MSA Toxgard® II Gas Monitor Owner's manual

Toxgard

®

II Monitor

Instruction Manual

THIS MANUAL MUST BE CAREFULLY READ BY ALL INDIVIDUALS WHO HAVE OR WILL

HAVE THE RESPONSIBILITY FOR USING OR SERVICING THE PRODUCT. Like any piece

of complex equipment, this device will perform as designed only if it is used and serviced

in accordance with the manufacturer’s instructions. OTHERWISE, IT COULD FAIL TO

PERFORM AS DESIGNED AND PERSONS WHO RELY ON THIS PRODUCT FOR THEIR

SAFETY COULD SUSTAIN SEVERE PERSONAL INJURY OR DEATH.

The warranties made by Mine Safety Appliances Company with respect to the product are

voided if the product is not used and serviced in accordance with the instructions in this

manual. Please protect yourself and others by following them. We encourage our cus-

tomers to write or call regarding this equipment prior to use or for any additional infor-

mation relative to use or service.

In the U.S., to contact your nearest stocking location, dial toll-free 1-800-MSA-INST

To contact MSA International, dial 724-776-8626.

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

Manufactured by

MSA NORTH AMERICA

1000 Cranberry Woods Drive, Cranberry Township, PA 16066

(L) Rev 9 711266

"! WARNING

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 onto 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 non-operation of the goods. This exclusion is

applicable to claims for breach of warranty, tortious conduct or any

other cause of action against seller.

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.

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.

"

WARNINGS

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.

FAILURE TO FOLLOW THE ABOVE WARNING CAN RESULT IN

SERIOUS PERSONAL INJURY OR DEATH.

