Manual GC Controller PDF

PolyGard® Gas Controller MGC-02
Analog Gas Controller

Serial Number - 15
User Manual
June 2005
PolyGard is a registered trademark of MSR GAMGC02E01
Phone: 0049(0)8531/9004-0 Fax: 0049(0)8531/9004-54 Specification subject to change without notice.

MSR-Electronic GmbH, Würdinger Str. 27, D 94060 Pocking www.msr-electronic.de Printed in Germany
User Manual PolyGard® MGC-02 Page 2
1 Description................................................................................................................................................ 4
2 Operating Instruction ............................................................................................................................... 5
2.1 Describtion Keypad User Interface ..................................................................................................... 5
2.2 Setting / Change Parameter or Set points .......................................................................................... 5
2.3 Code Level .......................................................................................................................................... 6
3 Menu Overview ......................................................................................................................................... 7
3.1 Malfunction management.................................................................................................................... 8
3.1.1 Acknowledge a malfunction ......................................................................................................... 8
3.1.2 Error Memory ............................................................................................................................... 8
3.1.3 System Errors .............................................................................................................................. 9
3.2 Status Alarm...................................................................................................................................... 10
3.3 Status Relay ...................................................................................................................................... 10
3.3.1 Manual operation of the relay .................................................................................................... 10
3.4 Menu Measuring Values ................................................................................................................... 11
3.5 Menu Relay Parameter ..................................................................................................................... 11
3.5.1 Relay Mode ................................................................................................................................ 12
3.5.2 Relay Function Static / Flash ..................................................................................................... 12
3.5.3 Latching Mode ........................................................................................................................... 12
3.5.4 Horn Function ............................................................................................................................ 13
3.5.5 External Relay operation............................................................................................................ 14
3.6 Menu MP Parameter ......................................................................................................................... 14
3.6.1 Activate – Deactivate MP........................................................................................................... 15
3.6.2 Selection Gastype...................................................................................................................... 15
3.6.3 Measuring range ........................................................................................................................ 16
3.6.4 MP Signal................................................................................................................................... 16
3.6.5 Threshold / Hysteresis ............................................................................................................... 16
3.6.6 Delay Alarm ON or OFF............................................................................................................. 16
3.6.7 Control Mode ............................................................................................................................. 17
3.6.8 Assigned MP Fault to Alarm ...................................................................................................... 17
3.6.9 Assigned Alarm to Alarm relay .................................................................................................. 17
3.6.10 Assigned MP Signal to analog Output ....................................................................................... 17
3.7 Menu System Parameter .................................................................................................................. 18
3.7.1 Service Mode ............................................................................................................................. 19
3.7.2 Software Version........................................................................................................................ 19
3.7.3 Maintenance Concept ................................................................................................................ 20
3.7.4 Average Function....................................................................................................................... 20
3.7.5 Systemtime, Systemdate ........................................................................................................... 20
3.7.6 Customer Password (Code 1).................................................................................................... 20
3.7.7 Analog Output ............................................................................................................................ 21
3.7.8 Define the Failure Relay ............................................................................................................ 21
3.7.9 Power On Time .......................................................................................................................... 21
3.7.10 Registration of expansions modules.......................................................................................... 21

4 Mounting / Electrical Connection ......................................................................................................... 22

4.1 Electrical Connection ........................................................................................................................ 22
4.2 Connection Diagram – Power suppy ................................................................................................ 23
4.3 Connection Diagram – Gas Controller Module GC 02...................................................................... 24
4.4 Connection Diagram – EP-02 Module No. 1..................................................................................... 25
5 Start-up Operation.................................................................................................................................. 30
5.1 Start-up.............................................................................................................................................. 30
5.2 Checklist Start-up operation.............................................................................................................. 31
6 Configuration- and Parameter card. ..................................................................................................... 32
6.1 Configurationscard Systemparameter .............................................................................................. 32
6.2 Configurationscard Alarmrelay.......................................................................................................... 32
6.3 Configurationscard Measuring Parameter ........................................................................................ 33
7 Specifications ......................................................................................................................................... 34
8 Appendix module overview ................................................................................................................... 35
9 Notes and General Information............................................................................................................. 36
9.1 Intended product application ............................................................................................................. 36
9.2 Installers` responsibilities .................................................................................................................. 36
9.3 Maintenance...................................................................................................................................... 36
9.4 Limited warranty ................................................................................................................................ 36

Analog Gas Controller System MGC-02
1 Description
The PolyGard® MGC-02 Gas Controller is used for the monitoring and warning of toxic- combustible- and
refrigerant- gases as well as temperature and humidity. The Gas Controller series MGC-02 can control up to 24
analog (Gas) Transmitters with 4 to 20 mA signal. For each Measuring Point (MP) are adjustable five freely alarm
thresholds. Every alarm threshold can be asigned to one of the maximum 20 alarmrelays (R) with changeover,
potential free contact. The Gas Controller can interface via 4 to 20 mA outputs to any compatible electronic analog
control, DDC/PLC control or automation system.
The free adjustable parameters and alarm threshold make a very flexible use in the gas measuring possible.
Simple and comfortable start-up is possibily with the factory adjusted parameters.
The configuration parameter settings and operation is easy to do without program knowledge.
The PolyGard® Gas Controller MGC-02 must not be used in areas showing explosive hazards.

2 Operating Instruction
The complete configuration, parameterization and service is made via keypad user interface in combination with
the display screen. Security is provided via two password levels.
Fault Alarm
MSR - Electronic
22.01.05 20:28
2.1 Describtion Keypad User Interface
Exits programming and saves settings, returns to the previous menu level.
Enter sub menus, stores security password.
Scrolls down & up in Main menu and Sub menus, increases or decreases a value.
Moves of cursor.
LED yellow Flashes when set one or more Alarm.

