Appendix E – List of User Configurable Parameters ................................................. 84
GB
GasGard XL Wall Mount Controller 5
SAFETY REGULATIONS MSA
1. Safety Regulations
Correct Use
1.1.
GasGard XL Wall Mount Controller (hereinafter referred to as Control Unit) is a
compact Control Unit in wall housing for connection of up to 8 EX, TOX and/or
OX sensors. The Control Unit is suitable for a large number of applications in
many industrial areas. Simplest installation and user-friendly configuration via
push buttons with comfortable editing and copying functions make the unit an
ideal control instrument for smaller, independent gas warning systems.
It is imperative that this operating manual be read and observed when using the
product. In particular, the safety instructions, as well as the information for the use
and operation of the product, must be carefully read and observed. Furthermore,
the national regulations applicable in the user's country must be taken into
account for a safe use.
Danger!
This product is supporting life and health. Inappropriate use,
maintenance or servicing may affect the function of the device and
thereby seriously compromise the user’s life.
Before use the product operability must be verified. The product must
not be used, if the function test is unsuccessful, it is damaged,
a competent servicing/maintenance has not been made,
genuine MSA spare parts have not been used.
Alternative use, or use outside these specifications will be considered as noncompliance. This also applies especially to unauthorised alterations to the product
and to commissioning work that has not been carried out by MSA or authorised
persons.
It is recommended to read the procedures of the EN 60079-29-2 for selection,
installation and maintain gas warning devices.
Liability Information
1.2.
MSA accepts no liability in cases where the product has been used
inappropriately or not as intended. The selection and use of the product are the
exclusive responsibility of the individual operator.
Product liability claims, warranties also as guarantees made by MSA with respect
to the product are voided, if it is not used, serviced or maintained in accordance
with the instructions in this manual.
6
GasGard XL Wall Mount Controller
GB
MSA DESCRIPTION
2. Description
General overview
2.1.
Fig. 1 GasGard XL
The control system is a wall mounted version of a permanent gas warning device.
It is used to monitor industrial premises and installations for the presence of
combustible, explosive, toxic gases or air/vapour mixtures and oxygen content.
The control system provides power to the sensors, signal conditioning and display
of measured gas concentrations, alarm thresholds, outputs for alarm devices and
self-monitoring diagnostics.
Recommended operational lifetime according to EN 50271 is 20 years.
The unit consist of up to 8 channels for monitoring active or passive sensors.
It can be used for:
EX-monitoring for protecting operational plants and individuals working there
by continuously monitoring the atmospheres for potentially explosive
gases/vapours in air before they reach the lower explosion limit – activating
alarms and initiating risk aversion measures.
It is approved in accordance with Directive 2014/34/EU [ATEX].
OX-monitoring for protecting individuals by continuously monitoring the
atmosphere for oxygen deficiency or oxygen enrichment or monitoring the
inerting of operational plants.
It is approved in accordance with Directive 2014/34/EU [ATEX].
TOX-monitoring for protecting individuals by continuously monitoring the
atmosphere toxic gas concentrations.
GB
GasGard XL Wall Mount Controller
7
DESCRIPTION MSA
6
2
89899 8
In case of reaching the set limit values, e. g. maximum/minimum concentration in
the atmosphere, an alarm will be activated.
Typical applications are:
Chemical and petrochemical industry,
Paint and solvent industry,
Gas-processing industry and
Municipal areas.
Control Unit
2.2.
7
1
Fig. 2 Enclosure
3
4
5
The Control Unit consist of the following basic modules:
Enclosure with mounting holes (7) and cable entries (5)
Power Supply (1)
Backup Battery (6)
Sensor Extension Board (4)
Channel Board (3)
Channel Relay Board (2)
Internal Fuse T4 A (8)
Internal Fuse T250 mA (9)
8
GasGard XL Wall Mount Controller
GB
MSA DESCRIPTION
2.2.1. Wall Mount Enclosure
The Control Unit has a plastic ABS enclosure in accordance with IP 56.
Dimensions 515 mm x 277 mm x 129 mm.
Cable entry points are not provided. They are predesigned on the bottom of the
enclosure.
The front panel is moulded with predesigned holes for fully equipped
configuration (8 channels).
