MSA GasGard XL User manual

GasGard®XL
Wall Mount Controller
Operating Manual
In North America, to contact your nearest stocking location, dial toll-free 1-800-MSA-INST
To contact MSA International, dial 1-412-967-3354
© MINE SAFETY APPLIANCES COMPANY 2008 - All Rights Reserved
This manual is available on the internet at www.msanet.com
Manufactured by
MSA NORTH AMERICA
P.O. Box 427, Pittsburgh, Pennsylvania 15230
(L) Y Rev 0 10091922

i
THIS MANUAL MUST BE CAREFULLY READ BY ALL INDIVIDUALS WHO HAVE OR WILL
HAVE THE RESPONSIBILITY FOR USING OR SERVICING THE PRODUCT. Like any piece
of complex equipment, this instrument will perform as designed only if it is used and serv-
iced 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 the product are
voided if the product is not used and serviced in accordance with the instructions in this
manual. Please protect yourself and others by following them. We encourage our cus-
tomers to write or call regarding this equipment prior to use or for any additional infor-
mation relative to use or repairs.
"! WARNING

MSA Permanent Instrument Warranty
1. Warranty- Seller warrants that this product will be free from
mechanical defect or faulty workmanship for a period of 18 months
from date of shipment, or one year from installation, whichever
occurs first, 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 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 goods sold under this contract. 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 MERCHANT ABILITY 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 non-conforming 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 non-operation of the goods. This exclusion is
applicable to claims for breach of warranty, tortious conduct or any
other cause of action against seller.
ii

Table of Contents
Chapter 1,
Product Introduction . . . . . . . . . . . . . . . . . . .1-1
Correct Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Chapter 2,
Description . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Wall Mount Enclosure . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Figure 2-1. Enclosure . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Backup Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Main Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Display Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Sensor Extension Board . . . . . . . . . . . . . . . . . . . . . . .2-4
Channel Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Channel Relay Board . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Graphic Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Figure 2-2. Front Panel . . . . . . . . . . . . . . . . . . . . . . . .2-6
Figure 2-3.Graphic Display . . . . . . . . . . . . . . . . . . . . .2-6
Control Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Channel Status Info LEDs . . . . . . . . . . . . . . . . . . . . . .2-7
Figure 2-4. Channel Status Info LEDs . . . . . . . . . . . . .2-7
Unit Status Info LEDs . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Figure 2-5. Unit Status Info LEDs . . . . . . . . . . . . . . . .2-9
iii

Chapter 3,
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Figure 3-1. Mounting Drawing . . . . . . . . . . . . . . . . . .3-2
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Figure 3-2. Connecting the Main Supply . . . . . . . . . . .3-3
Sensor Connection . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Chapter 4,
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Basic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Figure 4-1. Basic Screen . . . . . . . . . . . . . . . . . . . . . . .4-1
Status Info Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Using the Hotkeys . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Viewing Channel Information . . . . . . . . . . . . . . . . . . . . .4-6
Viewing Events Archive . . . . . . . . . . . . . . . . . . . . . . . . .4-7
List of Assigned Events . . . . . . . . . . . . . . . . . . . . .4-8
Chapter 5,
Configuration . . . . . . . . . . . . . . . . . . . . . . . . .5-1
(1) System Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
(2) Calibration Menu Direct Access . . . . . . . . . . . . . . .5-1
System Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Channel Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Relay Board Identification Mark . . . . . . . . . . . . . . . . .5-3
Setting Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Description of Channel Parameters . . . . . . . . . . . . . . .5-4
Modifying Channel Parameters . . . . . . . . . . . . . . . . . .5-6
Relay Setting Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Description of Relay Parameters . . . . . . . . . . . . . . . . .5-8
Example of Relay Configuration . . . . . . . . . . . . . . . .5-10
Modifying Output Relays . . . . . . . . . . . . . . . . . . . . . .5-10
Fixed Setting for Common Relays . . . . . . . . . . . . . . .5-12
General Setting Menu . . . . . . . . . . . . . . . . . . . . . . . . .5-12
iv

Manual Calibration (4 - 20 mA) . . . . . . . . . . . . . . . . .5-14
Chapter 6,
Configuration Software . . . . . . . . . . . . . . . . .6-1
Installation and Start up . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Menu Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Figure 6-1. Main Applications Screen . . . . . . . . . . . . .6-2
Multilingual System . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Setting Up Channels . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Figure 6-2. Setting up Channels . . . . . . . . . . . . . . . . .6-4
Setting Up Output Relays . . . . . . . . . . . . . . . . . . . . . . . .6-5
Figure 6-3. Setting up Output Relays . . . . . . . . . . . . .6-5
Chapter 7,
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Table 7-1. Accessories and Spare Parts . . . . . . . .7-1
Chapter 8,
Technical Specifications and Certifications .8-1
Table 8-1. Technical Specifications . . . . . . . . . . . .8-1
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
Appendix A,
Sensor List . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Table A-1.GasGard XL-compatible Sensors . . . . .A-1
Appendix B,
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . .B-1
Figure B-1.Flamegard Flame Detector . . . . . . . . . . . .B-1
Figure B-2. SafEye Open Path Gas Detector . . . . . . .B-1
Figure B-3. Ultima X (Two-wire) . . . . . . . . . . . . . . . . .B-2
Figure B-4. Ultima X (Three-wire) . . . . . . . . . . . . . . . .B-2
Figure B-5. Ultima X IR Sensor . . . . . . . . . . . . . . . . . .B-3
v

