmospheres. Explosion-proof integrity cannot be
maintained, if sensors and sensor housings are operated in other than the “as designed”
condition. Terminal access covers of sensor housings must be securely fastened. Sensor
housing must be installed in accordance with National Electrical Code acceptable
practices, for the class of hazardous atmospheres.

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Sensors are designed with sintered metal, or screen covers, that act as flame arres t ors.
Do not operate sensors without screen or sintered metal parts in place.
General Monitors’ gas detection systems are primarily safety devices for the protection of
personnel and facilities and must be “always ready”. With proper installation, calibration,
and maintenance, the system provides continuous monitoring of hazardous areas. The
user must assume all liability for misuse of General Monitors’ gas detection systems.
The system’s full two-year warranty will be voided if customer personnel, or third parties,
damage the system during repair attempts.
Customer Support
For additional product information not contained in this manual, please contact General
Monitors Customer Support (Section 6.1).

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1.0 Before Installation
1.1 Differences Between Models 610A and 610
610A differences:
•Wiring: Connectors must be rewired for 610A
•Auto-Calibration
•Front Panel: Polycarbonate with inlay
Ref er to Section 2.0, Installation, and Section 3.0, Startup and Operation, for details.
1.2 General Product Description
The Model 610A Controller is a four-channel system designed to continuously monitor for
potential explosive concentrations of most combustible gases/vapors. Normall y, onl y a
periodic calibration check is needed to assure dependable performance. The system
operates in the range of 0-100% LEL (Lower Explosive Limit) and is calibrated f or a
particular gas or vapor. There are relatively few combustible gases, which should not be
monitored; however, as a precaution, GMI should always be consulted to verif y the
f easibility of monitoring any gas or vapor other than those specif ied at the time of
purchase.
The Model 610A Controller consists of a controller plus four sensor assemblies. The
controller is fully solid-state. It should be mounted in a weather protected, non-hazardous
area. Several GMI mounting accessories are available for panel, wall or 19-inch rack
installation. For hazardous areas, an explosion-proof housing is available for Class I,
Division 1 and Division 2, Groups B, C & D.
NOTE: Sensor assemblies may be mounted outdoors in hazardous areas
(National Electric Code Class I, Division 1 and Division 2, Groups B, C & D).
GMI catalytic bead sensors must be connected to the controller in accordance with the
installation instructions in this manual.
NOTE: The 610A is dif f erent than its predecessor the 610. The 610A calib ration is
automatic where the 610 must be manually calibrated. Please check the
individual manuals for details about wiring, set up and operat io n of t hese t wo
units.