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).

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DESCRIPTION MSA
10 GasGard XL Wall Mount Controller
Standard common outputs are incorporate:
2 SPDT (Single Pole Double Throw) relays common alarm (ALARM 1 and
ALARM 2)
1 DPDT (Double Pole Double Throw) relay common fault
2 addressable common horn relays.
2.2.5. Display Board
The Display Board is located on the back side of the lid.
It includes microcontroller, watchdog, push buttons and graphic display (128x64).
2.2.6. Sensor Extension Board
The sensor extension board is used for fixing channel boards and for connecting
internal communication.
For Sensor connection please refer to Section 3.2.2.
2.2.7. Channel Board
There are two versions of channel boards available according to the requested
sensor type (passive sensors, 4-20 mA transmitters).
Every board includes 4 LEDs (A1, A2, Status, Power) and fits to Channel's
Connectors (4 on the Main Board, 4 on the Sensor Extension Board).
The sensors power and connection is designed as “fail-to-safe” (wrong
connection/configuration does not damage the remote sensor).
2.2.8. Channel Relay Board
Every Channel Relay Board provides 8 output relays and is connected to the
Main Board or to the Sensor Extension Board (one by one) via connectors.
Relays are fully configurable by user from the front panel or from the connected
PC via configuration software.
Two optional SPDT relays (Single Pole Double Throw) per channel (8 relays per
4 channels) are configurable for individual alarms:
Normally open/close
Normally energized/de-energized
Latching/non latching
Increasing/decreasing
N out of m voting
New re-invoked alarms (common horn relays only)
Grouping
Contacts are resistive load.

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MSA DESCRIPTION
GasGard XL Wall Mount Controller 11
2.3. Front Panel
The Front Panel allows communication with the Control Unit.
It is used to monitor the status of all connected field sensors, to determinate
system settings and to configure all parts.
On the panel there are:
LCD graphic display (5)
Four control LEDs per channel (6)
Three Common LEDs (1)
Alarm Acknowledgement button (4)
Alarm Reset button (2)
Four Control push buttons (3)
Fig. 3 Operator Panel
1 Common LEDs 4 Alarm Acknowledgement
2 Alarm Reset 5 Graphic Display
3 Control Push Buttons 6 Channel Status Info LEDs
6
5
1
2
3 4

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DESCRIPTION MSA
12 GasGard XL Wall Mount Controller
2.3.1. Graphic Display
The Control Unit has a 128 x 64 pixel large graphic display which shows
information of all channels.
Fig. 4 Graphic Display
2.3.2. Control Push Buttons
Using the control push buttons you can operate the menu prompt as shown
below. For more information please refer to Section 4.
Right button [ ]
Up Button [ ]
Left button [ ESC ]
Down button [ ]
Alarm Acknowledgement
Alarm Reset
ACK
RES

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MSA DESCRIPTION
GasGard XL Wall Mount Controller 13
2.3.3. Channel Board Status Info LEDs
For each of eight Control Channels there are four LEDs for monitoring the
operating status of the units.
Fig. 5 Channel Status Info LEDs
1 Power LED 3 Alarm 1 LED
2 Status LED 4 Alarm 2 LED
The Power LED (green) indicates the channel is under power and is enabled
by the system.
The Status LED (yellow) indicates the channel is in a fault condition.
When the LED is blinking (with 0.5 Hz) the channel is inhibited or in service.
The Alarm 1 LED (red) indicates that 1st alarm level has been reached. It
indicates different statuses:
4 Hz blinking : 1st alarm level has been reached (not acknowledged yet)
Steady: 1st alarm is acknowledged but is still inside alarm range.
0.5 Hz blinking: 1st alarm is configured as latching. Measured value is out
of alarm level (not reset yet).
The Alarm 2 LED (red) indicates that 2nd alarm level has been reached. It
indicates different statuses:
4 Hz blinking : 2nd alarm level has been reached (not acknowledged yet)
Steady: 2nd alarm is acknowledged but is still inside alarm range.
0.5 Hz blinking: 2nd alarm is configured as latching. Measured value is out
of alarm level (not reset yet).
1
3
4
2

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DESCRIPTION MSA
14 GasGard XL Wall Mount Controller
2.3.4. Channel Relay Board Status LED
Each Channel Relay Board has a small smd LED on the board marked as VD1,
which indicates different statuses:
0.5 Hz blinking Channel Relay Board is activated in the system and
works properly
Steady Channel Relay Board is activated in the system and is in
a fault condition
Off Channel Relay Board is activated in the system
2.3.5. Unit Status Info LEDs
Fig. 6 Channel Status Info LEDs
1 Power LED 3 System LED
2 Failure LED
The Power LED (green) indicates that the Control Unit is under power.
A blinking LED indicates power supply from battery.
The Failure LED (yellow) indicates that some sensor is in fault condition.
The System LED (yellow) indicates that the Control Unit has a system fault.
1
2
3

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MSA INSTALLATION
GasGard XL Wall Mount Controller 15
3. Installation
Before beginning the installation, with the help of the shipping
documents and the sticker on the shipment carton, check that the
delivered components are complete and correct.
The installation location for the Control Unit must be outside the potentially
explosive area and free of corrosive gases.
Sensors for use in the Ex area must have the appropriate Ex approval and must
be installed in accordance with all relevant local and national regulations.
MSA configures and calibrates all control systems with a checklist and all
systems are supplied with a data sheet for each measuring point.
The gas warning system must only be installed by qualified personnel after
reading the documentation supplied.
All relevant local and national regulations and instructions must be observed.
The correct assignment of each sensor and control system module must be ensured
during installation by referring to the serial numbers indicated on the data sheet.
3.1. Mechanical Installation
Fig. 7 Mounting Drawing
Mount the Control Unit as follows:
(1) Mark the holes as shown in Fig. 7 for the four fixing screws.
(2) Drill four holes of appropriate diameter for wall plugs.
(3) Remove the front panel from the enclosure.
(4) Fix the unit to the wall, by appropriate screws (M6 screws or 6,4mm SPAX)
(5) Attach lid with existing screws.

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INSTALLATION MSA
16 GasGard XL Wall Mount Controller
3.2. Electrical Installation
Attention!
The control system must be installed only in compliance with the
applicable regulations, otherwise the safe operation of the instrument
is not guaranteed.
During installation, use the internal earth connection to ground the
instruments.
If an external earth connection is permitted or demanded by the local
authorities, it serves merely as additional earthing.
The installation location shall be selected such that the environmental conditions
indicated in the technical data can be met.
When installing the Control Unit the following conditions must be met to comply
with the EMC Directive
To connect devices to the main power supply, a fault-free ground or fault-free
potential bonding conductor must be provided.
The user must ensure an appropriate supply voltage in accordance with EMC
directives.
If the devices are supplied from a direct voltage (DC) source, the supply cable
must be shielded.
All sensor and control cables must be shielded.
Shielded cables must have at least 80% coverage.
Control and sensor cables must be installed physically separate from power
supply cables.
Shielded cables must be laid in a group. If cable lengths are to be extended
using terminal boxes, the boxes must be shielded and the internal
connections must be kept as short as possible.
The control system can be simultaneously connected to AC mains voltage and
24 VDC in which case power will automatically switch over if the AC main supply
should fail.
Warning!
When opening the instrument's housing care must be taken of high
voltage danger from relay contacts and main power supply.
Only authorized person should be authorized to open the instrument.
The AC mains source shall not be subjected to voltage variations
exceeding the limits as specified in this Manual.
The AC mains source shall be free of any surges and sudden voltage
changes due to heavy electrical loads and disturbances as caused by
inductive or capacitive loads, false contacts and strong
electromagnetic interference.
In addition to the above, if the GasGard XL is supplied by a direct
voltage (DC) source, the supply cable must be properly shielded.

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MSA INSTALLATION
GasGard XL Wall Mount Controller 17
3.2.1. Power Supply
Standard power supply 85 - 265 VAC, 50-60 Hz / 24 VDC is used to power
internal circuits up.
Main voltage is connected to terminal L(Line), N(Neutral), and ground.
Fig. 8 Connecting Main Supply
3.2.2. Sensor connection
Sensor must be connected to the terminals on the main board or sensor
extension board (for details Appendix C and Appendix D).
Attention!
Follow the instructions for components subject to damage from static
electricity!
Incorrect connection of the sensors shall not damage both of Control Unit or
sensor.
The wiring diagrams for different sensors are shown in Appendix B. The sensors
must be connected to the terminals using shielded cables.
For the maximum cable length of sensors refer to the technical specification.

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OPERATION MSA
18 GasGard XL Wall Mount Controller
4. Operation
The control system’s user interface is the integrated operation/display unit. This
unit displays alarms and warnings as well as system parameters.
Connecting the operating unit to a PC permits a user friendly operator interface.
The input fields are set up as selection fields as much as possible, with all known
inputs displayed. Selection is cursor-controlled, which makes use of the integraed
operation/display unit very easy.
4.1. Basic Screen
The basic screen displays the information about active channels status (active,
inhibit, in service) including information about the system (system date and time).
Fig. 9 Basic Screen
1 System Date 5 Actual Value
2 Flamegard Status 6 Battery Status
3 Channel Number 7 Status Information
4 System Time 8 Events Archive
System Date and Time : Actual preset values for events archive
Channel Number : Position of the channel board counted from the left
to the right on the Main Board (1 … 4) and the
Sensor Extension Board (5 … 8).
Status Information : Information about the channel status (alarm, fault, in
service etc.; see symbols)
1
2
34
8
7
5
6

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MSA OPERATION
GasGard XL Wall Mount Controller 19
Actual Value : Measured value of gas concentration.
Events Archive : Last 1000 events (Alarms, Alarms
acknowledgement and reset, Faults, Calibrations
etc.) are stored in the memory and can be restored
by the operator.
Table of Status Info Symbols
Symbol Description
Alarm 1
Displayed if the alarm level is reached
Alarm 2
Displayed if the alarm level is reached
Overrange
Displayed if channel signal is above the range
(more than 105 % from FS).
Underrange
Displayed if channel signal is below the range
(less than -5 % from FS)
Sensor Fault
Displayed if a sensor connection is broken or shorted
Internal Channel Fault
Displayed if channel board has a system fault
In Service
Displayed if channel is in service mode (calibration)
Inhibit
Displayed if channel is inhibited
STEL Alarm
Displayed if the STEL alarm is reached
TWA Alarm
Displayed if the TWA alarm is reached
Battery is included and is under charging.
Battery is included but discharged
(The symbol starts blinking if the battery cable is
disconnected)
Battery not included