MSA Chillgard LC User manual

Chillgard®LC
Control Module
Instruction Manual
"! WARNING
THIS MANUAL MUST BE CAREFULLY READ BY ALL
INDIVIDUALSWHOHAVEORWILLHAVETHERESPONSIBILITY
FOR INSTALLING, USING, MAINTAINING OR SERVICING THIS
PRODUCT. Like any piece of complex equipment, this product
will perform as designed only if installed, used and serviced in
accordance with the manufacturer’s instructions. OTHERWISE,
IT COULD FAIL TO PERFORM AS DESIGNED AND PERSONS
WHO RELY ON THIS PRODUCT FOR THEIR SAFETY COULD
SUSTAIN SEVERE PERSONAL INJURY OR DEATH.
The warranties made by Mine Safety Appliances Company with respect to this product are
voided if the product is not installed, used and serviced in accordance with the instructions
in this manual. Please protect yourself and others by following them. We encourage our
customers to write or call regarding this equipment prior to use or for any additional
information relative to use or repairs.
MSA North America 1-800-MSA-INST or FAX [phone]
MSA International [phone] or FAX [phone]
In Canada 1-800-267-0672 or FAX [phone]
© Mine Safety Appliances Company 2008 - All Rights Reserved
This manual is available on the internet at www.msanet.com
Manufactured by
MSA NORTH AMERICA
PITTSBURGH, PENNSYLVANIA 15230
(L) REV 4 I MZ001-036 10036865

MSA
Permanent Instrument Warranty
1. Warranty- Seller warrants that this product
will be free from mechanical defect or faulty
workmanship for a period of two years
from date of shipment, provided it is
maintained and used in accordance with
Seller’s instructions and/or
recommendations. This warranty does not
apply to expendable or consumable parts
whose normal life expectancy is less than
one (1) year such as, but not limited to,
non-rechargeable batteries, filament units,
filter, lamps, fuses etc. The Seller shall be
released from all obligations under this
warranty in the event repairs or
modifications are made by persons other
than its own or authorized service
personnel or if the warranty claim results
from physical abuse or misuse of the
product. No agent, employee or
representative of the Seller has any
authority to bind the Seller to any
affirmation, representation or warranty
concerning the product. Seller makes no
warranty concerning components or
accessories not manufactured by the
Seller, but will pass on to the Purchaser all
warranties of manufacturers of such
components. THIS WARRANTY IS IN
LIEU OF ALL OTHER WARRANTIES,
EXPRESSED, IMPLIED OR STATUTORY,
AND IS STRICTLY LIMITED TO THE
TERMS HEREOF. SELLER
SPECIFICALLY DISCLAIMS ANY
WARRANTY OF MERCHANTABILITY OR
OF FITNESS FOR A PARTICULAR
PURPOSE.
2. Exclusive Remedy- It is expressly agreed
that Purchaser’s sole and exclusive remedy
for breach of the above warranty, for any
tortious conduct of Seller, or for any other
cause of action, shall be the repair and/or
replacement at Seller’s option, of any
equipment or parts thereof, which after
examination by Seller is proven to be
defective. Replacement equipment and/or
parts will be provided at no cost to
Purchaser, F.O.B. Seller’s Plant. Failure of
Seller to successfully repair any
nonconforming product shall not cause the
remedy established hereby to fail of its
essential purpose.
3. Exclusion of Consequential Damage-
Purchaser specifically understands and
agrees that under no circumstances will
seller be liable to purchaser for economic,
special, incidental or consequential
damages or losses of any kind whatsoever,
including but not limited to, loss of
anticipated profits and any other loss
caused by reason of nonoperation of the
goods. This exclusion is applicable to
claims for breach of warranty, tortious
conduct or any other cause of action
against seller.

