MSA Toxgard II Instruction Manual

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Toxgard® II Monitor

instruction manual

WARNING

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 c omplex equipment, the unit will perform as designed o nly if it is ins talled, used a nd serviced in acc ordance 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 the U.S., to contact your nearest stocking location, dial toll-free 1-800-MSA-INST. To contact M SA International, dia l 1-412-967-3354.

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

Manufactured by

MSA NORTH AMERICA

P.O. Box 42 7, Pi tt sb ur gh, P ennsylvan ia 15230

(L) Rev 7 711266

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MSA Permanent Instrument Warranty

1. Warranty- Seller warrants that this product will be free from mechanical defect or faulty workmanship for a period of eighteen (18) months from date of shipment or one (1) year from installation, whichever occurs first, 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, sensor elements, 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 MERCHANTABILITY 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 nonconforming 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 nonoperation of the goods. This exclusion is applicable to claims for breach of warranty, tortious conduct or any other cause of action against seller.

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WARNINGS

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 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. Since the monitors are not explosion-proof, they must be located in non-hazardous areas.

3. The Toxgard II monitor is designed to detect toxic gases or vapors in the air. It cannot measure the concentration of toxic gases or vapors in steam or inert or oxygen-deficient atmospheres. Neither will it indicate the presence of explosive or combustible mists or sprays, lubrication oils, nor explosive dusts, such as grain or coal dust.

4. As with all gas detection instruments of this type, high levels of or long exposure to certain compounds - all of which are not known, will contaminate the sensor. Calibrate the monitor frequently to ensure that system operation is dependable and its indications accurate.

5. The Toxgard II monitor must not be painted. Also, painting should not be done near the sample line inlet. If painting is being done in an area where the sample line inlet is located, care must be exercised to make sure that paint is not deposited on the sample inlet fitting of the monitor. Such paint deposits would interfere with the sampling process, whereby a sample of the atmosphere being monitored is drawn into the Toxgard II unit.

6. The only absolute method to ensure 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 should be included as part of the routine inspection of the system.

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7. The sensor is a sealed unit which contains an electrolyte. Should the sensor develop leakage, it should be immediately removed from the sensing head and properly discarded in accordance with local, state and federal laws. To obtain a replacement sensor, contact MSA at the address given in Chapter 5, "Obtaining Replacement Parts." Caution must be exercised so that the electrolyte does not contact skin eyes, clothing or circuitry. Get immediate medical attention if electrolyte contacts skin or eyes.

8. Perform periodic leak check on the sample line and all flow system components and fittings of the Toxgard II monitor.

9. 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 Toxgard II unit, beyond the scope of these maintenance instructions, or by anyone other than an authorized MSA serviceman, could cause the product to fail to perform as designed, and persons who rely on this product for their safety could sustain severe personal injury or death.

10. Properly vent the exhaust of the Toxgard II monitor to a safe area. Improper venting of the exhaust can cause personal injury or death.

11. Do not install additional filters into the sample inlet fittings. Adding the filters will impair instrument performance.

12. Ensure the gas sample and Toxgard II unit are at the same temperature; otherwise, condensation will form, possibly clogging or filling the sample line.

13. Do not mix units with different area classifications. All units used in a classified area must have the proper area classification. Otherwise, an explosion hazard exists, resulting in possible explosion, injury or death.

FAILUR E TO CO MP LY WITH T HE ABOVE WARNI N GS CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH.

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Table of Contents

Chapter 1

Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Unpacking Your Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

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

Figure 1-1. Toxgard II Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Identifying Your Uni t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Figure 1-2. Remote Sensor Model . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Figure 1-3. Shipping Carton Label Identifying Se nsor Type . . . . . . . . 1-3

Mounting Your Gas M oni t or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

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

Figure 1-4. Options and Accessories (Battery Back- up not shown) . . 1-4

" CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Gas Sampling Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

The Toxgard II Pump or Aspirator Model: . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Table 1-1. Performance Specifications

for Toxgard II Pump or Aspirator Model . . . . . . . . . . . . . . . . . 1-6

" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Installation of DC Pump or Aspirator Sampling . . . . . . . . . . . . . . . . . . . . . 1-6

Sample Line Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Exhaust Line Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Blocked Flow Detection of Sample Line . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Mounting the Air-lin e Toxgard II Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

" CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Flow Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Mounting the Toxgar d I I Remot e S en sor Mod ule . . . . . . . . . . . . . . . . . . . 1-9

Electrical Connections for Toxgard II Monitors . . . . . . . . . . . . . . . . . . . . 1-10

" WAR NING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 0

" CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Figure 1-5. Remote Sensor Mounting Method . . . . . . . . . . . . . . . . . 1-10

" CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

TOC-1

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Table of Contents

Figure 1-6. Toxgard II Cable Entries . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Rela ys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Rela y Spe cifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Tab le 1-2. Relay S p ecifica ti o ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Alarm Rel a y s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Alarm Feature s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Fau lt Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Horn Relay/Audible Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Audible Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Rela y Wiri n g w ith Inductive L oads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Milliamp Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Figure 1-7. Standard 4-20 mA Terminal W iring . . . . . . . . . . . . . . . . 1-14

Isolated 4-20 mA Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

For Signal Loads Less T han 50 Oh ms : . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

For Signal Loads G rea ter Tha n or Equal to 50 Ohms: . . . . . . . . . . . . . . 1-15

Under Line -pow ered Cond itio n s : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Under Battery-po were d C ondit i ons: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Digital Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

" WAR NING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Visual Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Horn/Alarm Ackno w le dge But t on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Remote Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Electrical Connect ions for the Remote S ensor Module . . . . . . . . . . . . . 1-16

" WAR NING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

For Combustible M odel s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Table 1-3. Wire Gauge Vs. Distance Between Units . . . . . . . . . . . . . 1-17

Table 1-4. Remote C ombustible Sensor Wiring Ca ble . . . . . . . . . . . . 1-18

" WAR NING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Figure 1-8. Combustible Remote Sensor . . . . . . . . . . . . . . . . . . . . . 1-18

Figure 1-9. Oxygen Remote Sensor Cable . . . . . . . . . . . . . . . . . . . 1-19

Figure 1-10. Oxygen and Toxic Remote Sensor . . . . . . . . . . . . . . . . 1-19

" WAR NING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

TOC-2

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Table of Contents

Oxygen Remote Sensor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

" WAR NING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 0

" WAR NING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1

Toxic Gas Remote Sensor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Figure 1- 1 1 . Toxic Gas Remote Se n so r Cab l e . . . . . . . . . . . . . . . . . . 1-21

" WAR NING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 2

Pump Wiri n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

Dip S witch Sett ings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -2 2

Tab le 1-5. SW2 S witch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -2 3

Figure 1-12. Pump Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

Tab le 1-6. SW3 S witch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -2 4

Controller/Calibrator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

Internal Push-buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

View ing Co n figuration Pa rame ters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -2 5

Table 1-7. Parameters Displayed During MODE Push-button Operation 1-26

Changing Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

Method 1 - Push-but tons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

Method 2 - Ultima Cont roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

Batt e ry Bac k u p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 8

Table 1-8. Expect ed Bat t ery Op era ting Time at 77

" WAR NING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 0

Banshee Horn Audibl e Set t ings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30

Figure 1-13. Banshee Horn Audible Settings . . . . . . . . . . . . . . . . . . . 1-31

" WAR NING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 2

Autocalibration Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

Duct-Mounted Remote Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . 1-32

F . . . . . . . . . . . . 1 - 3 0

Chapter 2

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Initial Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Figure 2-1. Gas Concentration Display . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Figure 2-2. Calibration Flag Display . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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

TOC-3

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Table of Contents

" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Non-combust ible Ch em ical s th at Re duce Sensor Sensiti vity . . . . . . . . . . 2-4

Cali b rato r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Toxgard II Monitor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Figure 2-3. Ultima Figure 2-4. Ultima

Table 2-1. Sensor Res pons e to Inter f era nts . . . . . . . . . . . . . . . . . . . . . 2-5

Toxgard II Monitor Calibration Output Signal . . . . . . . . . . . . . . . . . . . . . . 2-6

Calibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Chapter 3

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

" WAR NING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Table 3-1. Factory-set Span Values . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Calibration Kits 40 and 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Calibration Kits 41 and 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Span Gas Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Toxgard II Gas Monitor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Figure 3-1. Calibrati on Ki t 40 Cont ent s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Figure 3-2. Calibrati on Ki t 41 Cont ent s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Figure 3-3. Calibrati on Ki t 42 Cont ent s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Figure 3-4. Calibrati on Ki t 43 Cont ent s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Cali b ratio n Doc u menta tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

To Zero the Toxgard II Gas Monitor Only . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Procedure Number 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Figure 3-5. Zero Cap Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Figure 3-6. Calibration Tubing Set-up . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Figure 3-7. Zero Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Figure 3-8. Apply Zero Gas Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Figure 3- 9 . Ca libration E n d Display . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Figure 3- 1 0 . Calibrati o n F aul t F l a g . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Procedure Number 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Figure 3- 1 1 . Zero Cap Placem e nt . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

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Table of Contents

Figure 3-12. Zero Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Perform a Complete Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Procedure Number 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Zero i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Spanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Figure 3-13. Apply SPAN Gas Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Figure 3-14. Span Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Figure 3- 1 5 . Calibrati o n E n d Displa y . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 8

Figure 3-16. Span Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Procedure Number 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Zero i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Spanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

OXYGEN Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

25% Oxygen Toxgard II Gas Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

INITIAL Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Toxgard II Airline Monit or, Pum ped Version and Aspirat ed Ver si on

Cali b ratio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Cali b ratio n Proc edur e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 5

Figure 3-17. Typical DC Pump Version Installation . . . . . . . . . . . . . . 3-26

Figure 3-18. Typical Air Aspirator Version Installation . . . . . . . . . . . . 3-26

Zero Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Figure 3- 1 9 . Typical Ai r L ine Mo nitor Ins t a llati o n . . . . . . . . . . . . . . . . 3-2 7

Chapter 4

Specificat ions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Table 4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

"!WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Chapter 5

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

" CAUTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

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Table of Contents

Figure 5-1. Change Sensor Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Figure 5-2. Cap Location for Remote Combustible Gas Explosion-proof

Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Figure 5-3. Cap Location for Toxic Gas or Oxygen Gen era l-purpose

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

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

Figure 5-4. Cap Location for Remote Toxic Gas or Oxy gen

Explosion-proof Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Figure 5-5. Combustible Three-Pin Connector . . . . . . . . . . . . . . . . . . 5-5

Figure 5-6. CAL FAULT Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Table 5-1. Troubles hooti ng G uidelines . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Obtaining Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

" WAR NING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Table 5-2. Replacement Sensor Kits . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Tab le 5-3. S p a re Pa rts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Appendix A

Optional Duct Mount Kit . . . . . . . . . . . . . . . . . . . . . A-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Figure A-1. Ultima Duct Mount Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Figure A-2. Duct Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Table A-1. Dual mo dule D uct M ount Ki t Part s Li st . . . . . . . . . . . . . . . . A-4

Figure A-3. Remote Sensor Spacers . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Figure A-4. Remote Sensor Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

" WAR NING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Figure A-5. Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

" WAR NING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Figure A-6. Remote Sensor Base Plate . . . . . . . . . . . . . . . . . . . . . . . A-6

Figure A-7. Duct Mount and Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Appendix B

Definitions of Terms . . . . . . . . . . . . . . . . . . . . . . . . B-1

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Chapter 1, Set-up

Chapter 1 Set-up

Unpacking Your Unit

Several cartons may arrive with your order; locate the carton(s) marked as the Toxgard II Monitor. Upon receipt, ensure that your package contains:

• Toxgard II Monitor (FIGURE 1-1)

• Toxgard II Monitor Instruction Manual (P/N 711266).

If your unit is a Toxgard II Monitor with Digital Output, there will be an additional manual (P/N 711203)

• Toxgard II Remote Sensor Module, if ordered as a Remote Sensor model (FIGURE 1-2)

1. Remove the Toxgard II unit from its shipping container(s), taking care not to damage sensitive electrical components.

2. Search through the packing material and the containers to avoid discarding valuable parts.

Initial Inspection

1. Turn the coin slot lock 1/4-turn clockwise and open the door or use the key for the key lock, if so equipped.

2. Carefully inspect the components and assemblies inside the case. If damage or shortage is noted, advise the carrier promptly; make the proper claim with the carrier.

General Description

The Toxgard II Monitor is an easy -to-use, low-cost, one-sensor monitor. It is designed to sample t he environment where the monitor is mounted and to alert y ou to potentially dangerous levels of one of the following gases , depending on your particular model:

• Combust ible gas • Hydrog en Cyanide

• Oxygen • Hydrog en Chloride

• Carbon Monoxide • Nitric Oxid e

• Hydrog en Sulfide • Nitrogen Dioxide

• Chlorine • Sulfur Dioxide

• Chlorine Dioxide

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Chapter 1, Set-up

1-2

Figure 1-1.

Toxgard II Monitor

Page 13

Chapter 1, Set-up

Figure 1-2.

Remote Sensor Model

• All models are available as Remote Sensor models (FIGURE 1-2). Combustible gas models require the remote explosion-proof sensor module.

To determine your sensor type and options, check the shipping carton (FIGURE 1-3) and sensor ID label. Checked items are included in the carton.

Identifying Your Unit

To determine your model type and other inst alled options (FIGURES 1-1 and 1-4), check the ID label on the shipping carton (FIGURE 1-3). This label identifies :

• target gas, sensor location and range

• s ampling accessories (if applicable)

• visual and audible alarm options

• output accessories

• m ounting hardware.

Figure 1-3.

Shipping Carton Label Identifying Sensor Type

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Chapter 1, Set-up

Options and Accessories (Battery Back-up not shown)

Figure 1-4.

Mounting Your Gas Monitor

Generally, the unit or the r emote sensing module should be mounted close to the area where a leak is likely to occur or where the gas is expected. The Toxgar d II Monitor or Remote Sensing Module should be installed at a high level (ceiling), breathing level or low level (floor), depending on the density of the gas being monitored. Mount the unit so that the front display is not blocked or hidden from v iew.

WARNING

Do not locate the Toxgard II Monitor in an area which may contain a flammable mixture of gas and air; otherwise, an explosion may occur.

The general-purpose Toxgard II Monitor can be a source of ignition and must not be mounted in an area where a flammable mixture of combustible gas and air may be present; otherwise, an explosion may occur.

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Chapter 1, Set-up

Mount the Toxgard II Monitor or the Remote Sensing Module with its sensor inlet fitting (FIGURE 1-1 or 1-2) pointed downwards; otherw ise, the inlet may become clogged with particulate matter or liquids. Do not paint the Toxgard II Monitor. If painting is done in an area where a sensor is located, exercise CAUTION to ensure paint is not depos ited on the sensor inlet f itti ng. Suc h pain t depos its would interfere with the diffusion process, whereby a sample of the monitore d atmosph ere di ffuses in to the s ensor. Failu re to follow the ab ove can result in serious per sonal injur y or death.

CAUTION

Protect the Toxgard II Monitor from extreme vibration. Do not mount the sensing head in direct sunlight as this may cause the sensor to overheat.