Appendix C,
Individual Relay Connections . . . . . . . . . . .C-1
Figure C-1. Individual Relay Connections . . . . . . . . . .C-1
Appendix D,
Terminal Connectors . . . . . . . . . . . . . . . . . . .D-1
Figure D-1. Main Board . . . . . . . . . . . . . . . . . . . . . . . .D-1
Figure D-2. Sensor Extension Board . . . . . . . . . . . . .D-1
Figure D-3. Channel Relay Board . . . . . . . . . . . . . . . .D-2
vi

1-1
Chapter 1,
Product Introduction
Correct Use
The GasGard XL Wall Mount Controller is a compact control unit that:
• connects with up to eight active combustible, toxic and/or
oxygen sensors
• is used to monitor indoor industrial locations for the presence of
combustible, explosive, toxic gases or air/vapor mixtures and
oxygen content
• provides power to the sensors, signal conditioning and display of
measured gas concentrations, alarm thresholds, outputs for alarm
devices and self monitoring diagnostics
• is suitable for many applications and industrial areas
• provides simple installation, easy editing and copying functions
• is ideal for smaller, independent gas warning systems.
The user must carefully read and observe:
• this operating manual, particularly, the safety, use and operating
instructions
• the national regulations applicable in the user's country, including
requirements specific to explosive risk approval.
Use or alterations outside these instructions is considered as
non-compliance.
This product is supporting life and health. Incorrect use,
maintenance or servicing can affect its function and seri-
ously compromise the user’s life. When turned ON for the
first time, the controller performs a self-check. Do Not use
the monitor if it fails the self-check, which is indicated by a
failure light. Do Not use the monitor if it is damaged, improp-
er servicing/maintenance has been performed, or if genuine
MSA spare parts have not been used.
"WARNING

2-1
Chapter 2,
Description
General Overview
The general-purpose control system enables:
• Combustible gas monitoring
• for protecting operational plants and workers by monitoring
atmospheres for potentially explosive gases/vapors in air
before they reach the lower explosion limit and by activating
alarms and initiating risk aversion measures.
• Oxygen monitoring
• for protecting individuals by monitoring the atmosphere for
oxygen deficiency or oxygen enrichment.
• Toxic gas monitoring
• for protecting individuals by continuously monitoring the
atmosphere for toxic gas concentrations.
NOTE: An alarm activates if set limit values are reached
(e.g. minimum/ maximum concentration in the atmosphere).
Typical applications are:
• Chemical and petrochemical industry
• Paint and solvent industry
• Gas-processing industry
• Municipal areas.

2-2
Control Unit
Wall Mount Enclosure
The Control Unit:
• is housed in an ABS enclosure in accordance with IP 56
and NEMA 4X
• dimensions are 515 mm x 277 mm x 129 mm (20 x 11 x 5 inches)
• cable entry points are not provided, but are are predesigned on the
bottom of the enclosure (0.75" or M20)
• front panel is molded with predesigned holes for fully equipped
configuration (eight channels)
• is mounted by four screws (1/4 - 20 or M6).
Figure 2-1. Enclosure
1 Power Supply 5 Cable entries
2 Channel Relay Board 6 Backup Battery
3 Channel Board 7 Enclosure with mounting holes
4 Sensor Extension Board

2-3
Power Supply
• The 100 W power supply accepts main AC and DC power.
• In case of loss of main power, the power supply automatically
switches to backup battery.
• Power source for detector is 24 VDC.
Backup Battery
Two batteries in series (12 VDC/2.2 Ah lead acid) can be used in the
Control Unit as an option. The batteries supply 20 minutes of backup for
eight catalytic combustible sensors.
To activate battery backup, the pc software must be configured. Go to
Settings, Service Function, Device Settings. Check the Battery Backup
box to activate, save and then download settings to the Control Unit.
Do not use primary non-rechargeable batteries.
Operation under back-up power is indicated by the Power LED blinking
on the front panel.
Main Board
The Main board microcontroller includes:
• watchdog
• internal buzzer (85 dB)
• standard common outputs
• battery charger circuit.
All necessary information is stored on the Main board.
The 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.
NOTE: Communication doesn’t interfere with operation of the
Control Unit.

2-4
• For SCADA visualization software, all three interfaces can be used.
• For service access, as a safety precaution, only the two ModBus
RTU communications can be used.
Standard common outputs are incorporated:
• two SPDT (Single Pole Double Throw) relays common alarm
(ALARM 1 and ALARM 2)
• one DPDT (Double Pole Double Throw) relay common fault
• two addressable common horn relays.
Display Board
The Display board, located on the back side of the lid, includes:
• microcontroller
• watchdog
• push buttons
• graphic display (128x64).
Sensor Extension Board
The sensor extension board is used to:
• attach channel boards
• connect internal communication.
NOTE: See Chapter 3, "Sensor Connection".
Channel Board
The channel boards are set to communicate with 4-20 mA transmitters.
Every board:
• includes four LEDs (A1, A2, Status, Power)
• attaches to the Channel connectors
(four on the Main board, four on the Sensor Extension board).
Sensor power and connection is designed as "fail-safe"
(wrong connection/configuration does not damage the remote sensor).