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

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

Figure 1-4. Options and Accessories

(Battery Back-up not shown) . . . . . . . . . . . . .1-4

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

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

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

Table 1-1. Performance Specifications

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

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

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

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

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

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

Mounting the Air-line Toxgard II Monitor . . . . . . . . . . . .1-9

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

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

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

Mounting the Toxgard II Remote Sensor Module . . . . .1-10

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

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

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

" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

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

" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

TOC-1

Figure 1-7. Connection of

Protective Earth Ground Conductors . . . . . .1-12

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

Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13

Relay Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .1-13

Table 1-2. Relay Specifications . . . . . . . . . . . . . .1-13

Alarm Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13

Alarm Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13

Fault Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14

Horn Relay/Audible Outputs . . . . . . . . . . . . . . . . . . .1-14

Audible Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14

Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15

Relay Wiring with Inductive Loads . . . . . . . . . . . . . . .1-15

Milliamp Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15

Isolated 4-20 mA Output . . . . . . . . . . . . . . . . . . . . . .1-16

Digital Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16

Figure 1-7. Standard 4-20 mA Terminal Wiring . . .1-16

Visual Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17

Horn/Alarm Acknowledge Button . . . . . . . . . . . . . . . . .1-17

" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17

Remote Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

Electrical Connections

for the Remote Sensor Module . . . . . . . . . . . . . . . . .1-18

" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

For Combustible Models . . . . . . . . . . . . . . . . . . . . . .1-19

Table 1-3. Wire Gauge

Vs. Distance Between Units . . . . . . . . . . . . .1-19

Table 1-4. Remote Combustible Sensor

Wiring Cable . . . . . . . . . . . . . . . . . . . . . . . . .1-19

Wiring the Toxgard II Monitor/Less Sensor

Using the Internal Terminal Block . . . . . . . . . . . . . . .1-19

At the Toxgard II Remote Sensor Location . . . . . . .1-20

Figure 1-8. Combustible Remote Sensor . . . . . . .1-20

" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20

Figure 1-9. Oxygen Remote Sensor Cable . . . . . .1-21

Figure 1-10. Oxygen and Toxic Remote Sensor . .1-21

Oxygen Remote Sensor Wiring . . . . . . . . . . . . . . . . .1-22

At the Toxgard II Monitor/Less Sensor Location . . . .1-22

At the Toxgard II Remote Oxygen Sensor Location .1-22

TOC-2

TOC-3

" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22

" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23

Toxic Gas Remote Sensor Wiring . . . . . . . . . . . . . . .1-23

At the Toxgard II Monitor/Less Sensor Location . . . .1-23

" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23

At the Toxgard II Remote Toxic Sensor Location . . .1-24

" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24

Figure 1-11. Toxic Gas Remote Sensor Cable . . .1-24

Pump Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25

Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25

Table 1-5. SW2 Switch Settings . . . . . . . . . . . . . .1-25

" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25

Table 1-6. SW3 Switch Settings . . . . . . . . . . . . . .1-26

Figure 1-12. Pump Wiring . . . . . . . . . . . . . . . . . . .1-26

Controller/Calibrator Operation . . . . . . . . . . . . . . . . . .1-27

Internal Push-buttons . . . . . . . . . . . . . . . . . . . . . . . . . .1-27

Viewing Configuration Parameters . . . . . . . . . . . . . . . .1-27

Table 1-7. Parameters Displayed

During MODE Push-button Operation . . . . .1-28

Changing Parameter Settings . . . . . . . . . . . . . . . . . . .1-29

Method 1 - Push-buttons . . . . . . . . . . . . . . . . . . . . . .1-29

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29

When the unit returns to normal operation: . . . . . . . .1-30

Alarm Setting: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30

Method 2 - Ultima Controller . . . . . . . . . . . . . . . . . . .1-30

Battery Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30

Table 1-8. Expected Battery Operating Time

at 77° F . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32

Banshee Horn Audible Settings . . . . . . . . . . . . . . . . . .1-32

" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32

" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33

Figure 1-13. Banshee Horn Audible Settings . . . .1-33

Autocalibration Option . . . . . . . . . . . . . . . . . . . . . . . . .1-34

Duct-Mounted Remote Sensor Installation . . . . . . . . .1-34

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

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

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

Non-combustible Chemicals

that Reduce Sensor Sensitivity . . . . . . . . . . . . . . . . . .2-4

Table 2-1. Sensor Response to Interferants . . . . .2-4

Figure 2-3. Ultima Calibrator . . . . . . . . . . . . . . . . . .2-6

Figure 2-4. Ultima Controller . . . . . . . . . . . . . . . . . .2-6

Calibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

Toxgard II Monitor Controller . . . . . . . . . . . . . . . . . . . .2-7

Toxgard II Monitor Calibration Output Signal . . . . . . . .2-7

Chapter 3,

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

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

" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

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

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

Figure 3-1. Calibration Kit 40 Contents . . . . . . . . . .3-3

Calibration Kits 41 and 43 . . . . . . . . . . . . . . . . . . . . . . .3-4

Figure 3-2. Calibration Kit 41 Contents . . . . . . . . . .3-4

Figure 3-4. Calibration Kit 43 Contents . . . . . . . . . .3-5

Figure 3-3. Calibration Kit 42 Contents . . . . . . . . . .3-5

Calibration Kit 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Figure 3-5. Calibration Kit 54 Contents . . . . . . . . . .3-6

Span Gas Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Toxgard II Gas Monitor Calibration . . . . . . . . . . . . . . . . .3-7

Calibration Documentation . . . . . . . . . . . . . . . . . . . . .3-7

" CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

To Zero the Toxgard II Gas Monitor Only . . . . . . . . . .3-8

Procedure Number 1 . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Figure 3-6. Zero Cap Placement . . . . . . . . . . . . . . .3-9

Figure 3-7. Calibration Tubing Set-up . . . . . . . . . .3-10

Figure 3-8. Zero Gas Connection . . . . . . . . . . . . .3-10

Figure 3-9. Apply Zero Gas Flag . . . . . . . . . . . . . .3-11

Figure 3-10. Calibration End Display . . . . . . . . . . .3-11

Figure 3-11. Calibration Fault Flag . . . . . . . . . . . .3-12

Procedure Number 2 . . . . . . . . . . . . . . . . . . . . . . . . .3-13

TOC-4

Figure 3-12. Zero Cap Placement . . . . . . . . . . . . .3-13

Figure 3-13. Zero Gas Connection . . . . . . . . . . . .3-14

Perform a Complete Calibration . . . . . . . . . . . . . . . .3-15

Procedure Number 1 . . . . . . . . . . . . . . . . . . . . . . . . .3-16

Zeroing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

Spanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

Figure 3-14. Apply SPAN Gas Flag . . . . . . . . . . . .3-18

Figure 3-15. Span Set-up . . . . . . . . . . . . . . . . . . . .3-19

Figure 3-16. Calibration End Display . . . . . . . . . . .3-20

Figure 3-17. Span Gas Connection . . . . . . . . . . . .3-20

Procedure Number 2 . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Zeroing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Spanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

OXYGEN Calibration . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

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

INITIAL Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Toxgard II Airline Monitor, Pumped Version

and Aspirated Version Calibration . . . . . . . . . . . . . .3-26

Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . .3-26

Figure 3-18. Typical DC Pump Version

Installation . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

Figure 3-19. Typical Air Aspirator Version

Installation . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

Zero Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

Figure 3-20. Typical Air Line Monitor Installation . .3-28

Chapter 4,

Specifications . . . . . . . . . . . . . . . . . . . . . . . . .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

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

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

TOC-5

" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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

