Honeywell MGC2-K, PolyGard 2 User Manual

PolyGard 2 Multi Gas Controller MGC2-K

Controller for Analog Sensors / Honeywell Sensors

User Manual

Version 26.03 2020 en

PolyGard is a registered trademark of MSR	GAMGC2-K_E_0320
Phone [phone] Fax: [phone]	Specification subject to change without notice
MSR-Electronic GmbH, Bgm.-Schoenbauer-Str. 13, D 94060 Pocking	www:msr-electronic.de Made in Germany

User Manual - PolyGard®2
Multi-Gas-Controller MGC2-K Honeywell	Page 2

1	Intended Use..........................................................................................................			4
2	Functional Description .........................................................................................			4
	2.1		General ...................................................................................................................................	4
3	Installation .............................................................................................................			5
	3.1		Mounting Instructions..............................................................................................................	5
	3.2		Installation Work .....................................................................................................................	5
4	Electrical Connection ...........................................................................................			6
	4.1		Wiring......................................................................................................................................	6
	4.2		Wiring Diagrams .....................................................................................................................	7
5	Intended Use for the Display Unit........................................................................			8
6	Description ............................................................................................................			8
7	Operation ...............................................................................................................			8
	7.1	Function of the Keys and LEDs on the Keypad ......................................................................		8
	7.2	Setting / Changing of Parameters and Set Points ..................................................................		9
	7.3		Code Levels ............................................................................................................................	9
8	Menu Overview....................................................................................................			10
	8.1		Fault Management ................................................................................................................	12
	8.1.1		Error Memory ....................................................................................................................	12
	8.1.2		System Messages and System Errors ..............................................................................	12
	8.2		Alarm Status .........................................................................................................................	13
	8.3		Relay Status..........................................................................................................................	13
	8.4		Menu Measuring Values .......................................................................................................	14
	8.5		Display Parameters ..............................................................................................................	14
	8.5.1		Software Version ...............................................................................................................	14
	8.5.2		Language ..........................................................................................................................	15
	8.5.3		Service Phone Number .....................................................................................................	15
	8.5.4		Customer Password ..........................................................................................................	15
	8.5.5		Error Time Delay ...............................................................................................................	15
	8.5.6		LCD Function ....................................................................................................................	16
	8.6		Menu Relay Parameters .......................................................................................................	16
	8.6.1		Relay Mode .......................................................................................................................	16
	8.6.2		Relay Operation Mode ......................................................................................................	16
	8.6.3		Relay Function Static / Flashing........................................................................................	17
	8.6.4		Alarm Quantity...................................................................................................................	17
	8.6.5		Horn Function....................................................................................................................	17
	8.6.6		External Override ..............................................................................................................	18
	8.6.7		Delay Mode of Alarm Relay ..............................................................................................	19
	8.6.8		Assignment to Fault ..........................................................................................................	19
	8.6.9		Assignment to Maintenance Message ..............................................................................	19
	8.7		MP Parameters .....................................................................................................................	20
	8.7.1		Activate – Deactivate MP ..................................................................................................	20
	8.7.2		Selection of Gas Type and Measuring Range ..................................................................	20
	8.7.3		Alarm Thresholds / Hysteresis ..........................................................................................	23
	8.7.4		Delay for Alarm ON and/or OFF........................................................................................	24
	8.7.5		Average Overlay ...............................................................................................................	24
	8.7.6		Latching Mode Assigned to Alarm ....................................................................................	24
	8.7.7		MP Fault Assigned to Alarm..............................................................................................	25

PolyGard® is a registered trademark of MSR	GAMGC2-K_E_0320
Phone [phone] Fax: [phone]	Specification subject to change without notice
MSR-Electronic GmbH, Bgm.-Schoenbauer-Str. 13, D 94060 Pocking	www:msr-electronic.de Made in Germany

