MSA General Motions MC600 User manual

MODEL MC600
Multi-Channel Controller
for Hydrocarbon, H2S and Toxic
Gas Monitoring Applications
The information and technical data disclosed in
this document may be used and disseminated
only for the purposes and to the extent
specifically authorized in writing by General
Monitors.
Instruction Manual 12-15
General Monitors reserves the right to change
published specifications and designs without
prior notice.
Part No. MANMC600
Revision T/12-15

Model MC600
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Warranty
General Monitors warrants the Model MC600 to be free from defects in
workmanship or material under normal use and service within two (2) years from
the date of shipment.
General Monitors will repair or replace without charge any such defective
equipment found to be deficient during the warranty period. General Monitors’
personnel will make full determination of the nature of and responsibility for,
defective equipment.
Defective or damaged equipment must be shipped prepaid to General Monitors’
plant or representative from which shipment was made. In all cases, this
warranty is limited to the cost of equipment supplied by General Monitors. The
customer will assume all liability for the misuse of this equipment by its
employees or other personnel.
NOTE: The Model MC600 Multi-Channel Controller System is easy to install;
however, this manual should be read and understood before attempting
to install or operate the device.
All warranties are contingent upon proper use in the application for which the
product was intended and do not cover products which have been modified or
repaired without General Monitors’ approval, or which have been subjected to
neglect, accident, improper installation or application, or on which the original
identification marks have been removed or altered.
Except for the express warranty stated above, General Monitors disclaims all
warranties with regard to the products sold, including all implied warranties of
merchantability and fitness and the express warranty stated herein are in lieu of
all obligations or liabilities on the part of General Monitors for damages including,
but not limited to, consequential damages arising out of, or in connection with,
the use or performance of the product.
Warnings
This instruction manual includes numerous cautions and warnings that are
included to prevent injury to technicians who are handling the equipment and to
prevent damage to your detection system.
WARNING: TOXIC, COMBUSTIBLE AND FLAMMABLE GASES AND VAPORS
ARE VERY DANGEROUS. USE EXTREME CAUTION WHEN
THESE HAZARDS ARE PRESENT.
WARNING: HYDROGEN SULFIDE (H2S) IS AN EXTREMELY TOXIC GAS AND
EXPOSURE MAY RESULT IN A LOSS OF CONSCIOUSNESS OR
DEATH.

Model MC600
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System Integrity Verification
General Monitors’ mission is to benefit society by providing solutions through
industry-leading safety products, services, and systems that save lives and
protect capital resources from the dangers of hazardous flames, gases, and
vapors.
The safety products you have purchased should be handled carefully and
installed, calibrated, and maintained in accordance with their product instruction
manuals. Remember, these products are for your safety.
To ensure operation at optimum performance, General Monitors recommends
that certain preventive startup and maintenance tasks be performed.
Commissioning Safety Systems
Before power up, verify wiring, terminal connection, and stability of mounting for
all integral safety equipment including, but not limited to:
Power Supplies
Control Modules
Field detection devices
Signaling/output devices
Accessories connected to field and signaling devices
After the initial application of power (and any factor-specified warm-up period) to
the safety system, verify that all signal outputs to and from devices and modules
are within the manufacturer’s specifications. Initial calibration, calibration
checking and testing should be performed per the manufacturer’s
recommendations and instructions.
Proper system operation should be verified by performing a full, functional test of
all component devices of the safety system, ensuring that the proper levels of
alarming occur.
Fault/Malfunction circuit operation should be verified.
Periodic Testing/Calibration of Field Devices
Periodic testing/calibrating should be performed per the manufacturer’s
recommendations and instructions. Testing/Calibration procedures should
include, but not be limited to:
Verify zero reading
Apply a known concentration of gas, or simulated test device provided by
the manufacturer
Verify integrity of all optical surfaces and devices
When testing produces results outside of the manufacturers’ specifications,
recalibration or repair/replacement of the suspect device(s) should be performed
as necessary. Calibration intervals should be independently established through
a documented procedure, including a calibration log maintained by plant
personnel or third party testing services.

Model MC600
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Periodic System Verification
The following system verifications should be performed at least annually:
Verify wiring, terminal connections and stability of mounting for all integral safety
equipment, including, but not limited to:
Power supplies
Control modules
Field detection devices
Signaling/output devices
Accessories connected to field and signaling devices
Proper system operation should be verified by performing a full, functional test of
all component devices of the safety system, ensuring that the proper levels of
alarming occur.
Fault/Malfunction circuit operation should be verified. In addition, calibration
intervals should be independently established through a documented procedure,
including a calibration log maintained by plant personnel or third party testing
services.