General Warnings and Cautions
"!WARNING
1. The Control Module described in this manual
must be installed, operated, and
maintained in strict accordance with the
labels, cautions, warnings, instructions, and
within the limitations stated.
2. The Control Module must not be installed in
outdoor areas or in locations where
explosive concentrations of combustible
gases or vapors might occur in the
atmosphere: Class 1, Group A, B, C, and D
areas as defined by the NEC. Because the
Control Module is not explosion-proof, it
must be located in non-hazardous areas.
3. Use only genuine MSA replacement parts
when performing any maintenance
procedures provided in this manual. Failure
to do so may seriously impair instrument
performance. Repair or alteration of the
Chillgard LC System, beyond the scope of
these maintenance instructions or by
anyone other than authorized MSA service
personnel, could cause the product to fail
to perform as designed, and persons who
rely on this product for their safety could
sustain serious personal injury or death.
4. The Chillgard LC Control Module must be
installed, located and operated in
accordance to all applicable codes. These
codes include, but are not limited to, the
National Fire Prevention Code and National
Electric Code.
5 Protect the Chillgard LC Control Module from
vibration and heating; otherwise, improper
operation may result, which can result in
personal injury or death.
6. Do not exceed the relay contact ratings listed
in Section 1, TABLE B-1 Otherwise, relay
operation may fail, which can result in
personal injury or death.
Failure to comply with the above warnings can result in serious personal injury or death.
Chillgard LC Control Module General Warnings and Cautions

Table of Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Table 1-1. Chillgard LC System General Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Figure 1-1. Chillgard LC Control Module Standard Version
(24 Volt AC/DC or 110/220 AC Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Figure 1-2. Chillgard LC Control Module With Internal Transformer . . . . . . . . . . . . . . . . . . . . . 1-1
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Connection of the Chillgard Instruments Using RS-485 Communications . . . . . . . . . . . . . . . . . . . . . . . 1-3
Multiple Sensor Modules with a Chillgard LC Control Module (Daisy Chain). . . . . . . . . . . . . . . . . . 1-3
Multiple Sensor Modules with a Chillgard LC Control Module (Two Branch). . . . . . . . . . . . . . . . . . 1-3
Figure 1-3. Connection of the Sensor and LC Instruments Using RS-485 Communications . . 1-3
Figure 1-4. Multiple Sensor Modules with a Chillgard LC Control Module (Daisy Chain) . . . . . 1-4
Figure 1-5. Multiple Sensor Modules with a Chillgard LC Control Module (Two Branch) . . . . . 1-4
Section 2
Installation and Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Unpacking the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
"WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Initial Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Location of the Control Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-1. Basic LC Control Module with Door Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Wiring Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Opening the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Unit Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
"!CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Table 2-1. Option Switch Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figure 2-2. Transformer Version LC Control Module with Door Open . . . . . . . . . . . . . . . . . . . 2-2
Figure 2-3. Standard Version Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-4. Transformer Version Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Wiring to the Chillgard Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Table 2-2. Chillgard Dip Switch Positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-5. Chillgard LS Sensor Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-6. Chillgard M-100 Jumper Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Analog Signal Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
"!CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Chillgard LC Control Module Table of Contents
TOC - 1

Relay Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Setup Date, Time, and Logging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Initial Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
"WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Section 3
Display Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Figure 3-1. Display Screen Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Figure 3-2. Start-up and Normal Operation Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Figure 3-3 Set-up Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Figure 3-4 Span Calibration Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Figure 3-5 Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Figure 3-6 Calibration Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Figure 3-7 Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Figure 3-8 Data Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Figure 3-9 Alarm Level Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Figure 3-10 Setup Alarm Latching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Figure 3-11 Setup Alarm Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Figure 3-12 Audio Alarm Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Figure 3-13 Analog Outputs and Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Figure 3-14 Setup Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Figure 3-15 Setup Logging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Figure 3-16 Review Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Section 4
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Obtaining Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
"!WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Table 4-1. Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Table 4-2. Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Section 5
Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Number of Data Points Used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
User Setup Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Viewing Alarms/Events and Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Figure 5-1. Log Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Section 6
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Diffusion Version Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Calibration Equipment - (FIGURE 6-1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
"!WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Table of Contents Chillgard LC Control Module
TOC - 2

