MSR ELECTRONIC PolyGard 2 CGC6 User manual

User Manual
PolyGard®2 CGC6 Compact Controller
July 17, 2023 – Revision
March 27, 2023
INTEC Controls | 12700 Stowe Drive, Suite 100, Poway, CA 92064 | [phone] & (888) GO.INTEC | inteccontrols.com

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Table of Contents
1 General................................................................................................................................... 6
1.1 Applicability..........................................................................................................................................6
1.2 Intended Use.........................................................................................................................................6
1.3 Safety......................................................................................................................................................6
1.4 Responsibility Installer and Operator ............................................................................................6
1.5 Services..................................................................................................................................................7
1.6 Limited Warranty.................................................................................................................................7
1.7 Dispose of Device................................................................................................................................7
2 Functional Description ........................................................................................................... 8
2.1 General...................................................................................................................................................8
2.2 Functional Output ...............................................................................................................................8
3 Installation ............................................................................................................................. 9
3.1 Mounting Instructions ........................................................................................................................9
3.2 Installation Work .................................................................................................................................9
4 Electrical Connection ........................................................................................................... 10
4.1 General Notes.................................................................................................................................... 10
4.2 Terminal Connection ....................................................................................................................... 11
4.3 Connection Diagram ........................................................................................................................ 12
5 Commissioning..................................................................................................................... 13
5.1 General Notes.................................................................................................................................... 13
5.2 Registration of a DT6A Unit ........................................................................................................... 14
5.3 Check Registration ........................................................................................................................... 14
5.4 Retrieving the address again......................................................................................................... 14
5.5 Reset to Factory Settings................................................................................................................ 14
5.6 Deregistration of a DT6A Unit ....................................................................................................... 15
6 Operating Modes .................................................................................................................. 15
6.1 Restart (Diagnostic and Warm-up Stage).................................................................................... 15
6.2 Measuring Mode ............................................................................................................................... 16
6.3 Special Mode ..................................................................................................................................... 16
6.3.1 Maintenance and Calibration Mode .............................................................................. 16
6.3.2 Faults .................................................................................................................................... 16
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7.6 Code Levels........................................................................................................................................ 19
Code level 1 (code not changeable) ............................................................................................ 19
Code level 3 (customer password is settable) .......................................................................... 19
8 Menu Overview .................................................................................................................... 19
8.1 Error Status......................................................................................................................................... 22
8.1.1 Error Memory...................................................................................................................... 22
8.1.2 System Messages and System Errors............................................................................ 22
8.2 Alarm Status....................................................................................................................................... 23
8.3 Relay Status ....................................................................................................................................... 24
8.4 Menu Measuring Values.................................................................................................................. 24
8.5 Display Parameters .......................................................................................................................... 25
8.5.1 Software Version ............................................................................................................... 25
8.5.2 Language.............................................................................................................................. 25
8.5.3 Service Phone Number..................................................................................................... 25
8.5.4 Customer Password........................................................................................................... 26
8.5.5 Error Time Delay ................................................................................................................ 26
8.5.6 LCD Function....................................................................................................................... 26
8.6 Installation and Calibration ........................................................................................................... 26
8.7 Installation ......................................................................................................................................... 27
8.8 Deregister Unit.................................................................................................................................. 27
8.9 Relay Parameters.............................................................................................................................. 27
8.9.1 Relay Mode.......................................................................................................................... 27
8.9.2 Relay Operation Mode...................................................................................................... 28
8.9.3 Relay Function Static/Flashing....................................................................................... 28
8.9.4 Signal Source ...................................................................................................................... 29
8.9.5 Alarm Trigger Quantity..................................................................................................... 29
8.9.6 Horn Function ..................................................................................................................... 29
8.9.7 External Override............................................................................................................... 31
8.9.8 Delay Mode of Alarm Relay............................................................................................. 32
8.9.9 Assignment to Fault .......................................................................................................... 32
