MSA GasGard XL User manual

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Installation & Maintenance Instructions
GASGARD XL WALL MOUNT
CONTROLLER

Order no.: 10081908/02
Operating Manual
GasGard XL Wall Mount Controller

MSA AUER GmbH
D-12059 Berlin
Thiemannstrasse 1
Germany
© MSA AUER GmbH. All rights reserved.

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MSA CONTENTS
GasGard XL Wall Mount Controller 3
EC Declaration of Conformity
MANUFACTURED
BY:
Mine Safety Appliances Company
1000 Cranberry Woods Drive
Cranberry Township, PA 16066 USA
The manufacturer or his in the community established authorized representative
MSA AUER GmbH, Thiemannstrasse 1, D-12059 Berlin
declares that the product GasGard XL
based on the EC-Type Examination Certificate: FTZU 07 ATEX 0066 X
Complies with the ATEX directive 94/9/EC, Annex III. Quality Assurance Notification
complying with Annex IV of the ATEX Directive 94/9/EC has been
issued by DEKRA EXAM in Bochum, Notified Body number: 0158.
The product is in conformance with the EMC directive 2004 / 108/ EC, with the
following harmonised standards:
DIN EN 50270: 2007-05 Typ 2, DIN EN 61000-6-4: 2002-08
We further declare that the product complies with the provisions of LVD
Directive 73/23/EC as amended by Directive 93/68/EC, with the following
harmonised standard:
DIN EN 61010: 2002-08
MSA AUER GmbH
Dr. Axel Schubert
R & D Instruments Berlin, February 2008

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CONTENTS MSA
4GasGard XL Wall Mount Controller
Contents
1. Safety Regulations .............................................................................................. 6
1.1. Correct Use ................................................................................................ 6
1.2. Liability Information .................................................................................... 6
2. Description........................................................................................................... 7
2.1. General overview ....................................................................................... 7
2.2. Control Unit ................................................................................................ 8
2.3. Front Panel............................................................................................... 11
3. Installation ......................................................................................................... 15
3.1. Mechanical Installation............................................................................. 15
3.2. Electrical Installation ................................................................................ 16
4. Operation ........................................................................................................... 18
4.1. Basic Screen ............................................................................................ 18
4.2. Controls.................................................................................................... 20
4.3. Viewing Channel Information ................................................................... 22
4.4. Viewing Events Archive............................................................................ 23
5. Configuration..................................................................................................... 26
5.1. System Menu ........................................................................................... 26
5.2. Relay Setting Menu.................................................................................. 34
5.3. General Setting Menu .............................................................................. 38
5.4. Calibration ................................................................................................ 40
6. Configuration Software..................................................................................... 49
6.1. Installation and Start ................................................................................ 49
6.2. Using of Application ................................................................................. 49
6.3. Multilingual System .................................................................................. 51
6.4. Setting Up Channels ................................................................................ 51
6.5. Setting Up Output Relays......................................................................... 52
6.6. Channel Calibration.................................................................................. 53
7. Maintenance....................................................................................................... 53
8. Technical Specifications and Certifications ................................................... 54
8.1. Technical Specifications........................................................................... 54
8.2. Marking, Certificates and Approvals......................................................... 56
8.3. Special conditions for safe use according to SIL 2................................... 57
9. Ordering Information......................................................................................... 58
9.1. Controller.................................................................................................. 58
9.2. Accessories/Spares ................................................................................. 58
9.3. Spare Parts .............................................................................................. 59

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MSA CONTENTS
GasGard XL Wall Mount Controller 5
Appendix A – Sensor List ............................................................................................ 60
A-1 List of sensors compatible with GasGard XL............................................ 60
Appendix B – Wiring Diagrams ................................................................................... 61
B-1 Sensor type D-7100 ................................................................................. 61
B-2 Sensor type D-7010 ................................................................................. 61
B-3 Sensor Type D-715 K............................................................................... 62
B-4 Sensor Type D-7152 K............................................................................. 62
B-5 Sensor Type D-7711 K............................................................................. 63
B-6 Sensor Type D-7711 K-PR....................................................................... 63
B-7 Series 47 K Standard & PRP ................................................................... 64
B-8 Series 47 K-HT......................................................................................... 64
B-9 Sensor Type DF-7010 .............................................................................. 65
B-10 Sensor Type DF-7100 .............................................................................. 65
B-11 Sensor Type DF-9200 .............................................................................. 66
B-12 Sensor Type DF-9500 .............................................................................. 66
B-13 Sensor Type DF-9500 with Safety Barrier................................................ 67
B-14 Sensor Type DF-9500 with Current Separator ......................................... 67
B-15 Sensor GD10 ........................................................................................... 68
B-16 ULTIMA X (2-wire).................................................................................... 68
B-17 ULTIMA X (3-wire).................................................................................... 69
B-18 Sensor Type DF-8603 .............................................................................. 69
B-19 Sensor Type DF-8201 .............................................................................. 70
B-20 Sensor Type DF-8250 .............................................................................. 70
B-21 Sensor Type DF-8510 .............................................................................. 71
B-22 Sensor Type FlameGard .......................................................................... 71
B-23 Sensor Type SafeEye 4xx/UV.................................................................. 72
B-24 Sensor Type ULTIMA X IR....................................................................... 72
B-25 Transmitter RG3 LCD............................................................................... 73
B-26 Sensor Type DF-7500 .............................................................................. 73
B-27 Sensor Type DF-9500C ........................................................................... 74
B-28 Sensor Type DF-9500C ........................................................................... 74
B-29 Sensor Type D500S ................................................................................. 75
B-30 Sensor Type Chillgard M100.................................................................... 75
Appendix C – Individual Relays Connection .............................................................. 76
Appendix D – Terminal Connectors ............................................................................ 77
GasGard XL......................................................................................................... 77
Main Board .......................................................................................................... 78
Sensor Extention Board....................................................................................... 79
Channel Relay Board .......................................................................................... 80