Model MC600
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About This Manual
This manual provides instructions for installing and operating the Model MC600
Multi-Channel Controller. Maintenance and specification information is also
provided, as well as, programming information for the MODBUS registers. The
intended audience includes field service technicians, MODBUS programmers
and other technical staff involved in installing and using an MC600 system.
Format Conventions
Several format conventions are used throughout the book for notes and cautions,
warnings, as well as, MODBUS notations.
Notes, Cautions and Warnings
NOTE: Notes provide supplementary details such as, exception conditions,
alternate methods for a task, time saving tips and references to related
information.
CAUTION: Cautions describe precautions to prevent damage to equipment.
WARNING: Warnings describe precautions to prevent serious injury to people
working with equipment.
MC600 Menu Formats
Menu keywords and LCD digital display messages are shown in bold,
e.g. Cal Fault.
MC600 navigation buttons are shown in text paragraphs formatted in
bold, surrounded by square brackets, e.g. [ACCEPT] or [MODE]
MODBUS Register Formats
Hexadecimal numbers are indicated by a trailing lowercase “h”, such as, 000Eh.
Other Sources of Help
Extensive documentation, white papers and product literature for our complete
line of safety products can be found at http://www.MSAsafety.com/detection

Model MC600
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Related Documentation
The detection instruments that you connect to the MC600 each have their own
documentation and you will need to refer to the instruction manual for each
instrument in order to calibrate and maintain the instrument. A list of the manuals
for the MC600-compatible detection instruments follows:
Model TS400 Instruction Manual, part number MANTS400
Model TS420 Instruction Manual, part number MANTS420
Model TS4000 Instruction Manual; part number MANTS4000
Model TS4000H Instruction Manual; part number MANTS4000H
Model IR400 Instruction Manual, part number MANIR400
Model IR700 Instruction Manual, part number MANIR700
Model IR2100 Instruction Manual, part number MANIR2100
Model IR5000 Instruction Manual, part number MANIR5000
Model IR5500 Instruction Manual, part number MANIR5500
Model IR7000 Instruction Manual, part number MANIR7000
Model S4000C Instruction Manual, part number MANS4000C
Model S4000CH Instruction Manual, part number MANS4000CH
Model S4000T Instruction Manual, part number MANS4000T
Model S4000TH Instruction Manual, part number MANS4000TH
Model S4100C Instruction Manual, part number MANS4100C
Model S4100T Instruction Manual, part number MANS4100T
Model S214 Instruction Manual, part number MANS214
Model S216A Instruction Manual, part number MANS216A
Model S104 Instruction Manual, part number MANS104
Model S106A Instruction Manual, part number MANS106A
Observer Instruction Manual
Observer-H Instruction Manual, part number MANOBSERVER-H
Surveyor Instruction Manual, part number BB6019
Contacting Customer Support
For additional product information not contained in this manual, please contact
General Monitors Customer Support; refer to Section 6.0 for contact information.

Model MC600
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1.0 Quick Start Installation Instructions
The main steps in a typical MC600 installation are listed below. There is some
variation in the installation process at each site, depending on the exact site
configuration.
Installation Step
Refer to Section
1. Unpack the equipment and prepare for the
installation.
Section 1.1, 1.2
2. Mount the MC600 cabinet in place
Section 1.3
3. Mounting sensors and instruments
Section 1.4
4. Connecting sensors and instruments to the
MC600
Section 1.5
5. Connecting MODBUS, HART, and relay
devices from instruments to MC600
Section 1.6, 1.7, 1.8
6. Connect the MC600 cabinet to an external
power supply if necessary, and then power on
the MC600 system
Section 1.9
Table 1: MC600 Installation Overview
1.1 Unpacking the MC600 Equipment
Please keep the following precautions in mind when you unpack and install the
MC600 cabinet and cabling.
Installation and maintenance must be carried out by suitably, skilled and
competent personnel only.
Contact with the PCB components should be avoided in order to prevent
damage from static electricity to equipment and personnel. Special care
must be taken to wear grounding apparel and to ensure that only the
connection points are touched whenever you are handling or installing
the MC600.
Each MOS H2S sensor is shipped with a red plastic cap fitted over the
sensor head. Inside the cap is a desiccant. DO NOT remove this cap
until you are ready to power the system. SAVE the cap and RE-CAP the
sensor anytime the system power is off for more than one hour.
All equipment shipped by General Monitors is packaged in shock absorbing
containers, which provide considerable protection against physical damage. The
contents should be carefully removed and checked against the packing list.
If any damage has occurred or there is any discrepancy in the order, please
notify General Monitors as soon as possible. All subsequent correspondence
with General Monitors must specify the equipment part number and the serial
number.