User Manual - PolyGard®2
Multi-Gas-Controller MGC2-K Honeywell			Page 3
	8.7.8 Alarm Assigned to Alarm Relay ........................................................................................		25
	8.7.9 MP Assigned to Analog Output .........................................................................................		25
	8.8	Menu System Parameters ....................................................................................................	26
	8.8.1	System Information ...........................................................................................................	26
	8.8.2	Maintenance Interval .........................................................................................................	26
	8.8.3	Average Function ..............................................................................................................	26
	8.8.4	Power On Time .................................................................................................................	27
	8.8.5	Deadband..........................................................................................................................	27
	8.8.6	AO Function ......................................................................................................................	28
	8.8.7	Relay Multiplication ...........................................................................................................	29
	8.9	Operating Data......................................................................................................................	30
	8.10	Test Function for Relays .......................................................................................................	31
	8.11	Test Function for Analog Output...........................................................................................	32
	8.12	Calibration.............................................................................................................................	33
	8.12.1 Zero Calibration of Analog Output.....................................................................................		34
	8.12.2 Calibration of the Digital Sensors......................................................................................		34
	8.12.3	Credit Menu.......................................................................................................................	34
	8.13	Setting RS-485 Address .......................................................................................................	34
9	Commissioning ...................................................................................................		35
	9.1	General Notes.......................................................................................................................	35
	9.2	Visual Inspection...................................................................................................................	35
	9.3	Selection Gas Type with Unit................................................................................................	35
10	Configuration and Parameter Cards..................................................................		36
	10.1	Configuration Card System Parameters ...............................................................................	36
	10.2	Configuration Card Alarm Relays / Signal Outputs ..............................................................	36
	10.3	Configuration Card MC2 of Analog Measuring Points..........................................................	37
11	Routine Maintenance and Scheduled Testing ..................................................		38
	11.1	Routine Maintenance ............................................................................................................	38
	11.2	Routine Testing.....................................................................................................................	38
12	Technical Data MGC2 .........................................................................................		39
13	EC – Declaration of Conformity .........................................................................		40
14	Part Disposal .......................................................................................................		41
15	Notes and General Information..........................................................................		41
	15.1	Installers’ Responsibilities.....................................................................................................	41
	15.2	Disclaimer .............................................................................................................................	41
	15.3	Warranty ...............................................................................................................................	42
	15.4	Copyright Notice ...................................................................................................................	42

PolyGard® is a registered trademark of MSR	GAMGC2-K_E_0320
Phone [phone] Fax: [phone]	Specification subject to change without notice
MSR-Electronic GmbH, Bgm.-Schoenbauer-Str. 13, D 94060 Pocking	www:msr-electronic.de Made in Germany

User Manual - PolyGard®2
Multi-Gas-Controller MGC2-K Honeywell	Page 4

1 Intended Use

The PolyGard 2 MGC2 is designed for detection and warning detection of toxic, combustible or dangerous atmosphere in many commercial and industrial applications.

The intended sites are all areas being directly connected to the public low voltage supply, e.g. residential, commercial and industrial ranges as well as small enterprises (according to EN50 082).

The PolyGard 2 Multi Gas Controller MGC2 must not be used in potentially explosive atmospheres. The sensor must only be employed in areas within the environmental conditions specified in the Technical Data.

2 Functional Description

2.1General

The Multi-Gas-Controller is designed for the connection of max. three analog sensors with 4-20 mA signal and eight Honeywell sensors.

The controller monitors the measured values and activates the alarm relays if the set local alarm thresholds for pre-alarm and main alert have been exceeded or if there are the alarm messages coming from the eight digital sensors via RS-485 communication.

The SIL 2 compliant self-monitoring function in the MGC2 activates the fault message in case of an internal error as well as in case of a fault at the 4-20 mA input / output current signals or if there is a communication error to the digital sensors.

Other options such as three-color status LED, warning buzzer, digital input for acknowledgment or test function ensure proper adaptation to the wide range of applications in gas detection technology.

