MSA Toxgard II User manual

Toxgard®II Monitor
instruction manual
"! WARNING
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, the unit will perform as
designed only if it is 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 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 customers to write or call regarding this equipment
prior to use or for any additional information relative to use or repairs.
In the U.S., to contact your neareststocking location, dial toll-free 1-800-MSA-INST.
To contact MSA International, dial 1-412-967-3354.
© MINE SAFETY APPLIANCES COMPANY 2006 - 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) Rev 7 711266

MSA Permanent Instrument Warranty
1. Warranty- Seller warrants that this product will be free from
mechanical defect or faulty workmanship for a period of
eighteen (18) months from date of shipment or one (1)
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 (1) year such as,
but not limited to, non-rechargeable batteries, sensor
elements, 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 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.

"WARNINGS
1. Each instrument described in this manual must be
installed, operated and maintained in strict accordance
with its labels, cautions, warnings, instructions, and within
the limitations stated.
2. These monitors must not be installed in areas or 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. Since the
monitors are not explosion-proof, they must be located in
non-hazardous areas.
3. The Toxgard II monitor is designed to detect toxic gases or
vapors in the air. It cannot measure the concentration of
toxic gases or vapors in steam or inert or oxygen-deficient
atmospheres. Neither will it indicate the presence of
explosive or combustible mists or sprays, lubrication oils,
nor explosive dusts, such as grain or coal dust.
4. As with all gas detection instruments of this type, high
levels of or long exposure to certain compounds - all of
which are not known, will contaminate the sensor.
Calibrate the monitor frequently to ensure that system
operation is dependable and its indications accurate.
5. The Toxgard II monitor must not be painted. Also, painting
should not be done near the sample line inlet. If painting is
being done in an area where the sample line inlet is
located, care must be exercised to make sure that paint is
not deposited on the sample inlet fitting of the monitor.
Such paint deposits would interfere with the sampling
process, whereby a sample of the atmosphere being
monitored is drawn into the Toxgard II unit.
6. The only absolute method to ensure proper overall
operation of a gas detection instrument is to check it with
a known concentration of the gas for which it has been
calibrated. Consequently, a calibration check should be
included as part of the routine inspection of the system.

7. The sensor is a sealed unit which contains an electrolyte.
Should the sensor develop leakage, it should be
immediately removed from the sensing head and properly
discarded in accordance with local, state and federal
laws. To obtain a replacement sensor, contact MSA at the
address given in Chapter 5, "Obtaining Replacement
Parts." Caution must be exercised so that the electrolyte
does not contact skin eyes, clothing or circuitry. Get
immediate medical attention if electrolyte contacts skin or
eyes.
8. Perform periodic leak check on the sample line and all flow
system components and fittings of the Toxgard II monitor.
9. 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 Toxgard II unit,
beyond the scope of these maintenance instructions, or
by anyone other than an authorized MSA serviceman,
could cause the product to fail to perform as designed,
and persons who rely on this product for their safety could
sustain severe personal injury or death.
10. Properly vent the exhaust of the Toxgard II monitor to a
safe area. Improper venting of the exhaust can cause
personal injury or death.
11. Do not install additional filters into the sample inlet fittings.
Adding the filters will impair instrument performance.
12. Ensure the gas sample and Toxgard II unit are at the same
temperature; otherwise, condensation will form, possibly
clogging or filling the sample line.
13. Do not mix units with different area classifications. All units
used in a classified area must have the proper area
classification. Otherwise, an explosion hazard exists,
resulting in possible explosion, injury or death.
FAILURE TO COMPLY WITH THE ABOVE WARNINGS CAN RESULT
IN SERIOUS PERSONAL INJURY OR DEATH.