8.9.10 Assignment to Maintenance Message .......................................................................... 33
7 Display Unit for CGC6 Series ................................................................................................ 17
7.1 Intended Use for the Display Unit................................................................................................ 17
7.2 Description......................................................................................................................................... 17
7.3 Operation ........................................................................................................................................... 17
7.4 Function of the Keys and LEDs on the Keypad.......................................................................... 17
7.4.1 Status LEDs.......................................................................................................................... 17
7.4.2 Setting / Changing of Parameters and Set Points...................................................... 18
7.5 Measuring Point................................................................................................................................ 18
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8.11 System Parameters .......................................................................................................................... 42
8.11.1 System Information........................................................................................................... 42
8.11.2 Maintenance Interval........................................................................................................ 42
8.11.3 Average Function............................................................................................................... 43
8.11.4 Power-On Time................................................................................................................... 43
8.11.5 Deadband ............................................................................................................................ 44
8.11.6 AO Function......................................................................................................................... 44
8.12 Operating Data.................................................................................................................................. 45
8.13 Test Function for Alarm Relays ..................................................................................................... 47
8.14 Test Function for Analog Output .................................................................................................. 48
8.15 Calibration.......................................................................................................................................... 49
8.15.1 Zero Calibration ................................................................................................................. 50
8.15.2 Gain Calibration ................................................................................................................. 51
8.15.3 Burning Clean ..................................................................................................................... 52
8.15.4 Zero Calibration of Analog Output ................................................................................ 53
8.16 Addressing ......................................................................................................................................... 53
9 Configuration and Parameter Cards ..................................................................................... 54
9.1 Configuration Card System Parameters...................................................................................... 54
9.2 Configuration Card Alarm Relays / Signal Outputs .................................................................. 54
9.3 Configuration Card (Digital Measuring Points) ......................................................................... 55
9.4 Stored threshold values for alarm triggering............................................................................ 56
10 Maintenance and Inspection................................................................................................. 57
10.1 Inspection........................................................................................................................................... 57
10.2 Functional Test.................................................................................................................................. 57
10.3 Maintenance and Calibration ........................................................................................................ 58
10.4 Repairs ................................................................................................................................................ 58
11 Technical Data ...................................................................................................................... 59
11.1 CGC6 .................................................................................................................................................... 59
11.2 SB2Unit1.............................................................................................................................................. 60
11.3 System................................................................................................................................................. 60
8.10 MP Parameters .................................................................................................................................. 33
8.10.1 Activate/Deactivate MP.................................................................................................... 33
8.10.2 Selection of Gas Type and Measuring Range.............................................................. 34
8.10.3 Alarm Thresholds / Hysteresis........................................................................................ 38
8.10.4 Delay for Alarm ON and/or OFF...................................................................................... 39
8.10.5 Average Value Overlay (VDI 2053 Functionality)...................................................... 39
8.10.6 Assignment of Latching Mode <> Alarm ...................................................................... 40
8.10.7 Assignment of MP Fault <> Alarm.................................................................................. 40
8.10.8 Assignment of Alarm <> Alarm Relay ........................................................................... 41
8.10.9 Assignment of MP <> Analog Output............................................................................ 41
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INTEC Controls | 12700 Stowe Drive, Suite 100, Poway, CA 92064 | [phone] & (888) GO.INTEC | inteccontrols.com
CGC6 – UserManual

1 General
It is important to read this user manual thoroughly and clearly in order to understand the
information and instructions. The PolyGard®2 devices must be used within product specification
capabilities. Due to on-going product development, MSR-Electronic GmbH | INTEC Controls
reserves the right to change specifications without notice. The information contained herein is
based upon data considered to be accurate. However, no guarantee is expressed or implied
regarding the accuracy of these data.
1.1 Applicability
PolyGard2-Series:
•CGC6 Compact Controller
1.2 Intended Use
The PolyGard2 CGC6 Compact Controller is designed for detection and warning detection
of toxic, combustible or dangerous atmosphere in many commercial and industrial applications.
The PolyGard2 CGC6 must not be used in potentially explosive atmospheres.
The intended sites for indoor use within the ambient conditions defined in the technical data are all
areas being directly connected to the public low voltage supply, e.g. residential, commercial and
industrial ranges as well as small enterprises.
1.3 Safety
The operating instructions must be carefully read, understood and followed by all persons who
install, use, maintain and check the product. The product can only fulfil its intended functions if it is
installed, used, maintained, cared for and checked in accordance with the instructions provided by
MSR-Electronic GmbH | INTEC Controls.
1.4 Responsibility Installer and Operator
It is the responsibility of the installer and operator to ensure that all PolyGard®2 equipment is
installed and used in compliance with all national and local codes. The device must be checked for
correct installation and functionality by a qualified person before measurement operation is started.
In Germany, BGR 500 Chapter 2.33 must be applied for this purpose.
The PolyGard®2 devices are tested for function by the manufacturer before delivery. During
commissioning, a documented functional test is also required. The installation should only be carried
out by trained installation technicians, taking into account the current safety procedures for control
installations.
