Msa Chillgard LS User Manual

Chillgard® LS
Refrigerant Monitor

Instruction Manual

THIS MANUAL MUST BE CAREFULLY READ BY ALL INDIVIDUALS WHO HAVE OR WILL
HAVE THE RESPONSIBILITY FOR USING OR SERVICING THE PRODUCT. Like any piece
of complex equipment, this instrument will perform as designed only if it is used and
serviced in accordance with the manufacturer’s instructions. OTHERWISE, IT COULD
FAIL TO PERFORM AS DESIGNED AND PERSONS WHO RELY ON THIS PRODUCT FOR
THEIR SAFETY COULD SUSTAIN SEVERE PERSONAL INJURY OR DEATH.

The warranties made by Mine Safety Appliances Company with respect to the product
are voided if the product is not used and serviced in accordance with the instructions in
this manual. Please protect yourself and others by following them. We encourage our
customers to write or call regarding this equipment prior to use or for any additional
information relative to use or repairs.

IN NORTH AMERICA: 1-800-MSA-INST. or FAX [phone]
IN CANADA: 1-800-267-0672 or FAX [phone]
MSA INTERNATIONAL [phone] or FAX [phone]

© MINE SAFETY APPLIANCES COMPANY 2009 - All Rights Reserved

This manual is available on the internet at www.msanet.com

Manufactured by

MSA NORTH AMERICA

P.O. Box 427, Pittsburgh, Pennsylvania 15230

(L) Rev 7 10035164

"

WARNING

i

Chillgard LS Diffusion Refrigerant Monitor

Chillgard LS Pumped Refrigerant Monitor

MSA Permanent Instrument Warranty

1. Warranty- Seller warrants that this product will be free from

mechanical defect or faulty workmanship for a period of two years
from date of shipment, provided it is maintained and used in
accordance with Seller's instructions and/or recommendations. This
warranty does not apply to expendable or consumable parts whose
normal life expectancy is less than one (1) year such as, but not
limited to, non-rechargeable batteries, filament units, filter, lamps,
fuses etc. The Seller shall be released from all obligations under
this warranty in the event repairs or modifications are made by
persons other than its own or authorized service personnel or if the
warranty claim results from physical abuse or misuse of the
product. No agent, employee or representative of the Seller has
any authority to bind the Seller to any affirmation, representation or
warranty concerning the goods sold under this contract. Seller
makes no warranty concerning components or accessories not
manufactured by the Seller, but will pass on to the Purchaser all
warranties of manufacturers of such components.

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

2. Exclusive Remedy- It is expressly agreed that Purchaser's sole

and exclusive remedy for breach of the above warranty, for any
tortious conduct of Seller, or for any other cause of action, shall be
the repair and/or replacement at Seller's option, of any equipment
or parts thereof, which after examination by Seller is proven to be
defective. Replacement equipment and/or parts will be provided at
no cost to Purchaser, F.O.B. Seller's Plant. Failure of Seller to
successfully repair any non-conforming product shall not cause the
remedy established hereby to fail of its essential purpose.

3. Exclusion of Consequential Damage- Purchaser specifically

understands and agrees that under no circumstances will seller be
liable to purchaser for economic, special, incidental or
consequential damages or losses of any kind whatsoever, including
but not limited to, loss of anticipated profits and any other loss
caused by reason of non-operation of the goods. This exclusion is
applicable to claims for breach of warranty, tortious conduct or any
other cause of action against seller.

ii

1. Each instrument described in this manual must be installed,
operated, and maintained in strict accordance with its labels,
cautions, warnings, instructions, and within the limitations stated.

2. These monitors must not be installed in outdoor areas or in areas
or locations where explosive concentrations of combustible gases
or vapors might occur in the atmosphere: Class 1, Group A, B, C,
and D areas as defined by the NEC. Because the monitors are not
explosion-proof, they must be located in non-hazardous areas.