Initial Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Figure 6-1. Calibration Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Calibration Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Calibration Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
"!WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Figure 6-2. Applying Calibration Gas to the Chillgard LS Refrigerant Monitor. . . . . . . . . . . . . . 6-2
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Single or Four-Point Pumped Version Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Calibration Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Table 6-1. RP Calibration Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Calibration Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Calibration Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Figure 6-3. Kit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Figure 6-4. Using Zero Scrubber for Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Figure 6-5. Using Zero Gas Cylinder for Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Calibration Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Figure 6-6. Span Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Appendix A
RS-232 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
RS-232 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Table A-1. RS-232 Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Table A-2. Information Structure (Chillgard LC Control Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Table A-3. Data Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Table A-4. Alarm Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Table A-5. Alarms and Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Appendix B
Installation Outline Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Figure B-1. Installation Outline Drawing for Standard Version . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Figure B-2. Installation Outline Drawing for Transformer Version. . . . . . . . . . . . . . . . . . . . . . . B-3
Chillgard LC Control Module Table of Contents
TOC - 3

Section 1
General Information
Introduction
General Description
The Chillgard LC unit is a control module which
can communicate with up to eight Chillgard LS
or twelve Chillgard M100 Refrigerant Sensors.
The Chillgard LC Control Module can be
installed remotely from the sensors, thus
enabling remote control of that Chillgard LS or
the Chillgard M100 Sensor.
The Chillgard LC comes in two major versions
based upon the power supply in the unit:
•24 Volt AC/DC or 110/220 VAC version
•Internal Transformer version - 120 Volt input,
24 VAC output for powering Remote Sensor
Modules.
See FIGURES 1-1 and 1-2 to identify your unit.
Table 1-1. Chillgard LC System
General Operating Specifications
OPERATING SPECIFICATIONS
VOLTAGE RATING 100 to 240 VAC, 50-60 Hz, 25 W
24 VDC +10% -0%
24 VAC +10%
Transformer Version: 120 V, 60 Hz, 75 VA
POWER
REQUIREMENTS
.15 amps at 120 VAC;
.10 amps at 240 VAC
0.6 amps at 24 VAC
0.1 amps at 24 VDC
Minimum wire size: #18 AWG
The LC Controller can power the
Chillgard LS and seven Chillgard
M-100 sensors
TROUBLE RELAY Normally energized, Form C contact:
240 VAC, 5 amp resistive SPDT
ALARM 1 RELAY One relay, Form C contacts: 240
VAC, 5 amps resistive SPDT
ALARM 2 RELAY One relay, Form C contacts: 240
VAC, 5 amps resistive SPDT
ALARM 3 RELAY One relay, Form C contacts: 240
VAC, 5 amps resistive SPDT
ANALOG OUTPUTS 4 to 20 mA sourcing, 500 ohm load,
0-6 VDC, 2 K ohm load
MAXIMUM OUTPUT
SIGNAL LOAD FOR
4-20 mA OUTPUT 600 ohms (includes wiring)
Figure 1-1. Chillgard LC Control Module
Standard Version
(24 Volt AC/DC or 110/220 AC Version)
Figure 1-2. Chillgard LC Control Module
With Internal Transformer
Chillgard LC Control Module Section 1, General Information
1-1