LED red: Flashes at System- or Sensor Failure or Maintenance needed.
2.2 Setting / Change Parameter or Set points
Desired menu window open.
Code window opens, if no code level approved.
After input valid code the cursor jumps on the first position segment which can be changed.
Push the cursor onto the position segment, which is to be changed.
Change the Parameter /Set Point.
Saving the changed value.
Finish

2.3 Code Level
All changes of parameters and set point values are protected by four digit numeric Code (= password).
The code level 1 permits the operation of the MGC- 02. This code level is intended for the customer. The code can
be individually changed over the code level 2.
With the code level 2 all parameters and set points are released, this code level are reserved for the service
technician.
A third code level permits additionally an activate or deactivate of measuring points (MP) and expansions modules
(EP).
The release of the code level is deleted if 15 minutes not press a push button.
All menu windows can without release code level be regarded.

3 Menu Overview
The operation of the Gas Controller MGC-02 is made by a easy to learn, simply and logical menu structure.
The operating menu contains the following levels:
• Starting menu with Date and Time.
• Main Menu
• Sub Menu 1 and 2
Starting Menu Main Menu Sub Menu
MSR-Gas-Control
10.02.05 10:38
System Errors
Display and Reset Erros
See from point 3.1
Status Alarm
Display the status of actual alarms
See at point 3.2
Display the status of relay

Status Relay Manual operation of relay
Reset Function of relay
See from point 3.3
Measuring Values
Display the measuring values
See at point 3.4
Relay Parameter
Display and Change the relay parameter
See from point 3.5
Display and Change the Measuring point parameter

MP Parameter
Activate or Deactivate MP
Assigned the alarms to the Alarmrelay
See from point 3.6
System Parameter Display and Change the system parameter
See from point 3.7

3.1 Malfunction management

The integrated malfunction management record the last 15 malfunctions with date and time stamps in the menu
„System Errors“. Additionally a record of the malfunction occurs in the “Error memory”, which can be selected and
cleared only by the service technician.
A malfunction is overlayed as text message in the starting menu. The failure relay which is defined in the system
parameter „Failure relay“ is activating. The red LED in the front of the gas controller flashed.
During the malfunction of a measuring point (MP) additionally the alarms are activated, which are defined in the
menu „MP Parameter“.
3.1.1 Acknowledge a malfunction

Attention:
Acknowledging of a malfunction is only possible after the removal of the cause.
System Errors Select Menu “System Errors”
MP 01 < 3mA Example: Failure MP 01 < 3 mA

05.02 10.38
MP 01 < 3mA Malfunction Reset?

Reset ??
Malfunction Reset
MP 01 < 3mA Error still

Ereased or
exists
Malfunction Ereased Cause not eliminate

Acknowledgement not possible
3.1.2 Error Memory

The menu „Error memory“ in the main menu „System Error„ is to be opened only by the code level 2
In the error memory the last 20 malfunction message are listed for the service technician. Even if they in the menu
„System Error“ were already acknowledged. The deletion of each individual message occurs similar to the
acknowledgement of a malfunction.

3.1.3 System Errors

Following System Error Message are recorded.
MP XX > 22 mA Current signal at analog Input XX > 22 mA.
Cause: Short-circuit at analog Input or Transmitter not calibrated, Transmitter defective.
Solution: Check cable to Transmitter, Make Calibration, Change the Transmitter.
MP XX < 3 mA Current signal to analog Input XX < 3 mA.

Cause: Wire break at analog Input or Transmitter not calibrated, Transmitter defective.
Solution: Check cable to Transmitter, Make Calibration, Change the Transmitter.
GC Error: Internal Communication Error I/O Board to LCD Board.

Cause: Internal Error.
Solution: Change the Gas Controller.
EP 0X Com Fehler: Communication Error to Expansions module (EP 0X).

(Only active, if a EP announced).
Cause: EP module address not correct. (See Start-up 5.0)
Bus cable break to EP 0X module.
No power supply at the EP 0X module.
EP module defective.
Solution: Check the EP Module address.
Check the Bus cable and the Power supply.
Change the EP 0X module.
Maintenance: System maintenance is necessary.

Cause: Maintenance date exceeded.
Solution: Make the maintenance.

3.2 Status Alarm

Display the actual alarms in sequence of accumulating. Only the measuring points are overlayed, where an alarm
is set. Changes are not possible in this menu.
MP 02
A1 A2
Symbol Describtion Function

Measuring
MP 02
(MP) Point No.
A1 = Alarm 1 ON
A2 = Alarm 2 ON
AX Status Alarm A3 = Alarm 3 ON
A4 = Alarm 4 ON
A5 = Alarm 5 ON
3.3 Status Relay

Display the actual status of the Alarm relay. Manual operation of the alarm relays.
R 01
OFF
Setting
Status
R 01 Relay No. 01 Select Relay No.
OFF = Relay Off (No gas alarm)
ON = Relay On (Gas alarm)
OFF Status Relay OFF
Manual OFF = Relay manual Off
Manual ON = Relay manual On
3.3.1 Manual operation of the relay

The manual operation of the alarm relays occurs in the menu „Status Relay”. If a relay is in the manual ON or OFF
status, shines the yellow alarm LED at the Gas Controller continuously.
The external operation of the alarm relay over an assigned digital input has the priority before the manual
operation in the menu "Status Relay" and Gas alarm.
In the menu „Status Relay “manually operated relays are again deleted by selection of the function "Automatic".
Acknowledging the relays by Latching mode occurs also in this menu.
R 01
OFF Select Relay
Manual ON
Select Function Manual operation
Manual ON = Relay ON
Manual OFF Select Function Manual OFF = Relay OFF
Automatic = Manual operation delete
Reset ? = Acknowledging Latching mode
Take over Function

Manual OFF

3.4 Menu Measuring Values

In this menu occurs the Display of the current value (CV) and average value (AV) with gas unit and gas type for
each active measuring point (MP) as well as the defined mode of control (CV or AV mode).
MP 01 CO ppm
50 *AV 33 CV
Setting
Status
Measuring
MP 01 Select MP No
Point No.
CO Gas type CO See 3.6.2
ppm Gas unit See 3.6.2
CV Current value CV Current value of Gas Concentration
AV Average value Avergae value (10 measured values within the time unit)
* Control mode Display, with Control mode is select. (CV or AV)
Not active Status MP Not active MP not announced
Error Malfunction MP Current signal < 3 mA or > 22 mA
3.5 Menu Relay Parameter