PolyGard® is a registered trademark of MSR	GAMGC2-K_E_0320
Phone [phone] Fax: [phone]	Specification subject to change without notice
MSR-Electronic GmbH, Bgm.-Schoenbauer-Str. 13, D 94060 Pocking	www:msr-electronic.de Made in Germany

User Manual - PolyGard®2
Multi-Gas-Controller MGC2-K Honeywell	Page 5

3 Installation

Electronics can be destroyed by electrostatic discharge (ESD). Therefore, the installation work should be done only by persons connected to ground, e. g. with a wrist strap connected to ground or by standing on a conductive floor (acc. to DIN EN 100015).

3.1 Mounting Instructions

When choosing the mounting site please pay attention to the following:

•Choose mounting location of the sensor according to the local regulations.

•Mount the sensor at a location with minimum vibration and minimum variation in temperature (avoid 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 local instructions.

3.2Installation Work

Assembly work must only be carried out under gas-free conditions.

Do not drill holes in the housing. Use only the providing know-outs.

•Open housing cover.

•Break out the required pre-embossed knockouts on the housing for cable glands and Sensor Cartridge.

•Cables are introduced from above.

•The MGC2 Controller is fixed to the wall through the four marked mounting points at the back side of the housing. These mounting points are accessible after opening the housing. See figure below.

•The dimensions XX depend on the type and can be read on the back of the housing, it is115 mm.

•The mounting points are covered by closing the cover at the end of the assembly.

• Close the cover.

Installation of Controller:

XX

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PolyGard® is a registered trademark of MSR	GAMGC2-K_E_0320
Phone [phone] Fax: [phone]	Specification subject to change without notice
MSR-Electronic GmbH, Bgm.-Schoenbauer-Str. 13, D 94060 Pocking	www:msr-electronic.de Made in Germany

User Manual - PolyGard®2
Multi-Gas-Controller MGC2-K Honeywell	Page 6

4 Electrical Connection

Assembly work must only be carried out under gas-free conditions!

Consider static electricity instructions (ESD)!

4.1Wiring

•The technical requirements and regulations for wiring, electrical safety, as well as project specific and environmental and local conditions etc. must be observed when mounting.

•We recommend the following cable types1:

	Europe		USA / Canada
Power supply 230 V	NYM-J	3 x 1.5 mm2	14 AWG / 300 V
Alarm message 230 V (also possible together with power supply)	NYM-J	X x 1.5 mm2	14 AWG / 300 V
Signal message, bus connection, warning devices 24 V	J-Y(St)Y 2x2 x 0.8 mm2		min. 300 V
Possibly connected external analog transmitters	J-Y(St)Y 2x2 x 0.8 mm2		min. 300 V

1The recommendation does not consider local conditions such as fire protection etc.

•Use copper conductors only for the terminal is only for connection to copper wire.

•Avoid any influence of external interferences by using shielded cables for the bus line, but do not connect the shield.

•Remove the cable isolation as short as possible. It is important to ensure that bare wires, e.g. wire shields do not come into contact with the mounted PCB (risk of short-circuit).

•Low voltage wire and mains connected wire must be fixed separately by cable ties or similar, to secure against looseness.

•Analog sensors are connected directly to the spring type terminals of the module. The correct polarity must be observed.

•The alarm signals are available as voltage-free change-over contacts. If required, the voltage supply is available at the terminal L.

The exact position of the terminals for the sensors and alarm relays is shown in the connection diagrams.

PolyGard® is a registered trademark of MSR	GAMGC2-K_E_0320
Phone [phone] Fax: [phone]	Specification subject to change without notice
MSR-Electronic GmbH, Bgm.-Schoenbauer-Str. 13, D 94060 Pocking	www:msr-electronic.de Made in Germany

User Manual - PolyGard®2
Multi-Gas-Controller MGC2-K Honeywell	Page 7

4.2 Wiring Diagrams

Wiring Diagram Example

Power Supply

24 VDC

	<![if ! IE]> <![endif]>+24 V	<![if ! IE]> <![endif]>GND NC
X1	3	2	1

Relay drawn de-energized

Relays Mode = Energized (Alarm ON = Relay OFF)