Table 1-1. Chillgard LC System
General Operating Specifications
OPERATING SPECIFICATIONS
AUDIO ALARM
DRIVE OUTPUT 24 VDC 50-ohm load maximum
(available only with non-beacon
models)
OPERATING
TEMPERATURE 0 to 40oC (32 to 104oF)
STANDARD
VERSION
DIMENSIONS
7.5" high, 12.5" wide, 3.5" deep
19.05 cm high, 31.75 cm wide,
8.89 cm deep
STANDARD
VERSION WEIGHT 3.5 pounds (1.59 kilograms)
TRANSFORMER
VERSION
DIMENSIONS
14.7" high, 11.2" wide, 5" deep
373 mm high, 284 mm wide,
127 mm deep
TRANSFORMER
VERSION WEIGHT 8.4 pounds (3.82 kilograms)
TRANSPORT AND STORAGE CONDITIONS
TEMPERATURE -40oC to +60oC (-40oF to 140oF)
HUMIDITY 99% RH non-condensing
POLLUTION
DEGREE AND
INSTALLATION
CATEGORY 2
Terminology
Become familiar with the following terminology.
ZERO- A zero (0) indication on the meter
display usually indicates fresh air (no refrigerant
gas present).
ZEROING- The process of placing a zero gas on
the unit during calibration.
SPAN- Full-scale or up-scale reading on
meter display.
SPANNING- The process of placing a full-scale or
span gas on the unit during calibration.
SPAN GAS VALUE- The gas concentration that
gives the instrument a full-scale or up-scale value.
This value is printed on the calibration gas
cylinder containing the gas.
FLOW RATE- Volume of gas drawn through the
sample line per minute.
EXHAUST GAS- Sample gas after it passes
through the sensor.
PUMP- The electric motor driven device that
moves the gas sample to the refrigerant monitor.
ALARMS- The Chillgard LC System has three
alarms to alert the user at specific,
user-adjustable refrigerant gas concentrations.
(Level 1 = Caution, Level 2 = Warning and Level
3 = Alarm.)
RELATIVE HUMIDITY- The percent of water vapor
saturation in air at a given temperature.
POINT NUMBER- The location or area from which
a gas sample is drawn. Up to four, eight, or 12
areas, sequentially numbered from 1 to 12, can
be sampled.
FRESH AIR- Air that has no possibility of
containing refrigerant gas.
TEMPERATURE EFFECT- The gas response
displayed by the instrument (PPM) can change
+3 ppm for each degree (C) that the instrument is
operating above/below the temperature at which
the instrument was last calibrated.
Section 1, General Information Chillgard LC Control Module
1-2

Connection of the Chillgard
Instruments Using RS-485
Communications
The Chillgard LC instrument acts as the Master
device in the network. The LC instrument initiates
and controls all communications on the network.
The LC instrument sends out commands and
requests for data from individual sensors. When
the instruments are powered up, the LC unit
automatically detects the number and gas type of
all instruments on the network.
In a simple system using a single sensor module
and an LC Control module, the two modules are
connected together; both units have the RS-485
terminators "IN" (FIGURE 1-3). Refer to Section
2, Installation and Setup, for setting the address
switches and FIGURES 2-2 and 2-3 for the
location of the termination jumpers.
NOTE:Each sensor must have a different address.
The total length of the RS-485 cable cannot
exceed 1000 feet (304 meters).
MSA recommends Belden #9841
low-capacitance cable.
Multiple Sensor Modules with a
Chillgard LC Control Module
(Daisy Chain)
See FIGURE 1-4.
NOTE:Up to eight Chillgard LS Sensors can be
connected to a Chillgard LC Controller.
(They must be addressed as Points 1
through 8.)
•LS1 devices can be on points 1 through 8.
•LS4 devices must be on point 1 and/or 5
and will also use the next three physical
addresses.
•LS4 on point 1 takes addresses 1, 2, 3, and 4.
•LS4 on point 5 takes addresses 5, 6, 7, and 8.
•LS4 cannot be on addresses 9, 10, 11, or 12.
Multiple Sensor Modules with a
Chillgard LC Control Module
(Two Branch)
See FIGURE 1-5. Each end of the network must
have the terminator IN; modules in the middle
must have terminators OUT. RS-485 connections
from the Chillgard LC Control unit must have no
more than two terminations.
Figure 1-3. Connection of the Sensor and LC
Instruments Using RS-485 Communications
Chillgard LC Control Module Section 1, General Information
1-3

Figure 1-4. Multiple Sensor Modules
with a Chillgard LC Control Module (Daisy Chain)
Figure 1-5. Multiple Sensor Modules
with a Chillgard LC Control Module (Two Branch)
Section 1, General Information Chillgard LC Control Module
1-4

