Msa Chillgard 5000 User Manual

Operating Manual

Chillgard 5000

Refrigerant Monitor

Order No.: 10178535/01

CR 800000027642

MSAsafety.com

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 sa fety could sust ain serious pe rsonal 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 pr otect 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 inst allation, operation, servicin g, 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.

1000 Cranberry Woods Drive Cranberry Township, PA 16066 USA Phone 1-800-MSA-2222 Fax 1-800-967-0398

For your local MSA contacts please go to our website www.MSAsafety.com

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

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

Chillgard 5000

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

Chillgard 5000

12 Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

13 Ordering Information

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

14 Appendix A: Start-up Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

15 Appendix B: Installation of Optional Equipment

15.1 Strobe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

15.2 External Horn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

15.3 External Alarm Activation Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

15.4 External Alarm Silencing Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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

Chillgard 5000

MSA Permanent Instrument Warranty

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) year s from the date of delivery, provided it is maintained and u sed in accordance with MSA's instructions and/or recommendations.

This warranty does not apply to expendable or consumable part s whose normal life expectancy is less than one (1) year, such as, b ut not limited to, nonrechargeable batteries, filament units, filter, lamps, fuses, etc. MSA shall be released from all obligations under this warranty in the e vent 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 representative 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 manufacturers of such components.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED, IMPLIED, OR STATUTORY, AND IS STRICTLY LIMITED TO THE TERMS HEREOF. SELLER SPECIFICALLY DISCLAIMS ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE.

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 co nduct of the Seller , or for any other cause of a ction, 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 MSA 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 custome rs to write or call reg arding this eq uipment p rior to use o r for any additional information relative to use or repairs.

Chillgard 5000

Warnings and Cautions

2 Warnings and Cautions

The Chillgard 5000, hereafter also referred to as "the device", is a gas monitor intended for indoor u se in mechanical equipment rooms or commercial spaces where refrigerant equipment, such as centrifugal 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 part s and how to orde r 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. Otherwise, an explosion can occur.

The device is not intrinsically safe. Do not use the device in areas classified as hazardous or locati ons where explosive concentrations of combustible gases or vapors can occur.

Failure to follow these warnings can result in serious bodily injury or death.

Chillgard 5000

Warnings and Cautions

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 don e ne ar 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 condensatio n can collect. Cond ensation 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 ope ration of a gas de tection instr ument is to do

a check with a known concentration of the gas for which it has been calibr ated. 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 po we r con nection s of th e de vice. Pu t th e circuit b reake r in a location that is easy to access and near the device. Clearly mark the circuit breaker as the disconnecting 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.

Chillgard 5000

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 a lerts 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 (RT U) 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.

Description

The Chillgard 5000 requires minimal maintenance and incorporates predictive diagnostics that continuously check key detector components to ensure proper operation. When the device is insta lled, operated, and maintained according to MSA's recommendations, it provides reliable protection and longterm stability.

Chillgard 5000

3.1 Identifying Your Unit

Fig. 1 Front of device

Description

17″ resistive touchscreen user interface 2 Power indicator

NOTE: Optional strobe not shown.

Fig. 2 Back of device

1 Mounting locations (10″ x 14 5/8″)

Chillgard 5000

Fig. 3 Right side of device

2 2

1 AC power wiring cutout 2 Protective earth grounding cutout (optional) 3 Relay wiring cutout 4 Approval and unit identification label

Description

Fig. 4 Left side of device

1 Latches (lockable with padlock) 2 Signal wiring cutouts

Chillgard 5000

Fig. 5 Bottom of device

1 Sample line identification labels 2 Internal alarm sounder 3 Calibration port 4 IP rated vent 5 Exhaust port (do not block)

Description

Fig. 6 Internal touchpoints

1 Fuses 2 AC wiring cover 3 Internal filters 4 ESD tie-off location

Chillgard 5000

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 ma in 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 soun der clockwise or counterclockwise.

Description

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".

Chillgard 5000

3.5 Communications

The device has both digital and analog outputs for use with external controllers or building management 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

Description

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)

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

Gas Concentration (ppm)

Chillgard 5000

Analog Output Settings

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

0–10 Vdc

The voltage output can be used to identify any active gas sample line.

Description

Sample Line

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

While the device is in calibration mode, the output is 10 Vdc.

Vdc 4 or 8 pt system

Vdc 16 pt system

Chillgard 5000

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 prot ect ive

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 locati ons 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. Otherwise, an explosion can occur.