		Relay										Relay										Relay								Relay Voltage
	Alarm 1										Alarm 2											Fault								Max. 230
X2		3			2			1		X3		3			2			1		X4		3			2			1

Multi Gas Controller MGC2 24 VDC

Digital

Field Bus

Analog

Analog

Digital

Input

Output

Input

Output

DI11

DI22 GND3

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BUSA1

BUSB2

AO013

GND4 X12

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24VDC1

AI012

AI023 AI034

GND5

Horn6

Beacon7

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<![if ! IE]> <![endif]>Bus B

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1

2

3

1

2

3

1

2

3

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<![if ! IE]> <![endif]>4-20mA

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<![if ! IE]> <![endif]>4-20mA

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PolyGard® is a registered trademark of MSR						GAMGC2-K_E_0320
Phone [phone] Fax: [phone]					Specification subject to change without notice
MSR-Electronic GmbH, Bgm.-Schoenbauer-Str. 13, D 94060 Pocking		www:msr-electronic.de Made in Germany

User Manual - PolyGard®2
Multi-Gas-Controller MGC2-K Honeywell	Page 8

Display Unit for Series MGC2-K

5 Intended Use for the Display Unit

The display is used as visual indication, operating, commissioning and calibration unit for gas detecting and measuring instruments of the series PolyGard®2 (PG2).

6 Description

The parameters, gas types, units, etc. specified in the description are only examples.

7 Operation

The complete configuration and service are made via operating keys in combination with the LCD display screen. Security is provided via four password levels against unauthorized intervention

Version for PG2 series

Operation via 6 buttons

7.1 Function of the Keys and LEDs on the Keypad

Exits programming, returns to the previous menu level.

Enters sub menus, saves parameter settings.

Scrolls up & down within a menu, changes a value.

Changes cursor position.

The status LEDs indicate the operating state.

Green: Continuous:	= Normal operation
Flashing:	= Maintenance message
Yellow: Continuous:	= Failure
Slowly flashing:	= Warming-up
Fast flashing:	= Special mode
Red:	=Alarm

The backlight of the display changes from green to red when an alarm is active.

PolyGard® is a registered trademark of MSR	GAMGC2-K_E_0320
Phone [phone] Fax: [phone]	Specification subject to change without notice
MSR-Electronic GmbH, Bgm.-Schoenbauer-Str. 13, D 94060 Pocking	www:msr-electronic.de Made in Germany

User Manual - PolyGard®2
Multi-Gas-Controller MGC2-K Honeywell	Page 9

7.2 Setting / Changing of Parameters and Set Points

Open desired menu window.

Code input field opens automatically, if required.

After input of valid code, the cursor jumps onto the first position segment to be changed.

Push the cursor onto the position segment, which has to be changed.

Set the desired parameter / set point with the keys.

Input of value finished.

Change further parameters in the same menu.

Save the changed value?

YES, and back to higher menu level.

NO, (previous value isn’t overwritten) and back to higher menu level.

7.3 Code Levels

All inputs and changes are protected by a four-digit numeric code (= password) against unauthorized intervention according to the regulations of all national and international standards for gas warning systems. The menu windows of status messages and measuring values are visible without entering a code.

The access to a code level is cancelled if no button is pushed within 15 minutes or if there is no data communication between display and basic board.

The code levels are classified in order of priority: Priority 1 has top priority.

Priority 1: (code not changeable)

Code level priority 1 is intended for the service technician of the installer to change parameters and set-points. This password allows working on all settings. For opening the parameter menus, you must first activate the service mode after code release.

Priority 2: (code not changeable)

This functionality isn’t available.

Priority 3: (customer password is settable)

Customer password is inactive in delivery state and is activated by entering a value. Same behaviour as priority 1 password, only changing the customer password is not possible.

Normally the code is only known by the service technician who has last changed it since it can be changed individually via priority 1.

Priority 4: (password 1234) (code not changeable)

Code level priority 4 allows the operator after activation of the operation mode “Service Mode” to read all parameters as well as all test functions of the alarm relays, analog outputs and LCD.