Section 2
Installation and Set-up
Receiving
Unpacking the System
To unpack the equipment:
1. Carefully remove the Chillgard LC Control
Module from its shipping container(s) in
order to prevent damage to sensitive
electrical components. If any damage is
found, report it to the shipper immediately.
"WARNING
Do not install or operate a damaged unit. It
may not function properly and may not alert
you to any gas conditions.
2. Search through all packing material and
containers to avoid inadvertently discarding
usable or valuable parts. Report any
shortages immediately to MSA.
Initial Inspection
With the front door open, carefully inspect
components and assemblies inside the enclosure.
If damage or shortage is evident, advise and
promptly file the proper claim with the carrier.
Location of the Control
Module
"WARNING
Explosion Hazard!
Unit must not be located in areas that may
contain a flammable mixture of gas and air;
failure to follow this requirement can result
in death, serious injury, or equipment or
property damage.
Figure 2-1. Basic LC Control Module with Door Open
Chillgard LC Control Module Section 2, Installation and Set-Up
2-1

Wiring Connections
Opening the Unit
All wiring to the Chillgard LC unit is made via the
bottom entries. Open the unit to provide complete
access to all wiring connections.
Ensure that all wiring codes are followed. These
codes include, but are not limited to, the National
Electrical Code.
"CAUTION
Component Damage!
Monitor components must be protected from
splashing, spraying, or dripping water.
Failure to do so may cause damage to
internal components.
Unit Power Wiring
"!CAUTION
Instrument Damage!
Correct power voltage must be connected to
the instrument. Failure to use correct voltage
may result in instrument damage.
A separate, dedicated power source is
recommended for the refrigerant control module to
ensure that the unit remains powered when other
circuits are shut down for servicing, routine
maintenance or shift changes. Supply earthground
is installed on lug first and all component
earthgrounds are connected afterwards.
Standard Version
The control module uses a wide range power
supply which can accept AC power from 100 to
240 volts, 50 or 60 Hz. If 24 Volt AC or DC is
available, power can be supplied directly to the
control board (FIGURE 2-3). The 24 Volt power
source used with this equipment must be
separated from mains by double or reinforced
insulation. If the 110/220 Volt power option is
available, power can be supplied to terminal block
as shown in FIGURE 2-1.
Transformer Version
If the Chillgard LC unit contains the internal
transformer, supply power as shown in
FIGURE 2-4. The resulting 24 VAC output from
the transformer can be used to power up to five
diffusion LS units or two pumped four-point LS
units. However, voltage drop will occur over
extended line lengths with multiple sensors.
Ensure minimum required voltage is present at
the sensor terminals for each sensor module.
"WARNING
If insufficient voltage is supplied, unit could
display incorrect readings. check each
sensormoduleforminimumrequiredvoltage
at each unit.
With 18 AWG wire, a Chillgard LS Sensor Module
can be located a maximum distance of 450 feet
from the Chillgard LC Control Module. Two
Chillgard LS four-point Sensor Modules
daisy-chained from the Chillgard LC Control
Module can be connected a maximum of 150 feet
from the Chillgard LC Control Module. With 18
AWG wire, seven Chillgard M-100 sensors can be
daisy-chained from the LC Control Module to a
distance of 1500 feet.
"CAUTION
If the Chillgard LC transformer or other AC
power is used to power the Chillgard M-100
Sensor, the Chillgard M-100 AC power must
be isolated from the LC power for proper
operation.
Table 2-1. Option Switch Table
SWITCH 1
CUSTOMER RS232
PORT SPEED SET
19,200 BPS 8, N, 1 UP
9,600 BPS 8, N, 1 DN
SWITCH 2 N/A
SWITCH 3 N/A
Figure 2-2. Transformer Version LC Control Module
with Door Open
Section 2, Installation and Set-Up Chillgard LC Control Module
2-2

Figure 2-3. Standard Version Wiring Diagram
Figure 2-4. Transformer Version Wiring Diagram
Chillgard LC Control Module Section 2, Installation and Set-Up
2-3

