Operating Manual Gasgard 100 Control System Order No.: 10153908/00 MSAsafety.com
Warning! THIS MANUAL MT BE CAREFULLY READ BY ALL INDIVIDUALS WHO HAVE OR WILL HAVE THE RESPONSIBILITY FOR ING OR SERVICING THE PRODUCT. Like any piece of complex equipment, this instrument will perform as designed only if it is used and serviced in accordance with the manufacturer s instructions. OTHERWISE, IT COULD FAIL TO PERFORM AS DESIGNED AND PERSONS WHO RELY ON THIS PRODUCT FOR THEIR SAFETY COULD STAIN 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 service. IN NORTH AMERICA: 1-800-MSA-INST or FAX (724) 776-9783 IN CANADA: 1-88-267-0672 or FAX (416) 663-5908 MSA INTERNATIONAL: (724) 776-8626 MINE SAFETY APPLIANCES COMPANY 2014 - All Rights Reserved This manual is available on the internet at www.msasafety.com MSA NORTH AMERICA 1000 Cranberry Woods Drive Cranberry Township, Pennsylvania 16066
Contents Contents 1. MSA Permanent Instrument Warranty... 4 1.1. Warranty... 4 1.2. Exclusive Remedy... 4 1.3. Exclusion of Consequential Damage... 4 2. Safety Regulations... 5 2.1. Warnings... 5 3. System Overview... 6 3.1. System Component Overview... 7 4. System Configuration... 9 5. Preconfigured Features... 11 5.1. System Operational Relay... 11 5.2. Horn Acknowledge and Latched Alarm Reset Option... 15 5.3. Sensor Fault Relay Setup... 17 6. Installation and Configuration Check List... 18 7. Specifications... 19 8. Appendix... 20 Gasgard 100 Control System 3
MSA Permanent Instrument Warranty 1. MSA Permanent Instrument Warranty 1.1. Warranty Seller warrants that this product will be free from mechanical defect or faulty workmanship for a period of 18 months from date of shipment, or one 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 year such as, but not limited to, nonrechargeable batteries, filament units, filter, lamps, fuses etc. The Seller shall be released from all obligations under this warranty in the event repairs or modifications are made by persons other than its own or authorized service personnel or if the warranty claim results from physical abuse or misuse of the product. No agent, employee or representative of the Seller has any authority to bind the Seller to any affirmation, representation or warranty concerning the goods sold under this contract. Seller makes no warranty concerning components or accessories not manufactured by the Seller, but will pass on to the Purchaser all warranties of manufacturers of such components. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED, IMPLIED OR STATUTORY, AND IS STRICTLY LIMITED TO THE TERMS HEREOF. SELLER SPECIFICALLY DISCLAIMS ANY WARRANTY OF MERCHANT ABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE. 1.2. Exclusive Remedy It is expressly agreed that Purchaser's sole and exclusive remedy for breach of the above warranty, for any tortious conduct of Seller, or for any other cause of action, shall be the repair and/or replacement at Seller's option, of any equipment or parts thereof, which after examination by Seller is proven to be defective. Replacement equipment and/or parts will be provided at no cost to Purchaser, F.O.B. Seller's Plant. Failure of Seller to successfully repair any non-conforming product shall not cause the remedy established hereby to fail of its essential purpose. 1.3. 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. 4 Gasgard 100 Control System
Safety Regulations 2. Safety Regulations 2.1. Warnings The Controller described in this manual must be installed, operated and maintained in strict accordance with its labels, cautions, warnings, instructions, and within the limitations stated. Misuse can result in death or serious injury. If a portion of the system fails, remaining system functions may not operate properly. In this case, do not use the system until proper repairs are made. This device uses custom firmware developed by YOKOGAWA and is identified as S22 or S7 at the end of the main unit model code. Do not modify firmware. Doing so may render the device inoperable. S7 version of the MW100 is the only Class 1 Division 2 approved rack offered with the Gasgard 100 Control System. Failure to use the correct rack can result is death or serious injury. The Gasgard 100 Control System comes preconfigured with relay assignments for indication of a variety of faults, as outlined in the manual. Do not modify settings. Modifying these settings will compromise the unit s ability to notify the user of an inoperable system which can result in death or serious injury. Gasgard 100 Control System 5
System Overview 3. System Overview Thank you for purchasing the Gasgard 100 Control System. The Gasgard 100 Control System utilizes the MW100 Data acquisition system by YOKOGAWA. This manual covers useful information about the instruments functions, installation and wiring procedures and operating procedures that are specific to the Gasgard 100 Control System operation. The standard features of the MW100 Data acquisition system can be found in the YOKOGAWA User Manuals referenced below. Please visit the website of YOKOGAWA Corporation of America at www.yokogawa.com/us to access all available MW100 manuals. The MW100 User Manual and Viewer Software User Manual are available on the MW100 CD that ships with the product. Manual Title Manual No. Description MW100 User Manual IM MW100-01E Describes information about the instrument s functions, installation and wiring procedures, operating procedures, and handling precautions. MW100 Data Acquisition Unit Operation Guide MW100 Communication Command Manual MW100 Connecting Ethernet and Checking the Connection Precautions on the Use of the MX100/MW100 MX100/MW100 Data Acquisition Unit Installation and Connection Guide IM MW100-02E IM MW100-17E IM MW100-71E IM MX100-71E IM MX100-72E Describes the handling of the MW100 Data Acquisition Unit and the basic operations of the MW100 Viewer Software. Describes the communication command of the MW100 main module. Explains the procedure to check the Ethernet connection. Summarizes the precautions regarding the use of the MW100 Data Acquisition Unit. Describes the installation procedures and wiring procedures of the MW100 Data Acquisition Unit. MW100 Viewer Software IM MW 180-01E Describes the functions and operations of the MW100 Viewer Software that comes standard with the MW100 main modules. The Gasgard 100 Control System is a fully integrated measurement and recording system with webenabled Ethernet connectivity for shared, real-time trend monitoring using a web browser. The Gasgard 100 Control System offers many advanced features, including the following: Communicate with both analog and Modbus field devices Interface with PLCs and other control devices through Modbus/TCP and Modbus/RTU Ethernet provides easy connection to allow modification to your system. Configure, save and view data remotely from a PC A highly flexible system architecture allowing one to configure a system with combinations of analog input, relays and analog outputs Create customized viewing screen on a PC by choosing bar graphs, digital read outs, trending analysis and more Delivers access for multiple users to monitor and share measured data by simply connecting the Gasgard 100 Control System simultaneously to multiple PCs 6 Gasgard 100 Control System
System Overview Create customized hourly, daily, weekly and monthly reports that can be saved to the system s compact flash (CF) media and automatically uploaded to an FTP server for further processing and review Built-in trigger function allows data recording to be started based on alarm values, time, external contact input or other parameters Data thinning function allows portions of measured data to be omitted at regular intervals during measurement, before data is recorded 3.1. System Component Overview The Gasgard 100 Control System consists of the YOKOGAWA MW100 data acquisition rack, a set of DIN rail mounted terminal blocks for custom wiring, an optional 240 W power supply for powering field devices, and an optional horn relay and alarm acknowledge kit. The Gasgard 100 Control System is offered in two sizes: a system with expansion capabilities to a total of six (6) I/O modules and a system with up to three (3) I/O modules. The following YOKOGAWA MW100 content is offered with the Gasgard 100 Control System. Main Module The main module is equipped with power supply connectors, Ethernet ports, and other devices facilitating supply of power to and control of the input/output modules, and connection to networks. Data acquisition via serial communication is also possible through use of the RS-422A/485 serial communication function. I/O Modules The following three modules are available with the Gasgard 100 Control System. YOKOGAWA offers ten additional I/O modules that are not supported by MSA. Contact YOKOGAWA for more information on these modules. 10-CH, Medium-Speed Universal Input Module (MX110-UNV-M10) 8-CH, Medium-Speed Analog Output Module (MX120-VAO-M08) 10-CH, Medium-Speed Digital Output Module (MX125-MKC-M10) Base Plate The base plate is equipped with connectors for connecting the main module and input/output modules. Two different base plates are available to hold from one to six input/output modules. The offering is a six I/O module plate for the large system and a 3 I/O plate for the small system. By attaching the DIN rail mounting brackets that came with the product to the base plate, you can rack-mount or panel-mount the Gasgard 100 Control System main unit. Gasgard 100 Control System 7
System Overview PC Software The Gasgard 100 Control System comes with the Viewer software program that allows users to view measured data acquired by the Gasgard 100 Control System. The Viewer consists of the two software components described below. MW 100 IP Config Software Sets the IP address on the Gasgard 100 Control System. This software is used when setting an IP address for the first time, or if the current IP address needs to be changed. The default IP address is set to 192.168.0.10 at the factory. MW 100 Viewer Enables you to (1) display measured, computed, and thinning data that has been stored, (2) read values and perform computation over an area using cursors, and (3) convert the measured and computed data into various formats such as Excel. Gasgard 100 Control System Reference Guides The following references are available to support Gasgard 100 Control System installation and configuration. Quick-Start Map Available on our website: www.msasafety.com Videos Configuration videos are available on MSA TV (msatv.msasafety.com) or through AR codes on the quickstart map. Videos cover topics including configurations of inputs, alarms and relays, among others. Installation Outline Drawing Available on our website: www.msasafety.com The I/O drawing covers all installation and wiring details. 8 Gasgard 100 Control System
System Configuration 4. System Configuration The Gasgard 100 Control System is a highly configurable system. System configuration is facilitated through the use of the on-board Ethernet connection. To access the Gasgard 100 Control System viewing and configuration screens, perform the following: (1) Attach the Gasgard 100 Control System to your PC through the use of a cross over cable or to your network. (2) The Gasgard 100 Control System comes preconfigured with an IP address of 192.168.0.10. If another IP address is to be used, run the IP configuration tool found on the MW100 CD that comes with the product. Details on how to use this tool can be found in the YOKOGAWA User Manual or by watching the Gasgard 100 Control System configuration videos found on www.msasafety.com Step Configuration Descriptions Reference Materials 1 Installation and Wiring YOKOGAWA User s Manual Chapter 2 Installation and Wiring I/O Drawing SK 3015-1046 2 Configuring the Network Connection YOKOGAWA User s Manual Chapter 2 Connecting the Ethernet Cable YOKOGAWA User s Manual Chapter 3 Communication Settings 3 Initial Setup YOKOGAWA User s Manual Chapter 3 System Settings 4 Setting Up an Analog Input YOKOGAWA User s Manual Chapter 1 Functions of the 10-CH, Medium Speed Universal Input Module YOKOGAWA User s Manual Chapter 3 Setting Measurement Conditions Appendix, Scaling Values for Range and Alarm Levels for instructions 5 Configuring Alarms YOKOGAWA User s Manual Chapter 1 Alarms YOKOGAWA User s Manual Chapter 3 Setting Alarms Appendix, Scaling Values for Range and Alarm Levels for instructions 6 Configuring the Relay Settings YOKOGAWA User s Manual Chapter 1 Functions of the 10-CH, Medium Speed Digital Output Module YOKOGAWA User s Manual Chapter 3 Digital Output Settings 7 Configuring Analog Output Settings YOKOGAWA User s Manual Chapter 1 Functions of the 8-CH, Medium Speed Analog Output Module YOKOGAWA User s Manual Chapter 3 Analog/PWM Output Settings Gasgard 100 Control System 9
System Configuration Step Configuration Descriptions 8 Configuring Modbus Master Settings Reference Materials YOKOGAWA User s Manual Chapter 3 Communication Settings 9 Configuring the Display Screens YOKOGAWA User s Manual Chapter 3 Measured Data Monitor Display/Settings 10 Configuring Acknowledge and Horn Silence Feature YOKOGAWA User s Manual Chapter 4 Troubleshooting and Maintenance 11 Troubleshooting YOKOGAWA User s Manual Chapter 4 Troubleshooting and Maintenance 10 Gasgard 100 Control System
Preconfigured Features 5. Preconfigured Features The system is preconfigured to facilitate indication of faults as well as to activate the optional horn and alarm acknowledge feature. These configurations set by the factory for these features are outlined below. 5.1. System Operational Relay For proper system fault notification, the factory has configured multiple relays to supply notification of various system faults to an on-board PLC. This PLC then provides a common, normally closed system fault dry contact. Review the I/O Drawing for customer wiring point. The configuration of these relays was accomplished by setting the items listed below. The relays configured in this example are relays #057-060 (6 position rack). For a three position rack, these are replaced with 027-030. Warning! Do not modify any of the listed settings listed below. Modifying these settings will compromise the unit s ability to notify the user of an inoperable system which can result in death or serious injury. System Setting -> Timer Setting Fig. 1 Timer Setting Gasgard 100 Control System 11
Preconfigured Features System Setting -> Event Action Setting Fig. 2 Event Action Setting Channel Setting -> Math Channel Setting Fig. 3 Math Channel Setting 12 Gasgard 100 Control System
Preconfigured Features Channel Setting -> DO Channel Setting Fig. 4 DO Channel Setting Gasgard 100 Control System 13
Preconfigured Features Channel Setting -> Alarm Setting (MATH) Fig. 5 Alarm Setting (MATH) 14 Gasgard 100 Control System
Preconfigured Features 5.2. Horn Acknowledge and Latched Alarm Reset Option The factory has configured the settings listed below for proper operation of the Horn Acknowledge and latched alarm reset options. When this option is purchased, the factory will mount and connect two pushbuttons to perform these operations. The horn will be controlled by system relay 056 (026 on a three position rack). The user must configure alarm levels to control this relay for the horn to activate. The Latched Alarm reset button is connected and configured to operate on input 001. Warning! The user must configure alarms to control the appropriate relay for proper horn operation. Do not modify any of the highlighted settings listed below. Modifying these settings will compromise the functionality of the horn relay and latched relay reset feature. Channel Setting -> AI/DI Channel Setting Fig. 6 AI/DI Channel Setting Gasgard 100 Control System 15
Preconfigured Features System Setting -> Event Action Setting Fig. 7 Event Action Setting Channel Setting -> DO Channel Setting Fig. 8 DO Channel Setting 16 Gasgard 100 Control System
Preconfigured Features 5.3. Sensor Fault Relay Setup An alarm level must be configured for each sensor attached to the system to determine if that sensor is in a fault condition. These alarm levels must be configured for relay 057 (027 on a three position rack) which has been allocated as the sensor fault relay. The Alarm type should be L for Low alarm, the alarm will trip when the reading drops below the assigned value. The sensor fault alarm value depends upon the full scale sensor range and milliamp level of the alarm. To configure this alarm, refer to the table in Appendix to find the appropriate value to set the alarm level. Channel Setting -> Alarm Setting (AI/DI) or Channel Setting Alarm Setting (MATH) Fig. 9 Alarm Setting (AI/DI) or Channel Setting Alarm Setting (Math) Warning! The user must configure alarms to control the appropriate relay for proper sensor fault detection. Failure to properly configure and monitor the sensor fault relay can compromise the unit s ability to notify the user of an inoperable sensor which can result in death or serious injury. Gasgard 100 Control System 17
Installation and Configuration Check List 6. Installation and Configuration Check List Ensure that all wiring connections were made in accordance with all applicable code. Reference the installation outline drawing and wiring label located on the inside door of the device for details. It is a best practice to perform a system level test of your gas detection system once all field transmitters and output devices such as strobes and horns are wired and operating. This check should be performed after all configuration of the Gasgard 100 controller has been completed. The following is a suggested test procedure for ensuring proper operation of your gas detection system. (1) Apply test gas to each field sensor. Verify that outputs such as LEDs, relays and milli-amp signal function correctly. (2) Check channel reading for the transmitter receiving gas. Ensure the reading is accurate. (3) Check the alarm status of the Gasgard 100 Control System. Verify that the correct channel alarms activate. (4) Check that the Gasgard 100 Control System relays are appropriately assigned. Verify that the relays activate when the associated alarm is enabled Make any necessary configuration and/or wiring adjustments to ensure your system is operating as intended. 18 Gasgard 100 Control System
Specifications 7. Specifications Power Supply Operating Temperature W/O internal 240 W Power Supply Option 12 to 28 VDC W/ internal 240 W Power Supply Option 100 to 240 VAC 50/60 Hz Rack -20 C to 50 C (-4 F to 122 F) Enclosure -20 C to 45 C (-4 F to 113 F) 24 x 24 Fiberglass enclosure (accepts up to 6 I/O), no internal power supply. -20 C to 35 C (-4 F to 95 F) 24 x 24 Fiberglass enclosure (accepts up to 6 I/O), with a 240 W Internal power supply. Types of Measurement Connection Modes Terminal Connections Relay Contact Ratings Enclosure Dimensions Ingress Protection Approvals (Rack Only) -20 C to 45 C (-4 F to 113 F) 16 x 20 small enclosure (accepts up to 3 I/O), no internal power supply. ma (standard), DC Voltage, DI (non-voltage contact), level (5 V logic) 2 wire or 3 wire, ma; RS485 (Modbus) Max 2.5 m² (12 AWG) stranded wire Configurable Rack Relays SPST (Form A), Normally Energized/De-energized 250 VDC/0.1 A, 250 VAC/2 A, or 30 VDC/2 A (resistance load) Horn Relay SPST (Form A), Normally De-energized 240 VAC/5 A, or 24 VDC/5 A System Fault Relay SPST (Form A), Normally Energized 240 VAC/4 A, or 24 VDC/2 A 24.6" L x 24,1" W x 9.0" D (accepts up to 6 I/O) or 20.2" L x 16.2" W x 9.0" D (accepts up to 3 I/O) Supplied with NEMA 4X Components CSA: CSA22.2 No 61010-1, overvoltage category II, measurement category II, pollution degree 2 UL: Conforms to UL61010B-1 (CSA NRTL/C) CE: EMC directive; EN61326 Class A; EN61000-3-2; EN61000-3-3 Low voltage directive; EN61010-1; overvoltage category II, measurement category II, pollution degree 2 FM: Class I Division 2 Groups A, B, C, D For additional, module specific specifications please see YOKOGAWA User Manual Chapter 5. Gasgard 100 Control System 19
Appendix 8. Appendix Full Scale Range Lower Scale Upper Scale Scaled Fault Alarm Level based on ma Fault Level Designated by Gas Transmitter (Fault Levels are 10 % high to account for any meaurement errors) 0.5 1.0 1.5 2.0 2.5 3.0 3.5 20 ma 0 20 0.550 1.100 1.650 2.200 2.750 3.300 3.850 5 Volts 0 5 0.138 0.275 0.413 0.550 0.688 0.825 0.963 0.1-0.025 0.1-0.022-0.018-0.015-0.011-0.008-0.004-0.001 0.3-0.075 0.3-0.065-0.054-0.044-0.034-0.023-0.013-0.003 0.5-0.125 0.5-0.108-0.091-0.073-0.056-0.039-0.022-0.005 1-0.25 1-0.216-0.181-0.147-0.113-0.078-0.044-0.009 2-0.5 2-0.431-0.363-0.294-0.225-0.156-0.088-0.019 3-0.75 3-0.647-0.544-0.441-0.338-0.234-0.131-0.028 5-1.25 5-1.078-0.906-0.734-0.563-0.391-0.219-0.047 10-2.5 10-2.156-1.813-1.469-1.125-0.781-0.438-0.094 20-5 20-4.313-3.625-2.938-2.250-1.563-0.875-0.188 25-6.25 25-5.391-4.531-3.672-2.813-1.953-1.094-0.234 30-7.5 30-6.469-5.438-4.406-3.375-2.344-1.313-0.281 50-12.5 50-10.781-9.063-7.344-5.625-3.906-2.188-0.469 100-25 100-21.563-18.125-14.688-11.250-7.813-4.375-0.938 200-50 200-43.125-36.250-29.375-22.500-15.625-8.750-1.875 300-75 300-64.688-54.375-44.063-33.750-23.438-13.125-2.813 500-125 500-107.813-90.625-73.438-56.250-39.063-21.875-4.688 600-150 600-129.375-108.750-88.125-67.500-46.875-26.250-5.625 1000-250 1000-215.625-181.250-146.875-112.500-78.125-43.750-9.375 2000-500 2000-431.250-362.500-293.750-225.000-156.250-87.500-18.750 3000-750 3000-646.875-543.750-440.625-337.500-234.375-131.250-28.125 4000-1000 4000-862.500-725.000-587.500-450.000-312.500-175.000-37.500 5000-1250 5000-1078.125-906.250-734.375-562.500-390.625-218.750-46.875 8000-2000 8000-1725.000-1450.000-1175.000-900.000-625.000-350.000-75.000 10000-2500 10000-2156.250-1812.500-1468.750-1125.000-781.250-437.500-93.750 12000-3000 12000-2587.500-2175.000-1762.500-1350.000-937.500-525.000-112.500 20 Gasgard 100 Control System
Appendix Defining a fault condition for a channel in the Gasgard 100 Control System unit requires extending the measurement range beyond the normal measurement range. For example the measurement range of the transmitter output is 4 to 20 ma. Most fault conditions are transmitted as milliamp values between the range of 0 to 4 ma. The 4 to 20 ma range can be related to more meaningful engineering units; for example: 0 to 100 % LEL or 0 to 25 % O 2. The alarm setpoints on the Gasgard 100 Control System unit are configured using engineering units; for example, to alarm at 8 ma on a 0 to 100 % LEL output sensor, the alarm is set to a value of 25 % LEL. Setting fault alarms is done in a similar manner. The fullscale range of the channel in the Gasgard 100 Control System unit is set to appropriate engineering units as shown in the Table above. The lower scale takes into account the extension of the engineering units beyond the measurement range of 4 to 20 ma to the full milliamp range of 0 to 20. To set the fault alarm value, find the intersecting value in the Table above after selecting your fullscale (FS) engineering unit range and milliamp fault value sent by the transmitter. For example, on a transmitter with a milliamp output of 0 to 20 ma, engineering units of 0 to 100 % LEL and fault level of 3 ma, the Gasgard 100 Control System is configured as follows: Lower scale: -25 Upper scale: 100 Fault alarm value: -4.375 Gasgard 100 Control System 21
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