3. The Chillgard LS Refrigerant Monitor is designed to detect
refrigerant gases in the air. It cannot measure the concentration of
these gases in a steam type atmosphere.

4. As with all gas detection instruments of this type, high levels of or
long exposure to certain compounds in the tested atmosphere
contaminate the sensor. In atmospheres where the monitor may be
exposed to such materials, calibration must be performed
frequently to ensure that system operation is dependable and its
indications accurate.

5. The Chillgard LS Refrigerant Monitor must not be painted.
Painting will interfere with the sampling process of the instrument.
If painting is being done in an area where the instrument is located,
care must be exercised to insure that paint is not put or splashed
on the instrument.

6. The only absolute method to assure the proper overall operation
of a gas detection instrument is to check it with a known
concentration of the gas for which it has been calibrated.
Consequently, a calibration check must be included as part of
the routine inspection of the system.

7. The sensor is a sealed unit. Do not attempt to modify or adjust the
sensing cell.

8. Use only genuine MSA replacement parts when performing any
maintenance procedures provided in this manual. Failure to do so
may seriously impair instrument performance. Repair or alteration
of the Chillgard LS Refrigerant Monitor, beyond the scope of these
maintenance instructions or by anyone other then an authorized
MSA service person, could cause the product to fail to perform as
designed, and persons who rely on this product for their safety
could sustain serious personal injury or death.

9. Ensure that the Chillgard LS Refrigerant Monitor is installed in a
clean and dry area as possible.Install splash or rain shields on the
instrument to keep water and other contaminants away from the
instrument. If you fail to follow this warning, equipment damage
can occur.

iii

"!

WARNINGS

10.Ensure that the Chillgard LS Refrigerant Monitor and the area the
instrument is monitoring is at the same temperature before
operation of the instrument; otherwise, condensation will form and
possibly clog or fill the gas sensor in the instrument rendering the
instrument inoperable.

11. Protect the Monitor from vibration and heating; otherwise, improper
operation may result, which can result in personal injury or death.

FAILURE TO FOLLOW THE ABOVE WARNINGS CAN RESULT IN SERIOUS
PERSONAL INJURY OR DEATH.

iv

v

Table of Contents

Chapter 1

General Information . . . . . . . . . . . . . . . . . . . .1-1

Figure 1-1. Identification Label Location . . . . . . . . .1-1

Terminology Used in this Manual . . . . . . . . . . . . . . . . . .1-2

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Table 1-1. General Operating Specifications

for all Models . . . . . . . . . . . . . . . . . . . . . . . . .1-4

Table 1-2. Typical Chillgard LS / R-11

Cross-Sensitivity Response Data . . . . . . . . . .1-5

Table 1-3. Typical Chillgard LS / R-12

Cross-Sensitivity Response Data . . . . . . . . . .1-5

Table 1-4. Typical Chillgard LS / R-22

Cross-Sensitivity Response Data . . . . . . . . . .1-6

Table 1-5. Typical Chillgard LS / R-123

Cross-Sensitivity Response Data . . . . . . . . . .1-6

Table 1-6. Typical Chillgard LS / R-134 A

Cross-Sensitivity Response Data . . . . . . . . . .1-7

Chapter 2

Installation and Set-up . . . . . . . . . . . . . . . . . .2-1

Unpacking the System . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Initial Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Sensor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Pumped Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Diffusion Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Mounting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Five rules for proper mounting . . . . . . . . . . . . . . . . . . .2-3

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Figure 2-1. Diffusion Style Mounting Dimensions . .2-4

Figure 2-2. Four-Point Pumped Style

Mounting Dimensions . . . . . . . . . . . . . . . . . . .2-5

Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Opening the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Figure 2-3. Diffusion Style Electrical Connections . .2-7