Wiring to the Chillgard Sensors
The Chillgard LC Control Module can
communicate to up to 12 sample points.
Communication between these devices is
achieved through RS-485 modbus protocol
[see the Chillgard LS Instruction Manual
(P/N 10035164) and/or the Chillgard M-100
Instruction Sheet (P/N 10073591) for definition of
protocol]. This protocol allows for daisy-chaining
of the sensor modules to the control module. See
FIGURE 2-3 for wiring to the control module.
Addressing
Each sensor module must have a distinct
address. The sensor module address switch is
used to specify the addresses of each sensor
module (FIGURE 2-5 and 2-6). The addresses
also determine the point number on the display.
"WARNING
If the addresses of each sensor module are
not unique to each unit, the control module
may not recognize one or more of the sensor
modules.
The dip switch positions are shown in TABLE 2-2.
Table 2-2. Chillgard LS Dip Switch Positions
POINT ID DIP SWITCH
1234
1100 0 0 0 --
2101 1 0 0 --
3102 0 1 0 --
4103 1 1 0 --
5104 0 0 1 --
6105 1 0 1 --
7106 0 1 1 --
8107 1 1 1 --
NOTE: 1 indicates closed.
For four-point sensor modules, there are two valid
dip switch settings: 100 and 104.
•If dip switch setting 100 is chosen, addresses
101 to 103 will be assigned to the four-point
unit and will not be available for use on other
units.
Figure 2-5. Chillgard LS Sensor Board Connections
Section 2, Installation and Set-Up Chillgard LC Control Module
2-4

Figure 2-6. Chillgard M-100 Jumper Locations
Chillgard LC Control Module Section 2, Installation and Set-Up
2-5

•If dip switch setting 104 is chosen, addresses
105 to 107 will be assigned to the four-point
unit and will not be available for use on other
units.
Analog Signal Output Wiring
The unit has two available analog outputs. The
4 to 20 mA analog output is software-selectable
between 10% or 100% of full scale:
•4-20 mA, isolated, current sourcing
•0-6 VDC outputs, 0.5-Volt steps to indicate
point being monitored. For example, 1.5 V
represents point 3 at the milliamp output.
Analog output wiring should enter the unit through
the hole provided on the left side of the unit. The
maximum wire size that these connectors can
accept is Listed #12 AWG; the maximum cable
length is 500 feet (166 meters).
It is suggested that Listed #18 AWG, twisted-pair
wire be used. If shielded wire is necessary,
ground the shields of all cables at the receiving
end of the signal. Do not ground or connect the
shields at the Chillgard LC Control Module. See
FIGURE 2-2 for connecting the analog outputs.
"!CAUTION
Bundle low voltage wiring together (lower than
30 volts), separate from high voltage wiring
(higher than 30 volts).
Optional Alarm Beacon
Your unit may have an optional alarm kit installed.
This kit is made up of a beacon on the top of the
unit. It is factory-wired so no additional wiring is
necessary; it lights when an Alarm 3 indication is
given by the instrument. Connection is made to
the strobe connector (FIGURE 2-2). IP rating
shown on the strobe light applies to the
strobe only.
Relay Outputs
Alarm Relays
There are three alarm relay outputs:
•Alarm 1 (factory-set to trip at 50 ppm)
•Alarm 2 (factory-set to trip at 150 ppm)
•Alarm 3 (factory-set to trip at 1000 ppm;
300 ppm for R 123)
Each relay can be set up as latching/non-latching
and/or normally-energized/normally de-energized.
Contacts are Form C at 240 Volts AC 5 amps
resistive. User can adjust alarm trip points via the
front panel (see Section 3, FIGURE 3-11).
Alarm Relay Connections Wiring
Three refrigerant level alarm relay outputs are
provided. All alarm relays are Form C, SPDT
relays which can be wired to either closed or
opened contacts in an alarm condition. Use copper
conductors only.
Each relay has contacts for:
•NORMALLY OPEN (NO)
•COMMON (COM)
•NORMALLY CLOSED (NC)
The function of each relay connector terminal is
indicated on FIGURE 2-2.
NOTE:The maximum wire size that these
connectors can accept is #12 AWG.
Fault Relay
There is one relay (the Fault relay) within the unit
that indicates that a trouble or start-up condition
exists. This relay is configured from the factory
and operates differently than the alarm relays. It
operates in a normally-energized mode.
This relay is energized when the instrument is:
•normally operating,
•in the calibration mode, or
•in the setup condition.
The relay is de-energized when:
•a fault is detected,
•the unit is in the start-up state, or
•the main power is lost.
This means that power is no longer provided to
the relay coil. It is not possible to change the
configuration of the Trouble relay.
The relay connector function or identification:
•NORMALLY OPEN (NO),
•COMMON (COM),
•NORMALLY CLOSED (NC)
as marked in FIGURE 2-2 refers to the relay
contacts as if the relay is de-energized or in the
trouble condition. A relay contact is provided
between the Normally Closed (NC) and Common
(COM) position. This contact will be made in the
event that main power to the unit is lost or any
other trouble condition exists.
Section 2, Installation and Set-Up Chillgard LC Control Module
2-6