Table of Contents
Chapter 1
Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Unpacking Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Initial Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Figure 1-1. Toxgard II Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Identifying Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Figure 1-2. Remote Sensor Model . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Figure 1-3. Shipping Carton Label Identifying Sensor Type . . . . . . . . 1-3
Mounting Your Gas Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
"WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Figure 1-4. Options and Accessories (Battery Back-up not shown) . . 1-4
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Gas Sampling Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
The Toxgard II Pump or Aspirator Model: . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Table 1-1. Performance Specifications
for Toxgard II Pump or Aspirator Model . . . . . . . . . . . . . . . . . 1-6
"WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Installation of DC Pump or Aspirator Sampling . . . . . . . . . . . . . . . . . . . . . 1-6
Sample Line Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Exhaust Line Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Blocked Flow Detection of Sample Line . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Mounting the Air-line Toxgard II Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
"WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Flow Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Mounting the Toxgard II Remote Sensor Module . . . . . . . . . . . . . . . . . . . 1-9
Electrical Connections for Toxgard II Monitors . . . . . . . . . . . . . . . . . . . . 1-10
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Figure 1-5. Remote Sensor Mounting Method . . . . . . . . . . . . . . . . . 1-10
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Table of Contents
TOC-1

Figure 1-6. Toxgard II Cable Entries . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Relay Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Table 1-2. Relay Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Alarm Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Alarm Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Fault Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Horn Relay/Audible Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Audible Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Relay Wiring with Inductive Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Milliamp Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Figure 1-7. Standard 4-20 mA Terminal Wiring . . . . . . . . . . . . . . . . 1-14
Isolated 4-20 mA Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
For Signal Loads Less Than 50 Ohms: . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
For Signal Loads Greater Than or Equal to 50 Ohms: . . . . . . . . . . . . . . 1-15
Under Line-powered Conditions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Under Battery-powered Conditions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Digital Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Visual Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Horn/Alarm Acknowledge Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Remote Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Electrical Connections for the Remote Sensor Module . . . . . . . . . . . . . 1-16
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
For Combustible Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Table 1-3. Wire Gauge Vs. Distance Between Units . . . . . . . . . . . . . 1-17
Table 1-4. Remote Combustible Sensor Wiring Cable . . . . . . . . . . . . 1-18
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Figure 1-8. Combustible Remote Sensor . . . . . . . . . . . . . . . . . . . . . 1-18
Figure 1-9. Oxygen Remote Sensor Cable . . . . . . . . . . . . . . . . . . . 1-19
Figure 1-10. Oxygen and Toxic Remote Sensor . . . . . . . . . . . . . . . . 1-19
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Table of Contents
TOC-2

Oxygen Remote Sensor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Toxic Gas Remote Sensor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Figure 1-11. Toxic Gas Remote Sensor Cable . . . . . . . . . . . . . . . . . . 1-21
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Pump Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Table 1-5. SW2 Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Figure 1-12. Pump Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Table 1-6. SW3 Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Controller/Calibrator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Internal Push-buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Viewing Configuration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Table 1-7. Parameters Displayed During MODE Push-button Operation 1-26
Changing Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Method 1 - Push-buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Method 2 - Ultima Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Battery Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Table 1-8. Expected Battery Operating Time at 77oF . . . . . . . . . . . . 1-30
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
Banshee Horn Audible Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
Figure 1-13. Banshee Horn Audible Settings . . . . . . . . . . . . . . . . . . . 1-31
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Autocalibration Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Duct-Mounted Remote Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . 1-32
Chapter 2
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Initial Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-1. Gas Concentration Display . . . . . . . . . . . . . . . . . . . . . . . . 2-1
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figure 2-2. Calibration Flag Display . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Table of Contents
TOC-3

"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Non-combustible Chemicals that Reduce Sensor Sensitivity . . . . . . . . . . 2-4
Calibrator . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 2-4
Toxgard II Monitor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-3. Ultima®Calibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-4. Ultima®Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Table 2-1. Sensor Response to Interferants . . . . . . . . . . . . . . . . . . . . . 2-5
Toxgard II Monitor Calibration Output Signal . . . . . . . . . . . . . . . . . . . . . . 2-6
Chapter 3
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Table 3-1. Factory-set Span Values . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Calibration Kits 40 and 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Calibration Kits 41 and 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Span Gas Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
"CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Toxgard II Gas Monitor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Figure 3-1. Calibration Kit 40 Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Figure 3-2. Calibration Kit 41 Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Figure 3-3. Calibration Kit 42 Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Figure 3-4. Calibration Kit 43 Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Calibration Documentation . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
To Zero the Toxgard II Gas Monitor Only . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Procedure Number 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Figure 3-5. Zero Cap Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Figure 3-6. Calibration Tubing Set-up . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Figure 3-7. Zero Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Figure 3-8. Apply Zero Gas Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Figure 3-9. Calibration End Display . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Figure 3-10. Calibration Fault Flag . . . . . . . .. . . . . . . . . . . . . . . . . . . 3-10
Procedure Number 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Figure 3-11. Zero Cap Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Table of Contents
TOC-4