2-5
Channel Relay Board
Every Channel Relay board:
• provides eight output relays
• is connected to the Main board or Sensor Extension board (one by
one) via connectors.
Relays are fully user-configurable from the front panel or connected PC
via configuration software.
Two optional SPDT (Single Pole Double Throw) relays per channel
(eight relays per four channels) are configurable for individual alarms:
• Normally open/closed
• Normally energized/de-energized
• Latching/non latching
• Increasing/decreasing
• N out of m voting
• Grouping
NOTE: Contacts are resistive load.

Front Panel
The Front Panel enables communication with the Control Unit
and is used to:
• monitor the status of all connected field sensors
• determine system settings
• configure all settings.
Graphic Display
The Control Unit has a large, 128 x 64 pixel graphic display which
shows information for all channels. See Chapter 4 for symbol
explanation.
Figure 2-3.Graphic Display
Figure 2-2. Front Panel
1 Common LEDs 4 Alarm Acknowledgement
2 Alarm Reset 5 Graphic Display
3 Control Push Buttons 6 Channel Status Info LEDs
2-6

2-7
Control Push Buttons
Using the control push buttons, the user can operate the menu prompt
as shown below. For more information, see Chapter 4.
Channel Status Info LEDs
Each of the eight Control Channels has four LEDs for monitoring unit
operating status.
Figure 2-4. Channel Status Info LEDs
Right button [ ↵ ]
Up Button [  ]
Left button [ ESC ]
Down button [

]
Alarm Acknowledgement
Alarm Reset

2-8
1. The green Power LED:
Channel is powered and enabled by the system.
2. The yellow Status LED:
Channel is in a fault condition.
• Blinking LED (0.5 Hz):
Channel is disabled.
3. The red Alarm 1 LED:
First alarm level is reached. It further indicates the specific status:
• 4 Hz blinking:
First alarm level is reached, but not yet acknowledged
• Steady:
First alarm level is acknowledged, but still inside alarm range
• 0.5 Hz blinking:
First alarm is configured as latching. Measured value is out of
alarm level and not yet reset.
4. The red Alarm 2 LED:
Second alarm level is reached. It further indicates specific status:
• 4 Hz blinking:
Second alarm level is reached, but not yet acknowledged
• Steady:
Second alarm is acknowledged, but still inside alarm range
• 0.5 Hz blinking:
Second alarm is configured as latching. Measured value is out
of alarm level and not yet reset.

2-9
Unit Status Info LEDs
1. Green Power LED:
Control Unit is powered.
• Blinking LED:
battery power supply.
2. Yellow Failure LED:
Sensor is in fault condition.
3. Yellow System LED:
Control Unit has a system fault.
Figure 2-5. Unit Status Info LEDs

3-1
Chapter 3,
Installation
NOTE: Reference shipping documents and carton label to check that
delivered components are correct before installation.
• The installation location for the Control Unit must be outside the
potentially explosive area and free of corrosive gases.
• Sensors for use in the potentially explosive area must have the
appropriate approval and be installed in accordance with all
relevant local and national regulations.
• The gas warning system must be installed by qualified personnel
after reading the supplied documentation.
• All relevant local and national regulations and instructions must be
observed.

3-2
Mechanical Installation
Mount the Control Unit as follows:
1. Mark holes for the four fixing screws as shown in FIGURE 3-1.
2. Drill four holes of appropriate diameter for the wall plugs.
3. Lift the front panel from the enclosure.
4. Attach the unit to the wall with the appropriate screws.
5. Return the lid to the resting position.
Electrical Installation
The control system must be installed in compliance with
applicable regulations; otherwise, an unsafe condition may
exist.
During installation, use the internal earth connection to ground the
instruments.
"CAUTION
Figure 3-1. Mounting Drawing [dimensions in inches (mm)]

3-3
If an external earth connection is permitted or demanded by the
local authorities, it serves merely as additional earthing.
• Select an installation location that complies with the environmental
conditions indicated in the technical data.
• When installing the Control Unit, the following conditions must be
met to comply with the European EMC Directive
• A fault-free ground or fault-free potential bonding conductor
must be provided when connecting devices to the main
power supply.
• 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 internal connections must be kept as short as possible.
• The control system can be simultaneously connected to
AC voltage and 24 VDC (to enable an automatic power switch
to 24 VDC voltage if the AC main supply fails).
Power Supply
• Standard power supply 110-230 VAC/24 VDC (100 W) is used to
power internal circuits and attached sensors.
• A switch or circuit-breaker shall be included in the building
installation in close proximity to the equipment and within easy
reach of the operator. It shall be marked as the disconnecting
device for the equipment.
• Main voltage is connected to terminal L (Line), N (Neutral), and
ground.