-Manual test function of the alarm relays (functional test of the connected actuators),

-Manual test function of the analog outputs (functional test of the connected actuators),

-Manual test function of the LCD (functional test of the LCD display and the LEDs).

PolyGard® is a registered trademark of MSR	GAMGC2-K_E_0320
Phone [phone] Fax: [phone]	Specification subject to change without notice
MSR-Electronic GmbH, Bgm.-Schoenbauer-Str. 13, D 94060 Pocking	www:msr-electronic.de Made in Germany

User Manual - PolyGard®2
Multi-Gas-Controller MGC2-K Honeywell	Page 10

8 Menu Overview

Menu operation is done via a clear, intuitive and logical menu structure. The operating menu contains the following levels:

•Starting menu with indication of the device type if no MP (Measuring Point) is registered. Otherwise scrolling display of the gas concentrations of all registered sensors in 5-second intervals. If alarms are active, only the values of the sensors currently in alarm status will be displayed.

•Main menu

•Submenu 1 to 3

Power On Time			Power On Time of the basic device
	19s		Second counter counts down, when communication between display <> basic
			device is OK. In case of communication error, the count-down will stop.
	Seconds indicator = 0
		Honeywell
		MGC2-K			MGC2-K	= Multi Gas Controller Kompakt
			After about 5 seconds
		D1 CH4 % LEL			“Warn-up Time” is displayed. As soon as the sensor warm-up period has
		Warm-up Time
					expired, the measured value is displayed = measuring mode.

Starting menu	Main menu
	System Errors

Alarm Status

Relay

Status

Measuring Values

Display

Parameter

Installation &

Calibration

Submenu 1

Reading and acknowledgement of errors

See from point 8.1

Display of the alarm status of active alarms

See from point 8.2

Display of the relay status

See from point 8.3

Display of measuring values

See from point 8.4

General display parameters without safety relations See from point 8.5

Reading and change of the relay, measuring point and system parameters as well as test and calibration functions

Service Mode

OFF

PolyGard® is a registered trademark of MSR	GAMGC2-K_E_0320
Phone [phone] Fax: [phone]	Specification subject to change without notice
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User Manual - PolyGard®2
Multi-Gas-Controller MGC2-K Honeywell	Page 11

The following menu items are only accessible in Service ON mode (password protected)

!! Service ON = Special mode = Fault message is active!!

Relay Parameter

See from point 8.6

MP Parameter

System Parameter

Operating Data

Relay

Test Function

Analog Outputs

Test Function

Calibration

Addressing

See from point 8.7

See from point 8.8

See from point 8.9

See from point 8.10

See from point 8.11

See from point 8.12

See from point 8.13

PolyGard® is a registered trademark of MSR	GAMGC2-K_E_0320
Phone [phone] Fax: [phone]	Specification subject to change without notice
MSR-Electronic GmbH, Bgm.-Schoenbauer-Str. 13, D 94060 Pocking	www:msr-electronic.de Made in Germany

User Manual - PolyGard®2
Multi-Gas-Controller MGC2-K Honeywell	Page 12
8.1 Fault Management
A pending fault activates the yellow LED (Fault).
		MP 1 Comm.Error
The integrated fault management records the first 50 occurred faults with time		1	1T 2h 6‘
stamps in the menu “System Errors”. The timestamp shows the days, hours and
minutes that have elapsed since the fault has occurred.

Additionally, a record of the faults occurs in the “Error memory”, which can only be read and deleted by the service technician (code level 1 (3)).

8.1.1 Error Memory

The menu “Error Memory” in the main menu “System Errors” can only be opened via the code level priority 1.

In the error memory, the first 50 faults that have occurred and have already been acknowledged in the menu

“Error Status” are listed for the service technician in a power failure safe way.

Attention:

This memory should always be read during maintenance, relevant faults should be tracked and entered in the service logbook, and finally the memory should be emptied.

8.1.2 System Messages and System Errors

The warning device includes a diagnostic module for the continuous monitoring of the relevant functions and parameters as well as a processor-independent watchdog. These features set the device into the safe mode "Fault" in case of an internal or external error. The following table shows all possible errors, possible causes, the related troubleshooting and the resulting device status.

Once the cause has been eliminated, the warning device restarts with the diagnostic mode on its own. It isn’t necessary to acknowledge the error message. In the event of an error, the error is output as plain text in the version with display instead of the measured value and in the Error status menu. In case of two or more errors, the value is output with a cumulative, bit-coded error code.

Error Type	Cause	Remedy	Fault	Analog	Centr.		Display
			Relay	Output	Bus	Error Code		Text Mess.
	Error messages from MGC2							DP1-
Sensor element defective		Replace			Error	0x8	001 h	Sensor
			Error	< 2 mA	code is
		sensor
					sent
Temperature < -25 °C > +60 °C	Ambient temp.	Temp.!				0x8	002 h	Overtemp.
Measured value processing						0x8	002 h	ADC error
RAM / ROM / µC error	Internal	Replace device	Error	< 2 mA		0x8	008 h	CPU error
EEPROM error						0x8	010 h	EE error
No response alarm relay					Error	0x8	020 h	I/O error
	Short-circuit or	Check wiring /			code is
Deviation of analog output signal	Interruption at the	load	Error	X mA	sent	0x8	020 h	I/O error
< 5 % >	analog output
	Internal	Replace device
	Sensor head not	Check
Communication error to sensor	fitted correctly		Error	< 2 mA		0x9	000 h	Comm. error
	Internal	Replace
		Sensor
Hardware Watch Dog triggered	Internal, < system	Replace device	Error	< 1 mA	Comm.	Reset		Reset
	voltage, µC defect.				STOP
Operating voltage limits exceeded	External	Check voltage	Error	< 2 mA	Comm.	0x8	008 h	Tension
too high / too low	Internal	Replace device			STOP
Maintenance due	Maintenance date	Perform	No effect			0x8	080 h*	Maintenance
	reached	maintenance
PolyGard® is a registered trademark of MSR							GAMGC2-K_E_0320
Phone [phone] Fax: [phone]				Specification subject to change without notice

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User Manual - PolyGard®2
Multi-Gas-Controller MGC2-K Honeywell	Page 13

8.2 Alarm Status

Display of the currently pending alarms in plain text in the order of their arrival. Only those measuring points are displayed, where at least one alarm is active.

Alarms in latching mode and the overrange message can be acknowledged in this menu (only possible if the alarm isn’t active any more).

Alarm 1 and Alarm 2 are evaluated both by the sensor (alarm bit transmitted by communication) and by the locally set thresholds.

Alarm Status				AP 1				AP 1		Check if no
				’’A1				Reset?		Gas present?
	Symbol	Description			Function
	AP 1	Measuring Point No.			Analog measuring point 1 = 1 - 3, where an alarm is pending
	DP 4	Measuring Point No.			Digital measuring point 4 = 4 - 11, where an alarm is pending
	‘A1	Alarm status			‘A1 =	Alarm 1 active
	‘‘A1				‘‘A1 =	Alarm 1 in latching mode, can be acknowledged

8.3 Relay Status

Reading of the current status of alarm relays.

The actual relay status is displayed, depending on the relay mode (energized <> de-energized).

Selection of the alarm relay 1 – 5
	Relay					Relay	1
	Status					Status	OFF
					Selection of the next alarm relay
		Symbol	Description		Function
1			Alarm Relay		Alarm relay = 1 - 5
		OFF	Relay Status		Deenergized
		ON	Relay Status		Energized

PolyGard® is a registered trademark of MSR	GAMGC2-K_E_0320
Phone [phone] Fax: [phone]	Specification subject to change without notice
MSR-Electronic GmbH, Bgm.-Schoenbauer-Str. 13, D 94060 Pocking	www:msr-electronic.de Made in Germany