Figure 3-12. Zero Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Perform a Complete Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Procedure Number 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Zeroing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Spanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Figure 3-13. Apply SPAN Gas Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Figure 3-14. Span Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Figure 3-15. Calibration End Display . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Figure 3-16. Span Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Procedure Number 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Zeroing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Spanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
OXYGEN Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
25% Oxygen Toxgard II Gas Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
INITIAL Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Toxgard II Airline Monitor, Pumped Version and Aspirated Version
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Figure 3-17. Typical DC Pump Version Installation . . . . . . . . . . . . . . 3-26
Figure 3-18. Typical Air Aspirator Version Installation . . . . . . . . . . . . 3-26
Zero Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Figure 3-19. Typical Air Line Monitor Installation . . . . . . . . . . . . . . . . 3-27
Chapter 4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Table 4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
"!WARNING. . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 4-3
Chapter 5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
"WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
"CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Table of Contents
TOC-5

Figure 5-1. Change Sensor Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Figure 5-2. Cap Location for Remote Combustible Gas Explosion-proof
Sensor . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 5-3
Figure 5-3. Cap Location for Toxic Gas or Oxygen General-purpose
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
"!CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Figure 5-4. Cap Location for Remote Toxic Gas or Oxygen
Explosion-proof Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Figure 5-5. Combustible Three-Pin Connector . . . . . . . . . . . . . . . . . . 5-5
Figure 5-6. CAL FAULT Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Table 5-1. Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Obtaining Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Table 5-2. Replacement Sensor Kits . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Table 5-3. Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Appendix A
Optional Duct Mount Kit . . . . . . . . . . . . . . . . . . . . . A-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Figure A-1. Ultima Duct Mount Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Figure A-2. Duct Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Table A-1. Dual module Duct Mount Kit Parts List . . . . . . . . . . . . . . . . A-4
Figure A-3. Remote Sensor Spacers . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Figure A-4. Remote Sensor Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Figure A-5. Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
"WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Figure A-6. Remote Sensor Base Plate . . . . . . . . . . . . . . . . . . . . . . . A-6
Figure A-7. Duct Mount and Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Appendix B
Definitions of Terms . . . . . . . . . . . . . . . . . . . . . . . . B-1
Table of Contents
TOC-6

Chapter 1
Set-up
Unpacking Your Unit
Several cartons may arrive with your order; locate the carton(s)
marked as the Toxgard II Monitor. Upon receipt, ensure that your
package contains:
•Toxgard II Monitor (FIGURE 1-1)
•Toxgard II Monitor Instruction Manual (P/N 711266).
If your unit is a Toxgard II Monitor with Digital Output,
there will be an additional manual (P/N 711203)
•Toxgard II Remote Sensor Module, if ordered as a
Remote Sensor model (FIGURE 1-2)
1. Remove the Toxgard II unit from its shipping container(s),
taking care not to damage sensitive electrical components.
2. Search through the packing material and the containers to
avoid discarding valuable parts.
Initial Inspection
1. Turn the coin slot lock 1/4-turn clockwise and open the door
or use the key for the key lock, if so equipped.
2. Carefully inspect the components and assemblies inside the
case. If damage or shortage is noted, advise the carrier
promptly; make the proper claim with the carrier.
General Description
The Toxgard II Monitor is an easy-to-use, low-cost, one-sensor
monitor. It is designed to sample the environment where the
monitor is mounted and to alert you to potentially dangerous
levels of one of the following gases, depending on your
particular model:
•Combustible gas •Hydrogen Cyanide
•Oxygen •Hydrogen Chloride
•Carbon Monoxide •Nitric Oxide
•Hydrogen Sulfide •Nitrogen Dioxide
•Chlorine •Sulfur Dioxide
•Chlorine Dioxide
Chapter 1, Set-up
1-1