Model MC600
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NOTE: Each Model MC600 is thoroughly tested at the factory. However, a
system checkout is required upon initial start-up to ensure system
integrity.
1.2 Preparing for the Installation
To prepare installing the MC600 cabinet, you will need to choose a location and
gather the required tools. Separate preparation guidelines for mounting sensors
are provided in Section 1.5
1.2.1 Choosing a Location
The MC600 cabinet should be wall-mounted in a non-hazardous area. It can be
placed indoors or outdoors. You will need to select a location for the MC600 that
is near enough to the field-mounted devices to conform to the maximum cable
lengths specified for the field-mounted device.
NOTE: If a Class I Division 2 power supply is used, the cabinet can be mounted
in a hazardous Class I Division 2 area.
There must be adequate clearance beneath the MC600 cabinet to allow for cable
installation. Weather-protected locations with minimal shock and vibration are
preferred. Although the MC600 is largely immune to electromagnetic interference
(EMI), it should not be mounted in close proximity to radio transmitters or similar
equipment. The MC600 is provided with two ferrite clamps for use on the power
supply cable in case any interference is observed. Before installation, carefully
review the Environmental Specifications in Section 10.3 for allowable
temperature ranges and the Electrical Specifications in Section 10.4 for power
supply requirements.
1.2.2 Tools You Will Need
The following tools will be needed to install and cable the MC600:
Flat-head screwdriver maximum 3/16” (5 mm) width for terminal block
connections (included with unit)
Adjustable wrench for conduit or cable gland connections (not included)
#2 Phillips-head screwdriver (not included)

Model MC600
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1.3 Mounting the MC600 Cabinet in Place
Figure 1: Mounting Dimensions for the MC600 Cabinet
Before bolting the cabinet in place, make sure it is level. Fasten four ¼-inch bolts
into the four mounting holes on the corners of the enclosure. Use appropriate
mounting screws/bolts in regard to the mounting surface i.e. concrete, wood, etc.
Do not mount the MC600 onto drywall unless it is secured to the wooden studs
behind the drywall.
1.4 Mounting the Sensors and Instruments
The catalytic HC sensors, MOS H2S sensors and 4-20mA instruments, which will
be connected to the MC600, must be mounted in locations where they are
needed for gas detection. This can take place either before or after the MC600
cabinet is mounted in place. For detailed guidelines on selecting catalytic HC and
MOS H2S sensor locations, refer to Section 3.5.1.

Model MC600
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1.4.1 Mounting Sensors with General Monitors’ Accessories
Section 11.0 provides ordering information for several accessories for sensor
mounting, such as explosion-proof junction boxes, duct mounting kits,
splashguards, dust guards and remote calibration devices. Instructions for
mounting each type of 4-20mA instrument are provided in the instruction manual
for the instrument. For detailed guidelines on installing a sensor with a junction
box or duct mounting kit, refer to the following sections:
Mounting a Sensor with a GM Junction Box (Section 3.5.3)
Mounting a Sensor with a Duct Mounting Kit (Section 3.5.4)
1.4.2 Applying Sealants to Conduit Entries
Please keep the following warning in mind when installing housings and cabling
from catalytic HC and MOS H2S sensors and 4-20mA instruments in hazardous
areas. Make sure that the equipment maintains the appropriate seals for a Class
I hazardous location.
WARNING: Each conduit run within a hazardous location (and from a hazardous
to a non-hazardous location) must be sealed so that gases, vapors,
and/or flames cannot pass beyond the seal. The purpose of seals in
a Class I hazardous location is to prevent the passage of gases,
vapors, or flames from one electrical installation to another through
the conduit system. For information on Class I hazardous location
seals, see NEC articles 501-5 and 500-3d.
NOTE: For additional warnings and cautions, refer to Section 3.6.1
1.5 Connecting Sensors and Instruments to the
MC600
Once the MC600 cabinet is installed, you are ready to begin cabling from the
signal conditioning cards in the MC600 cabinet slots to field-mounted catalytic
HC sensors, MOS H2S sensors and 4-20mA instruments. To install wiring from
MOS H2S and catalytic HC sensors or instruments to the MC600, the end of the
wires that will be fastened to the MC600 signal card connector should be stripped
to approximately 0.25 inches, as shown below.
Figure 2: Pre-stripping Wiring
1.5.1 Cabling Warnings and Cautions
Please review the following cautions before proceeding to install cabling. For
information on non-hazardous location cabling to the MC600 cabinet, see NEC
article 504. For information on Class I location seals for sensors mounted in
hazardous areas, see NEC articles 501-5 and 500-3d