Display and change the parameter for each alarm relay.
Relay Parameter
(Main menu)
R 01
(Selection Relay No.)
Relay Mode
De- energized Relay Mode
See 3.5.1
Static / Flash
Relay Function
0s
See 3.5.2
Latching mode
No Activate Latching Mode
See 3.5.3
Time Quitt. DI
0s 0 0 Definition Horn Function
See 3.5.4
External mode
DI: ON = 0: OFF = 0 Definition external Relay Operation
See 3.5.5

3.5.1 Relay Mode

Definition Relay Mode:
Setting
Status
R 01 Relay No. Selection Relay
De- De- De-energized = Alarm ON = Relay ON
Relay Mode
energized energized Energized = Alarm ON = Relay OFF
3.5.2 Relay Function Static / Flash

Definition Relay Function
Setting
Status
0 = Relay Function static
0 Function 0 > 0 = Relay Function flashing ( = Periods time sec.)
Impulse / Break = 1:1
3.5.3 Latching Mode

Definition Latching Function
Setting
Status
No = Latching Mode non active
No Latching Mode No
Yes = Latching Mode active
Acknowledging of a latching relay in the menu „Status Relay“ is possible only if the gas concentration is again
smaller than the alarm threshold including hysteresis. In this condition the status Latching is overlay.
Example: Alarm relay R2 with Latching mode
On
Alarm 2 Gas Concentration greater smaller as Threshold
Off
Display in the Menu R2 R2 R2 R2 R2 R2

Status Relay Off On On On Latching Off
On
Relay 2
Off
Reset in the Menu On

Status Relay
Off

3.5.4 Horn Function

With this parameter the alarm relay is defined as horn relay with the following acknowledging possibilities.
• By press of one the arbitrary 6 pushbutton. (Only possible in the starting menu).
• Automatic acknowledging at time run off.
• By an external pushbutton. (Assignment appropriate digital input).
The horn function is activated only if at least one of the two parameters (time or digital input) is set.
Special function Response
After acknowledging the relay (over Pushbutton or externally) time starts. If this time run off and if the alarm still
acting, the relay is again set.
Setting
Status
0 = Acknowledge the relay at time run off, or over Pushbutton
Quitt Mode 0 1 = Acknowledge the relay over Pushbutton, af time run off and
alarm is still acting, relay is set again. (Response function).
Time for function Automatic acknowledging or Response function
Time 120
0 = non acknowledging function
DI 0 Assignment, which digital input acknowledges the relay.
Acknowledge the horn relay
On
Of
Time
On
Relay 4
Off
Acknowledging On
signal
Off
Special function „Response“. (Return of the horn relay)
On
Off
Time Time
On
Relay 4
Off
Acknowledging- On
signal
Off

3.5.5 External Relay operation.

Assigned one digital input (DI) for external set the alarm relay ON and/or OFF. This function has priority before a
gas alarm and/or manual switching in the menu „Status Relay“.
Setting
Status
DI-ON External On 0 If digital input closed, relay switch ON
DI-OFF External Off 0 If digital input closed, relay switch OFF
3.6 Menu MP Parameter

Display and Change Parameters, Assigned Alarms to Alarmrelay and activate each Measuring Point (MP).
MP Parameter
(Main Menu)
MP 01
active (Selection MP)
MP Mode
active Activate or deactivate MP
See 3.6.1
Gastype
Define Gastype
CO
See 3.6.2
Measuring range
300 ppm Define Meassuring range
See 3.6.3
MP-Signal
linear Adjustment signal form of transmitter
See 3.6.4
Threshold 1
40 ppm Define Threshold 1
See 3.6.5
Threshold 2
See 3.6.5
Threshold 3
See 3.6.5
Threshold 4
Define Threshold 4
120 ppm
See 3.6.5

Threshold 5
See 3.6.5
Hysteresis
Hysteresis
15 ppm
See 3.6.5
Delay ON time
0s Set Delay ON time
See 3.6.6
Delay OFF time

0s Set Delay OFF time
See 3.6.6
C/A Mode
Define Control Mode
CV
See 3.6.7
Alarm - 1 2 3 4 5
Assigned MP Fault to Alarm
Fault - 1 1 0 0 0
See 3.6.8
Assigned Alarm to Alarmrelay

A1; A2; A3; A4; A5; AO
Assigned MP to analog output
01; 02; 03, 04; 05; 0
See 3.6.9 and 3.6.10
3.6.1 Activate – Deactivate MP
Setting
Status
MP 01 Measuring point Selection MP No.
not active = Measuring point announced
Active MP Status
active not active = Measuring point not announced
3.6.2 Selection Gastype

Assign Gastype to attached gas transmitters.
Setting Measuring
Symbol Describtion Gastype Unit
Status range1
MP 01 Measuring point .
CO Carbon monoxide ppm 0 – 300
Ex Combusible Gase %LEL 0 – 100
NO Nitric monoxide ppm 0 – 50
NO2 Nitric dioxide ppm 0 – 25
NH3 Ammonia ppm 0 – 300
O2 Oxygen2 %V/V 0 – 25
CO Gastype CO CO2 Carbon dioxide ppm 0 – 2000
R11 Refrigerant gase ppm 0 –xxx
R123 Refrigerant gase ppm 0 – xx
Temp Temperature °C --
RH Humidity % RH 0 – 100
1
Non obligation Recommendation
2
During oxygen measurement falling signal!