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SAFETY REGULATIONS MSA
6GasGard XL Wall Mount Controller
1. Safety Regulations
1.1. Correct Use
GasGard XL Wall Mount Controller (hereinafter referred to as Control Unit) is a
compact Control Unit in wall housing for connection of up to 8 EX, TOX and/or
OX sensors. The Control Unit is suitable for a large number of applications in
many industrial areas. Simplest installation and user-friendly configuration via
push buttons with comfortable editing and copying functions make the unit an
ideal control instrument for smaller, independent gas warning systems.
It is imperative that this operating manual be read and observed when using the
product. In particular, the safety instructions, as well as the information for the use
and operation of the product, must be carefully read and observed. Furthermore,
the national regulations applicable in the user's country must be taken into
account for a safe use.
Danger!
This product is supporting life and health. Inappropriate use,
maintenance or servicing may affect the function of the device and
thereby seriously compromise the user’s life.
Before use the product operability must be verified. The product must
not be used, if the function test is unsuccessful, it is damaged, a
competent servicing/maintenance has not been made, genuine MSA
spare parts have not been used.
Alternative use, or use outside these specifications will be considered as non-
compliance. This also applies especially to unauthorised alterations to the product
and to commissioning work that has not been carried out by MSA or authorised
persons.
1.2. Liability Information
MSA accepts no liability in cases where the product has been used
inappropriately or not as intended. The selection and use of the product are the
exclusive responsibility of the individual operator.
Product liability claims, warranties also as guarantees made by MSA with respect
to the product are voided, if it is not used, serviced or maintained in accordance
with the instructions in this manual.

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MSA DESCRIPTION
GasGard XL Wall Mount Controller 7
2. Description
2.1. General overview
Fig. 1 GasGard XL
The control system is a wall mounted version of a permanent gas warning device.
It is used to monitor industrial premises and installations for the presence of
combustible, explosive, toxic gases or air/vapour mixtures and oxygen content.
The control system provides power to the sensors, signal conditioning and display
of measured gas concentrations, alarm thresholds, outputs for alarm devices and
self monitoring diagnostics.
The unit consist of up to 8 channels for monitoring active or passive sensors.
It can be used for:
EX-monitoring for protecting operational plants and individuals working there
by continuously monitoring the atmospheres for potentially explosive
gases/vapours in air before they reach the lower explosion limit – activating
alarms and initiating risk aversion measures.
It is approved in accordance with Directive 94/9/EC [ATEX].
OX-monitoring for protecting individuals by continuously monitoring the
atmosphere for oxygen deficiency or oxygen enrichment or monitoring the
inerting of operational plants.
It is approved in accordance with Directive 94/9/EC [ATEX].
TOX-monitoring for protecting individuals by continuously monitoring the
atmosphere toxic gas concentrations.

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DESCRIPTION MSA
8GasGard XL Wall Mount Controller
In case of reaching the set limit values, e. g. maximum/minimum concentration in
the atmosphere, an alarm will be activated.
Typical applications are:
Chemical and petrochemical industry,
Paint and solvent industry,
Gas-processing industry and
Municipal areas.
2.2. Control Unit
Fig. 2 Enclosure
The Control Unit consist of the following basic modules:
Enclosure with mounting holes (7) and cable entries (5)
Power Supply (1)
Backup Battery (6)
Sensor Extension Board (4)
Channel Board (3)
Channel Relay Board (2)
7
1
6
4
3
2
5

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MSA DESCRIPTION
GasGard XL Wall Mount Controller 9
2.2.1. Wall Mount Enclosure
The Control Unit has a plastic ABS enclosure in accordance with IP 56.
Dimensions 515 mm x 277 mm x 129 mm.
Cable entry points are not provided. They are predesigned on the bottom of the
enclosure.
The front panel is moulded with predesigned holes for fully equipped
configuration (8 channels).
The unit is mounted by 4 screws.
2.2.2. Power Supply
100 W for fully equipped unit from 4 to 8 channels.
The power supply accepts main AC and DC power. 24 VDC external power is
possible.
Switching power supply certified CE, UL, CSA
(85 to 265 VAC; 50/60 Hz).
In case of loss of main power the power supply automatically switches to backup
battery.
Power source for detectors from 18 to 32 VDC.
2.2.3. Backup Battery
Two batteries 12 VDC/2.2 Ah can be incorporated optionally into the Control Unit.
The batteries supply 20 minutes of backup for 8 catalytic combustion sensors.
Operating under back-up power is indicated on the front panel (Power LED starts
blinking).
2.2.4. Main Board
The Main Board is equipped by the most performance microcontroller which
offers many interfaces. Further it includes watchdog, internal buzzer (85 dB),
standard common outputs and battery charger circuit.
All necessary information is stored on the Main Board.
Following communications are possible:
1 Ethernet configurable for ModBus TCP/IP (galvanically isolated)
1 RS485 configurable for ModBus RTU (galvanically isolated)
1 USB configurable for ModBus RTU.
The communication shall not interfere with the operation of the Control
Unit.
For SCADA visualization software all three interfaces can be used. For service
access only both of ModBus RTU communications can be used (safety
precaution).