MSA Chillgard 5000 User manual

MSAsafety.com
Operating Manual
Chillgard 5000
Refrigerant Monitor
Order No.: 10178535/00

1000 Cranberry Woods Drive
Cranberry Township, PA 16066
USA
Phone 1-800-MSA-2222
Fax [phone]
For your local MSA contacts please go to our website www.MSAsafety.com
© MSA 2017. All rights reserved
WARNING!
Read this manual carefully before using the device. The device will perform as designed only if it is used and
maintained in accordance with the manufacturer's instructions. Otherwise, it could fail to perform as
designed and persons who rely on this device for their safety could sustain serious personal injury or death.
The warranties made by MSA with respect to the product are voided if the product is not installed and used
in accordance with the instructions in this manual. Please protect yourself and your employees by following
the instructions.
Please read and observe the WARNINGS and CAUTIONS inside.
WARNING!
Make sure any personnel who will be installing, using, or maintaining this device have access to the user
manual. If electronic access to the user manual (through the supplied Chillgard 5000 CD or MSA website)
is not possible, print a copy of the manual and keep it in an accessible location near the device.
Failure to obey the following guidelines and/or incorrect installation, operation, servicing, or maintenance of
the device can cause incorrect operation of the device. Personnel who rely on this product for their safety
can sustain serious personal injury or death.

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Contents
1 MSA Permanent Instrument Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Exclusive Remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Exclusion of Consequential Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Liability Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Identifying Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Visible Alarming Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.1 Touchscreen Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.2 Optional Strobe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3 Audible Alarming Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3.1 Internal Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3.2 Optional External Horn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4 Optional External Alarm Activation and Silencing Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5 Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5.1 Digital Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5.2 Analog Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.1 Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2 Receiving, Unpacking, and Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3 Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4 Sample and Exhaust Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.4.1 Tubing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.4.2 Routing and Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.4.3 End-of-Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4.4 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4.5 Exhaust Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.5 Wiring and Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.6 Electrical Power Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.7 Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5 Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1 Language/Date & Time/Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2 Point Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.3 Gas Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.4 Relay Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.5 Communications Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.1 Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.2 Routine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.2.1 Starting Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.2.2 Stopping Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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6.3 Zero Gas Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.4 Span Gas Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.5 Unsuccessful Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7 Routine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.1 Dashboard Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.2 Point Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.3 Point Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.3.1 Automatic Point Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.3.2 Manual Point Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.4 Predictive Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.5 Cautions, Warnings, and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.5.1 Non-Latching Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.5.2 Latching Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.6 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.6.1 Noncritical Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.6.2 Critical Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.7 Event Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.7.1 All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.7.2 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.7.3 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.7.4 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.8 Edit Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.8.1 Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.8.2 Gas Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.8.3 Point Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.8.4 Relay Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.8.5 Communications Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.8.6 About . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.1 Flow Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.2 Sensor Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.3 Pump Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.4 Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.1 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.1.1 Examine and Replace End-of-Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.1.2 Examine and Replace Internal Inline Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.1.3 Replace Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
10.1 Touchscreen Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
10.2 Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
11.1 Technical Specifications / Equipment Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
11.2 Gas Reading Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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12 Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
13 Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
13.1 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
13.1.1 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
13.1.2 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
13.1.3 Installation and Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
13.1.4 Calibration Gas Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
14 Appendix A: Start-up Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
15 Appendix B: Installation of Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
15.1 Strobe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
15.2 External Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
15.3 External Alarm Activation Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
15.4 External Alarm Silencing Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
16 Appendix C: Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
16.1 Alarm Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
16.2 Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
16.3 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
17 Appendix D: Modbus Holding Registers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
17.1 Chillgard 5000 - Modbus RTU (Holding Registers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...79
17.2 RESET Button Actions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
17.3 Unit Status Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
17.4 Channel Status Flags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
17.5 Gas Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
18 Appendix E: BACnet Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
18.1 Chillgard 5000 - BACnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
18.2 RESET Button Actions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
18.3 Unit Status Flags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
18.4 Channel Status Flags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
18.5 Gas Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