Figure 2-4. Four-Point Pumped Style

Electrical Connections . . . . . . . . . . . . . . . . . .2-7

For 24 V DC or AC Wiring . . . . . . . . . . . . . . . . . . . . . .2-8

For 110/220 VAC Wiring . . . . . . . . . . . . . . . . . . . . . . .2-8

Figure 2-5. Sensor Board Connections . . . . . . . . . .2-8

Analog Signal Output Wiring . . . . . . . . . . . . . . . . . . . .2-9

Chapter 3

Start-up and Initial Adjustments . . . . . . . . . .3-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

General Calibration (All Models) . . . . . . . . . . . . . . . . .3-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Chapter 4

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Figure 4-1. Calibration Equipment . . . . . . . . . . . . . .4-1

" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Diffusion Version Calibration . . . . . . . . . . . . . . . . . . . . .4-1

Calibration Equipment - (FIGURE 4-1) . . . . . . . . . . . .4-1

Initial Calibration Procedures . . . . . . . . . . . . . . . . . . . .4-2

Preparation for Calibration . . . . . . . . . . . . . . . . . . . . . .4-2

Initial Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Figure 4-2. Applying Calibration Gas

to the Chillgard LS Refrigerant Monitor . . . . .4-3

Calibration Guidelines . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Calibration Equipment . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Calibration Check Procedure . . . . . . . . . . . . . . . . . . . .4-5

Applying Calibration Gases to the Instrument . . . . . . .4-5

vi

" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Four-Point Pumped Version Calibration . . . . . . . . . . . . .4-6

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Calibration Equipment . . . . . . . . . . . . . . . . . . . . . . . . .4-6

" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Figure 4-3. Kit Components . . . . . . . . . . . . . . . . . . .4-7

" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Table 4-1. RP Calibration Gases . . . . . . . . . . . . . .4-8

Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . .4-8

Preparation for Calibration . . . . . . . . . . . . . . . . . . . . . .4-8

" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Initial Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Calibration Guidelines . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Calibration Equipment . . . . . . . . . . . . . . . . . . . . . . . .4-10

Calibration Check Procedure . . . . . . . . . . . . . . . . . . .4-10

Zeroing the Monitor . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Figure 4-4. Using Zero Scrubber

for Zero Calibration . . . . . . . . . . . . . . . . . . . .4-11

Figure 4-5. Using Zero Gas Cylinder

for Zero Calibration . . . . . . . . . . . . . . . . . . . .4-11

Figure 4-6. Span Calibration . . . . . . . . . . . . . . . . .4-12

" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

Chapter 5

Service and Replacement Parts . . . . . . . . . .5-1

Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . .5-1

Table 5-1.Troubleshooting Guidelines . . . . . . . . . .5-1

Table 5-2. Calibration Accessories Parts List . . . . .5-2

Table 5-3. Replacement Parts List . . . . . . . . . . . . .5-3

Service and Assistance . . . . . . . . . . . . . . . . . . . . . . . . .5-4

vii

Appendix A

Installation Outline Drawings . . . . . . . . . . . .A-1

Figure A-1. Diffusion Style Chillgard LS

Installation Drawing . . . . . . . . . . . . . . . . . . . .A-1

Appendix B

RS-485 Output . . . . . . . . . . . . . . . . . . . . . . . .B-1

Table B-1. Dip Switch Positions . . . . . . . . . . . . . . .B-1

Table B-2. Sensor Unit Register Addresses . . . . .B-2

viii

1-1

Chapter 1
General Information

The Chillgard LS Refrigerant Monitor provides a continuous indication of
a refrigerant concentration in air. It is capable of monitoring a refrigerant
from 0 to 1000 parts per million (ppm). Each instrument is factory­calibrated to a certain full-scale value of a specific refrigerant.

All Chillgard LS Refrigerant Monitors use infrared photo-acoustic
sensors. These sensors give an indication of refrigerant levels without
requiring oxygen to be present. Also, the sensors are not poisoned or
degraded in the presence of most silicon or sulfur compounds.

Each Chillgard LS Refrigerant Monitor is placed in an area where a
refrigerant is anticipated or must be controlled. The Monitor operates in
either the Diffusion style (gas diffuses into the sensor through the
opening located at the bottom of the unit) or the Pumped style (an
internal pump draws the sample into the sensor from a remote location).
The gas sensor determines the refrigerant concentration and outputs an
electrical analog signal proportionate to the concentration.

The Chillgard LS Refrigerant Monitor contains all components
necessary to properly sample an area or duct for a refrigerant.

This manual describes all of the various Chillgard LS Refrigerant
Monitors, although your monitor may not be equipped with all of the
options available.

To help determine what options are on your unit, see the identification
label on the side of the instrument (FIGURE1-1).

Figure 1-1. Identification Label Location

1-2

This label contains:

• model number

• the refrigerant that the unit will detect

• information concerning proper voltages and frequency
required to power the unit

Terminology Used in this Manual

FLOW RATE:

Volume of gas drawn through the sample line per minute.

EXHAUST GAS:

Sample gas after it passes through the sensor.

FRESH AIR:

Air that has no possibility of containing refrigerant gas. Contamination
with refrigerant gas would interfere with the calibration and the flushing
of the instrument.

ZERO:

A zero (0) output usually indicates ambient air present or no refrigerant
gases present.

SCRUBBER:

An activated carbon filter which removes and cleans the span gas in the
calibration operation prior to exhausting excess gas to ambient air.

ZEROING:

The process of placing a zero indication on the output of the instrument.

SPAN:

A full-scale or up-scale reading on the output of the instrument.

SPANNING:

The process of placing a full-scale or up-scale output of the instrument.

SPAN GAS VALUE:

The gas “concentration” that gives the instrument a full-scale or up­scale output; this value is usually printed on the gas cylinder.

General Description

The Chillgard LS Refrigerant Monitor:

• provides a continuous indication of a refrigerant
gas concentration

• operates on the photo acoustic principle, and measures the
concentration of a refrigerant in a complex mixture of
background gases.

In the photo acoustic principle, sample gas is delivered to an
enclosed chamber which is periodically bombarded with infrared
(IR) radiation. If the target gas is present, it absorbs IR with each
pulse of light. These pulses are miniature sound waves which are
picked up by a microphone. The sound level is directly proportional
to the target gas concentration present in the gas chamber.

• is capable of measuring a refrigerant 0 to 1000 ppm full scale

• is housed in a rugged plastic enclosure

• has a standard 4 to 20 mA and RS-485 output

• has five LEDs to indicate power, fault and alarm conditions

• is highly selective to enable operation in areas with varying
humidity or in areas containing other contaminants. It may be used
for applications requiring long-term stability and low maintenance.

Applications

The Chillgard LS Refrigerant Monitor is factory-calibrated for a
refrigerant and can be used for applications such as:

• ventilation control

• ambient air monitoring for health and safety purposes.

1-3

Table 1-1. General Operating Specifications for all Models

PERFORMANCE SPECIFICATIONS

LINEARITY 20 to 100 ppm +5 ppm

100 to 1000 ppm +6% of reading

REPEATABILITY +8 ppm

WARM-UP TIME 10 minutes

RESPONSE TIME 50% of a step-change in < 70 seconds

OPERATING TEMP. 0 to 40oC (32 to 104oF)

TEMP. EFFECT < 4% / 10oC

RELATIVE HUMIDITY 0 to 95%, RH non-condensing

RH EFFECT R11: less than 3% full scale

Other refrigerants: less than 1.5% full scale

OPERATING SPECIFICATIONS

POWER REQUIREMENTS 24 VDC, +10%, -0%, .85A

24 VAC, +10%, 50/60 Hz, .80A
100 to 240 VAC, 50/60, Hz, .3A

ANALOG OUTPUT 4 to 20 mA, non-isolated, sourcing

DEFAULT ALARM VALUES R123: 50, 150, 300 ppm

Other applications: 50, 150, 1000 ppm

MAX. OUTPUT SIGNAL LOAD 500 ohms

DIMENSIONS 7.1" high x 10" wide x 4.25" deep
DIFFUSION VERSION (188 mm high x 110 mm wide x 70 mm deep)

DIMENSIONS 14.7" high x 11.2" wide x 5" deep
PUMPED VERSION (373 mm high x 284 mm wide x 127 mm deep)

WEIGHT DIFFUSION VERSION 3.7 pounds (1.678 kg.)

WEIGHT PUMPED VERSION 9.5 pounds (4.308 kg.)

SAMPLE FLOW RATE Typically 1.5 LPM; .
PUMPED VERSION .75 LPM with maximum tubing length

MAX. SAMPLE TUBING LENGTH PUMPED VERSION 300 feet with 1/8" ID tubing

MAX. EXHAUST TUBING LENGTH PUMPED VERSION 30 feet with 1/4" ID tubing

TRANSPORT AND STORAGE CONDITIONS

TEMP. -40 to 60oCentigrade (-40 to 140oF)

HUMIDITY 0 to 99% relative humidity

POLLUTION DEGREE AND INSTALLATION CATEGORY 2

ALTITUDE 2000 meters maximum

1-4

Table 1-2. Typical Chillgard LS / R-11 Cross-Sensitivity Response Data

GAS CONCENTRATION (PPM) EQUIVALENT PPM R-11

Acetone 100 14

Methyl Ethyl Ketone 100 32

Methanol 1000 130

iso-Propanol 500 400

Methylene Chloride 100 0

Xylene 100 0

Ammonia 50 0

R-113 100 25

R-11 100 100

R-22 100 30

R-12 983 490

R-134 A 100 20

R-123 100 3

Propane 0.6% 18

Ethylene 500 20

TEST CONDITIONS: Calibrated 0-1000 PPM R-11 in N

2;

Temperature: 25OC

Table 1-3. Typical Chillgard LS / R-12 Cross-Sensitivity Response Data

GAS CONCENTRATION (PPM) EQUIVALENT PPM R-12

Acetone 100 3

Methyl Ethyl Ketone 1000 25

Methanol 1000 2

Methylene Chloride 1000 14

Trichloroethylene 1000 167

Ethyl Acetate 1000 22

Xylene (ortho-Xylene) 1000 5

R-113 100 35

R-11 100 5

R-22 100 1

R-12 100 100

R-134 A 100 2

R-114 100 45

TEST CONDITIONS: Calibrated 0-1000 PPM R-12 in N2; Temperature: 25OC

1-5

Table 1-4. Typical Chillgard LS / R-22 Cross-Sensitivity Response Data

GAS CONCENTRATION (PPM) EQUIVALENT PPM R-22

Acetone 100 <1

R-11 100 16

R-123 100 35

R-134 A 100 25

R-132 A 100 40

R-22 100 100

R-113 100 39

TEST CONDITIONS: Calibrated 0-1000 PPM R-22 in N

2;

Temperature: 25OC

Table 1-5. Typical Chillgard LS / R-123 Cross-Sensitivity Response Data

GAS CONCENTRATION (PPM) EQUIVALENT PPM R-123

Acetone 100 22

Methyl Ethyl Ketone 500 48

Methanol 100 2

iso-Propanol 100 5

Methylene Chloride 1000 14

Trichloroethylene 1000 4

Ethyl Acetate 100 42

Xylene (ortho-Xylene) 1000 5

Ammonia 910 7

Natural Gas 1000 5

R-113 100 80

R-11 100 <1

R-22 100 4

R12 100 8

R-134 A 100 140

R-123 100 100

TEST CONDITIONS: Calibrated 0-1000 PPM R-123 in N

2;

Temperature: 25OC

1-6