Ventilation patterns must be established bef ore positioning the Toxgard II unit or sensor assembly. Smoke tubes (P/N 458481) are useful in measuring the direction and r ate of air flow to determine areas where the gas of int erest may tend to accumulate.

Using suitable hardware (not supplied), m ount the Toxgard II monitor to any flat surface v ia its four mounting lugs (see FIGURE 1-6). Allow sufficient room t o open the unit front door.

The Toxgard II unit is designed to meet NEMA 4X requirements, suitable for many damp, wet and/or outdoor locations.

Gas Sampling Options

Although the Toxgard II unit norm ally operates in the diffusion mode (i.e., gases or vapors to be detected enter the sensor input by natural molecular diffusion), a sam ple can be drawn into the instrument if the DC pump or air aspirator option was purchased.

The Toxgard II P ump or Aspirator Model:

• dr aws a gas sample from the monitored area, through a sample line (available separately) to the Toxgard II Gas Monitor sensor

• samples areas that are remote, inaccessible, too hot or too cold for direct sensor monitoring, such as:

• ducts carrying combustible or toxic gas

• wet wells

• printing drying ovens

• blanking or inerting operations

• has electronics physically located in the main monitor enclosure

(FIGURE 1-1)

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Chapter 1, Set-up

• c omes equipped with a special flow cap for use on the Toxgard II Gas Monitor to ensure proper sensor sampling.

• pr ov ides notification via the Toxgard II Monitor LED display and fault relays if a flow fault is detected.

Table 1-1. Performance Specifications

for Toxgard II Pump or Aspirator Model

SAMPLE TRANSPORT TIME

NOMINAL SAMPLE FLOW RATE

MINIM UM SAMPLE FLOW RATE

MAXIMU M SAMPLE TUBING LENGTH

MAXIMUM EXHAUST TUBING LENGTH

INLET FITTINGS EXHAUST FITTING

Only Remote Sensors with proper area ratings can be used in a hazardous ar ea. The Toxgard II Monitor cannot be installed in a hazardous area. Otherwise, an explosion hazard will exist resulting is a possible explosion, injury or death.

30 seconds at 0.5 lpm with 50 feet (15.25 meters) of .180 (4.57 mm) ID sample t ubing

2 CFH (1 LPM)

1 CFH (.500 LPM) 100 feet (30 meters); 3/16 " ID (4.76 mm)

25 feet (7.5 meters) maximum for Chlorine, Nitrogen Dioxide and Chlorine Dioxide

20 feet (6 meters)

1/4" (6.35 mm) OD Tube Fitting 1/4" (6.35 mm) OD Tube Fitting

WARNING

Installation of DC Pump or Aspirator Sampling

Sample Line Placement

• Remove all protective packaging plugs and/or caps from gas INLET, CALIBRATION and EXHAUST PORTS.

• In-line filter must be used in the sample line.

• M SA tubing is available (P/N 600771).

The pump or aspirator draws a gas sam ple to the Toxgard II Gas Monitor sensor (FIGURE 1-1):

• Can be extended up to 100 feet (30 Meters) away from the Toxgard II Gas Monitor.

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Chapter 1, Set-up

• Us es 1/4-inch (6.35 mm) OD tubing. The tubing must be compatible with the sampled gas. Sample tubing must also be 3/16" ID for 100-foot lines to prevent "Lo Flo."

• It takes a maximum of 30 seconds for the sample gas to reach the Toxgard II Gas Monitor when 50 feet (15.25 meters) of tubing is used:

• To decrease this time, shorten the sample line length.

• It is generally good practice to make the sample line as

short as possible.

• Depending on the gas characteristics, the end of the sampling tubing and the sample inlet should be mounted to best optimize sampling of that particular gas. Consult your architect, facility manager or safety engineer for guidance in proper placement of the sampling tube inlet.

• Testing for ventilation patterns is useful in establishing sample inlet location. Smoke tubes (P/N 458481) are useful in measuring the direction and rate of air flow to determine which areas to monitor.

• A particulate filter (purchased separately) should be used at the inlet end of the sample line to help prevent dirt and dust from clogging the sample line. This filter must be compatible with the gas being sampled.

• It is recommended that a stainless steel or Teflon* sample line be used for monitoring gases that are highly reactive such as:

• Nitrogen Dioxide

• Sulfur Dioxide.

• Use only a Teflon sample line for the following gases:

• Chlorine

• Chlorine Dioxide

• Hydrogen Chloride

• Ammonia.

• Wit h the above gases, do not use an end-of-line filter. The

sample line should be inspected periodically and replaced if dirty. Do not attempt to clean the sample line by applying compressed air.

NOTE: Do not run the sample tubing in water or across

areas of vibration, doorways, man ways or access ways; otherwise, a sample tubing leak or tripping hazard may result.

4. Using suitable hardware (not supplied):

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Chapter 1, Set-up

• Fasten the sample tubing to supports.

• Do not tightly pinch the tubing; otherwise, flow may

be restricted.

• Fasten the end of the sample tubing and sample inlet in the monitoring area.

• The sample inlet should be pointed downward to prevent dirt and water from entering the sample tubing line.

5. Install the end-of-line filter at the end of the sampling tubing.

6. Check for leaks along the entire length of the sample tubing line. Any leak will dilute the gas sample from the area of interest and give a lower than actual gas reading.

Exhaust Line Placement

1. For DC pump only: Attach 1/4-inch (6.35 mm) OD sample tubing

to the exhaust outlet fitting.

For Aspirated systems only:

Attach 3/8-inch (9.52 mm) OD sample tubing to the exhaust outlet fitting.

2. Route the exhaust tubi ng into a safe are a where the gas sample can be vent ed. Avoid an y sharp bends or elbows. Route the tubing to all ow any col lected water to drain.

• The maximum exhaust tubing length is 20 feet (6 meters). NOTE: Do not run the exhaust tubing in water or across

areas of vibration or across doorways, man ways or access ways; otherwise, a leak in the exhaust tubing or a tripping hazard may result.

3. Fasten the exhaust tubing to supports using suitable hardware (not supplied).

4. Fasten the end of the exhaust tubing in the area of interest by using suitable hardware (not supplied).

• Exhaust inlet should be pointed downward to prevent dirt

and water from entering the exhaust tubing line.

NOTE: Exhaust to a safe or non-hazardous area only.

5. Check for leaks along entire length of the exhaust tubing line.

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Chapter 1, Set-up

Blocked Flow Detection of Sample Line

Units equipped with the pump or air aspir ator options are supplied with a flow detector. This f low detector activates the fault relay when insufficient flow exis ts for proper gas detection.

Mounting the Air-line Toxgard II Monitor

WARNING

These units must not be located in areas which may contain a flammable mixture of gas and air; otherwise, an explosi on m ay occur.

CAUTION

Protect the Toxgard II Monitor from extreme vibration. Do not mount the sensing head in direct sunlight as this may cause the sensor to overheat.

1. Using suitable hardware (not supplied) mount the Toxgard II monitor to any flat surface; allow room to open the door.

2. Connect the source of compressed air being monitored to the pressure regulator (fittings not included). Install the regulator as close as possible to the sample take-off.

• The maximum regulator inlet pressure is 300 PSI.

• The regulator outlet pressure should be set to a nominal

10 PSI.

NOTE: An in-line filter trap (P/N 626967 or equivalent) is

recommended to prevent clogging of the flow system due to air line contamination, such as oil, dirt or moisture.

CAUTION

Do not exceed 300 pounds maximum inlet pressure; otherwise, damage to the unit may occur.

3. Ensure the pressure regulator is fully counter-clockwise to reduce the initial pressure to the unit.

Flow Block

The Toxgard II Monitor equipped with the flow block option can be used to allow a sample to be deliver ed from a pressurized stream to the Toxgard II unit. Inlet pressure to the flow block should not exceed 10 PSI.

Mounting the Toxgard II Rem ote Sensor Module

The Remote Sensor Module:

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Chapter 1, Set-up

• is mounted where the gas is expected to exist

• is mounted with the sensor pointing downward via the 3/4" NPT threads located on the end of the module, opposite the sensor

• can also be mounted with the mounting strap (P/N

655700); see FIGURE 1-5

• wiring is routed to the Toxgard II Monitor.

Permanently connect 3/8" OD tubing to the center post of the sensor inlet. Route this tubing to the Toxgard II Monitor, ensuring there are no kinks, leaks or other obstructions. Secure this tubing near the monitor; it is used to deliver check gas to the s ensor module during calibration.

Remote Sensor Mounting Method

Figure 1-5.

Electrical Connections for Toxgard II Monitors

• Rec ommended wire is three-conductor, 16 gauge (12 gauge maximum).

• Install an external switch or circuit breaker close to the unit for disconnection purposes.

• Install an over-current protection device (e.g., fuse) in the supply wiring to the unit; two-amp, slow acting fuses are recommended.

WARNING

Before wiring the Toxgard II Monitor, disconnect power source suppl ying the monit or; otherwi se, electri cal shock coul d occur.

CAUTION

Make all wiring connections and conduit runs according to accepted commercial wiring practices. Install the Toxgard II unit in compliance with the applicable requirements of the National Electrical Code and/or any other local code requirements.

NOTE: For Toxgard II with Digital Output Monitors, see

manual (P/N 711203) for wiring instructions.

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Chapter 1, Set-up

Figure 1-6.

Toxgard II Cable Entries

• Route power, ground, and (where applicable) signal wiring through the electrical entry holes in the case (FIGURE 1-6).

• S epar ate the power wiring from any signal wiring.

• The Toxgard II unit operates on an AC power source of 120 or

220 VAC (no selection switch is necessary).

CAUTION

If unsure of the power supply voltage available, contact your plant engineer or safety officer. Damage may occur to the instrument if the wrong power supply voltage is applied to the instrument.

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Chapter 1, Set-up

Outputs

Relays

Relay Specifications

Table 1-2. Relay Specifications

3 ALARMS

RELAYS

RELAY RATINGS

FAULT (NORMALLY-ENERGIZED)

HORN RELAY At 125 or 250 VOLTS AC,

NON-INDUCTIVE AT 30 VOLTS DC,

NON-INDUCTIVE AT 1/10 HP

Alarm Relays

There are three alarm relays, a fault relay and a horn relay in the Toxgard II Gas Monitor.

NOTE: Alarms are automatically disabled at the following

times to avoid "nuisance" alarms:

• during first minute of power-up, while cell stabilizes

• during calibration and for two minutes

following calibration.

SPDT (S ingle pole, do uble throw) SPDT (S ingle pole, do uble throw) SPST (Single pole, single throw), N/O

5.0 Amps

Alarm Features

There are alarm levels in the Toxgard II unit, and a relay for each level. There are many user-select able alarm features enabled or disabled by selecting or de-selecting them.

• Relays are standard electromechanical devices chosen for long life and high reliability.

• Relay contacts are brought out to the terminal block and used to control external lights, horns, and other equipment (FIGURE 1-6).

• Alarms generally default to 10, 20 and 30% of the full-scale reading and are set when the gas reading is above these values.

• The Oxygen Model is a special case where:

• Caution is set to 19.5%, negative acting

• Warning is set to 18% oxygen, negative acting

• A lar m is set to 22% oxygen, positive acting.

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Chapter 1, Set-up

• These default setpoints are factory-set. The user can change these setpoints; see Chapter 1, "Changing Parameter Settings."

• A r e available as N/O (normally-open) or N/C (normally-closed) contacts.

• For Normally-Open contacts:

• Upon activation, the relay contacts close to provide an

electrical path. These contacts remain closed as long as:

• The alarm condition exists within the Monitor or

• The latching mode is selected and the RESET

button has not been pushed.

• For Normally-Closed contacts :

• Upon activation, the relay contacts open to interrupt the

electrical path. These contacts remain open as long as:

• The alarm condition exists within the Toxgard II Gas Monitor or

• The latching mode is selected and the RESET button has not been pushed.

• S ee Chapter 1, "Dip Switch Settings" to determine the dip switch settings for the other alarm options.

Fault Relay

• During normal operation, the Fault relay is energized.

• When a fault is detected or power is cut or turned OFF, the

relay changes state. The form C contact can be wired as either normally-open (NO) or normally-closed (NC) for your needs.

• See the Chapter 5, TABLE 5-1, Troubleshooting Guidelines for causes of faults.

Horn Relay/Audible Outputs

Audible Outputs

• The Toxgard II Monitor comes equipped with one of the following audible alarms:

• Piezo Horn (standard) - 75 db at five feet

• Federal Horn - 95 db at five feet (not adjustable)

• Adjustable-Tone Banshee Horn - 95 db at five feet

(See Chapter 1, "Banshee Horn Audible Settings").

• The Audible Alarm sounds when the Toxgard II Monitor enters a Fault or Alarm State, if that option is enabled (see TABLE 1-5)

• These options are factory- set at time of purchase.

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Chapter 1, Set-up

Horn Relay

• This Single-pole, single-throw (SPST), normally-open (N/O) relay works in parallel with the instrument horn.

• These contac ts are open when the instrument horn is OFF or not selected for operation [see FIGURE 1-6 for terminal block (TB9) location].

• The contacts:

• close when the instrument horn activates

• remain closed until the horn is de-activated due to:

• elimination of the hazardous condition

• pres sing the HORN ACKNOWLEDGE button.

Relay Wiring with Inductive Loads

If you are connecting the relay s to motors, fluorescent lighting or other inductive loads, it is nec essary to suppress any spar ks that may occur at the relay cont act. These sparks will deteriorate or destroy the relay contacts, rendering the relay inoperative or useless. One way to reduce this destructive sparking is to install a Quencharc protector (MSA P/N 630413) across the contacts.

Milliamp Output

The Toxgard II Monitor may be connected to any device capable of accepting 4 to 20 mA analog si gnals such as the:

• M SA Model 5000 Monitor

• M SA Quad Gas unit

• P r ogrammable controllers

• DCS ’s , etc.

The standard unit is supplied with a non-isolated, 4-20 mA signal. An isolated 4-20 mA output option is als o available.

Figure 1-7.

Standard 4-20 mA Terminal Wiring

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Chapter 1, Set-up

NOTE: The return path for this signal is connected to the

Toxgard II Monitor "analog common" circuitry, and therefore, is not "isolated." The Toxgard II Monitor can be ordered from MSA with an optional current isolator module which fully isolates the instrument from supplementary instrumentation.

Isolated 4-20 mA Output

• The Toxgard II current output [the (+) or upper terminal of TB1] connects to the isolator input (+) terminal

• The Toxgard II signal return [the (-) or lower terminal of TB1] connects to the isolator input (-) terminal.

For Signal Loads Less Than 50 Ohms:

• The user load connects to the isolator output (S) and (-) terminals.

For Signal Loads Greater Than or Equal to 50 Ohms:

• The user load connects to the isolator output (+) and (-) terminals.

Under Line-powered Conditions:

• The Toxgard II isolated current output can drive a maximum load of 310 ohms (including wire).

Under Battery-powered Conditions:

• The Toxgard II isolated current output is limited to a maximum load of 100 ohms.

Digital Output

The Toxgard II Monitor can be used as part of a Ultima Plus high-speed digital network in order to report all internal parameters to a central location. All that is additionally required if this option is selected, is a net work communications board and a twisted-pair connection to the networ k. See Ultima Plus instructions for complete information conc erning this option.

WARNING

Since t he Toxg ard I I M onit or i s ty pi call y us ed a s a saf ety ins tru ment , it is rec ommen ded that the sta ndar d and op tiona l output s be use d in the pr oper manner ; otherwise, t he user may not be not ified of a condition that may not be considered normal.

Make w iring co nnect ions and c ondui t runs ac cordi ng to ac cepted commercial wiring practices. Install the Toxgard II unit in compliance

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Chapter 1, Set-up

with the applicable requirements of the National Electrical Code and/or any other local code requirements.

Visual Outputs

The unit comes equipped with the following vis ual alarms:

• front-panel LEDs for Fault, Caution and Warning (standard):

• Latched Alarms cause the front-panel LED to flash

• Unlatched Alarms cause the front-panel LED to turn ON.

Also, up to two top-mounted strobes can be added (optional):

• am ber (follows Warning settings)

• red (follows Alarm settings)

Wiring for these options is fact ory-performed at time of purchase.

Horn/Alarm Acknowledge Button

• A reset push-button is mounted on the enclosure exterior.

• A n internally-mounted terminal strip allows the user to wire an

external reset button.

• The reset button silences the audio horn and resets any latched relays or alarms with alarm setpoints no longer exceeded.

• The reset button silences the horn but not the beacon(s) when the alarms are latched and the gas concentration is still above the alarm setpoint.

If installing a RESET push-button:

1. Route a two-conductor cable to terminal block TB13.

• Route this cable with DC power to avoid noise interference from relay wiring.

2. Connect the two-conductor cable to the two positions of the N/O momentary switch.

3. Identify the cable to enable proper connection at the button.

4. Route the cable to the push-button location; wire the button.

Remote Sensors

Electrical Connections for the Remote Sensor Module

Before wiring the Toxgard II Remote Sensor Module, disconnect the power source feeding the Remote Sensor Module and the Toxgard

1-16

WARNING

Page 27

Chapter 1, Set-up

II Monitor/Less Sensor; otherwise, electrical shock could occur. Before removing the cover of an explosion-proof Toxgard II Remote Sensor Module, verify that the surrounding area does not contain a flammable mixture of combustible gas and air, since a source of ignition is exposed; otherwise, an explosion may occur if a metal ob ject contact s the circuit ry and produc es sparks.

Toxgard II Remote Sensor Modules (excluding t he combustible models) are supplied with 50 feet of cable. This cable has a connector on one end which plugs into its mate within the Toxgard II Monitor/Less Sensor. T he other end of the cable can be cut to the exact length needed.

The combustible Remote Sensor Module is wired with a three-conductor cable. This cable c an be acquired locally. Terminal strips within the Remote Sensor M odule and the Toxgard II Monitor/Less Sensor per mit easy wiring of this cable.

CAUTION

When installi ng a Toxgard II Rem ote Sensor M odule with its mati ng Toxgar d I I Mon i to r /L e s s Sensor, fo ll o w Na t ional Electrical and local proced ural Code s; fail ure t o do so ca n re sult i n a n uns afe cond iti on .

Maximum distance between the Toxgard II Remote Sensor and the Monitor is 50 feet. Do not splice additional cable to the supplied cable or run more than 50 feet of user-supplied cable.

For Combustible Models

Locate/acquire the proper length of three-conductor cable. TABLE 1-3 shows recommended wire gauge for the dis tance between the Remote Sensor and the Toxgard II Monitor/Less Sensor.

Table 1-3. Wire Gauge Vs. Distance Between Units

DISTANCE WIRE GAUGE

UP TO 15 FEET 16 AWG UP TO 25 FEET 14 AWG UP TO 50 FEET 12 AWG

TABLE 1-4 lists several suppliers of 12-AWG cable. If there is a possibility of electrical interf erence from external sources (such as large motors, welders, electrical heaters, etc.) use shielded cable.

The preferred colors of conductor s within the cable are black ( K), green (G) and white (W). If splices are necessary, solder and insulate each conductor; then, wrap ent ire splice with suitable electrical tape or covering. Do not use wire nuts or fasteners.

1-17

Page 28

Chapter 1, Set-up

Table 1-4. Remote Combustible Sensor Wiring Cable

THE FOLLOWING CABLES ARE THREE-CONDUCTOR, 12-AWG SHIELDED, .625" OD

CABLE SUPPLIERS CATALOG NUMBER

CAROL CABLE CO. ALPHA WIRE CORP. BELDEN WIRE & CABLE CO .

02725

1937/3

19206

Appropriate wiring conduit must be us ed between the Toxgard II Monitor and the Toxgard II Remote Sensor. The cable must be routed through conduit.

Wiring the Toxgard II Monitor/Less Sensor Using the Internal Terminal Block

1. Open the unit.

2. Locate TB2 in the upper-right portion of the main (lower) pc board.

3. Install wires onto positions 1, 2 and 3, noting the color used on each position.

At the Toxgard II Remote Sensor Location (FIGURES 1-8, 1-9 and 1-10)

1. Unscrew and open the Toxgard II Remote Sensor cover.

WARNING

Before removing the cover of an explosion-proof Toxgard II Remote Sensor, verify that the surrounding area does not contain a flammable mixture of combustible gas and air since a source of ignition is exposed; otherwise, an explosion may occur if a metal object contacts the circuitry and produces sparks.

1-18

Figure 1-8.

Combustible Remote Sensor

Page 29

Figure 1-9.

Oxygen Remote Sensor Cable

Chapter 1, Set-up

Figure 1-10.

Oxygen and Toxic Remote Sensor

2. Route the cable from the Toxgard II Monitor through the conduit opening and wire it to the terminal block in the bottom of the sensor.

NOTE: Separate the power and ground wiring from any

signal wiring.

3. Verify the identity of each conductor of the cable and connect the wire to the terminal block so that position 1 in the sensor is wired to position 1 on the Toxgard II Monitor TB2. Similarly, sensor positions 2 and 3 connect to Toxgard II positions 2 and 3.

If shielded wire is used:

• Cut the shield wire short.

• Do not connect the shield at the remote sensor.

1-19

Page 30

Chapter 1, Set-up

4. Screw the conduit into the conduit opening and relieve any excess slack in the cable.

5. Re-install the cover of the Toxgard II Remote Sensor.

WARNING

Do not allow the cover to remain off of an explosion-proof Toxgard II Sens or. si nce a sourc e of ig nitio n is expose d, an explo sion may occur if a metal object contacts the circuitry and produces sparks in an atm osphere of co mbustible ga s.

Oxygen Remo te Sensor Wiring

Fifty feet of four-conductor c able is supplied with the unit. This cable has a connector on one end which plugs into its mate within the Toxgard II Monitor/Less Sensor; the other end of t he cable can be cut to the exact length needed. Do not run more than 50 feet of cable or splic e on any additional cable.

At the Toxgard II Monitor/Less Sensor Location

The cable connects to J5 at t he upper right portion of the (lower) main pc board.

At the Toxgard II Remote Oxygen Sensor Location

1. Unscrew and open the Toxgard II Remote Sensor cover.

WARNING

2. Route Toxgard II Monitor cable through the conduit opening and wire it to the terminal block in sensor bottom.

3. Verify the identity of each conductor cable and connect the wire to the terminal block (FIGURE 1-9).

Note that there are four wires needed out of the six within the cable. Use the markings on the conductors at the end of the original cable or see FIGURE 1-9 for the colors of the wires that are needed.

CONDUCTOR ID

WHITE WITH BLUE WHITE WITH G REEN GREEN WITH WHIT E BLUE WITH WHITE

TERMINAL BLOCK

LOCATION

3 5 6 8

1-20

Page 31

Chapter 1, Set-up

• The other wire within the cable is not used.

• It is unnecessary to connect wire to the other terminal

positions within the remote sensor.

• Do not connect the shield at the remote sensor.

4. Screw the conduit or cable grip or gland into the conduit opening. Relieve any excess slack in the cable.

5. Re-install the cover on the Toxgard II Remote Sensor.

WARNING

Do not let the cover remain off of an explosion-proof Toxgard II Sensor. Since a source of ignition is exposed, an explosion may occur if a metal object contacts the circuitry and produces sparks in an atm osphere of co mbustible ga s.

Toxic Gas Remote Sensor Wiri ng

(FIGURE 1-11) Fifty feet of six-conductor cable is supplied with the unit.

• This cable has a connector on one end which plugs into its mate within the Toxgard II Monitor/Less Sensor.

• The other end of the cable can be cut to the exact length needed.

• Do not run more than 50 feet of cable or splice on additional cable.

At the Toxgard II Monitor/Less Sensor Location

The cable connects to J5 at t he upper right portion of the (lower) main pc board.

Figure 1-11.

Toxic Gas Remote Sensor Cable

1-21

Page 32

Chapter 1, Set-up

At the Toxgard II Remote Toxic Sensor Location

1. Open the Toxgard II Remote Sensor cover by unscrewing it.

WARNING

2. Route the cable from the Toxgard II Monitor through the conduit opening and wire it to the terminal block in the bottom of the sensor.

3. Verify the identity of each conductor cable and connect the wire to the terminal block (FIGURE 1-10).

CONDUCTOR ID

ORANGE WITH WHITE WHITE WITH BLUE WHITE WITH ORANGE WHITE WITH GREEN

GREEN WITH WHITE BLUE WITH WHITE

TERMINAL BLOCK

LOCATION

1 3 4 5

7 8

• There are no connections to positions 2 and 6 of the

terminal block within the remote sensor.

• Do not connect the shield at the remote sensor.

4. Screw the conduit or cable grip or gland into the conduit opening; relieve any excess slack in the cable.

5. Re-install the Toxgard II Remote Sensor cover.

WARNING

Do not allow the cover to remain off of an explosion-proof Toxgard II Sensor. Since a source of ignition is exposed, an explosion may occur if a metal object contacts the circuitry and produces sparks in an atm osphere of co mbustible ga s.

Pump Wiring

(FIGURE 1-12)

Dip Switch Settings

Many of the Toxgard II features can be set with the SW2 and SW3 Dip Switches located on the main monitor printed circuit

1-22

Page 33

Chapter 1, Set-up

board (FIGURE 1-1). TABLES 1-5 and 1-6 show the positions for user-selectable settings (FIGURE 1-5) :

Table 1-5. SW2 Switch Settings

NOTE: LE FT side of each SW2 Dip Swi tch indicates the ON posit ion and

*NO AUDIBLE ALARM WILL SOUND IF SWITCHES 3, 4 AND 5 ARE ALL OFF.

RIGHT side of each SW2 Dip Switch indicates the OFF position.

NUMBER FUNCTION

1 2

3* 4*

5* 6 7 8

SPARE FAULT ACTIVATES HO RN CAUTION ACTIVATES HORN WARNING ACTIVATES HORN ALARM ACTIVATES HORN CAUTION POSITIVE/NEGATIVE AC TION (OFF = POSITIVE) WARNING POSITIVE/NEGA TIVE ACTION (OFF = POSITIVE) ALARM POSITIVE/NEGATIVE ACT ION (OFF = POSITIVE)

Figure 1-12.

Pump Wiring

1-23

Page 34

Chapter 1, Set-up

Table 1-6. SW3 Switch Settings

NOTE: LEFT side of each SW3 Dip S witch indic ates the ON p osition an d

NOTE: The delay time selected v ia switches 6 - 8

RIGHT side of each SW3 Dip Switch indicates the OFF position.

NUMBER FUNCTION

1 2 3 4 5 6 7 8

will apply to any delay sw itch(es) 3 - 5 in th e ON position.

*OFF DELAY TIM E

SPARE (LEAVE IN OFF POSITI ON) SPARE OFF DELAY ON/O FF - CAUTION OFF DELAY ON/OFF - WARNING OFF DELAY ON/OFF - AL ARM

*OFF DELAY TIME - BIT2 *OFF DELAY TIME - BIT1 *OFF DELAY TIME - BIT0

BIT2 BIT1 BIT0

OFF OFF OFF 5 OFF OFF ON 15 OFF ON OFF 30 OFF ON ON 60

ON OFF OFF 90 ON OFF ON 120 ON ON OFF 150 ON ON ON 180

TIME

(IN SECONDS)

Controller/Calibrator Operation

The Toxgard II Monitor is fully compatible wit h the Ultima Controller and the Ultima Calibrator. T hese devices can be used to set various parameters in the Toxgard II Monitor, including alarm conditions, auto calibration conf iguration, etc.

The devices can also be used for calibrating the Toxgard II Monitor. When using these devices, point them at the front panel of the Toxgard II Monitor, aiming dir ectly at the triangular IR symbol (located next to the word "WARNING" at the center of

1-24

Page 35

Chapter 1, Set-up

the front panel). For full Calibrat or and Controller operational details, refer to instruction manual (P/N 813379).

Internal Push-buttons

A pair of internal push-buttons on the Toxgard II main pc board, lower-right corner (FIGURE 1-1) can be us ed in place of the Ultima Controller and Calibrator for most functions.

The right-hand button marked "CAL" is used to initiate all instrument calibration functions, eliminating t he need to use the Controller or Calibrator to perf orm calibration.

The left-hand button marked "MODE" allows t he user to scroll and view the Toxgard II conf iguration parameters. This operation is comparable with the Controller "s end display item" feature.

Viewing Configuration Parameters

At initial installation, use the Toxgard II MODE push-button (FIGURE 1-1) to review the Toxgar d II configuration parameters.

To scroll, press and release t he MODE push-button. The Toxgard II Monitor:

• temporarily stops displaying gas measurement readings

• displays a value and other relevant information for a parameter

(TABLE 1-7).

NOTE: Pressing and releasing the MODE push-button

within 10 seconds enables the user to scroll to the next parameter. If the user does not press the push-button within 10 seconds, the Toxgard II Monitor ends the parameter viewing mode and returns to a display of the actual gas measurement.

The Toxgard II Monitor is able to detect and notify the user of a hazardous condition even while scrolling the parameters. Although the LED continues scrolling, the hazardous condition is noted by the horn, relays and strobes (if equipped). When the scroll list ends, the LED display will show the alarm condition and gas measurement value.