6
MSA Permanent Instrument Warranty
Chillgard 5000
US
1 MSA Permanent Instrument Warranty
1.1 Warranty
MSA, the Safety Company warrants that this product will be free from mechanical defect or faulty
workmanship for a period of two (2) years from the date of delivery, provided it is maintained and used
in accordance with MSA'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, nonrechargeable batteries, filament units, filter, lamps,
fuses, etc. MSA shall be released from all obligations under this warranty in the event that 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 repre-
sentative of MSA has any authority to bind MSA to any affirmation, representation, or warranty
concerning the goods sold under this contract. MSA makes no warranty concerning components or
accessories not manufactured by MSA, but will pass on to the Purchaser all warranties of manufac-
turers of such components.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED, IMPLIED, OR STAT-
UTORY, AND IS STRICTLY LIMITED TO THE TERMS HEREOF. SELLER SPECIFICALLY
DISCLAIMS ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR
PURPOSE.
1.2 Exclusive Remedy
It is expressly agreed that the Purchaser's sole and exclusive remedy for breach of the above
warranty, for any tortious conduct of the Seller, or for any other cause of action, shall be the repair and/
or replacement at the Seller's option of any equipment or parts thereof, which after examination by the
Seller is proven to be defective. Replacement equipment and/or parts will be provided at no cost to
the Purchaser, F.O.B. Seller's Plant. Failure of the Seller to successfully repair any nonconforming
product shall not cause the remedy established hereby to fail of its essential purpose.
1.3 Exclusion of Consequential Damage
The Purchaser specifically understands and agrees that under no circumstances will the Seller be
liable to the 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 the Seller.
1.4 Liability Information
MSA accepts no liability in cases where the device has been used inappropriately or not as intended.
The selection and use of the device are the exclusive responsibility of the individual operator. Product
liability claims, warranties, and guarantees made by MSA with respect to the device are voided if the
device is not operated, serviced, and/or maintained in accordance with the instructions in this manual.
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.

7
Warnings and Cautions
Chillgard 5000
US
2 Warnings and Cautions
The Chillgard 5000, hereafter also referred to as "the device", is a gas monitor intended for indoor use
in mechanical equipment rooms or commercial spaces where refrigerant equipment, such as centrif-
ugal chillers, is used. The device is specified to support compliance with federal, state, and local safety
codes that govern emissions.
WARNING!
Install, operate, and maintain the device in strict accordance with its labels, cautions, warnings,
instructions, and stated limitations.
For any maintenance procedure provided in this manual, use only genuine MSA replacement parts.
Repair or alteration of the Chillgard 5000 system beyond the scope of these maintenance instructions
or by anyone other than authorized MSA service personnel can cause incorrect operation of the
device. For a list of approved parts and how to order them, refer to Section 13, "Ordering Information".
The device is intended for indoor use only. Do not use the device for outdoor applications.
Never operate the device without a connection to positive ground. Failure to connect the device to
positive ground can result in electrical shock. Electrical shock can cause damage to the device and
injury to personnel.
Make sure the device is not located in areas that contain a flammable mixture of gas and air. Other-
wise, an explosion can occur.
The device is not intrinsically safe. Do not use the device in areas classified as hazardous or locations
where explosive concentrations of combustible gases or vapors can occur.
Failure to follow these warnings can result in serious bodily injury or death.

8
Warnings and Cautions
Chillgard 5000
US
WARNING!
Make sure the device is installed in a clean, dry area that is protected from vibration, including but not
limited to a chiller, and heat sources.
Do not paint the device. Do not paint near any of the sample line inlets. If painting is done near the
device, make sure that paint is not deposited on the sample inlet fittings. Paint deposits can prevent
correct operation of the device.
Make sure the sample inlet lines to the device are clean and noncondensing.
Avoid any installation where condensation can collect. Condensation can clog or block sample lines,
which will prevent the device from receiving new or fresh gas samples in the area being monitored.
Install and maintain end-of-line filters in all sample inlet lines. Refer to Section 4.4.3, "End-of-Line
Filters".
The only absolute method of ensuring correct overall operation of a gas detection instrument is to do
a check with a known concentration of the gas for which it has been calibrated. Do a calibration check
as part of the installation and initial setup. Refer to Section 6.1, "Initial Setup". Do routine calibration
checks thereafter. Refer to Section 6.2, "Routine Operation".
Install a circuit breaker for the incoming power connections of the device. Put the circuit breaker in a
location that is easy to access and near the device. Clearly mark the circuit breaker as the discon-
necting unit for the device.
Properly vent the exhaust of the Chillgard 5000 system to a safe area. Improper venting of the exhaust
can cause serious personal injury or death. Refer to Section 4.4.5, "Exhaust Venting".
To prevent unauthorized or untrained personnel from opening the device enclosure, install a locking
mechanism through the metal loop on either latch on the left side of the device (Fig. 2).
Perform periodic leak tests on all sample lines.
Do not exceed the relay contact rating listed in Section 11.1, "Technical Specifications / Equipment
Ratings". Otherwise relay operation may fail.
Failure to follow these warnings can result in serious bodily injury or death.