Failure to follow these warnings can result in serious bodily injury or death.

Installation

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.

Chillgard 5000

(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 are a being monitored.

• 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.

Installation

Fig. 7 Mounting location

Chillgard 5000

Fig. 8 Front of device Fig. 9 Rear of device

Installation

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:

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

NOTICE

Use the appropriate tools to give a clean , smooth end to the tubing when it is cut.

Chillgard 5000

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 fo r 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.

Transport Time Line Length

(ft)

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

4pts 8pts 16pts

Installation

Transport time is similar for all tubing configurations.

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.

Chillgard 5000

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 ser vicing 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.

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)

Fig. 10 End-of-line filter

points in the direction of air flow into the sample line.

Installation

Examine and replace the end-of-line filters at regular intervals. The appropriate interval for replacement 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.

Chillgard 5000

4.4.5 Exhaust Venting

The use of exhaust tubing reduces pump noise from the device. Make sure to vent the exhaust of the device to the outside atmosphere (preferred) or a safe area. Do not use inline or end-of-line filters in the exhaust line. If possible, route the exhaust line so venting occurs to the outside atmosphere. Make sure to protect

the end of the exhaust tube from elements such as water, dirt, snow , ice, and insect s, which can cause clogs and prevent efficient venting.

If exhaust venting occurs indoors, make sure to route the exhaust line to:

• An area that is not monitored for refrigerant gases

• An area away from personnel

WARNING!

Make sure to remove the cap from the exhaust port before operating the device. Failure to do so will create back pressure that can result in inaccurate readings and damage to internal components.

Failure to follow these warnings can result in serious bodily injury or death.

Installation

4.5 Wiring and Grounding

The Chillgard Wiring Diagram (Fig. 11) gives the details of the wiring requirements for the device.

WARNING!

Make sure the device chassis is connected to the earth ground at the ground bar. Failure to follow these warnings can result in serious bodily injury or death.

NOTICE

Installations that require conformity to the CE mark must have a connection between the Chillgard 5000 device and a nearby earth ground potential.

T o achieve this connection, inst all a 10 AWG or larger copper wire between the grounding lug terminal strip on the right side of the Chillgard 5000 device and the grounding point (protective earth). The wire length cannot be longer than 6 ft (2 m).

Chillgard 5000

Installation

Fig. 11 Chillgard Wiring Diagram

Chillgard 5000

4.6 Electrical Power Supply Requirements

WARNING!

A qualified electrician must do electrical wiring. Wiring must comply with all applicable NEC/CEC and local electrical safety codes. Make sure that the copper conductors used to connect to supply mains meet all NEC/CEC and local

electrical safety codes. Never operate the device without a protective ground. Operating the device without a prot ect ive

ground can result in electrical shock. Electrical shock can cause damage to the device and injury to personnel.

T o prevent electrical shock, the ci rcuit board cover must be in place when power is on. Electrical shock can cause serious personal injury or death.

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. Failure to follow these warnings can result in serious bodily injury or death.

Installation

The device uses a power supply that accepts inputs of 100–240 V ac, 50/60 Hz, 200 VA maximum. Make sure the device is connected directly to the ac power source thr ough a dedicated circuit breaker . Use an approved 3-conductor wire (minimum 16 AWG), rated 300 Va c at 221°F (105°C), to complete

the ac power connection. Use only conduit hubs and hardware that are suitable for fiberglass enclosures. Do the following procedure to connect electrical power:

(1) Disconnect electrical power. (2) Install a circuit breaker for the incoming power connections of the device.

a) Put the circuit breaker in a location that is near the device and easy to access. b) Clearly mark the circuit breaker as the disconnecting unit for the device.

(3) If applicable, remove the locking mechanism. (4) Release the two latches on the left side of the device. (5) Open the enclosure. (6) Attach the ESD wrist strap to the ESD connection point inside the enclosure. (7) Use a ¼-in. hex driver to remove the 4 hex nuts on the circuit board cover. (8) Remove the circuit board cover.

(9) Remove the ac power wiring hole plug. (10) Install conduit hubs that are suitable for fiberglass enclosures through the ac power wiring hole

plug openings.

(11) Put the ac power wiring through the conduit.

Chillgard 5000

(12) Connect the ac power wiring to the L1 (HOT) and L2 (NEUTRAL) input terminals. Make sure the

connectors are seated securely.