The unit is mounted by 4 screws.
2.2.2. Power Supply
100 W for fully equipped unit from 4 to 8 channels.
The power supply is main AC.
Switching power supply certified CE, UL, CSA
(100 to 255 VAC; 50/60 Hz).
In case of loss of main power the power supply automatically switches to backup
battery (Power source for detectors from 24 VDC ±20 %.).
2.2.3. Backup Battery
Two batteries 12 VDC/2.2 Ah (connected in series) can be incorporated optionally
into the Control Unit. The batteries supply 20 minutes of backup for 8 catalytic
combustion sensors.
Operating under back-up power is indicated on the front panel (Power LED starts
blinking).
2.2.4. Main Board
The Main Board is equipped by the most performance microcontroller which
offers many interfaces. Further it includes watchdog, internal buzzer (85 dB),
standard common outputs and battery charger circuit.
All necessary information is stored on the Main Board.
Following communications are possible:
1 Ethernet configurable for ModBus TCP/IP (galvanically isolated)
1 RS485 configurable for ModBus RTU (galvanically isolated)
1 USB configurable for ModBus RTU.
The communication shall not interfere with the operation of the Control
Unit.
For SCADA visualization software all three interfaces can be used. For service
access only both of ModBus RTU communications can be used
(safety precaution).
GB
GasGard XL Wall Mount Controller 9
DESCRIPTION MSA
Standard common outputs are incorporate:
2 SPDT (Single Pole Double Throw) relays common alarm (ALARM 1 and
ALARM 2)
1 DPDT (Double Pole Double Throw) relay common fault
2 addressable common horn relays.
2.2.5. Display Board
The Display Board is located on the back side of the lid.
It includes microcontroller, watchdog, push buttons and graphic display (128x64).
2.2.6. Sensor Extension Board
The sensor extension board is used for fixing channel boards and for connecting
internal communication.
For Sensor connection please refer to Section 0.
2.2.7. Channel Board
There are two versions of channel boards available according to the requested
sensor type (passive sensors, 4-20 mA transmitters).
Every board includes 4 LEDs (A1, A2, Status, Power) and fits to Channel's
Connectors (4 on the Main Board, 4 on the Sensor Extension Board).
The sensors power and connection is designed as “fail-to-safe” (wrong
connection/configuration does not damage the remote sensor).
2.2.8. Channel Relay Board
Every Channel Relay Board provides 8 output relays and is connected to the
Main Board or to the Sensor Extension Board (one by one) via connectors.
Relays are fully configurable by user from the front panel or from the connected
PC via configuration software.
Two optional SPDT relays (Single Pole Double Throw) per channel (8 relays per
4 channels) are configurable for individual alarms:
Normally open/close
Normally energized/de-energized
Latching/non latching
Increasing/decreasing
N out of m voting
New re-invoked alarms (common horn relays only)
Grouping
Contacts are resistive load.
10GasGard XL Wall Mount Controller
GB
MSA DESCRIPTION
2.2.9. Safety Symbols according to EN 61010-1
The following table shows the safety symbols used on the device according to
EN 61010-1.
Table of Safety Symbols
Symbol Description
DC Voltage
AC Voltage
Earth Terminal
Protective Conductor Terminal
Caution, Risk of Electrical Shock
Caution, Risk of Danger
Front Panel
2.3.
The Front Panel allows communication with the Control Unit.
It is used to monitor the status of all connected field sensors, to determinate
system settings and to configure all parts.
On the panel there are:
LCD graphic display (5)
Four control LEDs per channel (6)
Three Common LEDs (1)
Alarm Acknowledgement button (4)
Alarm Reset button (2)
Four Control push buttons (3)
GB
GasGard XL Wall Mount Controller
11
DESCRIPTION MSA
6
2
5
1
Fig. 3 Operator Panel
1 Common LEDs 4 Alarm Acknowledgement
2 Alarm Reset 5 Graphic Display
3 Control Push Buttons 6 Channel Status Info LEDs
3 4
2.3.1. Graphic Display
The Control Unit has a 128 x 64 pixel large graphic display which shows
information of all channels.