1-25

Page 36

Chapter 1, Set-up

Table 1-7. Parameters Displayed During MODE Push-button

Operation

TEXT MESSA GE DESCRIPTIO N

MIN VALUE Minimum gas concentration of the previous time interval MAX VALUE Maximum gas concentration of the previous time interval AVG VALUE Average gas concentration of the previous time interval ZERO VALUE SPAN VALUE LEVEL #1 (CAUTION) LEVEL #2

(WARNING) LEVEL #3 (ALARM) CURRENT TIME Current time, in a 24-hour format

FUTURE CAL TIME

AVG INTERVAL

CURRENT DATE Display toggles between current day of month and year

FUTURE CAL DATE

PREVIOUS CAL DATE

MUX ADDR ESS Instrum ent addres s when used on a Ultima Pl us Network CALIBRATION

INTERVAL CAL SIGNAL STATUS ON/OFF status of the 3.75-mA signal during calibration TEMPERATURE T oxic sensor temperature VALUE VALUE VALUE

Gas concentration expected to be applied at the next calibration

Setpoint, enabled/disabled, latched/unlatched information

Time th at an Autoca l calibratio n will be perfo rmed (applic able only for o peration with an Autocal unit )

Time in terval (in ho urs) used to det ermine min imum, average and maximum gas concentration values

Date tha t the next Autoc al calibration will be perform ed. Display toggles between day of month and year (applic able only for o peration with an Autocal unit )

Date of the previous calibration

Days be tween Autocal c alibrations ( for Autocal opera tion only)

MSA diagnostic; please ignore

1-26

Page 37

Chapter 1, Set-up

Changing Parameter Settings

Method 1 - Push-buttons

The following parameters can be set by using the MODE and CAL push-buttons (located on t he Toxgard II Monitor main printed circuit board):

ALARM 1 ALARM 2 ALARM 3 SPAN GAS CALIBRATION

SIGNAL AVERAGE TERM

VALUE

ON/OFF LATCH/UNLATCH VALUE ON/OFF LATCH/UNLATCH VALUE ON/OFF LATCH/UNLATCH VALUE

VALUE

ON/OFF

VALUE

General

To enter the Par ameter Setting Mode:

1. Press and hold the MODE button.

2. While holding the MODE button, press the CAL button; then, release both buttons.

Once in the Parameter Setting Mode:

1. Use the MODE button to change the displayed value.

2. Use the CAL button to accept and save the displayed setting.

Once a single parameter is set:

• the display advances to the next parameter.

When changing an alarm value or span value:

• each press of the MODE button increases the value

• the step value of that increment is determined by the

full-scale range

• if an entry error is made:

1. Press the CAL button repeatedly until "END" displays.

2. Restart parameter setting mode and enter correct data.

1-27

Page 38

Chapter 1, Set-up

NOTE: During the Parameter Setting Mode, normal unit

operation is suspended until this mode is exited. No network communications, peripheral communications, or alarm updates occur in this mode. The current signal output will be equivalent to a CAL signal of 3.75 mA.

When "END" displays, the Parameter Setting Mode is complete and normal operation resumes.

• If no key is pressed during the Parameter Setting Mode:

• the unit returns to normal operation in one minute

• any values that were accepted by using the CAL button

are saved.

When the unit returns to normal operation:

Use the MODE button to display and verify the settings.

Alarm Setting:

• if the alarm is set to OFF (disabled):

• latching status and value are not shown

• once the upper limit is reached, the value rolls over to the

minimum value

• for toxic and oxygen units:

• the upper limit is the full-scale reading

• for combustible units:

• the upper limit is 60% LEL.

Method 2 - Ultima Controller

Parameters, alarm levels and their latched/ unlatched modes of operation are set and changed using an Ultima Controller (P/N 809086). Refer to the Ultima Cont roller Instruction Manual (P/N 813379) for full instr uctions.

Battery Backup

The Toxgard II Monitor can be configured wit h an (internal) rechargeable backup battery that perm its full instrument operation if main power is interrupted or t he Toxgard II Monitor is used as a transportable instrument for temporary gas monitoring of an area; the carrying handle and side- mount sensor are convenient options if the Toxgard II Monitor is used as a transportable gas monitor.

1-28

Page 39

Chapter 1, Set-up

This battery is:

• a 12-volt , sealed lead acid type with a nominal power rating of 2.2 amp-hours

• c ontinuously charged by the Toxgard II Monitor during normal operation.

Transfer to the backup batt ery is automatic when main power loss occurs. While operating on the backup battery, "BATT" lights on the Toxgard II display. When m ain power is restored, the "BATT" turns OFF, and the batt ery will start to recharge.

The amount of time that the bac kup battery can operate the Toxgard II Monitor depends on the:

• type of sensor

• ins talled options

• pr es ence of alarm conditions

• am bient conditions.

TABLE 1-7 can be used as an approx imation of expected battery operating time. In this table:

• " Minimum Time" represents a Toxgard II Monitor configured with:

• str obes flashing

• alarm conditions asserted

• Federal horn operational

• internal pump

• " Maxim um Time" represents a Toxgard II Monitor

configured with:

• no strobes

• no alarms

• no horn

• no pump.

• A c tual battery lifetime falls somewhere between the indicated

Minimum Time and Maximum Time values.

1-29

Page 40

Chapter 1, Set-up

Table 1-8. Expected Battery Operating Time at 77o F

SENSOR TYPE MINIMUM TIME MAXIM UM TIME

Combustible 1 hour 10 hours

Toxic o r oxygen 0.5 hours 24 hou rs

NOTE: As ambient temperature drops, the expected battery

operating time period decreases. At -4

F (-20oC),

the times shown in TABLE 1-8 are reduced to 60%.

During battery operation, the Toxgard II unit monitors backup battery voltage. When voltage is r educed to a level where continued operation yields unreliable instrument oper ation and possible battery damage the instrument LED dis plays Err6 for 3 seconds and then turns itself OFF until main operating power is restored.

WARNING

The "Faul t" relay mus t be connec ted to an alar ming device to alert the user the instr ument is no longer operational when th e above condi tion occurs.

NOTE: The Toxgard II battery pack requires up to 24-30

hours of uninterrupted main power to fully charge.

NOTE: Normally, the unit automatically transfers power to the

optional backup battery when the main power is lost. However, if the user wants to start the unit from an unpowered state using the battery, press SW6 on the main printed circuit board (FIGURE 1-12).

Banshee Horn Audible Settings

The Banshee Horn can produce several distinctly different sounds. These sounds and the volume of these sounds can be adjusted as follows:

1. Disconnect the main operating power from the Toxgard II Monitor.

2. If the Toxgard II Monitor is equipped with an internal back-up battery, carefully disconnect the WHITE wire from the battery (+) terminal.

NOTE: Record the position of the RED and BLACK

1-30

wires connecting the horn to TB12 on the Toxgard II Monitor main pc board. When this

Page 41

Chapter 1, Set-up

Figure 1-13.

Banshee Horn Audible Settings

procedure is complete, return these wires to their original positions.

3. Remove the four screws from the face of the horn.

4. Carefully separate the body halves of the horn.

5. To change the sound of the Banshee Horn, move the push-on jumper to the position to provide the desired sound (FIGURE 1-13).

NOTE: The internal horn label shows which sound

corresponds with each position.

6. To change the volume of the Banshee Horn, use a small, flat screwdriver to adjust the volume control shown on FIGURE 1-13.

NOTE: The loudest volume is obtained in the fully

clockwise position.

7. When settings are complete, verify that the internal rubber gasket lines up with the screw holes.

8. Carefully mate the two halves of the horn and place the excess slack of the RED and BLACK wires inside the T.

9. Replace the four screws and tighten to ensure a weatherproof seal.

10. Move the RED and BLACK wires connecting the horn and the Toxgard II Monitor main pc board into their original positions.

1-31

Page 42

Chapter 1, Set-up

11. Reconnect the main operating power, and reconnect the WHITE wire to the Toxgard II Monitor internal backup battery (if so equipped).

WARNING

Verify the proper o peration, sou nd and loud ness of the Ba nshee Horn; otherwise, the horn cannot properly alert the user.

Autocalibration Option

The Toxgard II Monitor is available with an autocalibration option This user-selectable option allows periodic, unmanned gas calibration of the system.

• This option is not available for units with sampling options, nor is it available for monitoring of the following target gases:

• chlorine

• chlorine dioxide

• hydrogen chloride

• nitrogen dioxide.

For installation details, refer to t he autocalibration Instruction Manual (P/N 815379).

Duct-Mounted Remote Sensor Installation

Refer to Appendix A for this opt ion.

1-32

Page 43

Chapter 2, Start-up

Chapter 2 Start-up

Initial Start-up

The Toxgard II Monitor is fact ory-calibrated and ready for immediate use. Its range and output are preset. Once power is applied to the unit, the display shows a test of all display words and segments. The software version number displays; then, a 25-second warm-up countdown for sensor st ability begins:

• a blank screen appears between each second of countdown time.

• There is no signal output during this warm-up time.

The Monitor shows the software v ersion number again; then, it begins to display the gas concentrat ion in the corresponding unit of measurement (FIGURE 2-1):

• ppm (for toxic gases)

• % Gas (for oxygen only)

• % LEL (for combustible gases).

Figure 2-1.

Gas Concentration Display

2-1

Page 44

Chapter 2, Start-u p

After initial start-up, the Toxgard II Monitor also displays a calibration flag as a reminder to perf orm a field calibration (FIGURE 2-2). While this message is display ed, the Toxgard II Monitor is functioning within factory- set calibration parameters. Once the first successful fi eld calibration is performed, the calibration flag turns OFF.

CAUTION

To ensure a fully functional sensor, perform a calibration check and adjustments at initial start-up.

During normal operation, the Toxgard II Monitor displays the gas concentration of the surrounding environment. The corresponding output signal can be transmitted t o a controller. For a complete listing of display and output conditi ons other than normal operation, see TABLE 5-1.

NOTE: The combustible gas model of the Toxgard II Monitor is

capable of detecting concentrations of certain combustible gases above 100% LEL. When exposed to these concentrations, the Toxgard II Monitor will display one of two modes:

• LOC % LEL - The Toxgard II Monitor has be en exposed to a high con cen trat ion of ga s (abov e th e LEL) and there is a possibility that the over-r ange condition may s till ex ist.

2-2

• 100 % LEL - The Toxgard II Monitor has been exposed to a high concentration of gas (above the LEL) and the over-range con dition definitely still exists.

Figure 2-2.

Calibration Flag Display

Page 45

Chapter 2, Start-up

CAUTION

In either mode, co rrect th e condit ion ca using th e exces sive g as leve l and vent or purge the area before attempting the following.

In the LOC % LEL mode, the output signal is also locked at full-scale. If this condition occurs, the Toxgard II Monitor must be unlocked by performing a "Zero Function," either with the Ultima Calibrator or Controller or by using the internal "CAL" push-button.

NOTE: The Ultima Calibrator and Controller are compatible

with both the Ultima Gas Monitor and the Toxgard II monitor.

In the LOC mode, The Toxgard II Monitor will not revert to a normal condition until a successful zero operation has been performed. This is an exclusive safety feature of the Toxgard II Monitor which pre-empts the possibility of ambiguous readings when the sensor is exposed to concentration of gas above 100% LEL.

In the 100% LEL mode, the combustible gas is over the 100% LEL range. It will return to normal operation when the gas concentration level falls below 100% LEL.

Calibration

As with any type of gas monit or, the only true check of its performance is to apply gas directly t o the sensor. The frequency of the calibration gas test s depends on the operating time and chemical exposures of the sensors. New sensors should be calibrated more often until the calibrat ion records prove sensor stability. The calibration frequency c an then be reduced to the schedule set by the safety off icer or plant manager. Before calibrating the sensors, it is good practice to apply power to the unit to allow the sensor to adapt to the new environment. This is especially important for the following unit s:

• chlorine

• nitric oxide

• hydrogen cyanide

• hydrogen chloride

• chlorine dioxide.

2-3

Page 46

Chapter 2, Start-u p

Sensors should be powered at least one half hour before any calibration attempt is made.

Combustible sensors located in areas wher e non-combustible chemicals may leak, particularly ones known to reduce the sensitivity (see following list) should be calibrated after such exposures.

Non-combustible Chemicals that Reduce Sensor Sensitivity

• Silanes, Silicates, Silicones and Halides (compounds containing Fluorine, Chlorine, Iodine or Bromine)

• TABLE 2-1 lists interferants for electrochemical sensors.

When it is determined that calibrat ion adjustments are required, the Toxgard II Monitor provides a one-man, non-intrusive method of adjustment at the unit.

Figure 2-3.

Ultima

Calibrator

To calibra te the unit, the internal push-buttons or one of the following accessories can be used:

• Calibr ator P/N 809997 (FIGURE 2-3)

• Controller P/N 809086 (FIGURE 2-4)

Calibrator

The Calibrator allows the following functions:

• Zero

• Calibr ation (zero and span)

• Display address for digital

output mod els .

Toxgard II Monitor Controller

The Controller also provides the above functions and access to t he additional following features:

2-4

Figure 2-4.

Ultima

Controller

Page 47

INTER-

FERANT

Acetone Acetylene Ammonia

Benzene

Carbon Dioxide

Carbon

Disulfide

Carbon

Monoxide

Chlorine

Dimethyl

Sulfide

Ethanol

Ethylene

Ethyl Ether

Freon 12

Freon 113 Freon 12Bl Freon 13Bl

Hexane Hydrogen Hydrogen

Chloride

Hydrogen

Cyanide

Hydrogen

Sulfide

Isopropanol

Mercaptan

(Ethyl)

Mercaptan

(Methyl)

Methane

Methanol

Methyl Amine

Methyl

Bromide

Methyl Ethyl

Ketone

Nitric Oxide

Nitrogen

Dioxide

Sulfur Dioxid e

Tichloroethylene

Chapter 2, Start-up

Table 2-1. Sensor Response to Interferants

CONCENTRATION

(PPM)

1000 0 0 0 0 0

12000

100 0 0

5000 0 0 0 2.5 0 0

10010070.21003-30

100 115 0 0 0 0

400 3 1000 -2 0 1000 1 0 1000 0 0 1000 0 0

500000000

500 28 0.5 15 0 -15 0

100 0 0

50000 0 0 0 1 0 0

100 0

500 0

200 0

100 10 2.2 2 -3 3 2 0 100 1

150 1 4.7 NA 400 0 0 35 7.5 0 1000 0

CO H2SSO2HCN NO

No Data

No Data No Data

No Data

000

20000000

15 2 0

No Data

0.1

No Data

CL2HCL NO CLO

No Data No Data No Data No Data No Data No Data No Data No Data

No Data No Data No Data No Data

0 0

500-6-0.245-102.5

520.43-0.200

No Data No Data No Data No Data

50 99 0.1 0 -0.3 0 0

No Data No Data No Data

No Data No Data No Data No Data No Data No Data No Data No Data No Data No Data No Data No Data No Data No Data No Data No Data

No Data No Data

200

2.4

No Data No Data No Data No Data

No Data No Data No Data No Data No Data

No Data

No Data No Data

No Data No Data No Data No Data

100 4

0 0

No Data

10 5 0 3 10 0 0 2.5 0 0 10 0 10 0 50 -8 -0.5 4.5 4 -0.25

504000000

572.7

574.5

No Data No Data

No Data

6.5

No Data No Data No Data No Data No Data

50 130 0 0 0.1 0 0

No Data No Data No Data No Data

No Data

No Data No Data No Data No Data

0 0

10 -2 -8.4 -10 -20 10 12 -1 2 6

No Data

No Data No Data No Data No Data No Data No Data

2-5

Page 48

Chapter 2, Start-u p

• Automatic calibration at timed intervals when used with MSA autocalibration module.

NOTE: If the autocalibration module was pur c hased for use

with the Toxgard II Monitor, consult the MSA Ultima Controller Instruction Manual (P/N 813379) for set-up and operation.

• Three levels of alarm

• Date of last successful calib ratio n

• M aximum and minimum gas readings over selected time periods

• Average gas readings over selected time periods

• Changing of span gas value from factory-set value

• Access to real-time clock for a time and date stamp

See Calibrator and Controller instruction m anual (P/N 813379) for proper calibration procedures.

Toxgard II Monitor Calibration Output Si gna l

The Toxgard II Monitor is shipped with the calibration output signal disabled so the output signal will t rack the gas concentration value during the calibration process. In some applications, it may be desirable to dis able or lock the output during calibration to a pre-determined output value to prevent activation of alarm devices. The calibration signal can be enabled using the Controller. When the calibrati on signal is enabled, the output signal is 3.75 milliamps during calibr ation.

NOTE: The Controller is compatible with both the Ultima Gas

Monitor and the Toxgard II Monitor.

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Chapter 3, Calibration

Chapter 3 Calibration

The Toxgard II Gas Monitor provides non-intrusive calibration through the use of the Calibrator or Controller. The unit can also be calibrated using the internally-mounted "CA L" push-button.

NOTE: The Calibrator and Controller are compatible with both

the Ultima Gas Monitor and the Toxgard II monitor.

When calibrating any Toxgard II Gas Monitor, refer to the Calibration Kit instructions.

When first placing the Toxgard I I Gas Monitor into operation it is good practice to perform a calibr ation. When replacing the sensor, it is necessary to do an initial calibration which allows the unit to store the initial sensor parameters for proper end-of-life indication. Refer to Chapter 3, "Initial Calibration."

Read the appropriate calibration instr uctions before attempting an actual calibration. Also, identify and become familiar with all of the calibration components. During the c alibration, it is necessary to quickly apply the span gas t o the unit. Prior connection of the calibration components will aid in the ease of unit calibration.

Equipmen t R equ ir ed

Three calibration kits (numbered 40, 41, and 54) are available from MSA for diffusion calibr ation of Toxgard II Gas Monitors. Kit 40 is also used to calibrat e the Toxgard II Air Line Monitor. Calibration Kits 42 and 43 are used to calibrate Toxgard II monitors with pumped samples. All Calibration Kits are housed in a convenient carrying case and contain all items necessary (less gas) for a complete and accurat e calibration.

The check or calibration gases can als o be carried in the case. See TABLE 3-1 for the appropr iate zero and span gas cylinders for your Toxgard II Gas Monitor .

WARNING

These calibration kits contain zero caps in place of zero calibration gas. Th ese cap s can o nly be used wh en the am bient a ir doe s not contai n the gas the mo nit or is de tecti ng. If there i s any doub t, use zero gas when zeroing the Toxgard II Monitor; otherwise, improper calibr ation could o ccur.

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Chapter 3, Calibrati on

Table 3-1. Factory-set Span Values

GAS TYPE RANGE

CARBON MONOXIDE

SULFUR DIOXIDE

HYDROGEN SULFIDE

NITRIC OXIDE NITROGEN DIOXIDE CHLORINE

HYDROGEN CYANIDE

HYDROGEN CHLORIDE

CHLORINE DIOXIDE

(4)

OXYGEN

NATURAL GAS PETROLEUM

VAPORS

(3)

SPAN GAS

PRESET VALUES

0-100 PPM 60 PPM 0-500 PP M 30 0 PPM

0-25 PPM 10 PPM

0-10 PPM 5 PPM

0-50 PPM 40 PPM 0-100 PPM 40 PPM 0-100 PPM 50 PPM

0-10 PPM 5 PPM

0-5 PPM 2 PPM

0-50 PPM 10 PPM

0-100 PPM 40 PPM

0-3 PPM 1 PPM

0-25% 20.8%

0-100% LEL 25% LEL(1 )

0-100% LEL 40% LEL(1 )

MSA RP

CYLINDER P/N

CALIBRATION

710882 40 10027938 40

10028070 40

710414 40

10028062

10028074 40

710332 41

710331 41

10028072 41

10028078 54

710331 41

10028028

(2) 40

10028034 40

KIT

40 40

(GASOLINE) GENERAL

SOLVENTS

(3)

0-100% LEL 55% LEL(1 )

NOTES: 1 Cali brated with Propane (.6% ga s by volume) 2 Not requ ired for standard cal ibration procedure 3 For co mbustible gas, it is goo d practice to calibrate unit with the gas

to be detected 4CLO 5 Change span gas valu e with Controller to us e low range calibration

is calibrated with CL2

cylinder.

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Chapter 3, Calibration

Calibration Kits 40 and 42

Calibration Kit 40 will calibrate all dif fusion Toxgard II Gas Monitors and Calibration Kit 42 will calibrat e all sample draw Toxgard II Gas Monitors for the following gases (FIGURE 3-1):

• Carbon Monoxide

• Oxygen

• Hydrogen Sulfide

• S ulfur Dioxide

• Nitric Oxide

• All Combustible gases.

Calibration Kits 41 and 43

Calibration Kit 41 will calibrate all dif fusion Toxgard II Gas Monitors and Calibration Kit 43 will calibrat e all sample draw Toxgard II Gas Monitors for the following gases (FIGURE 3-2):

• Chlorine

• Nitrogen Dioxide

• Chlorine Dioxide

• Hydrogen Cyanide.

NOTE: The calibration procedure for the sample draw Toxgard

II Monitor is the same as the procedure for the diffusion version, except calibration gas is applied to the calibration entry port of the inlet flow block.

Calibration Kit 54

Calibration Kit 54 will calibrate diffus ion Hydrogen Chloride Toxgard II Monitors (FIGURE 3-5).

Span Gas Values

The Toxgard II Monitor is fact ory-shipped with a preset span gas value that can be changed via the Cont roller (P/N 809086); otherwise, the span gas must correspond to preset concentrations. See TABLE 3-1 for factory-set span values.

CAUTION

To ensure a fully functional sensor, perform calibration checks and adjustments at initial start-up and at regular intervals.

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Chapter 3, Calibrati on

Item 1 - Tubing (P/N 711112)

- 3/16" I D side connects to Item 3;

- 1/4" ID side connects to sensor

Item 2 - Z ero Cap (P/N 710535)

Figure 3-1. Calibration Kit 40 Contents

(Your Kit may also include one or two gas cylinders)

Item 1 - Tubing (P/N 711112)

- 3/16" side co nnects to Ite m 2;

- 1/4" side connects to sensor

Item 2 - .25 LPM Flow Controller (P/N 478359)

Item 3 - 1 .5 LPM Flow Controller (P/ N 478358)

Item 3 - Calibration Ca p (P/N 7104 11)

(Your Kit may also include one or two gas cylinders)

3-4

Item 4 - Ze ro Cap (P/N 813774)

Figure 3-2. Calibration Kit 41 Contents

Page 53

Chapter 3, Calibration

Item 1 - Tubing (P/N 711113)

- 1/8" ID side connects to Ultima or Tox gard II Sensor

Item 2 - F low Controll er, Match Flo w (P/N 69734 4)

3/16" ID side connects to Item 2

Figure 3-3. Calibration Kit 42 Contents

(Your Kit may also include one or two gas cylinders)

Item 1 - Tubing (P/N 711113)

- 3/16" ID side connects to Item 2

- 1/8" ID side connects to Ultima or Toxgard II se nsor

Item 2 - Fl ow Controlle r, Match Flo w (P/N 697344 )

Figure 3-4. Calibration Kit 43 Contents

(Your Kit may also include one or two gas cylinders)

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Chapter 3, Calibrati on

Item 1 - Tubing (P/N 711112)

- 3/16" I D side connects to Item 3;

- 1/4" ID side connects to sensor

Item 2 - Zero Cap

(P/N 710535)

Item 4 - Desiccant

(P/N 10 064306)

Item 3 - 1.5 LPM

Flow Controller

(P/N 4783 58)

Item 5 - C alibration Cover Assem bly

(P/N 10066581)

Figure 3-5. Calibration Kit 54 Contents

(Your Kit may also include one or two gas cylinders)

NOTE: Item 5 (P/N 10066581) is used only for SAFEMTX Calibration

Toxgard II Gas Monitor Calibration

The only true check of any gas m onitor’s performance is to apply gas directly to the sensor. The calibration procedure must be performed regularly.

Calibration Documentation

The Toxgard II Monitor records t he date of the last successful calibration. This date can then be displayed on the front-panel LED (with the use of the Controller ) or transmitted to a

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Chapter 3, Calibration

Control Data Center if the Ultima Plus Digital Network option was purchased.

More frequent calibration may be required when the unit is new. Calibration frequency depends on operating time and chemical exposures of the instrument. Also perform calibration when installing or changing the power source of the control instrumentation. In some cases, it may be necessary to perform only a zero function of the Gas Monitor in lieu of a full zer o and span procedure. Check with your saf ety officer or safety engineer to determine if only a zero function is necessary.

NOTES:

• If the sensor element has been changed or r eplac ed, see Chapter 3, "Initial Calibration."

• If this is an oxygen sensor, see Chapter 3, "Oxygen Calibration."

• B efore calibrat ing Chlorine, Nitrogen Dioxide, Hydrogen

Chloride, Chlorine Dioxide, or Hydrogen Cyanide, apply power to the unit at least 1/2-hour before calibrating.

• Due to the unstable nature of Chlorine Dioxide (ClO

), Chlorine

gas is used as a calibration simulant. If using the MSA calibration system and gas cylinder (P/N 710331), the response ratio is 2:1 (the 2-ppm sample of Chlorine should be set to read 1 ppm of ClO ClO

Toxgard II Gas Monitor is 1 ppm.

). The default value for the calibration gas on the

To Zero the Toxgard II Gas Monitor Only

NOTE: Combustible sensor configurations are only available

with a remote sensor; side-mount and bottommount sensors are not available in a combustible sensor configuration.

Identify your Toxgard II Gas Monitor and select the proper one of the following two zeroing calibration proc edures.

• Use Procedure Number 1 to zero your unit for the foll owing gases:

• Carbon Monoxide

• Oxygen

• Hydrogen Sulfide

• Sulfur Dioxide

• Hydrogen Chloride

• Nitric Oxide

• All Combustible gases.

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Chapter 3, Calibrati on

• Use Procedure Number 2 to zero your unit for the following gases:

• Chlorine

• Nitrogen Dioxide

• Chlorine Dioxide

• Hydrogen Cyanide

Procedure Number 1

• This procedure uses items found in Calibration Kit 40, 42, and

54.

• For oxygen units, skip to Step 3.

1. If Using the zero cap (FIGURE 3-6): If the ambient air is suitable, with no traces of the gas of

interest, place the zero cap (P/N 710535), from the Calibration Kit, over the SensorGard inlet and wait two minutes; otherwise, use zero gas.

2. If Using zero gas cylinder:

a. Locate the zero gas cylinder and the 1.5 LPM Flow

Controller (P/N 478358).

3-8

Figure 3-6.

Zero Cap Placement

Page 57

Chapter 3, Calibration

b. Screw the Flow

Controller onto the top of the zero gas cylinder.

c. Locate the Tube

Assembly (P/N 711112).

d. Push the smaller

end of the Tube Assembly over the Flow Controller gas outlet.

• Ensure tubing completely

Calibration Tubing Set-up

Figure 3-7.

covers the gas outlet (FIGURE 3-7).

e. Connect the other end of the tubing

over the SensorGard inlet (FIGURE 3-8).

f. Turn on the gas flow by turning the knob on the

flow controller.

• Not ice the open arrow on the flow controller knob.

Figure 3-8.

Zero Gas Connection

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Chapter 3, Calibrati on

3. Point the Calibrator or Controller at the Toxgard II Gas Monitor display (FIGURE 1-2); press the ZERO button or push the right-hand internal CAL push-button (FIGURE 1-1) until the word "ZERO" appears; then, release.

NOTE: The zero or calibration process can be aborted at

any time during the 30-second countdown interval; simply press any button on the Calibrator or Controller while aiming it at the unit or by pushing the internal push-button.

The 30-second countdown interval is omitted for oxygen units. It is electronically zeroed.

The display shows:

• A countdown from 30 to 0 seconds

• APPLY ZERO GAS (FIGURE 3-9)

4. After the 30 second countdown:

• The display alternates between "CAL" and a value (for

example: 0 PPM). This value is the actual reading of the gas concentration the sensor is detecting.

• Once the gas value on the display is stable for 15

seconds, the alternating display stops. If the calibration is successful, the display will show END and 0 (FIGURE 3-10).

a. If using the zero cap: remove it. b. If using a zero ga s c y linder:

1) Turn OFF the gas flow by turning the flow controller knob.

2) Remove the tubing from the SensorGard.

• If the calibration signal is enabled during

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Figure 3-9.

Apply Zero Gas Flag

Page 59

Chapter 3, Calibration

Figure 3-10.

Calibration End Display

calibration, it will be held at the lockout value for an additional two minutes.

c. If a CAL FAULT flag appears on the unit (FIGURE 3-11),

this indicates:

• An unsuccessful attempt to zero or calibrate the

Toxgard II Gas Monitor

• The Toxgard II Gas Monitor is operating with the

calibration parameters defined before the calibration was attempted.

To extinguish the CAL FAULT flag, a complete calibration procedure must be performed.

• See Troubleshooting Guidelines found in Chapter 5.

The Toxgard II Gas Monitor allows automatic zero adjustment only within a pre-defined range. It cannot make any corrections outside this range, such as when an empty or wrong cylinder of gas is applied or failure to begin gas flow within the allotted 30-second countdown occurs.

Figure 3-11.

Calibration Fault Flag

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Chapter 3, Calibrati on

5. If Using Zer o Ga s : After a successful zeroing, remove the tubing from the Flow Controller and remove the Flow Controller from the cylinder; return all items to their appropriate location in the Calibration Kit.

If Using Zer o C a p:

Remove cap and return it to the Calibration Kit.

Procedure Number 2

This procedure uses the items found in Calibr ation Kit 41 and 43.

1. If Using the Zero Cap (FIGURE 3-12): If the ambient air is suitable, with no traces of the gas of interest, place the zero cap (P/N 813774) over the sensor inlet and wait two minutes; otherwise, use zero gas.

2. If Using Zero Gas Cylinder:

a. Locate the zero gas cylinder and the .25 LPM Flow

Controller (P/N 478359).

b. Screw the Flow Controller onto the top of the zero

gas cylinder.

c. Locate the Tube Assembly (P/N 711112).

3-12

Figure 3-12.

Zero Cap Placement

Page 61

Chapter 3, Calibration

Figure 3-13.

Zero Gas Connection

d. Push the smaller end of the Tube Assembly over the Flow

Controller gas outlet.

• Ens ure tubing completely covers the gas outlet (see FIGURE 3-6).

e. Connect the other end of the tubing over the SensorGard

inlet (FIGURE 3-13).

f. Turn ON the gas flow by turning the knob on the

flow controller.

• Not ice the open arrow on the flow controller knob.

3. Point the Calibrator or Controller at the Toxgard II Gas Monitor display (FIGURE 1-2) and press the ZERO button or push the right-hand internal push-button (FIGURE 1-1) until the word "ZERO" appears; then, release.. The display shows:

• A countdown from 30 to 0 seconds

• APPLY ZERO GAS (FIGURE 3-9)

NOTE: The zero or calibration process can be aborted at

any time during the 30-second countdown interval; simply press any button on the Calibrator while aiming it at the unit or by pushing the internal push-button.

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Chapter 3, Calibrati on

4. After the 30 second countdown:

• The display alternates between "CAL" and a value (example: 0 PPM). This value is the actual reading of the gas concentration the sensor is detecting.

• Once the gas value on the display is stable for 15 seconds, the alternating display stops. If the calibration is successful, the display will show END and 0 (FIGURE 3-10)

a. If Using the Zero Cap: remove it. b. If Using a Zero Gas Cylinder:

1) Turn OFF the gas flow by turning the flow controller knob.

2) Remove the tubing from the Sensor inlet.

• If the calibration signal is enabled during calibration, it will be held at the lockout value for an additional two minutes.

c. If a CAL FAULT flag appears on the unit (FIGURE 3-11),

this indicates:

• An unsuccessful attempt to zero or calibrate the Toxgard II Gas Monitor

• The Toxgard II Gas Monitor is operating with the calibration parameters defined before the calibration was attempted.

To extinguish the CAL FAULT flag, a complete calibration procedure must be performed.

5. If Using Zer o Ga s : After a successful zeroing, remove the tubing from the

Flow Controller and remove the Flow Controller from the cylinder; return all items to their appropriate location in the Calibration Kit.

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Chapter 3, Calibration

Perform a Complete Calibration

• If this is the first calibration after the sensor element is replaced, refer to "Initial Calibration."

• If this is an oxygen sensor, refer to "Oxygen Calibration."

• Fo r CL

one regulator (P/N 478359) for each of these gases. They will not work properly if one regulator is used for multiple gases.

Identify your particular Toxgard I I Gas Monitor and select the proper one of the following two c alibration procedures.

• Use Procedure Number 1 to calibrate the Toxgard II Gas Monitor for the following gases:

• Use Procedure Number 2 to calibrate the Toxgard II Gas Monitor for the following gases:

and CLO2 calibration, do not mix regulators. Use only

• Carbon Monoxide

• Oxygen

• Hydrogen Sulfide

• Sulfur Dioxide

• Hydrogen Chloride

• Nitric Oxide

• All Combustible gases.

• Chlorine

• Nitrogen Dioxide

• Chlorine Dioxide

• Hydrogen Cyanide.

Procedure Number 1

This procedure uses the items found in Calibr ation Kit 40, 42, and 54.

• For oxygen units, skip to Step 3.

• For Calibration Kit 54 diffusion Hydrogen Chloride, run HCL gas

through flow control regulator and tubing for five minutes before starting a calibration. Dedicate this flow control regulator and tubing for use with HCL gas only.

Zeroing

1. If Using the Zero Cap: If the ambient air is suitable, with no traces of the gas of

interest, place the zero cap (P/N 710535), from the

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Chapter 3, Calibrati on

Calibration Kit, over the SensorGard inlet and wait two minutes; otherwise, use zero gas (FIGURE 3-6).

2. If Using Zero Gas Cylinder: a. Locate the zero gas cylinder and the 1.5 LPM Flow

Controller (P/N 478358).

b. Screw the Flow Controller onto the top of the zero

gas cylinder. c. Locate the Tube Assembly (P/N 711112). d. Push the smaller end of the Tube Assembly over the Flow

Controller gas outlet.

• Ens ure tubing completely covers the gas outlet (FIGURE 3-7).

e. Connect the other end of the tubing over the SensorGard

inlet (FIGURE 3-8).

f. Turn on the gas flow by turning the knob on the

flow controller.

• Not ice the open arrow on the flow controller knob.

3. Point the Calibrator or Controller at the Toxgard II Gas Monitor display (FIGURE 1-2); press the CALIBRATE button or press and hold the right-hand internal push-button for about five seconds until the word SPAN appears on the display. Release the button when SPAN is showing.

NOTE: The zero or calibration process can be aborted at

any time during the 30-second countdown interval; simply press any button on the Calibrator or Controller while aiming it at the unit or press the internal push-button.

The 30-second countdown interval is omitted for oxygen units. It is electronically zeroed.

The display shows:

• A countdown from 30 to 0 seconds

• APPLY ZERO GAS (FIGURE 3-9)

4. After the 30 second countdown:

• The display alternates between "CAL" and a value

(example: 0 PPM). This value is the actual reading of the gas concentration the sensor is detecting.

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Chapter 3, Calibration

• Once the gas value on the display is stable for 15 seconds, the alternating display stops. If the calibration is successful, the display will show END and 0 (FIGURE 3-10).

a. If using the zero cap: remove it. b. If using a zero ga s c y linder:

1) Turn OFF the gas flow by turning the flow controller knob.

2) Remove the tubing from the Flow Controller.

• If the calibration signal is enabled during calibration, it will be held at the lockout value for an additional two minutes.

c. If a CAL FAULT flag appears on the unit (FIGURE 3-11),

this indicates:

• An unsuccessful attempt to zero or calibrate the Toxgard II Gas Monitor

• The Toxgard II Gas Monitor is operating with the calibration parameters defined before the calibration was attempted.

To extinguish the CAL FAULT flag, a complete calibration procedure must be performed.

• See Troubleshooting Guidelines found in Chapter 5.

Spanning

• If this is the first calibration after the sensor element is replaced, refer to "Initial Calibration."

• If this is an oxygen sensor, refer to "Oxygen Calibration" later in this chapter.

5. The Toxgard II Gas Monitor automatically begins the span countdown after a successful zeroing of the unit. The span countdown is also 30 seconds (FIGURE 3-14).

• The span process can be aborted at any time during the

countdown by simply pressing any button on the Calibrator while aiming it at the unit or by pressing the internal push-button.

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Chapter 3, Calibrati on

Figure 3-14.

Apply SPAN Gas Flag

6. Turn OFF the zero gas and remove the flow controller, if used previously.

7. Locate the span gas cylinder and the 1.5 LPM Flow Controller (P/N 478358).

8. Screw the Flow Controller onto the top of the span gas cylinder.

9. Locate the Tube Assembly (P/N 711112).

10. Push the smaller end of the Tube Assembly over the gas outlet of the Flow Controller.

• Ensure that the tubing completely covers the gas outlet

(FIGURE 3-7).

11. Connect the other end of the tubing over the SensorGard inlet (FIGURE 3-15).

12. Turn ON the gas flow by turning the flow controller knob.

• Notice the open arrow on the knob of the flow controller.

• If a CAL FAULT indication is on the Toxgard II Gas

Monitor display before the user is able to apply the gas (FIGURE 3-11), a steady state gas condition existed for longer than 15 seconds; this caused the unit to use a wrong reading as a span indication.

• I t is necessary to restart the calibration process to clear this condition.

• Ensure that any calibration gases are applied during the 30-second count down period.

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Chapter 3, Calibration

Figure 3-15.

Span Set-up

• I t is good practice to have all calibration components previously assembled.

13. After the 30 second countdown:

• The display alternates between "CAL" and a value. (for example: 60 PPM for 0 to 100 ppm carbon monoxide). This value is the actual reading of the gas concentration the sensor is detecting.

• Once the gas value on the display is stable for 15 seconds, the alternating display stops. If the calibration is successful, the display will show END for approximately two seconds. (FIGURE 3-16).

• There are no adjustments necessary.

• The display will show the

span gas value while the span gas is flowing to the unit. (For example, it may read 60 PPM or 25 % or 60 %LEL; FIGURE 3-17.)

14. Turn OFF the gas flow by turning the knob on the flow controller.

Figure 3-16.

Calibration End Display

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Chapter 3, Calibrati on

• If the calibration signal is enabled during calibration, it will be held at the lockout value for two additional minutes.

• When the span gas is removed from the sensor, the sensor reading may drift for a few minutes; this is normal sensor operation.

Figure 3-17.

Span Gas Connection

3-20

• If a CAL FAULT flag appears on the unit (FIGURE 3-11), this indicates:

• An unsuccessful attempt to calibrate the Toxgard II Gas Monitor

• The Toxgard II Gas Monitor is operating with the calibration parameters defined before the calibration was attempted.

To extinguish the CAL FAULT flag, a complete calibration procedure must be performed.

The Toxgard II Gas Monitor allows automatic zero and span adjustments only within a pre-defined range. It cannot make any corrections outside this range, such as when an empty or wrong cylinder of gas is applied or failure to begin gas flow within the allotted 30-second countdown occurs.

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Chapter 3, Calibration

15. After a successful calibration, remove the tubing from the Flow Controller and remove the Flow Controller from the cylinder; return all items to their appropriate location in the Calibration Kit.

16. For Calibration Kit 54 diffusion Hydrogen Chloride:

a. After a successful calibration, flush the flow control

regulator and tubing with 100% Nitrogen for five minutes. Use this flow control regulator with Hydrogen Chloride gas only.

b. Store the flow control regulator and tubing in the

desiccated sealed bag included in Calibration Kit 54 or equivalent dry container.

Procedure Number 2

This procedure uses the items found in Calibr ation Kit 41 and 43.

Zeroing

1. If Using the Zero Cap (FIGURE 3-12): If the ambient air is suitable, with no traces of the gas of

interest, place the zero cap (P/N 813774) over the sensor inlet and wait two minutes; otherwise, use zero gas.

2. If Using Zero Gas Cylinder:

a. Locate the zero gas cylinder and the .25 LPM Flow

Controller (P/N 478359).

b. Screw the Flow Controller onto the top of the zero

gas cylinder. c. Locate the Tube Assembly (P/N 711112). d. Push the smaller end of the Tube Assembly over the Flow

Controller gas outlet.

• Ens ure tubing completely covers the gas outlet (FIGURE 3-7).

e. Connect the other end of the tubing over the SensorGard

inlet (FIGURE 3-13).

f. Turn on the gas flow by turning the knob on the

flow controller.

• Not ice the open arrow on the flow controller knob.

3. Point the Calibrator at the Toxgard II Gas Monitor display (FIGURE 1-2) and press the Calibrator or Controller

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Chapter 3, Calibrati on

CALIBRATE button or press and hold the internal push-button for about five seconds until the word SPAN appears on the display. Release the button when SPAN is showing.

NOTE: The zero or calibration process can be aborted at

any time during the 30-second countdown interval; simply press any button on the Calibrator or Controller while aiming it at the unit or pushing the internal push-button.

The display shows:

• A countdown from 30 to 0 seconds

• APPLY ZERO GAS (FIGURE 3-9)

4. After the 30 second countdown:

• The display alternates between "CAL" and a value (example: 0 PPM). This value is the actual reading of the gas concentration the sensor is detecting.

• Once the gas value on the display is stable for 15 seconds, the alternating display stops. If the calibration is successful, the display will show END and 0 (FIGURE 3-10).

a. If Using the Zero Cap: remove it.

3-22

b. If Using a Zero Gas Cylinder:

1) Turn OFF the gas flow by turning the flow controller knob.

2) Remove the tubing from the SensorGard.

• If the calibration signal is enabled during

calibration, it will be held at the lockout value for an additional two minutes.

c. If a CAL FAULT flag appears on the unit (FIGURE 3-11),

this indicates:

• An unsuccessful attempt to zero or calibrate the Toxgard II Gas Monitor

• The Toxgard II Gas Monitor is operating with the calibration parameters defined before the calibration was attempted.

To extinguish the CAL FAULT flag, a complete calibration procedure must be performed.

• See Troubleshooting Guidelines found in Chapter 5.

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Chapter 3, Calibration

Spanning

• If this is the first calibration after the sensor element is replaced, refer to "Initial Calibration."

• If this is an oxygen sensor, refer to "Oxygen Calibration."

5. The Toxgard II Gas Monitor automatically begins the span countdown after a successful zeroing of the unit. The span countdown is also 30 seconds (FIGURE 3-13).

• The span process can be aborted at any time during the

countdown by simply pressing any button on the Calibrator while aiming it at the unit or by pressing the internal push-button.

6. Turn OFF the zero gas and remove the flow controller if used previously.

7. Locate the span gas cylinder and the .25 LPM Flow Controller (P/N 478359).

8. Screw the Flow Controller onto the top of the span gas cylinder.

9. Locate the Tube Assembly (P/N 711112).

10. Push the smaller end of the Tube Assembly over the gas outlet of the Flow Controller.

• Ensure that the tubing completely covers the gas outlet

(FIGURE 3-7).

11. Locate the calibration cap (P/N 710411) and push the tubing through the hole in the bottom of the cap.

12. Connect the other end of the tubing over the Sensor inlet and push the calibration cap over the entire sensor inlet (FIGURE 3-17).

13. Turn ON the gas flow by turning the flow controller knob.

• Notice the open arrow on the knob of the flow controller.

• If a CAL FAULT indication is on the Toxgard II Gas

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Chapter 3, Calibrati on

• I t is necessary to restart the calibration process to clear this condition.

• Ensure that any calibration gases are applied during the 30 second count down period.

• I t is good practice to have all calibration components previously assembled.

14. After the 30 second countdown:

• The display alternates between "CAL" and a value (for example: 60 PPM for 0 to 100 ppm carbon monoxide). This value is the actual reading of the gas concentration the sensor is detecting.

• Once the gas value on the display is stable for 15 seconds, the alternating display stops. If the calibration is successful, the display will show END for approximately two seconds (FIGURE 3-16).

• There are no adjustments necessary.

The display will show the span gas value while the span gas is flowing to the unit. (For example, it may read 60 PPM or 25 % or 60 %LEL; FIGURE 3-17).

15. Turn OFF the gas flow by turning the knob on the flow controller.

• If the calibration signal is enabled during calibration, it will

be held at the lockout value for two additional minutes.

• When the span gas is removed from the sensor, the

sensor reading may drift for a few minutes; this is normal sensor operation.

• If a CAL FAULT flag appears on the unit (FIGURE 3-11),

this indicates:

• An unsuccessful attempt to calibrate the Toxgard II Gas Monitor

• The Toxgard II Gas Monitor is operating with the calibration parameters defined before the calibration was attempted.

To extinguish the CAL FAULT flag, a complete calibration procedure must be performed.

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Chapter 3, Calibration

begin gas flow within the allotted 30-second countdown occurs.

16. After a successful calibration, remove the tubing from the Flow Controller and remove the Flow Controller from the cylinder; return all items to their appropriate location in the Calibration Kit.

OXYGEN Calibration

NOTE: If this is the first calibration after the sensor element is

replaced, perform an "Initial Calibration."

Oxygen calibration is slightly different from other gases. When the ZERO function is performed, the 30-second countdown is omitted because the Toxgard II unit performs the zero electronically. No calibration cap or zero gas is necessary.

To meet the stated specification, it is necessary to span the Oxygen Toxgard II Gas Monitor with t he Calibration Kit and an oxygen cylinder. The concentration of oxygen-in-air varies slightly due to changing relative humidity levels. These variations in oxygen levels are detected by the oxygen Toxgard II Gas Monitor. To meet the reproducibility s pecification, a calibration gas cylinder must be used to ensure the same oxygen concentration for every calibration.

25% Oxygen Toxgard II Gas Monitor

For the SPAN function, ambient air is generally adequate for the 25% oxygen Toxgard II Gas Monitor as the expected default span value is 20.8%. Therefore, when the display prompts "APPLY SPAN GAS" it would be adequate to simply allow the countdown to occur without applying gas.

NOTE: If the sensor is located in an area of normally low or

enriched oxygen, then a 20.8% oxygen sample must be applied when the display prompts: "APPL Y

SPAN GAS".

INITIAL Calibration

When a new sensor element is placed in t he sensor, an INITIAL Calibration must be performed. This procedur e enables the unit to gather data about the sensor t o make accurate decisions for the CHANGE SENSOR function and the CAL FAULT function to work properly.

The INITIAL calibration is accomplished by aiming and pressing the ZERO and CALIBRATE buttons of the calibrator

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Chapter 3, Calibrati on

simulta neously or by pressing and h olding the inte rnal, right-ha nd button f or ab out 10 s eco nds unt il the di spla y show s "ICAL"; release the button when "ICAL" is showing.

• The display should show "SET APPLY ZERO GAS"

• The remainder of the procedure is now the same as that for a

regular calibration.

• The presence of the words "SET" and "ICAL" on the display distinguish INITIAL Calibration from a regular calibration. If these words do not appear, abort the calibration; then, retry the above procedure.

NOTE: The zero or calibration process can be aborted at any

time simply by pressing any button during the 30-second countdown on the Calibrator while aiming at the unit or by pressing the internal push-button.

• The display leads the user through the zero and span routines as in a regular calibration.

NOTE: This procedure must be initiated only when a new

sensor element is installed.

Toxgard II Airline Monitor, Pumped Version and Aspirated Version Calibration (FIGURES 3-18 through 3-20)

Calibrat ion Procedure

1. Install the Regulator/Flow Controller onto the Zero Gas Cylinder.

2. Connect the larger end of the Calibration Tube Assembly (3/16" ID) to the Cylinder Regulator.

3. Insert the smaller end of the tube assembly (1/8" ID) into the calibration fitting and tighten the nut.

4. Initiate the calibration procedure on the Toxgard II Air Line Monitor, Pumped or Aspirated versions.

5. Press and hold the calibration valve button.

6. Open the Regulator/Flow Controller valve on the Gas Cylinder.

7. At the end of this sequence, the Toxgard unit displays END. Close the Regulator/Flow Controller valve and release the calibration valve button.

8. Remove the Zero gas and install the Regulator/Flow Controller onto the Span Gas Cylinder.

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Chapter 3, Calibration

Figure 3-18.

Typical DC Pump Version Installation

Figure 3-19.

Typical Air Aspirator Version Installation

3-27

Page 76

Chapter 3, Calibrati on

Figure 3-20.

Typical Air Line Monitor Installation

9. Press and hold the calibration valve button.

10. Open the Regulator/Flow Controller valve on the Span gas cylinder and allow the gas to flow until the reading stabilizes and the unit displays END.

11. Close the Regulator/Flow Controller valve; then, release the calibration valve button.

12. Return the unit to normal operation.

Zero Procedure

1. Install the Regulator/Flow Controller onto the Zero Gas Cylinder.

2. Connect the larger end of the Calibration Tube Assembly (3/16" ID) to the Cylinder Regulator.

3. Insert the smaller end of the tube assembly (1/8" ID) into the calibration fitting and tighten the nut.

4. Initiate the Zero procedure on the Toxgard II Air Line Monitor, Pumped or Aspirated versions.

5. Press and hold the calibration valve button.

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Chapter 3, Calibration

6. Open the Regulator/Flow Controller valve on the gas cylinder.

7. At the end of this sequence, the Toxgard unit displays END. Close the Regulator/Flow Controller valve and release the calibration valve button.

8. Return the unit to normal operation.

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Page 78

Chapter 4 Specifications

Table 4-1. Specifications

GAS TYPES

TEMPERATURE RANGE

DRIFT

NOISE

ACCURACY

TOXICS & OXYGEN

COMBUSTIBLES DUAL MODULE:

ZERO DRIFT

SPAN DRIFT

CARBON MONOXIDE OXYGEN HYDROGEN SULFIDE

CHLORINE SULFUR DIOXIDE NITRIC OXID E NITROGEN DIOXIDE

HYDROGEN CYANIDE

HYDROGEN CHLORIDE

COMBUSTIBLE GAS, H

COMBUSTIBLE GAS, PETROLEUM VAPORS

COMBUSTIBLE GAS, SOLVENTS

CHLORINE DIOXIDE

Chapter 4, Spec ificati ons

Combustibles, Oxygen & Toxics

OPERATING RANGE:

*EXTENDED RANGE:

Calibr ate within op erating rang e

Less than 1% FS

GAS LINEARITY REPEATABILITY

the greater of full scale (FS)

2% FS

10% FS or 2 ppm

+2% of scale

2% of sca le

10% FS or 2 ppm

0 to 40 (32 to +1 04oF)

-20 to +50 (-4 to +122oF)

-40 to +90 (-40 to +194

Less than 5%/year, typically

Less than 10%/year, typically

1% FS or 2

ppm +

1% FS

1% FS or 2

ppm +

5% FS or 1

ppm +

1% FS or 2

ppm +

1% FS or 2 ppm +

4% FS or 1 ppm +

4% FS or 2 ppm +

10% FS or 2 ppm

1% FS

1% FS +

5% FS or 1 ppm

4-1

Page 79

Chapter 4, Specifi cat ions

Table 4-1. Specifications

*Extended Range = The sensor may not meet all of the accuracy parameters listed.

STEP CHANGE RESPONSE

HUMIDITY ALTITUDE

SENSOR LIFE

HAZARDOUS AREA RATING

WIRING REQUIREMENTS

POWER INPUT

SIGNAL OUTPUT

RELAY OUTPUTS

PHYSICAL

BEACON

TIME TO REACH 20% OF SCALE

- OXYGEN & TOXICS TIME TO REACH

50% OF SCALE

- OXYGEN & TOXICS TIME TO REACH

50% OF SCALE COMBUSTIBLES

TIME TO REACH 90% OF SCALE COMBUSTIBLES

COMBUSTIBLES OXYGEN &TOXICS FULL

REPLACEMENT WARRANTY

mA OUTPUT

OXYGEN & TOXICS COMBUSTIBLES REMOTE SENSOR

4-20 mA

DIGITAL 5 AMP WITH

120-240 VAC; 5 AMPS WITH 30 VDC

SIZE WEIGHT CHARACTERISTICS

INTENSITY

Less than 12 seconds (typically 6 seconds)

Less than 30 seconds (typically 12 seconds)

Less than 10 seconds

Less than 30 seconds 15 to 95% RH, non-condensing

+10,000 feet (3,000 meters) 3 years , Typically 2 years , Typically

1 year Gener al-purpose o nly. Check Are a

Rating of Remote Sensor for allowable applications

OXYGEN & TOXICS

COMBUSTIBLES

120 - 220 VAC Supplie d by Toxgar d II Monitor

COMBUSTIBLES OXYGEN &

TOXICS

See Ul tima Plus spec ifications Three le vels of Alarm

One Fa ult Relay 16 x 23.3 x 5 inches

(40.6 x 59.2 x 12.7 cm) max. 13 pounds (5.9 kilograms) Strobe type 70 to 90 flashes per minute RED: 55 candella eff. AMBER: 230 cand ella eff.

2-wire 2-wire

+15%

current source

4-2

Page 80

Chapter 4, Spec ificati ons

Table 4-1. Specifications

HORNS

HAZARDOUS RATING

APPROVAL PARAMETERS

PIEZO FEDERAL BANSHEE NORMAL

CONFIGURATION

CLASS I, DIVISIO N 2 CONFIGURATION

WARNING

Explosion Hazard: Substitution of components may impair suitab ility for Cl ass I, Divisio n 2.

Explosion Hazard: Do not disconnect equipment unless power has been switched OFF or the area is known to be non-hazardous.

75 db at five feet 95 db at five feet 100 db at three fee t

Gener al-purpose uni t Unit can be configu red to meet

Class I , Division 2 Areas; thi s configuration will not have relays, pu mps, batteries, autoc alibration, o r horns as optio ns (it will have the st andard Piezo a larm buzzer)

Installation Category II Pollution Degree 2

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Chapter 5, Mainten ance

Chapter 5 Maintenance

General

The Toxgard II Monitor may be cleaned with a dry soft cloth and requires minimal periodic maintenance to assure trouble-free operation. However, the response to gas must be checked regularly to assure the instr ument is functioning.

NOTE: The only way to verify an instrument is functioning

properly is to perform a calibration test. This test does not necessarily mean the unit must be adjusted, but that it must be checked with ZERO and SPAN gas, and observed for acceptable readings

The more frequent the calibration t ests, the greater the chanc es for early detection of instrum ent failure resulting from instrument component failure, damage or power loss.

Maintain a written log of instrument readings obtained during calibration. Increase the frequenc y of calibration tests when the sensor nears end-of-service life, or when abnormally high variations with respect to the instrument log are observed.

The only routine maintenance item is the s ensing element itself, which has a limited lifetime. When the Toxgar d II Monitor’s read-out indicates that the sensor must be changed, there is ver y little sensor lifetime remaining. It is good practice to obtain a replacement sensing element before the sens ing element within your unit becomes inoperative.

The Toxgard II Monitor is constantly per forming a self-check. When a problem is found, it displays the appropriate error code. (Table 5-1, "Troubleshooting Guidelines"). When an er ror is detected within the unit, the mA output signal falls to 0 mA.

• The "Change Sensor" indication is not an error and does not affect the output.

Corrective Maintenance

See TABLE 5-1, "Troubleshooting" to ident ify an inoperative assembly in the Toxgard II monitor; then, replace it according to the following procedures.

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Chapter 5, Mainte nanc e

Sensor Replacement

Typically, the Toxgard II Monitor LED display shows a maintenance message when the sensor is due f or replacement (FIGURE 5-1).

1. To replace the sensor, remove power from the Toxgard II Monitor.

WARNING

Before removing the cover of an explosion-proof Toxgard II Monitor, sampl e th e are a ar ound t h e enc l os ure wi th a p or tab le c om bus t ibl e gas indicator (such as the MSA Passport sure the surrounding area does not contain a flammable mixture of combustible gas and air. When the enclosure is open and connected to power, a source of ignition exists which could cause the explosion of combustible gas, resulting in damage, serious personal injury and death.

Handle the sensor carefully; the electrochemical version is a sealed unit which contains a corrosive electrolyte. If electrolyte is leaking from the sens or, exe rci se CA UTION to ens ure t he elec trol yte d oes not co ntact sk in, eyes or clot hing, th us avoid ing bur ns. If co ntact occur s, rinse th e area imme diately w ith a larg e quantit y of water. In case of contact with eyes, immediately flush eyes with plenty of water for at least 15 minutes. Call a physician.

CAUTION

Do not install a lea king sensor in the sensing head assembly. The leaking sensor should be disposed of in accordance with local, state and federal laws. To obtain a replacement sensor, contact MSA at the address given under "Obtaining Replacement Parts."

2. There is no need to open the main or remote enclosure; simply unscrew the cap located on the bottom of the sensor assembly (FIGURES 5-2 through 5-4). For combustible versions, unscrew the gas-tight union (see FIGURE 1-6).

Personal Alarm) to make

5-2

Figure 5-1.

Change Sensor Flag

Page 83

Chapter 5, Mainten ance

Figure 5-2.

Cap Location for Remote Combustible Gas Explosion-proof Sensor

Cap Location for Toxic Gas or Oxygen General-purpose Model

Figure 5-3.

5-3

Page 84

Chapter 5, Mainte nanc e

Figure 5-4.

Cap Location for Remote Toxic Gas or Oxygen Explosion-proof Sensor

3. Identify the sensor element needed and obtain the same type of sensor element.

4. Toxic or Oxygen Sensors: Unplug the sensor by pulling it straight down; properly dispose of sensor.

Combustible Sensors:

• Combustible units have a three-pin connector; pry out the

locking clip and pull apart the connector (FIGURE 5-5).

5. Toxic or Oxygen Sensors: Before installing the sensor, check the pins of the sensor for a shorting clip; remove the shorting clip and the label beneath the clip before installing the sensor. Install the new sensor by aligning the pins; do not force onto pins.

Combustible Sensors:

Connect the three-pin connector on the new sensor (FIGURE 5-5). Carefully reconnect the union, taking care not to pinch the wires.

CAUTION

Do not over-tighten the sensor on the inlet fitting; otherwise, damage to the sensor may result.

8. Re-apply power to the Toxgard II Monitor.

9. Perform the INITIAL Calibr ation Procedure as outlined in the Toxgard II Monitor Calibrator or Toxgard II Monitor Controller instruction manual. This procedure differs slightly from a standard calibration procedure. Use of the INITIAL calibration procedure upon installation of a new sensor ensures the Toxgard II Monitor will perform a successful calibration. Failure to do so may result in a CAL FAULT reading (FIGURE 5-6).

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Page 85

Chapter 5, Mainten ance

Figure 5-5.

Combustible Three-Pin Connector

Figure 5-6.

CAL FAULT Reading

It is recommended that all other m aintenance be performed at an MSA factory-authorized service c enter. See TABLE 5-1 for troubleshooting guidelines.

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Chapter 5, Mainte nanc e

Table 5-1. Troubleshooting Guidelines

SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

Unit will not power up properly.

Display shows

CAL FAULT.

Display shows CAL.

Display flashes Err 1*.

Display flashes Err 2.

Display flashes Err 3.

Display shows

Err 4.

*Hydrogen Cyani de, Hydrogen Chloride and Sulfur Dioxide Sensor s NOTE: This NOTE and the following CAUTION apply to the Toxgard II Series

sensors for Hydrogen Cyanide (HCN), Hydrogen Chloride (HCL) and Sulfur Dioxide (S O detection function to alert the user of a sensor disconnection problem by displaying "ERR 1" on th e LCD display .

The sensor detection function is NOT present in the HCN, HCL, SO2 or 100 ppm H SO2 sensor disc onnection will NOT be i ndicated by an "ERr 1 " display. A periodic check with a known conce ntration of cali bration ga s must be performed regula rly to ensure proper sens or function. See "Cali bration" portion of Cha pter 2 in this manual for c alibration instructions .

Insufficient voltage or curre nt from powe r supply. Incorr ect wiring connections . Wire str ands touchi ng at input terminal block.

Cell sig nal too low or t oo high during calibration. Unstab le calibratio n signal.

Check power supply and interconnecting wires.

Check c alibration g as and flow sys tem; then, re calibrate (valid calibration or Initial Ca libration will clear display).

Replace cell and perform Initial

Old or d amaged cell .

Failed autocal calib ration

Sensor cell replacement was det ected or dis play was factory-set.

Sensor c ell detecte d as missing.

Damaged sensor body.

Calibration. (If orig inal cell is ne w, an Initial Calibration alone may solve the problem.)

If the unit i s incorrectly set u p for autocal, disable the autocal mode by setting th e future calibratio n date to 12-31-1993 or check the autocal flow system.

Perform Initial Cal ibration if un it is new or cell was replaced. Perform regular cal ibration if sa me cell was re-installed.

Inspect cell for proper placement. After recovery, see abov e SYMPTOM: "Display shows CAL".

Replace sensor body and perform Initial Calibration.

Invali d cell type. Replace or repair mai n board.

Non-volatile memory not detected .

Non-volatile memory reset or not in itialized.

Cycle power or repair main board.

Perform Initial Calibrat ion.

(Cell type changed.) Damaged sensor or

sensor body

) only. T he Toxgard I I Series produ ct line contai ns a sensor

S version of the Toxgard II series. Therefore, an HCN, HCL or

Replace sensor or sensor body and perfor m initial calib ration.

CAUTION

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Page 87

Chapter 5, Mainten ance

Table 5-1. Troubleshooting Guidelines

SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

Display flashes

Err 6.

Output signal not present.

Display shows SENSOR.

No response to manual ZERO or CAL command.

Display shows UND.

Low gas reading.

Display shows LO FLO

Battery power exhausted Connect to line power for recharg e. Wiring error Check connections.

Initial Calibration was not performed.

Sensor c ell missing. Sensor s ignal is

under-range. Error detected.

Sensor c ell output i s below acceptable signal level.

Unit is set up for AUTOCAL use, and a utocal unit or gases are not present.

Cell signal is under-range.

Clogge d sensor wat er stop disc.

Misal igned stop dis c. Re-align disc a nd gasket. Poor gas flow or damaged

cell. Rest ricted air flow . Clear tubing.

Pump in operative. Repla ce pump.

Perform Initial Cal ibration. See SYMPTOM: "Displa y flashes Err

1". See SYMPTOM: "Displa y shows UND". See "Sym ptom" co lumn for sp ecific

error. Replace sensing cell and

perform an Initial Calibration.

De-ac tivate AUTOCA L mode by se tting Future Ca libration date to 1 2-31-1993.

Perform regular zero or full calibration. If calibration fails, see above SYMPTOM: "Display shows CAL FAULT". If UND persists, replace cell and perform Initial Calibra tion. NOTE : Although sensor output is not present during UND condition with no gas present, output will correctly respond to the presence of gas. When gas is no longer present, output will no longer be present. This function serves to alert the user that an abnormal condition exists and calibration or other maintenance is required.

Clean or replace disc .

See SYMPTOM "Display shows CAL FAULT".

5-7

Page 88

Chapter 5, Mainte nanc e

Obtaining R epl acem en t Part s

See TABLE 5-2 for replacement sens or kits. To obtain a replacement sensor, address the order or inquiry to:

Mine Safety A ppliances Company Instrument Division P.O. B ox 427, Pittsbu rgh, PA 1523 0-0427

or call, toll-free, 1-800-MSA-INST.

WARNING

Use only genuine MSA replacement parts when performing any maintenance procedures provided in this manual. Failure to do so may seriously impair sensor performance. Repair or alteration of the Toxgard II Monitor, beyond the scope of these maintenance instructions or by anyone other than authorized MSA service personnel, could cause the product to fail to perform as designed and persons who rely on this product for their safety could sustain seriou s personal inj ury or death.

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Page 89

Chapter 5, Mainten ance

Table 5-2. Replacement Sensor Kits

GAS

Carbon Monoxide, 0- 100 ppm Carbon Monoxide, 0- 500

Sulfur Dio xide, 25 ppm

Hydrogen Sulfide, 10 ppm and 50 ppm

Hydrogen Sulfide, 100 ppm

Nitrogen Oxide, 100 ppm

Nitrogen Dioxide, 10 ppm

Chlorine or Chlorine Dioxide

Hydrogen Cyanide, 50 ppm

Hydrogen Chloride, 100 ppm

Oxygen, 0-25%

Combust ible Gas, 100% LEL

SENSORGARD REPLACEMENT PARTS

General -purpose CO, H2S, SO2 and NO

SENSOR KIT

PART NO.

813613

813615

813616

813618

813619

813620

710967

813622

813623

813723

813624

710222

General -purpose Ox ygen

General -purpose Cl

, ClO2, NO2 HCL and HCN

Combustible

Sensorgard gasket

NOTE:

Contat ct 1-800-MSA- INST for fac tory support in determin ing the appr opriate part

710225

812075

710436

812152

numbers for explosi on-proof or du ct mount S ensorgard s

5-9

Page 90

Chapter 5, Mainte nanc e

ITEM PART NO.

Main printed circuit board

Table 5-3. Spare Parts List

NOTE:

Order this replacement board according to info rmation prov ided on the la bel of the ex isting board . This label sh ould read:

"A-TOX-PCB-X-Y-Z" (X-Y-Z corresponds to the

first, sixth and seventh option code positi ons found on the namepl ate of the main unit)

Contac t 1-800-MS A-INST for factory -support in d etermining the appropriate part number.

Display printed circ uit board Plastic Support, display printed circuit

board Strobe, red Strobe, gasket Battery Power supply Piezo Bu zzer Horn, federal Pump kit, DC Pump kit, asp irated Air line f low assembl y Auto cal assembly Valve assembly, general-purpose Valve assembly, explosion-proof

711033

655654

634674 711168 655759 655623 637123 655656 711169 711213 711267 813675 813125 813243

5-10

Page 91

Appendix A, Optional Toxgard II Duct Mount Kit

Appendix A Optional Duct Mount Kit

General

The Remote Sensor Duct Mount Kit (FIGURE A-1) provides convenient sampling of gas within an air duct.

• This Kit enables duct gas sampling even when flow rate within the duct is at a high velocity.

• The user can calibrate the sensor via a calibration port without disassembling or removing the sensor from the duct.

• The sensor and the Kit are sealed to the duct to prevent gas within the duct from escaping.

• All Toxgard II remote sensors fit into the remote sensor model of the Duct Mount Kit.

The Remote Sensor Module Duct Mount Kit:

• A llows the sensor portion of the unit to be mounted on the duct (perhaps in an inaccessible location), while the read-out and calibration portion are placed in an easily accessible location to:

Figure A-1.

Ultima Duct Mount Kit

A-1

Page 92

Appendix A, Optional Toxgard II Duct Mount Kit

• save valuable maintenance time and money

• enhance calibrator safety.

Mounting

General

Mounting the Remote Sensor on a duct is easily done with the Duct Mount Kit. The proper location on the duct will permit your sensor to operate up to its pot ential.

Choose a location on the duct:

• Where the duct is flat or level:

• The Duct Mount Kit will not mount on a diameter of less

than eight inches (203 mm) of rounded or curved duct work.

• Additional gasketing may be necessary to properly seal the unit.

• A s far away from any bends or tees as possible, as those locations may have additional turbulence

• Where reasonable access is possible to enable sensor replacement

• That keeps the sensor pointing downward:

• It is good practice to mount the sensor on horizontal run

of the duct.

• Mount the sensor on top of the duct to allow water and dirt to naturally drip off the sensor within the duct and prevent clogging.

• That allows the dual module sensor calibration gas tubing to be routed to the read-out module. Any gas-compatible tubing can be used (not supplied in Kit).

• Keep this tubing as straight and short as possible.

• Beyond any filter or cleaning unit.

• Away from the lowest point on the duct, which tends to collect

additional dirt and dust.

• Away from any fans or blowers.

The Duct Mount Kit requires some as sembly before mounting. It is necessary to temporarily remove the sensor from the module housing and install the sealing gaskets. A ll necessary hardware is provided in the Kit.

A-2

Page 93

Appendix A, Optional Toxgard II Duct Mount Kit

Figure A-2.

Duct Template

Mounting

1. Locate the duct to be sampled.

2. Cut a rectangular hole [8.875 by 2.7 inches (225 by 68.5 mm)] in th e d u c t (FIGURE A-2) .

• The gasket on the bottom of Duct Mount Kit must sit flat on the duct.

• If necessary, pre-drill the fastener holes.

• Do not remove the gasket paper lining on the Duct

Mount Kit at this time.

• On rounded ducts, additional gasketing may be required for proper sealing.

3. Locate and identify all components in the Duct Mount Kit (TABLE A-1).

A-3

Page 94

Appendix A, Optional Toxgard II Duct Mount Kit

Figure A-3.

Remote Sensor Spacers

Table A-1 . D ua l m odule Duct Mount K it Parts List

DESCRIPTION PART NUMBER FIGURE

Two Tox gard II Gas Mo nitor Spacer s Toxgard I I Gas Moni tor Clamp Toxgard I I Gas Moni tor Enclosur e Gasket Toxgard I I Gas Moni tor Plate Toxgar d II Gas Moni tor Duct Mo unt Kit Bas e

Plate Two 1/4-inch Hex Nuts Two 1/4-inch Lock Washers Six 10-32 Screws Six #10 Lock Washer s

710779 A-12 710778 A-13 710770 A-6 710769 A-7

814862 A-14

631357 655245 634054 627852

4. Locate the Remote sensor of the Toxgard II Gas Monitor to be installed in the duct.

5. Unscrew the cover of the Remote sensor and set aside.

Figure A-4.

Remote Sensor Clamp

A-4

Page 95

Appendix A, Optional Toxgard II Duct Mount Kit

WARNING

Before removi ng the co ver of an explo sion-pro of Remote Sensor Toxgard II Gas Monitor, verify that the surrounding area does not contain a flammable mixture of combustible gas and air, since a source of ignition is exposed; otherwise, an explosion may occur if a metal object contacts the circuitry and produces sparks.

6. For Toxic or Oxygen Remote Sensor Toxgard II Gas

Monitors:

To disconnect the sensor wiring on the termination printed circuit board in the module, pull up on the connector inserted into J1 (FIGURE 1-8).

For Combust ible Remote Sensor Toxgard II Gas Monitor:

To disconnect the sensor wiring on the termination printed circuit board in the module, unscrew or loosen the screws on the terminal wiring connector.

• Befor e removing the wires, mark the identity of each wire to permit proper replacement (FIGURE 1-7).

7. To avoid damage, completely remove the black SensorGard by unscrewing the black plastic ring.

8. Using a strap or pipe wrench, carefully unscrew the sensor body from the module.

• Carefully remove sensor assembly from the sensor body.

• Ensure that wires and connector do not break when

removing the sensor body.

9. Place the enclosure plate and gasket from the Duct Mount Kit on the sensor body threads (FIGURE A-5).

10. Carefully feed the sensor wires from the sensor body back into the module opening.

11. Using a strap or pipe wrench, carefully screw the sensor body back into the module.

• Ensure that gasket is centered and not folded on the sensor threads.

Figure A-5.

Sensor

A-5

Page 96

Appendix A, Optional Toxgard II Duct Mount Kit

12. For Toxic or Oxygen Remote Sensor Toxgard II Gas

Monitors:

Re-connect the sensor wiring on the termination printed circuit board in the module by aligning the connector and inserting it into J1 (FIGURE 1-8).

For Combust ible Remote Sensor Toxgard II Gas Monitor:

Re-connect the sensor wiring onto the wiring termination printed circuit board in the module (FIGURE 1-7).

13. Re-install the cover of the Remote Sensor Toxgard II Gas Monitor.

WARNING

Do not let the cover remain off of an explosion-proof Remote Sensor Toxgard II Gas Monitor. Since a source of ignition is exposed, an explosion may oc cur if a metal object contacts the circuitry and produces sparks in an atmosphere of combustible gas.

14. Locate the Remote sensor Toxgard II Gas Monitor base plate and two #10-32 screws and lock washers.

15. Remove the four screws holding the module mounting bracket (FIGURE A-6).

A-6

Figure A-6.

Remote Sensor Base Plate

Page 97

Appendix A, Optional Toxgard II Duct Mount Kit

Figure A-7.

Duct Mount and Sensor

16. Fasten the Remote Sensor module to the bracket using two 10-32 screws and lock washers.

• These screws pass through the bracket and into two tapped holes in the module.

17. Push the Remote sensor Toxgard II Gas Monitor through the slit gasket on the Duct Mount base plate (FIGU R E A -7 ).

18. Fasten the sensor module bracket to the base plate using the 10-32 screws removed in step 15.

• Do not tighten completely.

19. Fasten the calibration tubing fitting into the center post of the SensorGard (FIGURE A-7).

A-7

Page 98

Appendix A, Optional Toxgard II Duct Mount Kit

20. Locate the two Remote sensor Toxgard II Gas Monitor spacers. Screw one end of each spacer into the Duct Mount Kit base plate.

21. Place the Remote sensor Toxgard II Gas Monitor clamp on the top of the spacers.

• Ensure the folded part of the clamp is mounted on the back side of the Remote Sensor Toxgard II Gas Monitor.

22. With the 1/4-inch hex nut and lock washers, secure the clamp onto the spacers (FIGURE A-7).

• Tighten the #10-32 screws that secure the module mounting bracket to the base plate.

23. Clean the area around the hole made in step 2.

• Ensure that no grease, metal shavings or other material is in the area where the gasket will be seated.

24. Remove the protective paper backing from the gasket found on the bottom of the Duct Mounting flange.

25. Install the entire assembly on the duct. Use proper fasteners to secure the Toxgard II Gas Monitor Duct Mount to the duct.

26. If necessary, tape or seal around the sensor gasket to prevent leaks.

27. Remove the top half of the calibration fitting and connect it to your calibration tubing.

• When calibrating, push the calibration fitting into its mate.

28. Install the read-out module by following the mounting instructions in the instructions manual for the single module model.

29. Refer to the instruction manual for wiring details.

A-8

Page 99

Appendix B, Definit i on of Ter ms

Appendix B Definitions of Terms

The following defines terminology used in this m anual that may be unfamiliar to some users:

Zero: A zero (0) indication on the meter display indicates an ambient air present, or no hazardous gases present.

Zeroing: The process of def ining a zero condition on the display. Span: An up-scale reading on the meter display Spanning: The process of defining an up-scale reading on

the display. SPAN Gas Value: The gas concentrati on which gives the

instrument an up-scale or full-scale value. This value is printed on the cylinder containing the gas.

Exhaust G as: The gas after it passes the sensor. Flow Rate: T he speed of the gas in the sample line. Pump: An electromechanical device which mov es the gas

sample to the Toxgard II inst rument. Upscale: Instrument alarms on gas concentrations greater than

or equal to the alarm value. Downscale: I nstrument alarms on gas concentrations less than

or equal to the alarm value. Non-latching: A larms reset automatically when the alarm

condition clears. Latching: Alarm relays and indicator lamps remain activ e (after

alarm condition clears) until they are manually de-activated by pressing the HORN/ALARM ACKNOWLEDGE button.

B-1