The required equipotential bonding connections (also e.g. secondary potential to ground) or
grounding measures are to be carried out according to the respective project regulations. It must be
ensured that no ground loops are created in order to avoid undesired interference in the
measurement electronics.
It is necessary to follow all instructions as well as the user documentation.
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1.5 Services
It is recommended that PolyGard®2 equipment be inspected on a regular basis. Performance
deviations can be corrected based on regular maintenance. Recalibration and parts replacement can
be performed in the field by a qualified technician using the appropriate tools.
Alternatively, the easily removable, plug-in sensor head can be returned to INTEC Controls for
service.
Regular maintenance is to be carried out according to the instructions.
1.6 Limited Warranty
MSR-Electronic GmbH | INTEC Controls does not assume any liability in case of improper or
incorrect use of the device. The installer and operator are exclusively responsible for the design
and use of the product. If the product is not used, maintained or repaired in accordance with
the instructions for use, warranty and product liability claims as well as claims arising from any
guarantees assumed by MSR-Electronic GmbH | INTEC Controls for the product will be forfeited.
MSR-Electronic GmbH | INTEC Controls warrants PolyGard®2 devices against defects in material or
workmanship for a period of 2 years (1 year for sensors) from the date of shipment. Should a
defect in material or workmanship occur during the warranty period, MSR-Electronic GmbH | INTEC
Controls will repair or replace the unit at its option. This warranty does not apply to units that have
been modified, after repair attempts, or that have been damaged unintentionally or intentionally.
The warranty also does not apply to units in which the sensing element has been poisoned. The
above warranty is in lieu of all other express warranties, obligations or liabilities.
This warranty applies only to PolyGard®2 units. MSR-Electronic GmbH | INTEC Controls is not liable
for consequential damages resulting from the purchase or use of PolyGard®2 devices.
If the PolyGard®2 CGC6 needs to be returned, an authorized RMA number issued by INTEC
Controls is required.
1.7 Dispose of Device
In accordance with Directive 2012/19/EU, the device must not be disposed of as
municipal waste. Return the device for disposal to your national sales organisation,
which you can contact if you have any questions about disposal.
Outside the EU, you have to consider the corresponding directives.
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2 Functional Description
2.1 General
The CGC6 is designed as a gas detection system for connection of max. 10 DT6A Units (DT6A +
Sensor SC2) via its own field bus. The function of the SC2 sensor head series is not the subject of
this user manual but can be found in the respective SC2 User Manual.
The controller monitors the measured values and activates the alarm relays if the specified max.
4 alarm thresholds for pre- and main alarm are exceeded. The analog 4–20 mA output provides
either a sum signal of all or certain measured values or the signal of one measured value.
The SIL2-compliant self-monitoring in the CGC6 as well as in the connected DT6A Units activates
the fault signal in the event of an internal fault as well as in the event of a fault in the field bus
communication (DT6A Unit) and in the event of a fault in the 4–20 mA output current signal.
2.2 Functional Output
SHORT DESCRIPTION OF THE FUNCTION DIGITAL OUTPUTS WITH RELAYS
Action Reaction
(GS = Gas Signal)
(AT =Alarm Threshold)
(HS = Hysteresis)
Alarm LED
Display / WAO
Alarm 1
Relay 1
Alarm 2
Relay 2
Alarm 3
Relay 5
Flashing/
Warning light
Alarm 4
Relay 4
Horn
Relay 3
(collective
fault)
GS < AT1
GREEN
Inactive
Inactive
OFF
OFF
Inactive
GS

AT1
RED slowly
flashing
Active
Inactive
OFF
OFF
Inactive
GS AT2
RED fast
flashing
Active
Active
OFF
OFF
Inactive
GS AT3
RED fast
flashing
Active
Active
ON
OFF
Inactive
GS

AT4
RED fast
flashing
Active
Active
ON
ON
Inactive
GS AT4
Taste Hupe Aus
RED fast
flashing
Active
Active
ON
OFF
Inactive
GS ≤ (AT3 –HS)
RED fast
flashing
Active
Active
OFF
OFF
Inactive
GS ≤ (AT2 –HS)
RED slowly
flashing
Active
Inactive
OFF
OFF
Inactive
GS ≤ (AT1 –HS)
GREEN
Inactive
Inactive
OFF
OFF
Inactive
Maintenance due (no
alarm, no fault)
GREEN flashing
Inactive
Inactive
OFF
OFF
Inactive
Internal error / fault
YELLOW
Inactive
Inactive
OFF
OFF
Active
Table 1: Function Digital Outputs with 3 Relays
Note 1: Relay 1 and 2: Operating mode energized
Status Inactive: Alarm OFF = relay coil energized
Status Active: Alarm ON or device without tension = relay coil de-energized
Relay 3: Operating mode energized
Status Inactive: No fault = relay coil energized
Status Active: Fault or device without tension = relay coil de-energized
Relays 4 and 5: Open-collector / transistor output, operating mode de-energized
Status OFF: Alarm OFF or device without tension
Status ON: Alarm ON
Note 2: Alarm thresholds can have the same value, therefore the relays and/or horn and warning light can be actuated
together.