Fig. 4 Graphic Display
12GasGard XL Wall Mount Controller
GB
MSA DESCRIPTION
2.3.2. Control Push Buttons
Using the control push buttons you can operate the menu prompt as shown
below. For more information please refer to Section 4.
]
]
]
ACK
RES
Right button [
Up Button [
Left button [ ESC ]
Down button [
Alarm Acknowledgement
Alarm Reset
GB
GasGard XL Wall Mount Controller 13
DESCRIPTION MSA
2
2.3.3. Channel Board Status Info LEDs
For each of eight Control Channels there are four LEDs for monitoring the
operating status of the units.
4
3
Fig. 5 Channel Status Info LEDs
1 Power LED 3 Alarm 1 LED
2 Status LED 4 Alarm 2 LED
1
The Power LED (green) indicates the channel is under power and is enabled
by the system.
The Status LED (yellow) indicates the channel is in a fault condition.
When the LED is blinking (with 0.5 Hz) the channel is inhibited or in service.
The Alarm 1 LED (red) indicates that 1st alarm level has been reached. It
indicates different statuses:
4 Hz blinking: 1st alarm level has been reached (not acknowledged yet)
Steady: 1st alarm is acknowledged but is still inside alarm range.
0.5 Hz blinking: 1st alarm is configured as latching. Measured value is out
of alarm level (not reset yet).
The Alarm 2 LED (red) indicates that 2nd alarm level has been reached.
It indicates different statuses:
4 Hz blinking: 2nd alarm level has been reached (not acknowledged yet)
Steady: 2nd alarm is acknowledged but is still inside alarm range.
0.5 Hz blinking: 2nd alarm is configured as latching. Measured value is out
of alarm level (not reset yet).
14GasGard XL Wall Mount Controller
GB
MSA DESCRIPTION
2
2.3.4. Channel Relay Board Status LED
Each Channel Relay Board has a small smd LED on the board marked as VD1,
which indicates different statuses:
0.5 Hz blinking
Channel Relay Board is activated in the system and
works properly
Steady
Channel Relay Board is activated in the system and is in
a fault condition
Off Channel Relay Board is activated in the system
2.3.5. Unit Status Info LEDs
3
1
Fig. 6 Channel Status Info LEDs
1 Power LED 3 System LED
2 Failure LED
The Power LED (green) indicates that the Control Unit is under power.
A blinking LED (0.5 Hz) indicates power supply from battery.
The Failure LED (yellow) indicates that some sensor is in fault condition.
The System LED (yellow) indicates that the Control Unit has a system fault.
GB
GasGard XL Wall Mount Controller 15
INSTALLATION MSA
3. Installation
Before beginning the installation, with the help of the shipping
documents and the sticker on the shipment carton, check that the
delivered components are complete and correct.
The installation location for the Control Unit must be outside the potentially
explosive area and free of corrosive gases.
Sensors for use in the Ex area must have the appropriate Ex approval and must
be installed in accordance with all relevant local and national regulations.
MSA configures and calibrates all control systems with a checklist and all
systems are supplied with a data sheet for each measuring point.
The gas warning system must only be installed by qualified personnel after
reading the documentation supplied.
All relevant local and national regulations and instructions must be observed.
The correct assignment of each sensor and control system module must be ensured
during installation by referring to the serial numbers indicated on the data sheet.
Mechanical Installation
3.1.
Fig. 7 Mounting Drawing
Mount the Control Unit as follows:
(1) Mark the holes as shown in Fig. 7 for the four fixing screws.
(2) Drill four holes of appropriate diameter for wall plugs.
(3) Remove the front panel from the enclosure.
(4) Fix the unit to the wall, by appropriate screws (M6 screws or 6.4 mm SPAX)
(5) Attach lid with existing screws.
16
GasGard XL Wall Mount Controller
GB
MSA INSTALLATION
Electrical Installation
3.2.
Attention!
The control system must be installed only in compliance with the
applicable regulations, otherwise the safe operation of the instrument
is not guaranteed.
During installation, use the internal earth connection to ground the
instruments.
If an external earth connection is permitted or demanded by the local
authorities, it serves merely as additional earthing.
The installation location shall be selected such that the environmental conditions
indicated in the technical data can be met.