3.6.3 Measuring range

The measuring range can be defined within 10 to 10000 freely. The measuring range in the table gastype are non
obligation recommendations.
The measuring range must agree with the signal (4 to 20 mA) attached gas transmitters.
(4 mA = Display 0 (ppm), 20 mA = Display Measuring range max. point)
3.6.4 MP Signal
Gas transmitter with electro-chemical - or catalytic beat gas sensors spends in rule a linear, for gas concentration
proportional 4 to 20 mA signal.
Semiconductors gas sensors spend a not linear (exponential) signal. This signal leads to a non linear 4 to 20 mA
signal of the gas transmitter.
The Gas Controller MGC-02 is for both type of gas transmitters prepared. The classification of signals is defined in
this menu.
Setting
Status
MP 01 Measuring Point Selection MP No.
linear = Transmitter with linear Output signal
Linear MP Signal linear Non linear = Transmitter with non linear Output signal (Only
Series AT from MSR-E)
3.6.5 Threshold / Hysteresis

For each measuring point five alarm thresholds for the free definition are available. If the gas concentration greater
the adjusted alarm threshold, the associated alarm is set. If the gas concentration falls below the alarm threshold
inclusive hysteresis the alarm is again put back.
Not Necessary alarm thresholds to be defined on measuring range end point, in order to avoid false alarms.
With O2 measurement ocurs an alarm release with falling measuring signal!
Default
Status
40 Threshold 1 Gasconcentration > Threshold 1 = Alarm 1
40 ppm Threshold 120 Threshold 4 Gasconcentration > Threshold 4 = Alarm 4
15 Hysteresis Gasconcentration < (Threshold X –Hysteresis)
= Alarm X OFF
3.6.6 Delay Alarm ON or OFF

Definition Delay Alarm ON and/or Alarm OFF. The function applies to all alarm by this MP.
Default
Status
Gasconcentration > Threshold: Alarm is only activated at
0s Delay Time ON 0
expiration of the defined time (sec.). 0 sec. = No Delay
Gasconcentration < Threshold: Alarm is only deactivated at
0s Delay Time OFF 0
expiration of the defined time (sec.). 0 sec. = No Delay

3.6.7 Control Mode

Definition of the alarm evaluation by Current (CV) or Average value (AV).
Default
Status t
CV = Control the Current Gas value
CV Evaluation CV
AV = Control the Average Gas value
Current- Average Value Function See: 3.7.4
3.6.8 Assigned MP Fault to Alarm

Define, which alarms are activated with a failure at the measuring point.
Default
Status
Alarm - 1 2 3 4 5 0 = Alarm not ON at MP Failure
Failure MP 11000
Fault - 1 1 0 0 0 1 = Alarm ON at MP Failure
3.6.9 Assigned Alarm to Alarm relay

Each of the 5 alarms can be assigned to a freely selectable alarm relay. Alarms, those not to be needed do not
receive assignment.
Default
Status
A1 01 01 = Alarm 1 activate Alarmrelay R 01
1 A3 03 03 = Alarm 3 activate Alarmrelay R 03
A5 00 00 = Alarm 5 activate no any Alarmrelay
0 = MP Signal no assigned to any analog output
0 A 0 1 = MP Signal assigned to analog output 1
2 = MP Signal assigned to analog output 2
3.6.10 Assigned MP Signal to analog Output

The measuring point signal can be assigned to one of the two analog Outputs. The signal defined in the control
mode (current or average value) is transmitted. The assignment occurs in the menu „assignment alarm < > alarm
relay” in the right place.
Analog output see also: 3.7.2

3.7 Menu System Parameter

Display and change the System Parameter for the Gas Controller
System Parameter
(Main Menu)
Service Mode
See 3.7.1
OFF
Software Version
GC02- XX See 3.7.2
Next maint. Date

TT.MM.JJ See 3.7.3
Service Phone
See 3.7.3
+49/(0)8531/90040
AV Overlay
See 3.7.4
120 s. 120 ppm
AV Time
1800 s See 3.7.4
Time system
See 3.7.5
EU
Time
See 3.7.5
hh:mm:ss
Date
See 3.7.5
TT.MM.JJ
Customers Pass
Change **** See 3.7.6
Analog Output 1
Max. See 3.7.7
Calibration AO 1
4.0=4 mA 20 = Siehe
20.0 See 3.7.7

Analog Output 2
Max. See 3.7.7
Calibration AO 2
See 3.7.7
4.0=4 mA 20 = 20.0
Failure Relay
05 See 3.7.8
Power On Time
30 s See 3.7.9
EP Module 1
Not active See 3.7.10
EP Module 2
Not active See 3.7.10
EP Module 3
See 3.7.10
Not active
EP Module 4
See 3.7.10
Not active
EP Module 5 See 3.7.10

Not active
3.7.1 Service Mode

If the Sevice mode is active (ON) then the alarms are not passed on to the alarm relays. (For Calibrate or Service
work). The service mode is Reset automatically after 60 minutes or in the menu “service mode” manually.
Default
Status
Off = Alarms activate the associated alarm relays
Off Service Mode Off
On = Alarms are not passed on to the alarm relays
3.7.2 Software Version
Default
Status
GC02- Software
XX = Software Version
XX Version

3.7.3 Maintenance Concept

In the MGC-02 system is a monitoring of the maintenance intervals, given by the Regulations or Customer,
integrated.
With start-up and/or after maintenance the date for next due maintenance is entered. With reaching this date on
the next morning at 9 o'clock the failure signal is activated and in the display the phone No. of the service
technician is overlay. The failure signal (maintenance) can be acknowledged by the operator. The maintenance
message (Service Phone No.) is put back after accomplished maintenance with input next maintenance date.
The service phone No. can be individually entered in the next menu.
Default
Status
TT.MM.JJ Maintenance date TT.MM.JJ = Input date for next maintenance.
0853.... Phone No. Input the individual service phone No.
3.7.4 Average Function

The Gas Controller calculate for each active measuring point the arithmetic average value from 10 measurements
within time unit defined in the menu „AV-time“. This average value is indicated in the menu “Measuring Values”
near the current value. At each Measuring Point the control mode of current value or average value for the alarm
evaluation is defined.
The alarm evaluation of the control mode average value is overlaid by the current value, if this exceeds alarm
threshold defined in the menu „AV-Overlay“.The overlay is delay with the time factor in this menu.
Default
Status
120 s 120 s sec. = Delay time average value Overlay. 0 = No overlay Function
AV- Overlay
120 ppm 120 ppm ppm = Threshold average Overlay
1800 s AV-Time 1800 s sec. = Time for calculate average value
3.7.5 Systemtime, Systemdate

Input and correction of the time and date. Selection of the time and date format.
Default
Status
EU = Display time and date in EU format
EU Time format EU
US = Display time and date in US format
hh.mm.ss = Input the correct time (EU format)
hh.mm.ss Time
hh.mm.ss am = Input the correct time (US format)
TT.MM.JJ = Input the correct date (EU format)
TT.MM.JJ Date
MM.TT.JJ = Input the correct date (US format)
3.7.6 Customer Password (Code 1)

Change the Systempassword for level 1
Default
Status
Customer-
1234 1234 1234 = Define the Customer Password with 4 characters
password

3.7.7 Analog Output

The Gas Contoller has two analog outputs (AO) with 4 to 20 mA signal. Each of the analog output can be assigned
the signal of one or more measuring points. The assignment occurs in the menu „MP Parameter“ for each MP. The
measuring point sends the signal, which is defined in the menu „C/A Mode“.
The Gas Controller determined from the signal of all assigned measuring points the minimum, the maximum or the
average value and spends in at analog output. The definition, which value is spent effected in the menu „Analog
Output X“.
The analog output can be calibrated with 4 and with 20 mA. In addition at the AO an ampere meter (measuring
range 25 mA) is attached and the respective factor changed to the analog output 4 and/or 20 mA corresponds.
During the calibration ocurrs no evaluation of the measuring point signals. This calibration occurs factory-set. The
factors should not be changed.
Default
Status
Min. = Spends the minimum value of all assigned MP
Select
Max. Max. Max. = Spends the maximum value of all assigned MP
Output mode
Average = Spends the average value of all assigned MP
4.0 4.0 4.0 = Calibration factor at 4 mA
Calibration
20.0 20.0 20.0 = Calibration factor at 20 mA
3.7.8 Define the Failure Relay

Define the Failure Relay. See also malfunction managemnet (3.1)
Default
Status
05 SSM Relay R05 R05 = Define failure relay
3.7.9 Power On Time

Gas sensors need a break-in period, until the chemical process of the sensor reaches a stable condition. During
this break-in period the current signal can lead to unwanted releasing of a pseudo alarm. Therefore at the Gas
Controller is started after switching on of the power supply the Power On Time. While this time runs off, the Gas
Controller does not spend alarms. The power on status is overlay in the starting menu.
Default
Status
30 s Power On Time 30 s XX = Define the Power On Time (sec.)
3.7.10 Registration of expansions modules

The gas Controller can manage, up to five expansions modules (EP-02). Each EP-02 has four analog inputs and
five alarm relay. Each attached EP-02 is announced in this menu. The Controller monitors the communication to
the announced EP-02 modules and spends at a communication error a fault signal. For the recognition of the
position of the EP-02 modules a module address is assigned to each module with the address selector. See table.
The table shows the assignment of the MP and relay numbers to the individual modules.
Default Module Relay

Symbol Describtion Function MP No.
Status Adr. No.
EP- Module No 1 Not active 1 06 to 10 05 to 08
Not Active = Module announced.
active Not active = Module not announced
EP- Module No 4 Not active 4 ---- 17 to 20
EP- Module No 5 Not active 5 ---- 21 to 24

4 Mounting / Electrical Connection

The Gas Controller is installed at the 4 marked mounting holes at housing back side to the wall. These mounting
holes are accessible after opening the housing. See Fig. 01
The dimension XX are depend from MGC-02 type and can be read from the back of housing.
The mounting holes are covered with the enclosed caps after the end of the assembly.
As recommend to consider with the selection of the assembly place:
• Assembly hight approx. 1.6 m for the simple condition.
• Cables are introduced both, from above and from downside.
• On the left side to keep at least 150 mm distance to open the transparent door.
• Defaults of the Customer.
XX
Fig. 01
XX
4.1 Electrical Connection

Ah the installation must be considered the technical requirements and regulations for wiring, electrical security, as
well as project specific and Environmental conditions etc..
We recommend the following cable typs:1

• Power supply NYM-J 3 x 1,5 mm2
• Alarm Relay NYM-J X x 1,5 mm2
• Gas Transmitter J-Y(St)Y 2x2 x 0,8
1
The recommendation does not consider local conditions such as fire protection etc..
The gas transmitter are connected directly at the module with the carge clamps. To consider the correct polarity.
The Alarms also connected directly at the module with the carge clamps. At the clamps of the alarm relays in each
case 2 contacts are present.
The alarms are available as DPDT, potenialfree contacts. If necessary the power supply volltage is available at the
clamps L1.
The exact position of the clamps for the transmitters and alarm relays is to be inferred the following connection
diagram.
The connection diagram contains those maximally possible number of expansion modules. Depending upon Gas
Controller type are however only individual modules equipped.

4.2 Connection Diagram – Power suppy

1N1
Power unit
L 90 to 230 VAC V+
50/60 Hz G+
V+
G G-
COM
1K1 only at 24 V/DC COM

Option EPS N o 1,1 A
equipped o 2,2 A
1K1
1F1
B10A
N PE
L L1L1 X1 1 2
2
1,5 mm
L N PE Power supply X1 1 2
2
Min. Cable diameter : 1,5 mm
90 to 230V / 50 Hz
Max. Fuse : 16 A Option EPS
Rated current : approx 2 A

4.3 Connection Diagram – Gas Controller Module GC 02
G+
G-
X1 1 2 X1110 1112
GND
24 V
0V
SDA
SCL
Module designation: 2N1
Power System Bus

Gas Controller GC 02
analog input digital output digital input analog
D1 D2 D3 D4 D5 output
Relay Relay Relay Relay Relay
> 4-20 mA
> 4-20 mA
> 4-20 mA
> 4-20 mA
< 24 VDC
< 24 VDC
< 24 VDC
< 24 VDC
+ AO 01
+ AO 02
+ DI 01
+ DI 02
+ DI 03
+ DI 04
R 01 R 02 R 03 R 04 R 05
GND
GND
GND
GND
X10 1 2 3 4 5 6 7 8 9 10 X2 1 2 3 4 5 6 7 8 9 1011 12 131415 X11 1 2 3 4 5 6 7 8 9
> GND
< 4-20 mA
< 4-20 mA
Maximum contact rating of relay 11
230 V/ 5 A ohmic load! 1K1
1K1 only at 14 12
Option EPS
equipped
X4 4 3 X4 4 3 X4 4 3 X4 4 3
4-20mA
4-20mA
4-20mA
4-20mA
24VDC
24VDC
24VDC
24VDC
AT-1110 AT-1110 AT-1110 AT-1110
MP 01 MP 02 MP 03 MP 04

4.4 Connection Diagram – EP-02 Module No. 1

(Module only equips at MGC-02 type -- 08-08; 12-12; 16-16; 20-16; 24-16)
X11/12 (2N1) GND
X1/1 (2N1) G+ X11/11 (2N1) SDA
X1/2 (2N1) G- X11/10 (2N1) SCL
X1 1 2 X1110 1112
9 01
Modulel-
GND
24 V
0V
SDA
SCL
78
23
adress 456
Power System Bus

Expansionsmodule EP 02
analog input digital output
D1 D2 D3 D4 D5
> 4-20 mA
> 4-20 mA
> 4-20 mA
> 4-20 mA
< 24 VDC
< 24 VDC
< 24 VDC
< 24 VDC
R 06 R 07 R 08 R 09 R 10
GND
GND
X10 1 2 3 4 5 6 7 8 9 10 X2 1 2 3 4 5 6 7 8 9 10 11 12 131415
Maximum contact rating of relay

230 V/ 5 A ohmic load!
L1
L1
X4 4 3 X4 4 3 X4 4 3 X4 4 3
4-20mA
4-20mA
4-20mA
4-20mA
24VDC
24VDC
24VDC
24VDC
AT-1110 AT-1110 AT-1110 AT-1110
MP 05 MP 06 MP 07 MP 08


(Module only equips at MGC-02 type -- 12-12; 16-16; 20-16; 24-16)
X11/12 (3N2) GND
X1/1 (3N2) G+ X11/11 (3N2) SDA
X1/2 (3N2) G- X11/10 (3N2) SCL
X1 1 2 X1110 1112
9 01
Module-
GND
24 V
0V
SDA
SCL
78
23
adress 456
Power System Bus

D1 D2 D3 D4 D5
> 4-20 mA
> 4-20 mA
> 4-20 mA
> 4-20 mA
< 24 VDC
< 24 VDC
< 24 VDC
< 24 VDC
R 11 R 12 R 13 R 14 R 15
GND
GND
X10 1 2 3 4 5 6 7 8 9 10 X2 1 2 3 4 5 6 7 8 9 10 11 12 131415

L1
L1
X4 4 3 X4 4 3 X4 4 3 X4 4 3
4-20mA
4-20mA
4-20mA
4-20mA
24VDC
24VDC
24VDC
24VDC
AT-1110 AT-1110 AT-1110 AT-1110
MP 09 MP 10 MP 11 MP 12


(Module only equips at MGC-02 type -- 16-16; 20-16; 24-16)
X11/12 (4N3) GND
X1/1 (4N3) G+ X11/11 (4N3) SDA
X1/2 (4N3) G- X11/10 (4N3) SCL
X1 1 2 X1110 1112
9 01
Module-
GND
24 V
0V
SDA
SCL
78
23
adress 456
Power System Bus

D1 D2 D3 D4 D5
> 4-20 mA
> 4-20 mA
> 4-20 mA
> 4-20 mA
< 24 VDC
< 24 VDC
< 24 VDC
< 24 VDC
R 16 R 17 R 18 R 19 R 20
GND
GND
X10 1 2 3 4 5 6 7 8 9 10 X2 1 2 3 4 5 6 7 8 9 10 11 12 131415

X4 4 3 X4 4 3 X4 4 3 X4 4 3
4-20mA
4-20mA
4-20mA
4-20mA
24VDC
24VDC
24VDC
24VDC
AT-1110 AT-1110 AT-1110 AT-1110
MP 13 MP 14 MP 15 MP 16


(Module only equips at MGC-02 type -- 20-16; 24-16)
X11/12 (5N4) GND
X1/1 (5N4) G+ X11/11 (5N4) SDA
X1/2 (5N4) G- X11/10 (5N4) SCL
X1 1 2 X1110 1112
9 01
Module-
GND
24 V
0V
SDA
SCL
78
23
adress 456
Power System Bus

analog input
> 4-20 mA
> 4-20 mA
> 4-20 mA
> 4-20 mA
< 24 VDC
< 24 VDC
< 24 VDC
< 24 VDC
GND
GND
X10 1 2 3 4 5 6 7 8 9 10
X4 4 3 X4 4 3 X4 4 3 X4 4 3
4-20mA
4-20mA
4-20mA
4-20mA
24VDC
24VDC
24VDC
24VDC
AT-1110 AT-1110 AT-1110 AT-1110
MP 17 MP 18 MP 19 MP 20


(Module only equips at MGC-02 type -- 24-16)
X11/12 (6N5) GND
X1/1 (6N5) G+ X11/11 (6N5) SDA
X1/2 (6N5) G- X11/10 (6N5) SCL
X1 1 2 X1110 1112
9 01
Module-
GND
24 V
0V
SDA
SCL
78
23
adress 456
Power System Bus

analog input
> 4-20 mA
> 4-20 mA
> 4-20 mA
> 4-20 mA
< 24 VDC
< 24 VDC
< 24 VDC
< 24 VDC
GND
GND
X10 1 2 3 4 5 6 7 8 9 10
X4 4 3 X4 4 3 X4 4 3 X4 4 3
4-20mA
4-20mA
4-20mA
4-20mA
24VDC
24VDC
24VDC
24VDC
AT-1110 AT-1110 AT-1110 AT-1110
MP 21 MP 22 MP 23 MP 24

5 Start-up Operation
5.1 Start-up
Before beginning of start-up the wiring of the Gas Controller including all field devices must be completely
terminated!
If EP-02 modules is present, the module address must according to the following table on each module examined
and if necessary corrected before switching on of supply voltage on.
The address adder for adjusting the module address is accessible after taking off the contact strip X1 (power).
Module designation Module Address MP No. Relay No.