9
Description
Chillgard 5000
US
3 Description
The Chillgard 5000 provides continuous monitoring of refrigerant gas levels for up to 16 points in
nonhazardous areas. With the ability to read down to 1 ppm, the device provides a response to a
refrigerant leak, supporting the safety of personnel and the environment, and equipment efficiency.
The device uses patented Photoacoustic Infrared technology to allow the accurate measurement of
refrigerant gases with minimum interference from other vapors. The device monitors refrigerant gases
up to 1000 ppm with an ability to maintain a gas list through an internal refrigerant library.
The Chillgard 5000 minimizes unnecessary maintenance costs associated with calibration and
sensors by utilizing a centralized sample draw system. The device is factory calibrated for six specific
refrigerants, with the flexibility to adjust the gas of interest in the field.
The device offers three levels of alarm—caution, warning, and alarm—that are all configurable
through the intuitive touchscreen display. Fault and service notifications provide alerts when servicing
is necessary. Audible and visual indications such as horns and strobes provide alerts about refrigerant
leaks.
Digital communications can be transmitted using the Modbus remote terminal unit (RTU) or BACnet™
master/slave token passing (MS/TP) protocol. Analog communications can be transmitted using a
4–20 mA or 0–10 Vdc current loop.
The Chillgard 5000 requires minimal maintenance and incorporates predictive diagnostics that contin-
uously check key detector components to ensure proper operation. When the device is installed, oper-
ated, and maintained according to MSA's recommendations, it provides reliable protection and long-
term stability.

10
Description
Chillgard 5000
US
3.1 Identifying Your Unit
Fig. 1 Front of device
NOTE: Optional strobe not shown.
Fig. 2 Back of device
17″resistive touchscreen user interface
2 Power indicator
1 Mounting locations (10″x 14 5/8″)
1
2
1
1
1
1

11
Description
Chillgard 5000
US
Fig. 3 Right side of device
Fig. 4 Left side of device
1 AC power wiring cutout
2 Protective earth grounding cutout (optional)
3 Relay wiring cutout
4 Approval and unit identification label
1 Latches (lockable with padlock)
2 Signal wiring cutouts
1
3
4
2
1
1
2
2

12
Description
Chillgard 5000
US
Fig. 5 Bottom of device
Fig. 6 Internal touchpoints
1 Sample line identification labels
2 Internal alarm sounder
3 Calibration port
4 IP rated vent
5 Exhaust port (do not block)
1 Fuses
2 AC wiring cover
3 Internal filters
4 ESD tie-off location
1
1
2
3
4
5
1
2
3
34
3

13
Description
Chillgard 5000
US
3.2 Visible Alarming Devices
The device provides visible alarm indicators through the touchscreen display and optional strobe.
3.2.1 Touchscreen Display
After the initial setup configuration, the touchscreen display shows a dashboard with the main function
buttons and tiles for the points that are enabled.
Notifications for all predictive warnings, alarms, and faults show on the dashboard.
3.2.2 Optional Strobe
The optional strobe provides a user-configurable visual indication of a gas leak.
For a list of approved parts and how to order them, refer to Section 13, "Ordering Information".
For installation instructions, refer to Section 15, "Appendix B: Installation of Optional Equipment".
3.3 Audible Alarming Devices
The device provides audible alarm indicators through the internal alarm and optional external horn.
3.3.1 Internal Horn
A horn inside the device provides an audible indicator of a gas leak. The level of sound output from
the internal horn is adjustable. To adjust the level of sound output, turn the sounder clockwise or coun-
terclockwise.
3.3.2 Optional External Horn
An optional external horn can be mounted in a location away from the device to provide an audible
indicator of a gas leak.
For a list of approved parts and how to order them, refer to Section 13, "Ordering Information".
For installation instructions, refer to Section 15, "Appendix B: Installation of Optional Equipment".
3.4 Optional External Alarm Activation and Silencing Stations
The device supports optional external stations for the activation and silencing of audible alarms.
Normally closed alarm activation and silencing switches can be wired in a single loop with a total
maximum loop length of 2500 ft (762 m).
For a list of approved parts and how to order them, refer to Section 13, "Ordering Information".
For installation instructions, refer to Section 15, "Appendix B: Installation of Optional Equipment".

14
Description
Chillgard 5000
US
3.5 Communications
The device has both digital and analog outputs for use with external controllers or building manage-
ment systems.
3.5.1 Digital Communication
The device is capable of Modbus RTU or BACnet MS/TP outputs. For setup instructions, refer to
Section 5.5, "Communications Output".
For a list of the registers that are available for exchange with the Modbus controller, refer to
Section 17, "Appendix D: Modbus Holding Registers".
For a list of the BACnet Objects that are available for exchange with the BACnet controller, refer to
Section 18, "Appendix E: BACnet Objects".
3.5.2 Analog Communication
The device is capable of the following types of analog outputs:
• 4–20 mA, isolated, current sourcing
• 0–10 Vdc for gas sample point identification
Scale Analog Output: 4–20 mA
Full scale is 1000 ppm.
Normal gas readings are at 4–20 mA. The reading is proportional to the detected gas concentration.
For the factory default of 100% full scale setting (0.016 mA = 1 ppm):
Output
(mA)
Gas Concentration
(ppm)
40
563
6125
7188
8250
9313
10 375
11 438
12 500
13 563
14 625
15 688
16 750
17 813
18 875
19 937
20 1000

15
Description
Chillgard 5000
US
Analog Output Settings
0–10 Vdc
The voltage output can be used to identify any active gas sample line.
While the device is in calibration mode, the output is 10 Vdc.
Warm-up Default = 3.5 mA
User adjustable between 0 and 3.75 mA
Calibration (nonconfigurable) 3.0 mA
Fault Default = 2.0 mA
User adjustable between 0.5 and 3.75 mA
Device over range (nonconfigurable) 21 mA
Sample Line Vdc
4 or 8 pt system
Vdc
16 pt system
111.0
221.5
332.0
442.5
553.0
663.5
774.0
884.5
9- 5.0
10 - 5.5
11 - 6.0
12 - 6.5
13 - 7.0
14 - 7.5
15 - 8.0
16 - 8.5

16
Installation
Chillgard 5000
US
4 Installation
4.1 Warnings and Cautions
WARNING!
The device is intended for indoor use only. Do not use the device for outdoor applications.
A qualified electrician must do electrical wiring.
All wiring must comply with all applicable NEC/CEC and local electrical safety codes.
To prevent electrostatic discharge (ESD), connect an ESD wrist strap to the ESD connection point
inside the device enclosure before doing work inside the enclosure. ESD can cause damage to the
device.
Do not touch the electronic circuit boards.
Do not install or operate a device that has damage.
Disconnect ac power before opening the device enclosure. Failure to do so can result in electrical
shock. Electrical shock can cause damage to the device and injury to personnel.
Never operate the device without a protective ground. Operating the device without a protective
ground can result in electrical shock. Electrical shock can cause damage to the device and injury to
personnel.
The device is not intrinsically safe. Do not use the device in areas classified as hazardous or locations
where explosive concentrations of combustible gases or vapors can occur.
Make sure the device is not located in areas that contain a flammable mixture of gas and air. Other-
wise, an explosion can occur.
Failure to follow these warnings can result in serious bodily injury or death.
4.2 Receiving, Unpacking, and Inspecting
(1) Upon receipt of the device, inspect the shipping container for signs of damage. Report any
damage to the carrier and record the information on the delivery receipt.
(2) Carefully remove the device from its shipping container to avoid causing damage to sensitive
electrical components. If damage has occurred, file the appropriate claim with the shipping
carrier immediately.
(3) Review all contents of the shipping container to make sure all of the following components are
included:
a) Device
b) Instruction manual CD
c) End-of-line filters (quantity determined by number of ports ordered)
d) Remote horn (if equipped)
e) Protective foam
(4) Notify MSA of any shortages immediately.
(5) Keep the original packaging in case it is necessary to return the device for service.
(6) Release the two latches on the left side of the device.
(7) Open the enclosure.

17
Installation
Chillgard 5000
US
(8) Carefully inspect the internal components and assemblies for damage or shortages. If damage
has occurred, file the appropriate claim with the shipping carrier immediately.
(9) Before installation and use, keep the device in a dry, secure place in the original shipping
container.
4.3 Mounting Guidelines
Do not mount the device directly to chiller, piping, or piping supports.
Mount the device:
• In a location that is easy to access and visible to personnel before they go into the area being moni-
tored.
• To a rigid surface that does not have vibration or mechanical shock.
• In a vertical position.
• Approximately 5 ft (1.5 m) above the ground (Fig. 7, Fig. 8).
• With at least 3 in. (7.62 cm) of clearance around all sides for proper ventilation, calibration, and
servicing. Make sure there is adequate space to connect the external wiring and sample line piping
(Fig. 8).
• With the appropriate hardware. Make sure the hardware is suitable for the mounting surface and
can withstand 70 lb (9 kg) without loosening or causing damage to the hardware or mounting
surface. Use all four mounting holes provided on the device (Fig. 9).
• Away from exposure to direct solar heating and other excessive heat sources.
• Away from wet or damp conditions.
• Away from areas that are dirty or exposed to oils or chemicals.
Fig. 7 Mounting location

18
Installation
Chillgard 5000
US
4.4 Sample and Exhaust Lines
4.4.1 Tubing Material
The device can use hard and soft tubing. The following are acceptable tubing types:
NOTICE
Use the appropriate tools to give a clean, smooth end to the tubing when it is cut.
Fig. 8 Front of device Fig. 9 Rear of device
US English System
¼ in. OD x 1/8 in. inside diameter (ID) Polyurethane tubing (ether based)
¼ in. OD x 3/16 in. ID Polyurethane tubing (ether based)
¼ in. OD Copper tubing
¼ in. OD Stainless steel tubing
SI Units
6 mm OD x 4 mm ID Polyurethane tubing (ether based)
6 mm OD Copper tubing
6 mm OD Stainless steel tubing

19
Installation
Chillgard 5000
US
4.4.2 Routing and Placement
MSA recommends the use of at least two gas-monitoring points per chiller for sufficient detection
monitoring. Due to installation and application variations, each system must be analyzed individually.
Do a smoke test of the mechanical room to determine the flow pattern and allow for optimal placement
of the sample lines. Ventilation smoke tubes for this use are available from MSA (P/N 458480). For a
list of approved parts and how to order them, refer to Section 13, "Ordering Information".
Keep the total line length of a point, including the sample line and exhaust line, at less than 1200 ft
(366 m). Keep lines as short as possible to minimize the transport time of the device.
Typically, refrigerants collect near the floor. Install the sample points 12–18 in. (30–46 cm) above the
floor.
For installations where water condensation in the sample lines is likely, MSA recommends installing
a water trap filter such as a Parker P/N F504-01AHX67 or equivalent.
Transport Time
Line Length
(ft) 4pts 8pts 16pts
0 19s 19s 19s
50 19 s 19 s 19 s
100 19 s 19 s 19 s
150 19 s 19 s 19 s
200 19 s 19 s 19 s
250 19 s 19 s 19 s
300 1 m 35 s 2 m 51 s 5 m 23 s
350 1 m 35 s 2 m 51 s 5 m 23 s
400 2 m 51 s 5 m 23 s 10 m 27 s
450 2 m 51 s 5 m 23 s 10 m 27 s
500 2 m 51 s 5 m 23 s 10 m 27 s
*Transport time is similar for all tubing configurations.

20
Installation
Chillgard 5000
US
4.4.3 End-of-Line Filters
WARNING!
Failure to use and maintain end-of-line filters can cause inaccurate readings and damage to internal
components, and make additional servicing necessary.
Failure to follow these warnings can result in serious bodily injury or death.
Install an end-of-line filter (MSA P/N 711561) in each sample line to decrease contaminants in the
sample lines and device.
Examine and replace the end-of-line filters at regular intervals. The appropriate interval for replace-
ment is determined by the environment of the installation.
For a list of approved parts and how to order them, refer to Section 13, "Ordering Information".
4.4.4 Connections
WARNING!
Install tubing with large enough bend radii to prevent kinking or pinching. Kinking or pinching of the
tubing can result in insufficient monitoring of an area.
Before connecting tubing to the device, clean all tubing with compressed air or nitrogen to remove
debris.
Failure to follow these warnings can result in serious bodily injury or death.
The device has Swagelok® compression fittings for connections to the sample and exhaust lines.
These fittings accept the hard and soft tubing specified in Section 4.4.1, "Tubing Material".
Do the following procedure to connect the sample and exhaust lines:
(1) Remove the cap from the compression fitting.
(2) Insert the tubing fully into the compression fitting and against the shoulder.
(3) Turn the nut until it is finger-tight on the tubing.
(4) Mark the nut at the 6 o'clock position.
(5) While holding the body of the fitting steady, tighten the nut 1 ¼ turns to the 9 o’clock position.
Fig. 10 End-of-line filter
Do the following procedure to install end-of-line
filters:
(1) Remove the new end-of-line filter from the bag.
(2) Slide the end of the end-of-line filter with flexible
tubing onto the sample line tubing. Make sure
the arrow on the body of the filter (Fig. 10)
points in the direction of air flow into the sample
line.