Figure 1-1.
Toxgard II Monitor
Chapter 1, Set-up
1-2

•All models are available as Remote Sensor models
(FIGURE 1-2). Combustible gas models require the remote
explosion-proof sensor module.
To determine your sensor type and options, check the shipping
carton (FIGURE 1-3) and sensor ID label. Checked items are
included in the carton.
Identifying Your Unit
To determine your model type and other installed options
(FIGURES 1-1 and 1-4), check the ID label on the shipping
carton (FIGURE 1-3). This label identifies:
•target gas, sensor location and range
•sampling accessories (if applicable)
•visual and audible alarm options
•output accessories
•mounting hardware.
Figure 1-2.
Remote Sensor Model
Figure 1-3.
Shipping Carton Label Identifying Sensor Type
Chapter 1, Set-up
1-3

Mounting Your Gas Monitor
Generally, the unit or the remote sensing module should be
mounted close to the area where a leak is likely to occur or
where the gas is expected. The Toxgard II Monitor or Remote
Sensing Module should be installed at a high level (ceiling),
breathing level or low level (floor), depending on the density of
the gas being monitored. Mount the unit so that the front display
is not blocked or hidden from view.
"WARNING
Do not locate the Toxgard II Monitor in an area which may contain
a flammable mixture of gas and air; otherwise, an explosion may
occur.
The general-purpose Toxgard II Monitor can be a source of ignition
and must not be mounted in an area where a flammable mixture of
combustible gas and air may be present; otherwise, an explosion
may occur.
Figure 1-4.
Options and Accessories (Battery Back-up not shown)
Chapter 1, Set-up
1-4

Mount the Toxgard II Monitor or the Remote Sensing Module with
its sensor inlet fitting (FIGURE 1-1 or 1-2) pointed downwards;
otherwise, the inlet may become clogged with particulate matter
or liquids. Do not paint the Toxgard II Monitor. If painting is done
in an area where a sensor is located, exercise CAUTION to ensure
paint is not deposited on thesensor inlet fitting. Such paint deposits
would interfere with the diffusion process, whereby a sample of
the monitored atmosphere diffuses into the sensor.Failureto follow
the above can result in serious personal injury or death.
"CAUTION
Protect the Toxgard II Monitor from extreme vibration. Do not mount
the sensing head in direct sunlight as this may cause the sensor
to overheat.
Ventilation patterns must be established before positioning the
Toxgard II unit or sensor assembly. Smoke tubes (P/N 458481)
are useful in measuring the direction and rate of air flow to
determine areas where the gas of interest may tend to
accumulate.
Using suitable hardware (not supplied), mount the Toxgard II
monitor to any flat surface via its four mounting lugs (see
FIGURE 1-6). Allow sufficient room to open the unit front door.
The Toxgard II unit is designed to meet NEMA 4X requirements,
suitable for many damp, wet and/or outdoor locations.
Gas Sampling Options
Although the Toxgard II unit normally operates in the diffusion
mode (i.e., gases or vapors to be detected enter the sensor input
by natural molecular diffusion), a sample can be drawn into the
instrument if the DC pump or air aspirator option was purchased.
The Toxgard II Pump or Aspirator Model:
•draws a gas sample from the monitored area, through a sample
line (available separately) to the Toxgard II Gas Monitor sensor
•samples areas that are remote, inaccessible, too hot or too cold
for direct sensor monitoring, such as:
•ducts carrying combustible or toxic gas
•wet wells
•printing drying ovens
•blanking or inerting operations
•has electronics physically located in the main monitor enclosure
(FIGURE 1-1)
Chapter 1, Set-up
1-5