(Yellow Label) (Switch position)
3N2 1 5 to 8 5 to 10
4N3 2 9 to 12 11 to 15
5N4 3 13 to 16 16 to 20
6N5 4 17 to 20 ----
7N6 5 21 to 24 ----
After switching On of the power supply and end of the Power On Time is the Gas Controller ready for use.
The Gas Controller is delivered with standard parameter and Set points. The registration the attached gas
transmitter and the assignment of the alarm relays to the individual alarms must always occurs with start-up.
Additional all other parameters are to be examined and adapted to the local conditions.
The standard parameter are to be taken from the following configuration and parameter card. We recommend to
register the individual parameters and being into the map.
We recommending to check the parameters and set points after the following check list.

5.2 Checklist Start-up operation
System Parameter
Parameter Finish
Announce existing EP-02 modules
Time and Date
Parameter Average Function
Password level 1 (Customer Password)
Function analog output
Define failure relays
Power On Time
Service Phone No.
Maintenance date
Relay Parameter
Parameter Finish
Relay R 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Relay Mode
Function Static / Flash
Latching Mode
Horn function
External Relay operation
MP Parameter
Parameter Finish
MP No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 8 19 20 21 22 23 24
MP Mode
Gastype
Measuring range
MP- Signal
Threshold 1
Threshold 2
Threshold 3
Threshold 4
Threshold 5
Hysteresis
Delay ON time
Delay OFF time
C/A Mode
Assigned Failure <> Alarm
Assigned Alarm <> Alarm relay

6 Configuration- and Parameter card.

Commission: Project No.
Customer: Service Technician
Start-up - company Number MP
Start-up - date:
6.1 Configurationscard Systemparameter
Service Software Mainten- Service AV- Overlay Time Costumers Power Failure
Version ance date Phone ppm Time AV- system pass On Relay
Time Time
Default 15 06.06.06 0853190040 120 120 1800 EU 1234 30 s 5
Registration Expansionsmodule EP-02 Analog output 1 Analog output 2

Calibration Calibration
EP-01 EP-02 EP-03 EP-04 EP-05 Mode = 4 = 20 Mode = 4 = 20
Not active Not active Not active Not active Not active Max. 4.0 20.0 Max. 4.0 20.0
6.2 Configurationscard Alarmrelay

Relay Mode Static Latching Horn External
No. Flash mode Function ON OFF
Time Quitt DI DI DI
Default Energezid 0s No 0 0 0 0 0
R01
R02
R03
R04
R05
R06
R07
R08
R09
R10
R11
R12
R13
R14
R15
R16
R17
R18
R19
R20

6.3 Configurationscard Measuring Parameter

MP MP Gas Meas MP- Thresholds Hyst Delay time CV/ Assigned MP fault < >Alarm Assigned Alarm <> Alarmrelay AO
No. Status type uring Signal (sec.) AV
range A1 A2 A3 A4 A5 ON OFF A1 A2 A3 A4 A5 A1 A2 A3 A4 A5
De Not CO 300 Linear 40 80 100 120 300 15 0 0 AV 1 1 0 0 0 R1 R2 R3 R4 -- 0
fault active
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

7 Specifications
Electrical
110/230 VAC 50/60Hz;
Power supply
24 VAC/DC -10% + 20%
Power Consumption (incl. max. AT)
MGC-02-04-04-XX 13 W, 500 mA
MGC-02-08-08-XX to MGC-02-12-12-XX 27 W, 1100 mA
MGC-02-16-16-XX to MGC-02-24-16-XX 55 W, 2200 mA
Option Emergency power supply Supply duration 60 minutes
4 to 20 mA, overload and short circuit
Analog Input (max. 24)
protected, input resistor 200 Ω
Power supply for external analog Transmitter 24 VDC max. 50 mA / channel
4 to 20 mA, overload and short circuit
Analog Output
protected, max. 500 Ω load
Alarm relay (max. 20) 250 VAC, 5 A, potentialfree, DPDT
Failure relay 250 VAC, 5 A, potentialfree, DPDT
Option Buzzer - Sound pressure 85 dB (Distance 300 mm)
- Frequency 3,5 kHz
Visualization
Display Two lines, each 16 characters, illumination.
Status LED Yellow = Status Alarm; Red = Failure
Operation 6 Push button
Gases 1
CO, CO2, NO, NO2, NH3, O2, combustible and
Gas Transmitter external
refrigerant Gases
Environmental
Humidity 15 – 95 % r. F. non condensing
Working temperature -5° C bis + 40° C
Storage temperature 0° C bis + 40° C
Physical
Enclosure Plastic housing with view cover
Color RAL 7035 (gray)
Protection IP 65
Weight MGC-02-04-04XX 2,7 kg
MGC-02-08-08 to MGC-02-12-12 4,0 kg
MGC-02-16-16 to MGC-02-20-16 6,0 kg
MGC-02-24-16 7,5 kg
Mounting Wall mounting
Cable entry M 16; M 20; M 25
Wire connection: Power supply Screw type: 2,5 mm2
Relay Carge clamp: min. 0,5 mm2, max. 1,5 mm2
Input Carge clamp: min. 0,5 mm2, max. 1,5 mm2
Dimensions: MGC-02-04-04XX (W x H x D) 298 x 260 x 140 mm
MGC-02-08-08 to MGC-02-12-12 (W x H x D) 298 x 420 x 140 mm
MGC-02-16-16 to MGC-02-20-16 (W x H x D) 298 x 570 x 140 mm
MGC-02-24-16 (W x H x D) 410 x 655 x 140 mm
EMV – Guidelines 89/336/EWG; CE
Guidelines Low voltage guideline 73/23/EWG
VDI 20532
Warranty Two year material and workmanship

