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MSA Toxgard II Instruction Manual Download Page 5

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 Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

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

Figure 1-3. Shipping Carton Label Identifying Sensor Type . . . . . . . . 1-3

Mounting Your Gas Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

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

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

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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

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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-line Toxgard II Monitor  . . . . . . . . . . . . . . . . . . . . . . . . . .  1-9

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

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

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

Flow Block  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1-9
Mounting the Toxgard II Remote Sensor Module  . . . . . . . . . . . . . . . . . . .  1-9
Electrical Connections for Toxgard II Monitors  . . . . . . . . . . . . . . . . . . . .  1-10

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WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

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

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

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

Table of Contents

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Summary of Contents for Toxgard II

Page 1: ...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 ...

Page 2: ...ranties 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 torti...

Page 3: ...h 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...

Page 4: ...on 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 per...

Page 5: ... 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 line Toxgard II Monitor 1 9 WARNING 1 9 CAUTION 1 9 CAUTION 1 9 Flow Block 1 9 Mounting th...

Page 6: ...r Signal Loads Greater Than or Equal to 50 Ohms 1 15 Under Line powered Conditions 1 15 Under Battery powered Conditions 1 15 Digital Output 1 15 WARNING 1 15 Visual Outputs 1 16 Horn Alarm Acknowledge Button 1 16 Remote Sensors 1 16 Electrical Connections for the Remote Sensor Module 1 16 WARNING 1 16 CAUTION 1 17 For Combustible Models 1 17 Table 1 3 Wire Gauge Vs Distance Between Units 1 17 Tab...

Page 7: ...ters 1 25 Table 1 7 Parameters Displayed During MODE Push button Operation 1 26 Changing Parameter Settings 1 27 Method 1 Push buttons 1 27 General 1 27 Method 2 Ultima Controller 1 28 Battery Backup 1 28 Table 1 8 Expected Battery Operating Time at 77o F 1 30 WARNING 1 30 Banshee Horn Audible Settings 1 30 Figure 1 13 Banshee Horn Audible Settings 1 31 WARNING 1 32 Autocalibration Option 1 32 Duc...

Page 8: ...43 3 3 Span Gas Values 3 3 CAUTION 3 3 Toxgard II Gas Monitor Calibration 3 3 Figure 3 1 Calibration Kit 40 Contents 3 4 Figure 3 2 Calibration Kit 41 Contents 3 4 Figure 3 3 Calibration Kit 42 Contents 3 5 Figure 3 4 Calibration Kit 43 Contents 3 5 Calibration Documentation 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 Calibrat...

Page 9: ...Toxgard II Gas Monitor 3 24 INITIAL Calibration 3 24 Toxgard II Airline Monitor Pumped Version and Aspirated Version Calibration 3 25 Calibration Procedure 3 25 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 19 Typical Air Line Monitor Installation 3 27 Chapter 4 Specifications 4 1 Table 4 1 Specificati...

Page 10: ...uidelines 5 6 Obtaining Replacement Parts 5 7 WARNING 5 8 Table 5 2 Replacement Sensor Kits 5 9 Table 5 3 Spare Parts 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 module Duct Mount Kit Parts List A 4 Figure A 3 Remote Sensor Spacers A 4 Figure A 4 Remote Sensor Cla...

Page 11: ...d 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 t...

Page 12: ...Figure 1 1 Toxgard II Monitor Chapter 1 Set up 1 2 ...

Page 13: ...e included in the carton Identifying Your Unit To determine your model type and other installed 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 sampling accessories if applicable visual and audible alarm options output accessories mounting hardware Figure 1 2 Remote Sensor Model Figure 1 3 Shipping Carton L...

Page 14: ... the gas being monitored Mount the unit so that the front display is not blocked or hidden from view 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 ma...

Page 15: ...ir flow to determine areas where the gas of interest may tend to accumulate Using suitable hardware not supplied mount the Toxgard II monitor to any flat surface via its four mounting lugs see FIGURE 1 6 Allow sufficient room to 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...