General-purpose Model . . . . . . . . . . . . . . . . .5-3

Figure 5-4. Cap Location for Remote Toxic Gas

or Oxygen Explosion-proof Sensor . . . . . . . .5-4

Figure 5-5. Combustible Three-Pin Connector . . . .5-4

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

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

Table 5-1. Troubleshooting Guidelines . . . . . . . . . .5-6

Obtaining Replacement Parts . . . . . . . . . . . . . . . . . . . .5-8

" 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

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

Table A-1. Dual Module Duct Mount Kit Parts List A-4

" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

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

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

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

" WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

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

Appendix B,

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

TOC-6

1-1

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 the environment where the monitor is mounted

and to alert you to potentially dangerous levels of one of the following

gases, depending on your particular model:

• Combustible gas • Hydrogen Cyanide

• Oxygen • Hydrogen Chloride

• Carbon Monoxide • Nitric Oxide

• Hydrogen Sulfide • Nitrogen Dioxide

• Chlorine • Sulfur Dioxide

• Chlorine Dioxide

1-2

Figure 1-1. Toxgard II Monitor

• 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 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 Label Identifying Sensor Type

1-3

Mounting Your Gas Monitor

Generally, the unit or the remote sensing module should be mounted

close to the area where a leak is likely to occur or where the gas is

expected. The Toxgard 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 view.

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 flam-

mable mixture of combustible gas and air may be present;

otherwise, an explosion may occur.

Mount the Toxgard II Monitor or the Remote Sensing Module

with its sensor inlet fitting (FIGURE 1-1 or 1-2) pointed down-

wards; otherwise, the inlet may become clogged with partic-

ulate matter or liquids. Do not paint the Toxgard II Monitor. If

Figure 1-4. Options and Accessories

(Battery Back-up not shown)

"

WARNING

1-4

painting is done in an area where a sensor is located, exer-

cise CAUTION to ensure paint is not deposited on the sen-

sor inlet fitting. Such paint deposits would interfere with the

diffusion process, whereby a sample of the monitored

atmosphere diffuses into the sensor. Failure to follow the

above can result in serious personal injury or death.

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 before positioning the Toxgard

II unit or sensor assembly. Smoke tubes (P/N 458481) are useful in

measuring the direction and rate of air 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 Toxgard II unit normally operates in the diffusion mode

(i.e., gases or vapors to be detected enter the sensor input by natural

molecular diffusion), a sample can be drawn into the instrument if the

DC pump or air aspirator option was purchased.

The Toxgard II Pump or Aspirator Model:

• draws 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)

"

CAUTION

1-5

• comes equipped with a special flow cap for use on the Toxgard II

Gas Monitor to ensure proper sensor sampling.

• provides 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 30 seconds at 0.5 lpm with 50 feet (15.25 meters)

TRANSPORT TIME of .180 (4.57 mm) ID sample tubing

NOMINAL SAMPLE 2 CFH (1 LPM)

FLOW RATE

MINIMUM SAMPLE 1 CFH (.500 LPM)

FLOW RATE

MAXIMUM SAMPLE 100 feet (30 meters); 3/16" ID (4.76 mm)

TUBING LENGTH 25 feet (7.5 meters) maximum for Chlorine, Nitrogen

Dioxide and Chlorine Dioxide

MAXIMUM EXHAUST 20 feet (6 meters)

TUBING LENGTH

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

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

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 haz-

ard will exist, resulting in a possible explosion, injury or

death.

Installation of DC Pump or Aspirator Sampling

Sample Line Placement

1. 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.

• MSA tubing is available (P/N 600771).

The pump or aspirator draws a gas sample 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.

"

WARNING

1-6

• Uses 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.

• With 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.

1-7

2. Using suitable hardware (not supplied):

• 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.

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

4. 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 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, 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.

1-8

Blocked Flow Detection of Sample Line

Units equipped with the pump or air aspirator options are supplied with

a flow detector. This flow detector activates the fault relay when

insufficient flow exists for proper gas detection.

Mounting the Air-line Toxgard II Monitor

These units must not be located in areas which may contain

a flammable mixture of gas and air; otherwise, an explosion

may occur.

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.

Do not exceed 300 pounds maximum inlet pressure; other-

wise, 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 delivered from a pressurized stream to the

Toxgard II unit. Inlet pressure to the flow block should not exceed

10 PSI.

"

WARNING

"

CAUTION

"

CAUTION

1-9

Mounting the Toxgard II Remote Sensor Module

The Remote Sensor Module:

• 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 sensor module during calibration.

Electrical Connections for Toxgard II Monitors

• Recommended wire is three-conductor, 16 gauge (12 gauge

maximum).

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

disconnection purposes.

Figure 1-5. Remote Sensor Mounting Method

1-10

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MSA Toxgard® II Gas Monitor Owner's manual

MSA Toxgard® II Gas Monitor Owner's manual

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