(13) Connect the ac power ground wire to the ground bar so the device chassis ground is connected

to the earth ground. (14) Make sure the wiring is not touching the sensor assembly. (15) Install the circuit board cover. (16) Use a ¼-in. hex driver to install the 4 hex nuts on the circuit board cover . (17) Disconnect the ESD wrist strap from the ESD connection point inside the enclosure. (18) Close the enclosure. (19) Latch the two latches. (20) If applicable, attach the locking mechanism. (21) Supply electrical power to the device.

4.7 Relay Outputs

Refer to the Chillgard Wiring Diagram (Fig. 11 ) for details. The Chillgard 5000 has the following five single-pole, double-throw (SPDT) relays. The relay contacts

are rated 8 A at 240 Vac/24 Vdc. Each relay can be connected as normally open (NO) or normally closed (NC).

Installation

•Fault

•Alarm

• Warning

•Caution

•Horn

Chillgard 5000

5Initial Setup

WARNING!

Make sure to remove the cap from the exhaust port before operating the device. Failure to do so will create back pressure that can result in inaccurate readings and damage to internal components.

Failure to follow these warnings can result in serious bodily injury or death. Remove the protective film from the touchscreen.

When power is supplied to the device, the green power indicator LED (Fig. 1) illuminates and the touchscreen shows a logo and a loading bar. The loading bar indicates the status of the initializing process.

If an error occurs during start-up, a pop -up identifies the specific problem.

Initial Setup

5.1 Language/Date & Time/Passw o rd

(1) On the "Initial Setup" screen, select "Language/Date &

Time/Password".

(2) On the "Language Setup" screen, select the appro-

priate language, then select "Next".

When a language is selected, the change is instantaneous.

(3) On the "Date & Time Setup" screen, select the "Date"

tab.

The date format can be MM/DD/YYYY or DD/MM/YYYY depending on the language setting.

Chillgard 5000

Initial Setup

(4) Select the "Month/Day/Y ear" fields, and use the alpha-

numeric keypad pop-up to enter values. Select to accept the values.

NOTE: An entry for the date is necessary to continue. If this

error pop-up shows, select "OK" to return to the previous screen and supply a value.

(5) Select the "Time" tab. (6) Select the "Hour/Minute" fields, and use the alphanu-

meric keypad pop-up to enter values. Select to accept the values.

The time format can be 12 hours (AM/PM) or 24 hours depending on the language setting.

(7) If applicable, select "AM" or "PM". (8) Select "Next".

NOTE: A valid entry for the time is necessary to continue. If

this error pop-up shows, select "OK" to return to the previous screen and supply a value.

Chillgard 5000

Initial Setup

(9) On the "Password" screen, select "Disabled" or

"Enabled" to disable or enable password prote ction for editable screens.

If password protection is disabled, the "Create Password" and "Verify Password" fields are inactive.

NOTE: If password protection is enabled, do the

following: a) Select the "Create Password" field, and use the

alphanumeric keypad pop-up to enter a value. Select to accept the value.

b) Select the "Verify Password" field, and use the

alphanumeric keypad pop-up to enter a value. Select to accept the value.

(10) Select "Next".

If password protection is enabled, the "Password Required " pop-up will show when any user tries to change an editable screen.

(1 1) The "Initial Setup" screen shows a check mark beside

the "Language/Date & Time/Password" step to indicate that it is complete. Select "Continue" to go to the point configuration setup.

Chillgard 5000

5.2 Point Configuration

Initial Setup

NOTE: At initial setup, all points except Point 1 are disabled

by default and are inactive on the "Point Configuration" screen. Configuration of Point 1 is required for device initialization.

(1) On the "Point Configuration" screen, select "Point 1". (2) Select "Next".

(3) On the "Point Configuration: Point #" screen, select

"Enable".

(4) Select the Name field, and use the alphanumeric

keypad pop-up to assign a name with up to 18 characters. Select to accept the value.

The entire 18 characters will only show on the "Point Detail" screen. Only 10 characters will show on the "Point Configuration" screen.

(5) Select "Save". (6) Repeat Step s (1) through (5) until all of the necessary

points have been configured.

(7) On the "Point Configuration" screen, select "Next".

(8) The "Initial Setup" screen shows a check mark beside

the "Point Configuration" step to indicate that it is complete. Select "Continue" to go to the gas configuration setup.

Chillgard 5000

+ 64 hidden pages