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3 Installation
Check for completeness and accuracy using the delivery documents and the identification
label on the device.
Electronics can be destroyed by electrostatic discharge (ESD). Therefore, the installation
work should be done only by persons connected to gr
ound, e. g. by standing on a
conductive floor or by taking appropriate grounding measures (acc. to DIN EN 100015).
3.1 Mounting Instructions
When choosing the mounting location, you have to consider the ambient conditions in order to get
representative measurement results. Please pay special attention to the following factors:
•External heat sources are not allowed on the installation site.
•Choose mounting location according to the local regulations.
•Consider ventilation conditions! Do not mount next to air passages or suction holes.
•The sample gas must pass the sensor even under adverse flow conditions. A flow test can be
performed for instance with smoke tubes.
•If the flow conditions are > 6 m/s, it is advisable to use a wind shield.
•Mount the device at a location with minimum vibration and minimum variation in temperature
(no direct sunlight).
•Avoid locations where water, oil etc. may influence proper operation and where mechanical
damage might be possible.
•Provide adequate space around the sensor for maintenance and calibration work.
•Observe possible constructor’s instructions
•The installation height of the DT6A Unit depends on the relative gas density of the
monitored gas type (see SC2 User Manual).
3.2 Installation Work
Assembly work must only be carried out under gas-free conditions.
The housing must neither be spot-drilled nor drilled through outside the knockouts.
The installation position of the gas detector is always with the sensor head downwards,
cables are introduced from above.
The housing is delivered in closed condition. Before breaking out the knockouts, the exact position
and size of the cable entries must be determined.
INTEC Controls recommends using a protective cap (C2-Z1) until commissioning to protect the
sensors on the DT6A Unit from dirt and damage. For sensors that can be poisoned by
silicones, such as all semiconductor and heat tone sensors, it is imperative to use a protective cap
(C2-Z1) and to remove it only after the silicones have dried and the unit is energized.
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Mounting Procedure:
•Open housing cover.
•Break out the required knockouts on the housing for cable entries.
•Fix the CGC6 and the DT6A to the wall through the 4 marked mounting points of the housing
(see Figure 1) .
•The dimensions XX depend on the type and can be read on the back of the housing.
•Close and screw the cover.
Mounting
130 mm (5,12 in.)
115 mm (4,53 in.) 130 mm (5, 12 in.)
115 mm (4,53in.)
Mounting
D = 4 mm
Mounting
Sensorhead
94 mm (3,7 in.)
115 mm (4,53 in.) 130 mm (5,12 in.)
79 mm (3,11 in.)
D = 4 mm
Figure 1: Installation of Controllers
/ of DT6A Unit
4Electrical Connection
Assembly work must only be carried out under gas-free conditions!
Consider static electricity instructions (ESD)!
4.1 General Notes
•Installation and connection of the electrical installation should only be performed by a
professional when de-energized, according to the connection diagram and in accordance with
the relevant regulations.
•The technical requirements and regulations for wiring, electrical security, as well as project
specific and environmental and local conditions etc. must be observed when mounting.
•All terminals are screw type. The permissible conductor cross section can be read from the
Technical Data.
•When selecting and installing the cables you have to comply with the regulations concerning
the RS-485 bus installation. The installations have to be executed in line topology. Cable
lengths and types have to be considered as well.
•Avoid any influence of external interferences by using shielded cables for the bus line, but do
not connect the shield.
Specicaons subject to change without noce. | GA_MSC2_Compact_E | 2023-03-27 | USA 230717 | Page 10 of 60
INTEC Controls | 12700 Stowe Drive, Suite 100, Poway, CA 92064 | [phone] & (888) GO.INTEC | inteccontrols.com
CGC6 – UserManual