When installing the Control Unit the following conditions must be met to comply
with the EMC Directive
To connect devices to the main power supply, a fault-free ground or fault-free
potential bonding conductor must be provided.
The user must ensure an appropriate supply voltage in accordance with EMC
directives.
All sensor and control cables must be shielded.
Shielded cables must have at least 80 % coverage.
Control and sensor cables must be installed physically separate from power
supply cables.
Shielded cables must be laid in a group. If cable lengths are to be extended
using terminal boxes, the boxes must be shielded and the internal
connections must be kept as short as possible.
Warning!
When opening the instrument's housing care must be taken of high
voltage danger from relay contacts and main power supply.
Only authorized person should be authorized to open the instrument.
The AC mains source shall not be subjected to voltage variations
exceeding the limits as specified in this Manual.
The AC mains source shall be free of any surges and sudden voltage
changes due to heavy electrical loads and disturbances as caused by
inductive or capacitive loads, false contacts and strong
electromagnetic interference.
Do not penetrate the housing of the power supply with screw drivers
or small parts. Care must be taken with screws falling into the power
supply!
GB
GasGard XL Wall Mount Controller
17
INSTALLATION MSA
3.2.1. Power Supply
Standard power supply 100 to 255 VAC, 50/60 Hz, 24 VDC ±20 % is used to
power internal circuits up.
Two options to power up the Gasgard XL are available by MSA:
1. Mains supply 100 to 255 VAC only
2. Mains supply 100 to 255 VAC and 24 VDC internal backup battery
Main voltage is connected to terminal L (Line), N (Neutral), and ground.
Fig. 8 Connecting Main Supply
3.2.2. Sensor connection
Sensor must be connected to the terminals on the main board or sensor
extension board (for details Appendix C and Appendix D).
Attention!
Follow the instructions for components subject to damage from static
electricity!
Incorrect connection of the sensors shall not damage both of Control Unit or
sensor.
The wiring diagrams for different sensors are shown in Appendix B. The sensors
must be connected to the terminals using shielded cables.
For the maximum cable length of sensors refer to the technical specification.
18GasGard XL Wall Mount Controller
GB
MSA OPERATION
2
8
6
4. Operation
The control system’s user interface is the integrated operation/display unit.
This unit displays alarms and warnings as well as system parameters.
Connecting the operating unit to a PC permits a user friendly operator interface.
The input fields are set up as selection fields as much as possible, with all known
inputs displayed. Selection is cursor-controlled, which makes use of the integrated operation/display unit very easy.
Basic Screen
4.1.
The basic screen displays the information about active channels status (active,
inhibit, in service) including information about the system (system date and time).
1
3
7
4
5
Fig. 9 Basic Screen
1 System Date 5 Actual Value
2 FlameGard Status 6 Battery Status
3 Channel Number 7 Status Information
4 System Time 8 Events Archive
System Date and Time : Actual preset values for events archive
Channel Number : Position of the channel board counted from the left
to the right on the Main Board (1 … 4) and the
Sensor Extension Board (5 … 8).
Status Information: Information about the channel status (alarm, fault, in
service etc.; see symbols)
GB
GasGard XL Wall Mount Controller
19
OPERATION MSA
Actual Value : Measured value of gas concentration.
Events Archive : Last 1000 events (Alarms, Alarms
acknowledgement and reset, Faults, Calibrations
etc.) are stored in the memory and can be restored
by the operator.
Table of Status Info Symbols
Symbol Description
Alarm 1
Displayed if the alarm level is reached
Alarm 2
Displayed if the alarm level is reached
Overrange
Displayed if channel signal is above the range
(more than 105 % from FS).
Underrange
Displayed if channel signal is below the range
(less than -5 % from FS)
Sensor Fault
Displayed if a sensor connection is broken or shorted
Internal Channel Fault
Displayed if channel board has a system fault
In Service
Displayed if channel is in service mode (calibration)
Inhibit
Displayed if channel is inhibited
STEL Alarm
Displayed if the STEL alarm is reached
TWA Alarm
Displayed if the TWA alarm is reached
Battery is included and is under charging.