8 Appendix module overview

Gas Controller GC 02
X1 X2
1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
MSR - Electronic
22 .01 .05 20: 28
X10 X11
1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 9 101112
R1 R2 R3 R4 R5 Systembus
Status LED Relay Status LED
X1 X2
1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
9 01
78
2 3
456
Adress-
selector
X10 X11
X11
1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 9 101112
R1 R2 R3 R4 R5 Systembus
Status LED Relay Status LED

9 Notes and General Information

It is important to read user manual thoroughly abd clearly understand the information and instructions. The
PolyGard® - MGC-02 Gas monitoring, control and alarm system must be used within product specification
capabilities. The appropriate operating and maintenance instructions and recommendations must be followed.
Due to ongoing product development, MSR reserves the right to change specifications without notice. The
information contained herein is based upon data considered to be accurate. However, no guarantee is expressed
or implied regarding the accuracy of this data.
9.1 Intended product application

The PolyGard® MGC-02 are designed and manufactured for control applications for energy savings and OSHA air
quality compliance in commercial buildings and manufacturing plants (i.e.,detection and automatic exhaust fan
control for automotive maintenance facilities, enclosed parking garages, engine repair shops, warehouses with
forklifts, fire stations, tunnels, etc.).
9.2 Installers` responsibilities

It is the installer`s responsibility to ensure that all PolyGard® MGC-02 are installed in compliance with all national
and local codes and OSHA requirements. Installation should be implemented only by individuals familiar with
proper installation techniques and with codes, standards and proper safety procedures for control installations and
the latest edition of the National Electrical Code (ANSI/NFPA70). It is also essential to strictly follow all instructions
as provided in the user manual.
9.3 Maintenance
It is recommended that the PolyGard® MGC-02 performance check is done on a routine schedule. Any
performance deviations may be serviced based on needed requirements.
9.4 Limited warranty

MSR warrant the PolyGard® MGC-02 for a period of two (2) years from the date of shipment against defects in
material or workmanship. Should any evidence of defects in material or workmanship occur during the warranty
period, MSR will repair or replace the product at their own discretion, without charge.
This warranty does not apply to units that have been altered, had repair attempted, or been subjected to abuse,
accidental or otherwise. The above warranty is in lieu of all other express warranties, obligations or liabilities.
This warranty extends only to the PolyGard® MGC-02. MSR shall not be liable for any incidental or consequential
damages arising out of or related to the use of the PolyGard® MGC-02.


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PolyGard® Gas Controller MGC-02

Analog Gas Controller

PolyGard is a registered trademark of MSR GAMGC02E01

Phone: 0049(0)8531/9004-0 Fax: 0049(0)8531/9004-54 Specification subject to change without notice.

PolyGard is a registered trademark of MSR GAMGC02E01

Phone: 0049(0)8531/9004-0 Fax: 0049(0)8531/9004-54 Specification subject to change without notice.

4 Mounting / Electrical Connection ......................................................................................................... 22

PolyGard is a registered trademark of MSR GAMGC02E01

Phone: 0049(0)8531/9004-0 Fax: 0049(0)8531/9004-54 Specification subject to change without notice.

Analog Gas Controller System MGC-02

PolyGard is a registered trademark of MSR GAMGC02E01

Phone: 0049(0)8531/9004-0 Fax: 0049(0)8531/9004-54 Specification subject to change without notice.

2.1 Describtion Keypad User Interface

Enter sub menus, stores security password.

LED yellow Flashes when set one or more Alarm.

2.2 Setting / Change Parameter or Set points

Desired menu window open.

Code window opens, if no code level approved.

Push the cursor onto the position segment, which is to be changed.

Change the Parameter /Set Point.

Saving the changed value.

PolyGard is a registered trademark of MSR GAMGC02E01

Phone: 0049(0)8531/9004-0 Fax: 0049(0)8531/9004-54 Specification subject to change without notice.

2.3 Code Level

PolyGard is a registered trademark of MSR GAMGC02E01

Phone: 0049(0)8531/9004-0 Fax: 0049(0)8531/9004-54 Specification subject to change without notice.

Starting Menu Main Menu Sub Menu

Display the status of relay

Display and Change the Measuring point parameter

PolyGard is a registered trademark of MSR GAMGC02E01

Phone: 0049(0)8531/9004-0 Fax: 0049(0)8531/9004-54 Specification subject to change without notice.

3.1 Malfunction management

3.1.1 Acknowledge a malfunction

System Errors Select Menu “System Errors”

MP 01 < 3mA Example: Failure MP 01 < 3 mA

MP 01 < 3mA Malfunction Reset?

MP 01 < 3mA Error still

Malfunction Ereased Cause not eliminate

3.1.2 Error Memory

PolyGard is a registered trademark of MSR GAMGC02E01

Phone: 0049(0)8531/9004-0 Fax: 0049(0)8531/9004-54 Specification subject to change without notice.

3.1.3 System Errors

MP XX < 3 mA Current signal to analog Input XX < 3 mA.

GC Error: Internal Communication Error I/O Board to LCD Board.

EP 0X Com Fehler: Communication Error to Expansions module (EP 0X).

Maintenance: System maintenance is necessary.

PolyGard is a registered trademark of MSR GAMGC02E01

Phone: 0049(0)8531/9004-0 Fax: 0049(0)8531/9004-54 Specification subject to change without notice.

3.2 Status Alarm

Symbol Describtion Function

3.3 Status Relay

3.3.1 Manual operation of the relay

Take over Function

PolyGard is a registered trademark of MSR GAMGC02E01

Phone: 0049(0)8531/9004-0 Fax: 0049(0)8531/9004-54 Specification subject to change without notice.

3.4 Menu Measuring Values

3.5 Menu Relay Parameter

PolyGard is a registered trademark of MSR GAMGC02E01

Phone: 0049(0)8531/9004-0 Fax: 0049(0)8531/9004-54 Specification subject to change without notice.

3.5.1 Relay Mode

3.5.2 Relay Function Static / Flash

3.5.3 Latching Mode

Example: Alarm relay R2 with Latching mode