•comes equipped with a special flow cap for use on the Toxgard
II Gas Monitor to ensure proper sensor sampling.
•provides notification via the Toxgard II Monitor LED display and
fault relays if a flow fault is detected.
Table 1-1. Performance Specifications
for Toxgard II Pump or Aspirator Model
SAMPLE
TRANSPORT TIME 30 seconds at 0.5 lpm with 50 feet (15.25 meters) of
.180 (4.57 mm) ID sample tubing
NOMINAL SAMPLE
FLOW RATE 2 CFH (1 LPM)
MINIMUM SAMPLE
FLOW RATE 1 CFH (.500 LPM)
MAXIMUM SAMPLE
TUBING LENGTH 100 feet (30 meters); 3/16" ID (4.76 mm)
25 feet (7.5 meters) maximum for Chlorine, Nitrogen
Dioxide and Chlorine Dioxide
MAXIMUM
EXHAUST TUBING
LENGTH 20 feet (6 meters)
INLET FITTINGS 1/4" (6.35 mm) OD Tube Fitting
EXHAUST FITTING 1/4" (6.35 mm) OD Tube Fitting
"WARNING
Only Remote Sensors with proper area ratings can be used in a
hazardous area. The Toxgard II Monitor cannot be installed in a
hazardous area. Otherwise, an explosion hazard will exist resulting
is a possible explosion, injury or death.
Installation of DC Pump or Aspirator
Sampling
Sample Line Placement
•Remove all protective packaging plugs and/or caps from gas
INLET, CALIBRATION and EXHAUST PORTS.
•In-line filter must be used in the sample line.
•MSA tubing is available (P/N 600771).
The pump or aspirator draws a gas sample to the Toxgard II
Gas Monitor sensor (FIGURE 1-1):
•Can be extended up to 100 feet (30 Meters) away from the
Toxgard II Gas Monitor.
Chapter 1, Set-up
1-6

•Uses 1/4-inch (6.35 mm) OD tubing. The tubing must be
compatible with the sampled gas. Sample tubing must also be
3/16" ID for 100-foot lines to prevent "Lo Flo."
•It takes a maximum of 30 seconds for the sample gas to reach
the Toxgard II Gas Monitor when 50 feet (15.25 meters) of
tubing is used:
•To decrease this time, shorten the sample line length.
•It is generally good practice to make the sample line as
short as possible.
•Depending on the gas characteristics, the end of the sampling
tubing and the sample inlet should be mounted to best optimize
sampling of that particular gas. Consult your architect, facility
manager or safety engineer for guidance in proper placement of
the sampling tube inlet.
•Testing for ventilation patterns is useful in establishing sample
inlet location. Smoke tubes (P/N 458481) are useful in
measuring the direction and rate of air flow to determine which
areas to monitor.
•A particulate filter (purchased separately) should be used at the
inlet end of the sample line to help prevent dirt and dust from
clogging the sample line. This filter must be compatible with the
gas being sampled.
•It is recommended that a stainless steel or Teflon* sample line
be used for monitoring gases that are highly reactive such as:
•Nitrogen Dioxide
•Sulfur Dioxide.
•Use only a Teflon sample line for the following gases:
•Chlorine
•Chlorine Dioxide
•Hydrogen Chloride
•Ammonia.
•With the above gases, do not use an end-of-line filter. The
sample line should be inspected periodically and replaced if
dirty. Do not attempt to clean the sample line by applying
compressed air.
NOTE: Do not run the sample tubing in water or across
areas of vibration, doorways, man ways or access
ways; otherwise, a sample tubing leak or tripping
hazard may result.
4. Using suitable hardware (not supplied):
Chapter 1, Set-up
1-7

•Fasten the sample tubing to supports.
•Do not tightly pinch the tubing; otherwise, flow may
be restricted.
•Fasten the end of the sample tubing and sample inlet in
the monitoring area.
•The sample inlet should be pointed downward to
prevent dirt and water from entering the sample
tubing line.
5. Install the end-of-line filter at the end of the sampling tubing.
6. Check for leaks along the entire length of the sample
tubing line. Any leak will dilute the gas sample from the
area of interest and give a lower than actual gas reading.
Exhaust Line Placement
1. For DC pump only:
Attach 1/4-inch (6.35 mm) OD sample tubing
to the exhaust outlet fitting.
For Aspirated systems only:
Attach 3/8-inch (9.52 mm) OD sample tubing
to the exhaust outlet fitting.
2. Route the exhaust tubing into a safe area where the gas
sample can be vented. Avoid any sharp bends or elbows.
Route the tubing to allow any collected water to drain.
•The maximum exhaust tubing length is 20 feet (6 meters).
NOTE: Do not run the exhaust tubing in water or across
areas of vibration or across doorways, man ways or
access ways; otherwise, a leak in the exhaust
tubing or a tripping hazard may result.
3. Fasten the exhaust tubing to supports using suitable
hardware (not supplied).
4. Fasten the end of the exhaust tubing in the area of interest
by using suitable hardware (not supplied).
•Exhaust inlet should be pointed downward to prevent dirt
and water from entering the exhaust tubing line.
NOTE: Exhaust to a safe or non-hazardous area only.
5. Check for leaks along entire length of the exhaust tubing line.
Chapter 1, Set-up
1-8

Blocked Flow Detection of Sample Line
Units equipped with the pump or air aspirator options are
supplied with a flow detector. This flow detector activates the
fault relay when insufficient flow exists for proper gas detection.
Mounting the Air-line Toxgard II Monitor
"WARNING
These units must not be located in areas which may contain a
flammable mixture of gas and air; otherwise, an explosion may occur.
"CAUTION
Protect the Toxgard II Monitor from extreme vibration. Do not mount the
sensing head in direct sunlight as this may cause the sensor to overheat.
1. Using suitable hardware (not supplied) mount the Toxgard II
monitor to any flat surface; allow room to open the door.
2. Connect the source of compressed air being monitored to
the pressure regulator (fittings not included). Install the
regulator as close as possible to the sample take-off.
•The maximum regulator inlet pressure is 300 PSI.
•The regulator outlet pressure should be set to a nominal
10 PSI.
NOTE: An in-line filter trap (P/N 626967 or equivalent) is
recommended to prevent clogging of the flow
system due to air line contamination, such as oil, dirt
or moisture.
"CAUTION
Do not exceed 300 pounds maximum inlet pressure; otherwise,
damage to the unit may occur.
3. Ensure the pressure regulator is fully counter-clockwise to
reduce the initial pressure to the unit.
Flow Block
The Toxgard II Monitor equipped with the flow block option can
be used to allow a sample to be delivered from a pressurized
stream to the Toxgard II unit. Inlet pressure to the flow block
should not exceed 10 PSI.
Mounting the Toxgard II Remote Sensor Module
The Remote Sensor Module:
Chapter 1, Set-up
1-9

•is mounted where the gas
is expected to exist
•is mounted with the sensor
pointing downward via the
3/4" NPT threads located
on the end of the
module, opposite the
sensor
•can also be mounted with
the mounting strap (P/N
655700); see FIGURE 1-5
•wiring is routed to the
Toxgard II Monitor.
Permanently connect 3/8" OD
tubing to the center post of
the sensor inlet. Route this
tubing to the Toxgard II
Monitor, ensuring there are no
kinks, leaks or other
obstructions. Secure this tubing near the monitor; it is used to
deliver check gas to the sensor module during calibration.
Electrical Connections for Toxgard
II Monitors
•Recommended wire is three-conductor, 16 gauge (12 gauge
maximum).
•Install an external switch or circuit breaker close to the unit for
disconnection purposes.
•Install an over-current protection device (e.g., fuse) in the
supply wiring to the unit; two-amp, slow acting fuses
are recommended.
"WARNING
Before wiring the Toxgard II Monitor, disconnect power source
supplying the monitor; otherwise, electrical shock could occur.
"CAUTION
Make all wiring connections and conduit runs according to accepted
commercialwiring practices. Install the Toxgard IIunit in compliance
with the applicable requirements of the National Electrical Code
and/or any other local code requirements.
NOTE: For Toxgard II with Digital Output Monitors, see
manual (P/N 711203) for wiring instructions.
Figure 1-5.
Remote Sensor Mounting Method
Chapter 1, Set-up
1-10