Remote Alarm Silence Switch
The audible alarm and latched refrigerant level
alarms can be remotely reset through a switch that
has a momentary contact opening (normally closed
set of contacts). Connections are made as shown in
FIGURE 2-3 with the wiring entering the enclosure
through the hole on the left side of the instrument.
The switch must have signal-level contacts, typically
gold plated. The maximum distance from the reset
switch to the control module, using 18 AWG wire, is
250 feet. The maximum wire size that these
connectors can accept is #12 AWG.
Audible Alarm Output
An output is provided to drive the horn on the
bottom of the unit (FIGURE 2-2).
"CAUTION
All field wiring must be done in accordance
with national and local electrical codes.
Start-Up
The following steps outline the procedures to
power-ON the Chillgard LC Control Module:
1. Before applying power to the unit, verify
proper power will be applied to the unit.
2. Turn the instrument ON at the circuit breaker
or fuse that supplies power to the
instrument. (The instrument does not have
a power switch.)
•A green LED indicates that power is ON
and communication is established to a
sensor module.
NOTE:The display will begin to indicate the gas
concentration of each point connected to the
Chillgard LC Control Module.
After power-ON, allow for unit stabilization
(about 30 minutes) before checking calibration
of instrument.
Setup Date, Time, and
Logging
The data log on the LC unit must be
initialized by setting the date and time under the
Setup - Setup Time and Date Menu.
Setup logging next on the following menu:
1. Turn ON logging.
2. Set the log frequency.
3. Clear the log file to reset any readings.
4. Reset the LC unit to re-initialize the log to a
clean start.
"CAUTION
If this is not done, data recorded will not
have a time stamp and data review will not
be possible.
Initial Calibration
"WARNING
Calibrate after installation; otherwise, false
or erroneous readings can result.
See Chillgard LS Instruction Manual
(P/N 10035164) for calibration or calibration check
instructions. See Chillgard M100 Instruction Sheet
(P/N 10073591) for calibration or calibration check
instructions.
Chillgard LC Control Module Section 2, Installation and Set-Up
2-7

Section 3
Display Screens
All instrument operation is performed via the front
panel which consists of four keys and a two-line
by 20-character LCD display. There is no reason
to open the unit for set-up, calibration or
diagnostic testing of the instrument. The most
commonly used, self-explanatory screens appear
on the following pages. Simply follow the
on-screen menus. The step-by step approach
guides you through each operation.
•The Display Screen Overview (FIGURE 3-1)
shows a general system function flow. See
the following FIGURES for specific Display
Screen details:
•Start-up and Normal Operation Screens
(FIGURE 3-2)
•Calibration Screens
(FIGURES 3-4 through 3-5)
•Information Screens
(FIGURES 3-7 through 3-8 and
FIGURE 3-16)
•Set-up Screens
(FIGURES 3-3 and 3-10 through 3-15).
Chillgard LC Control Module Section 3, Display Screens
3-1

Figure 3-1. Display Screen Overview
Section 3, Display Screens Chillgard LC Control Module
3-2

Figure 3-2.
Start-up and Normal Operation Screens
Figure 3-3.
Set-up Screens
Chillgard LC Control Module Section 3, Display Screens
3-3