Page 16: ...xide MAXIMUM EXHAUST TUBING LENGTH 20 feet 6 meters INLET FITTINGS 1 4 6 35 mm OD Tube Fitting EXHAUST FITTING 1 4 6 35 mm OD Tube Fitting WARNING Only Remote Sensors with proper area ratings can be used in a hazardous area 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 Installation of DC Pum...

Page 17: ...8481 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 gas...

Page 18: ...9 52 mm OD sample tubing to the exhaust outlet fitting 2 Route the exhaust tubing into a safe area where the gas sample can be vented Avoid any sharp bends or elbows Route the tubing to allow any collected 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...

Page 19: ...g 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 moist...

Page 20: ...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 supplying the monitor otherwise electrical shock could ...

Page 21: ...g 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 Figure 1 6 Toxgard II Cable Entries Chapter 1 Set up 1 11 ...

Page 22: ...s during calibration and for two minutes following calibration Alarm Features There are alarm levels in the Toxgard II unit and a relay for each level There are many user selectable 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...

Page 23: ...ushed See 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 ...

Page 24: ...t lighting or other inductive loads it is necessary to suppress any sparks that may occur at the relay contact 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 c...

Page 25: ... 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 ...

Page 26: ...nal 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 ...

Page 27: ...le with its mating Toxgard II Monitor Less Sensor follow National Electrical and local procedural Codes failure to do so can result in an unsafe condition 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 thre...

Page 28: ...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 c...

Page 29: ...ch 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 Figure 1 9 Oxygen Remote Sensor Cable Figure 1 10 Oxygen and Toxic Remot...

Page 30: ...er 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 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 ...

Page 31: ...posed an explosion may occur if a metal object contacts the circuitry and produces sparks in an atmosphere of combustible gas Toxic Gas Remote Sensor Wiring 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 ...

Page 32: ...ID TERMINAL BLOCK LOCATION ORANGE WITH WHITE 1 WHITE WITH BLUE 3 WHITE WITH ORANGE 4 WHITE WITH GREEN 5 GREEN WITH WHITE 7 BLUE WITH WHITE 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 ...

Page 33: ... SW2 Dip Switch indicates the OFF position NUMBER FUNCTION 1 SPARE 2 FAULT ACTIVATES HORN 3 CAUTION ACTIVATES HORN 4 WARNING ACTIVATES HORN 5 ALARM ACTIVATES HORN 6 CAUTION POSITIVE NEGATIVE ACTION OFF POSITIVE 7 WARNING POSITIVE NEGATIVE ACTION OFF POSITIVE 8 ALARM POSITIVE NEGATIVE ACTION OFF POSITIVE NO AUDIBLE ALARM WILL SOUND IF SWITCHES 3 4 AND 5 ARE ALL OFF Figure 1 12 Pump Wiring Chapter 1...

Page 34: ...E BIT2 BIT1 BIT0 TIME IN SECONDS 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 Controller Calibrator Operation The Toxgard II Monitor is fully compatible with the Ultima Controller and the Ultima Calibrator These devices can be used to set various parameters in the Toxgard II Monitor including alarm conditions auto calibration configu...

Page 35: ...xgard II MODE push button FIGURE 1 1 to review the Toxgard II configuration parameters To scroll press and release the 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 paramet...

Page 36: ...performed applicable only for operation with an Autocal unit AVG INTERVAL Time interval in hours used to determine minimum average and maximum gas concentration values CURRENT DATE Display toggles between current day of month and year FUTURE CAL DATE Date that the next Autocal calibration will be performed Display toggles between day of month and year applicable only for operation with an Autocal ...

Page 37: ...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 valu...

Page 38: ... 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 Controll...

Page 39: ... time that the backup battery can operate the Toxgard II Monitor depends on the type of sensor installed options presence of alarm conditions ambient conditions TABLE 1 7 can be used as an approximation of expected battery operating time In this table Minimum Time represents a Toxgard II Monitor configured with strobes flashing alarm conditions asserted Federal horn operational internal pump Maxim...

Page 40: ...ger operational when the above condition 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...

Page 41: ...n 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 e...

Page 42: ...itor 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 the autocalibration Instruction Manual P N 8153...

Page 43: ... displays then a 25 second warm up countdown for sensor stability 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 version number again then it begins to display the gas concentration in the corresponding unit of measurement FIGURE 2 1 ppm for toxic gases Gas for oxygen only LEL for combustible gas...

Page 44: ...orresponding output signal can be transmitted to a controller For a complete listing of display and output conditions 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...

Page 45: ... 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 monitor the only true check of its performance is to apply gas directly to the sensor The frequency of the calibration gas tests depend...

Page 46: ...rochemical sensors When it is determined that calibration adjustments are required the Toxgard II Monitor provides a one man non intrusive method of adjustment at the unit To calibrate the unit the internal push buttons or one of the following accessories can be used Calibrator P N 809997 FIGURE 2 3 Controller P N 809086 FIGURE 2 4 Calibrator The Calibrator allows the following functions Zero Cali...

Page 47: ...No Data No Data No Data No Data No Data No Data Freon 13Bl 1000 0 0 No Data No Data No Data No Data No Data No Data No Data Hexane 500 0 0 0 0 0 0 No Data No Data 0 Hydrogen 500 28 0 5 15 0 15 0 No Data No Data 0 Hydrogen Chloride 100 0 0 No Data No Data 0 No Data 100 4 No Data Hydrogen Cyanide 10 5 0 3 10 0 0 2 5 0 0 Hydrogen Sulfide 10 0 10 0 50 8 0 5 4 5 4 0 25 Isopropanol 50 40 0 0 0 0 0 No Da...

Page 48: ...librator and Controller instruction manual P N 813379 for proper calibration procedures Toxgard II Monitor Calibration Output Signal The Toxgard II Monitor is shipped with the calibration output signal disabled so the output signal will track the gas concentration value during the calibration process In some applications it may be desirable to disable or lock the output during calibration to a pre...

Page 49: ...ing the calibration it is necessary to quickly apply the span gas to the unit Prior connection of the calibration components will aid in the ease of unit calibration Equipment Required Three calibration kits numbered 40 41 and 54 are available from MSA for diffusion calibration of Toxgard II Gas Monitors Kit 40 is also used to calibrate the Toxgard II Air Line Monitor Calibration Kits 42 and 43 ar...

Page 50: ...10331 41 HYDROGEN CYANIDE 0 50 PPM 10 PPM 10028072 41 HYDROGEN CHLORIDE 0 100 PPM 40 PPM 10028078 54 CHLORINE DIOXIDE 4 0 3 PPM 1 PPM 710331 41 OXYGEN 0 25 20 8 10028028 2 40 NATURAL GAS 3 0 100 LEL 25 LEL 1 10028034 40 PETROLEUM VAPORS 3 GASOLINE 0 100 LEL 40 LEL 1 GENERAL SOLVENTS 3 0 100 LEL 55 LEL 1 NOTES 1 Calibrated with Propane 6 gas by volume 2 Not required for standard calibration procedu...

Page 51: ...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 diffusion Hydrogen Chloride Toxgard II Monitors FIGURE 3 5 Span Gas Values The Toxgard II Monitor is factory ...

Page 52: ...linders Item 1 Tubing P N 711112 3 16 ID side connects to Item 3 1 4 ID side connects to sensor Item 2 Zero Cap P N 710535 Item 3 1 5 LPM Flow Controller P N 478358 Item 1 Tubing P N 711112 3 16 side connects to Item 2 1 4 side connects to sensor Item 2 25 LPM Flow Controller P N 478359 Item 3 Calibration Cap P N 710411 Item 4 Zero Cap P N 813774 Chapter 3 Calibration 3 4 ...

Page 53: ...ne 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 Sensor Item 2 Flow Controller Match Flow P N 697344 Item 1 Tubing P N 711113 3 16 ID side connects to Item 2 1 8 ID side connects to Ultima or Toxgard II sensor Item 2 Flow Controller Match Flow P N 697344 Chapter 3 Calibration 3 5 ...

Page 54: ...n be displayed on the front panel LED with the use of the Controller or transmitted to a 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 Item 1 Tubing P N 711112 3 16 ID side connects to Item 3 1 4 ID side connects to sensor Item 2 Zero Cap P N 710535 Item 3 1 5 LPM Flow Controller P N 478358 It...

Page 55: ...ride 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 ClO2 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 ClO2 The default value for the calibration gas o...

Page 56: ...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 Figure 3 6 Zero Cap Placement Chapter 3 ...

Page 57: ...Controller gas outlet Ensure 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 Notice the open arrow on the flow controller knob Figure 3 7 Calibration Tubing Set up Figure 3 8 Zero Gas Connection Chapter 3 Calibration 3 9 ...

Page 58: ...ctronically 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...

Page 59: ...n 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 3...

Page 60: ...es the items found in Calibration 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 z...

Page 61: ...e 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 butt...

Page 62: ... 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 The Toxgard II Gas Monitor allows automatic zero adjustment only wit...

Page 63: ...ses Carbon Monoxide Oxygen Hydrogen Sulfide Sulfur Dioxide Hydrogen Chloride Nitric Oxide All Combustible gases Use Procedure Number 2 to calibrate the Toxgard II Gas Monitor for the following gases Chlorine Nitrogen Dioxide Chlorine Dioxide Hydrogen Cyanide Procedure Number 1 This procedure uses the items found in Calibration Kit 40 42 and 54 For oxygen units skip to Step 3 For Calibration Kit 54...

Page 64: ...librator 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 Calibr...

Page 65: ... 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 Spanning If...

Page 66: ...f 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...

Page 67: ...alue 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...

Page 68: ... 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 ...

Page 69: ... 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 P...

Page 70: ...alue 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 SensorGard If the calibration signal is enabled during calibration it will be held at the lock...

Page 71: ...as 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 c...

Page 72: ...nit 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 appea...

Page 73: ...evels are detected by the oxygen Toxgard II Gas Monitor To meet the reproducibility specification 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 ...

Page 74: ...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 Calibration 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 ...

Page 75: ...Figure 3 18 Typical DC Pump Version Installation Figure 3 19 Typical Air Aspirator Version Installation Chapter 3 Calibration 3 27 ...

Page 76: ...ormal 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 ho...

Page 77: ...er 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 Chapter 3 Calibration 3 29 ...

Page 78: ...ITY REPEATABILITY CARBON MONOXIDE the greater of 2 full scale FS 1 FS or 2 ppm OXYGEN 2 FS 1 FS HYDROGEN SULFIDE 10 FS or 2 ppm 1 FS or 2 ppm CHLORINE 10 FS or 2 ppm 5 FS or 1 ppm SULFUR DIOXIDE 10 FS or 2 ppm 1 FS or 2 ppm NITRIC OXIDE 10 FS or 2 ppm 1 FS or 2 ppm NITROGEN DIOXIDE 10 FS or 2 ppm 4 FS or 1 ppm HYDROGEN CYANIDE 10 FS or 2 ppm 4 FS or 2 ppm HYDROGEN CHLORIDE 10 FS or 2 ppm 10 FS or ...

Page 79: ...cally FULL REPLACEMENT WARRANTY 1 year HAZARDOUS AREA RATING General purpose only Check Area Rating of Remote Sensor for allowable applications WIRING REQUIREMENTS mA OUTPUT OXYGEN TOXICS 2 wire COMBUSTIBLES 2 wire POWER INPUT OXYGEN TOXICS 120 220 VAC 15 COMBUSTIBLES REMOTE SENSOR Supplied by Toxgard II Monitor SIGNAL OUTPUT 4 20 mA COMBUSTIBLES current source OXYGEN TOXICS DIGITAL See Ultima Plu...

Page 80: ... Areas this configuration will not have relays pumps batteries autocalibration or horns as options it will have the standard Piezo alarm buzzer APPROVAL PARAMETERS Installation Category II Pollution Degree 2 WARNING Explosion Hazard Substitution of components may impair suitability for Class I Division 2 Explosion Hazard Do not disconnect equipment unless power has been switched OFF or the area is...

Page 81: ...ion 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 sensing element itself which has a limited lifetime When the Toxgard II Monitor s read out indicates that the sensor must be changed there is very little sensor lifetime remaining It is good practice to obtain a replacement ...

Page 82: ...al version is a sealed unit which contains a corrosive electrolyte If electrolyte is leaking from the sensor exercise CAUTION to ensure the electrolyte does not contact skin eyes or clothing thus avoiding burns If contact occurs rinse the area immediately with a large quantity of water In case of contact with eyes immediately flush eyes with plenty of water for at least 15 minutes Call a physician...

Page 83: ...Figure 5 2 Cap Location for Remote Combustible Gas Explosion proof Sensor Figure 5 3 Cap Location for Toxic Gas or Oxygen General purpose Model Chapter 5 Maintenance 5 3 ...

Page 84: ...ect 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 Calibration Procedure as outlined in the Toxgard II Monitor Calibrator or Toxgard II Monitor Controller instruc...

Page 85: ...t all other maintenance be performed at an MSA factory authorized service center See TABLE 5 1 for troubleshooting guidelines Figure 5 5 Combustible Three Pin Connector Figure 5 6 CAL FAULT Reading Chapter 5 Maintenance 5 5 ...

Page 86: ...ement After recovery see above SYMPTOM Display shows CAL Damaged sensor body Replace sensor body and perform Initial Calibration Display flashes Err 2 Invalid cell type Replace or repair main board Display flashes Err 3 Non volatile memory not detected Cycle power or repair main board Display shows Err 4 Non volatile memory reset or not initialized Cell type changed Perform Initial Calibration Dam...

Page 87: ...e activate AUTOCAL mode by setting Future Calibration date to 12 31 1993 Display shows UND Cell signal is under range Perform regular zero or full calibration If calibration fails see above SYMPTOM Display shows CAL FAULT If UND persists replace cell and perform Initial Calibration NOTE Although sensor output is not present during UND condition with no gas present output will correctly respond to ...

Page 88: ...SA 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 thei...

Page 89: ...lorine Dioxide 710967 Hydrogen Cyanide 50 ppm 813622 Hydrogen Chloride 100 ppm 813623 Oxygen 0 25 813723 Combustible Gas 100 LEL 813624 SENSORGARD REPLACEMENT PARTS General purpose CO H2S SO2 and NO 710222 General purpose Oxygen 710225 General purpose Cl2 ClO2 NO2 HCL and HCN 812075 Combustible 710436 Sensorgard gasket 812152 NOTE Contatct 1 800 MSA INST for factory support in determining the appr...

Page 90: ... the main unit Contact 1 800 MSA INST for factory support in determining the appropriate part number Display printed circuit board 711033 Plastic Support display printed circuit board 655654 Strobe red 634674 Strobe gasket 711168 Battery 655759 Power supply 655623 Piezo Buzzer 637123 Horn federal 655656 Pump kit DC 711169 Pump kit aspirated 711213 Air line flow assembly 711267 Autocal assembly 813...

Page 91: ...moving 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 Allows 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 place...

Page 92: ...at 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 ...

Page 93: ...t 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 Figure A 2 Duct Template Appendix A Optional Toxgard II Duct Mount Kit A 3 ...

Page 94: ...late 710769 A 7 Toxgard II Gas Monitor Duct Mount Kit Base Plate 814862 A 14 Two 1 4 inch Hex Nuts 631357 Two 1 4 inch Lock Washers 655245 Six 10 32 Screws 634054 Six 10 Lock Washers 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 3 Remote Sensor Spacers Figure A 4 Remote Sensor Clamp Append...

Page 95: ...screw or loosen the screws on the terminal wiring connector Before 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 wi...

Page 96: ...tall 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 occur 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 a...

Page 97: ...sensor Toxgard II Gas Monitor through the slit gasket on the Duct Mount base plate FIGURE 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 Figure A 7 Duct Mount and Sensor Appendix A Optional Toxgard II Duct Mount Kit A 7 ...

Page 98: ...se 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 h...

Page 99: ... value This value is printed on the cylinder containing the gas Exhaust Gas The gas after it passes the sensor Flow Rate The speed of the gas in the sample line Pump An electromechanical device which moves the gas sample to the Toxgard II instrument Upscale Instrument alarms on gas concentrations greater than or equal to the alarm value Downscale Instrument alarms on gas concentrations less than o...

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