Battery is included but discharged
(The symbol starts blinking (0.5 Hz) if the battery cable is
disconnected)
Battery not included
20GasGard XL Wall Mount Controller
GB
MSA OPERATION
If FlameGard is connected to the mA channel board then basic screen contains
further symbols defining the FlameGard status:
FlameGard is connected – No Flame
Warning - FlameGard is in 1st alarm condition
Alarm FlameGard is in 2
nd
alarm condition
The channel where alarm condition is reached as the first one is
identified by blinking value.
The Display board screen displays
text “Communication OFF” in case
of communication failure between
Display board and Main board.
Controls
4.2.
On the front panel there are 4 control push buttons for operating and configure
the Control Unit.
Symbol Description
ENTER
Pressing this button will enter a lower menu or accept the change.
UP
Pressing this button will change the values / options forward.
(Holding this button and pressing the DOWN button will change
the values / options backward).
DOWN
Pressing this button will replace the cursor to the next position.
ESCAPE
Pressing this button will escape the upper menu or cancel the
change.
ACKNOWLEDGEMENT
ACK
In case of alarm pressing will disable audible signal.
GB
GasGard XL Wall Mount Controller
21
OPERATION MSA
RES
Pressing this button will reset alarm relays to normal operating
conditions (only in case of measured value drops below latching
alarm level).
Using the Hotkeys
Pressing some of the control push buttons on the front panel for a longer period
will start some additional features of the basic screen.
UP
RESET
Pressing this button for 5 seconds will change the language from
English to the local one.
ESCAPE
Pressing this button for 5 seconds will start the GasGard XL
Selftest Process:
a test of the LCD display
a test of all LEDs
a test of internal buzzer.
After finishing the selftest the actual firmware version for every
assigned board will be displayed:
10 Alarm2 Acknowledgement 37 Main Power Supply OFF
11 Alarm2 Reset 38 Main Power Supply ON
12 UnderRange 39 Low Battery
13 OverRange 40 Battery FAULT
14 STEL alarm ON 41
Common Coil Relay Horn2
FAULT
15 STEL alarm OFF 42
Common Coil Relay Horn1
FAULT
16 STEL alarm Acknowledgement 43
Common Coil Relay Alarm2
FAULT
17 TWA alarm ON 44
Common Coil Relay Alarm1
FAULT
18 TWA alarm OFF 45
Common Coil Relay Fault
FAULT
19 TWA alarm Acknowledgement 46 RAM Check FAULT
20 Sensor FAULT 47 ROM Check FAULT
21 System FAULT 48 System Password entered
22 Start of Calibration 49
Calibration Password
entered
23 ZG accepted 50 Read FAULT
24 SG accepted 51 Write FAULT
25 FAULT of ZG result 52 Test Mode ON
26 FAULT of SG result 53 Test Mode OFF
GB
GasGard XL Wall Mount Controller 25
OPERATION MSA
List of Assigned Channel Identifications
C1 Channel Board 1
C2 Channel Board 2
C3 Channel Board 3
C4 Channel Board 4
C5 Channel Board 5
C6 Channel Board 6
C7 Channel Board 7
C8 Channel Board 8
R1 Channel Relay Board 1
R2 Channel Relay Board 2
DB Display Board
MB Main Board
RTC Real Time Clock
26GasGard XL Wall Mount Controller
GB
MSA CONFIGURATION
5. Configuration
All parameters of the GasGard XL Control Unit can be configured by pressing
control pushbuttons on the front panel, or using configuration software tool
( Section 6).
There are two menus that allow changing unit parameters:
System Menu
The operator can change any parameter needed according to application
requirements. The system menu is accessible only via access password.
From the system menu it is possible to enter additional menus for setting up
the Control Unit:
Relay Setting Menu for setting up individual relay parameters
Calibration Menu for calibrating all channels
General Setting Menu for setting up units general parameters
Direct access to the Calibration Menu
The operator can calibrate every channel, but he is not able to change
anything else on the configuration of the unit.
This function is accessible only via access password.
There are different passwords for System Menu and direct access to the
Calibration Menu.
Passwords can be set in the General Setting Menu.
System Menu
5.1.
The system menu includes all parameters that allow fully configuring the
complete unit as: