MSA 9010 SIL Operating Manual
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MSA 9010 SIL Operating Manual

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P R O D U C T M A N U A L
Unit F, 230 Parkway Point, Springhill Parkway,
Glasgow Business Park, Glasgow, UK, G69 6GA
www.frontline-safety.co.uk
t:
+44(0)141 771 7749
e:
sales@frontline-safety.co.uk
Company Reg No: SC260789 VAT Reg No: GB 828 8779 58

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  • Page 1 P R O D U C T M A N U A L Unit F, 230 Parkway Point, Springhill Parkway, Glasgow Business Park, Glasgow, UK, G69 6GA www.frontline-safety.co.uk +44(0)141 771 7749 sales@frontline-safety.co.uk Company Reg No: SC260789 VAT Reg No: GB 828 8779 58...
  • Page 2 Operating Manual Model 9010/9020 SIL Control Unit Order No.: 10171754/00 MSAsafety.com...
  • Page 3 MSA Europe GmbH Schlüsselstrasse 12 8645 Rapperswil-Jona Switzerland info.ch@MSAsafety.com www.MSAsafety.com © MSA 2016. All rights reserved...

  • Page 4: Table Of Contents

    Contents Safety Regulations ..............Correct Use .
  • Page 5 Markings, Certificates and Approvals ..........10.1 ATEX Directive .

  • Page 6: Safety Regulations

    Safety Regulations Safety Regulations Correct Use The Control Unit 9010/9020 SIL, hereafter called control unit, is designed for use as fixed gas warning device. It is used to monitor industrial premises and installations for combustible, explo- sive and toxic gases or air/vapour mixtures and for oxygen content. The control unit provides: •...

  • Page 7: Liability Information

    MSA or authorised persons. Liability Information MSA accepts no liability in cases where the device has been used inappropriately or not as intended. The selection and use of the device are the exclusive responsibility of the individual operator.

  • Page 8: Description

    The control unit enables connection of one or two detectors/transmitters, depending on its design. The board is available in two versions: • Control Unit 9010 SIL for connecting one general purpose input (catalytic combustion detector or semiconductor detector or 4/20 mA transmitter) •...
  • Page 9 Description The Control Unit 9010/9020 SIL fulfils the requirements of ATEX directive as well as SIL 2 requirements based on EN 61508 standard. The control units connected to detectors or transmitters that operate in potentially hazardous areas must be configured according to ATEX directive requirements for detection of combustible gases or oxygen.
  • Page 10 Description Symbols and Abbreviations Used in this Manual Description Acknowledgement Electromagnetic Compliance Full Scale Light Emission Diode Lower Explosive Limit - measurement units for gas detection point detectors Lower Explosion Limit meter - measurement units for gas detection open path detec- LELm tors Printed Circuit Board...
  • Page 11 Ethernet connector (Modbus TCP) WARNING relay "Heartbeat" LED indication (Firmware) HORN relay USB connector (for MSA service only) Backplane connector - Label with actual firmware version is on the back Heartbeat LED Indication Description: Red/green are fading on and off...

  • Page 12: Front Panel

    Description Front Panel Depending on configuration, there are 2 different front panels available for 9010 Module (1 display unit) and 9020 module (2 display units). Fig. 3 9010 Fig. 4 9020 Status LEDs (red/yellow) Site Information Tag System Failure LED (yellow) Display POWER LED (green) Keypad...

  • Page 13: Leds

    Description LEDS Red alarm status LEDs (C, W, A) for the optical indication of reaching the alarm thresholds. Yellow failure status LED (F) for the optical indication of a possible failure or Status LEDs out-of-service condition. Status LED information is available for both channels individually if Control Unit 9020 SIL is used.

  • Page 14: Status Of Control Unit

    Description Measured Values The display shows the actual gas concentration. The decimal point position can be set in Access Code No.4. Measuring Units The measuring units can be set to LEL, LELm, PPM, %Vol, g/m3 or no units. For more information about measuring units setting, see chapter 5.4. Access code 4 - Configuration operations.

  • Page 15: Input Signal Configuration

    Description Input Signal Configuration The input configuration is set in Access Code 52, P2, see chapter 5.7. Alarms and Overrange Functions The alarm set-points are: • CAUTION (C) caution threshold • WARNING (W) warning threshold • ALARM (A) alarm threshold (STEL or TWA) •...
  • Page 16 Description A) Input Signal is Over 103 % FS Non ATEX mode ATEX Mode Display "EEEE "EEEE" C,W,A *Activated *Activated FAILURE Activated Activated HORN *Activated *Activated 4-20 mA Output As it is configured in Access Code 4, P20 22 mA * Can be acknowledged by operator pressing UP or DOWN key B) Input Signal Returns Back to Measuring Range Interval Non ATEX mode...

  • Page 17: Configuration Jumpers

    Description Configuration Jumpers For setting some pre-defined basic features, configuration jumpers are used. There are two jumpers available on the main board (see Fig. 5 for jumper location). Jumper CV18 - for configuration of DC power mode (internal or external). Jumper No.

  • Page 18: Digital Interfaces

    To access the web interface, enter the IP address of the control unit into the address bar of a web browser. The default username "Customer" and the default password "MSA" have to be entered to see all information.

  • Page 19: Installation

    (instruction manual for selected detector or transmitter). The correct assignment of each detector and control unit must be ensured during installation by referring to the serial numbers indicated on the calibration data sheet provided by MSA. Mechanical Installation Depending on the version the control unit can be installed as a module in 19" rack or as a stand- alone unit (wall mounted version).

  • Page 20: Electrical Installation

    External devices used (horns, beacons, motors, etc.) must be shielded from radio frequencies and must conform to EMC directives. • MSA cannot be held liable for malfunctions and/or damage caused by electrical disturbances that are due to natural phenomena (e.g. lightning strikes). Model 9010/9020 SIL...
  • Page 21 Before opening the housing, it must be confirmed that power is off for all poles. MSA recommends protecting the control unit with appropriate external switches (auto- matic switches, differential switches) as close as possible to the installed unit, the instal- lation should comply with the standards IEC 60947-1 and IEC 60947-3.
  • Page 22 Set Access Code 2: P4 as activated (A) Set Access Code 2: P5 as activated (A) Contact MSA for any technical questions. For local MSA contacts go to our website www.MSAsafety.com. Contacts are shown in non-energized state in the two connection diagrams.
  • Page 23 Installation MAIN SUPPLY 100 - 230 VAC; 50 - 60 Hz ALARM CHANNELS A and B EARTH GROUND BACK UP SUPPLY 24 VDC FAILURE CHANNELS A and B HORN CUT OUT/ALARMS RESET (REMOTE) WARNING CHANNELS A and B ELECTRONIC EARTH (GROUND) GND - EARTH (GROUND) + DATA CAUTION CHANNELS A AND B...
  • Page 24 Installation Detector or Transmitter Connections If the control unit is supplied with a pre-calibrated option for passive detectors, MSA recommends to record the serial numbers of individual modules and connected detectors for proper identifica- tion. The Control Unit 9020 SIL has one serial number for both channels (A and B), so the channel type needs to be recorded as well.
  • Page 25 Installation Connectable Detectors and Transmitters The following types of active and passive MSA detectors can be connected to the 9010/9020 SIL unit: Measuring 4-20 mA Designation Passive detector Principle Transmitter Series 47K* Catalytic D-7100 Catalytic D-7010 Catalytic DF-7100 Catalytic DF-7010...

  • Page 26: Initial System Check After Installation

    Installation Maximum relay current at 24 VDC = 30 mA Maximum relay current at 24 VDC = 30 mA (**) External push button for horn deactivation and reset Fig. 9 „CAUTION“ output connection to external relay and for button for remote acknowledgement and alarm reset Initial System Check after Installation The entire system must be checked after the initial installation ensuring correct function in accor-...

  • Page 27: Operation

    4/20 mA analog output is as set in Access Code 4, P20. The FAILURE indication is activated if the ATEX mode is set. Sequence shown here for 9010 SIL: During start-up procedure the green POWER LED on the front panel flashes.

  • Page 28: Configuration Menu

    Operation Configuration Menu If required, the control units are delivered already configured and calibrated by MSA based on the specifications provided by the customer. The configuration is recorded in the CALIBRATION DATA SHEET. Modifications can be made via the various steps in each of the Access Codes recorded below.

  • Page 29: Example For Use Of The Keys For Access To The Access Codes

    Operation Example for Use of the Keys for Access to the Access Codes Press ENTER key for 3 seconds until the green POWER LED starts blinking. Press the UP or DOWN key to select password. Then confirm with ENTER key. Press the UP or DOWN key to select a desired Access Code number.
  • Page 30 Operation ATEX mode – Operating Modes of the Control Unit with one of the Access Codes Entered When the configuration menu is entered: • The connected detectors are monitored in the background and alarm thresholds are active. • The Failure LED is on (for both channels for Control Unit 9020 SIL).

  • Page 31: Settings Parameters

    Settings Parameters Settings Parameters Access Code 1 - Calibration WARNING! During a calibration, the detectors that are being calibrated are set to inhibit. Therefore a safe operation of the area usually monitored by the now inhibited detectors must be ensured by other means.
  • Page 32 Settings Parameters Step Function Detector Sensitivity Reduction Warning Possible settings: A: enabled, nA: disabled, default: nA / disabled CAL symbol is displayed if the detector signal during the calibration is below 50 % of the signal achieved during previous calibration Display Actual Detector Signal (depends on connected detector / transmitter) It displays actual Ux value in mV for passive detectors or value in mA for transmitters.

  • Page 33: Access Code 2 - Settings For Particular Operating Conditions

    Settings Parameters Access code 2 - Settings for Particular Operating Conditions Step Function Note Time Out Function If enabled the control unit automatically returns one step back in For selected channel the menu if no key is pressed within 2 min Always activated In ATEX Maximum time for getting into normal operating mode is 6 minutes mode...

  • Page 34: Access Code 3 - Simulation And Functionality Operations Table

    Settings Parameters Step Function Note Undervoltage Indication of External 115/230 VAC It is not possible to de-enable A - Enabled both P4 and P5 undervoltage nA - Disabled indications. At least one of If enabled it indicates a missing of 24 VDC on the output of main each other must be enabled.
  • Page 35 Settings Parameters Step Function Note Display Module Parameters Display the following information in automatic sequence: General Information • Device Type (9010/9020) • Firmware Version (Fx.y) • Firmware Build • ATEX Mode Individual for each channel • Offset Value (0-9000) • Full Scale Value (1-9000) •...
  • Page 36 Settings Parameters Step Function Note View STEL / TWA "ALARM" Thresholds Values Displays the average STEL / TWA value Available only if "PPM" measuring depending on setting in Access Code 4. units are set. If ppm symbol is blinking then STEL or TWA time interval is not reached yet.

  • Page 37: Access Code 4 - Configuration

    Settings Parameters Access code 4 - Configuration Step Function Note Supply Current For catalytic combustion and Possible settings: semiconductor detectors 100 - 450 mA for 9010 unit only. 100 - 350 mA for 9020 unit If detector current is below Minimum 4-20 mA Transmitter Supply Current selected value then failure F1.6 is displayed and...
  • Page 38 Settings Parameters "C" (CAUTION) SETTINGS - OUTPUT WITH OPTO-COUPLER "CAUTION" Alarm Direction and Threshold Selection of the direction of activation of the alarms If LEL units are chosen in u: rising, ATEX mode, only rising d: falling alarm type is selectable Settings the alarm threshold Permissible values: 0-100 % FS Caution Opto-Coupler State...
  • Page 39 Settings Parameters "A" (ALARM) SETTINGS - OUTPUT WITH RELAY "ALARM" Alarm Direction and Threshold Selection of the direction of activation of the alarms If LEL units are chosen in u: rising, ATEX mode, only rising alarm d: falling type is selectable Settings the intervention threshold Permissible values: 0-100 % FS For 9020 unit status of...
  • Page 40 Settings Parameters "A" (ALARM) SETTINGS - OUTPUT WITH RELAY Decimal Places Defines a number of decimal places for gas concentration displayed Full scale range Max.decimal places Default setting 1000 - 9000 100 - 999 10 - 99 1- 9 Region Settings for region China (complies with CCCF standards) Settings for Europe and International region (complies with ATEX standards if ATEX mode is activated)

  • Page 41: Access Code 6 - Basic Setup

    Settings Parameters Access Code 6 - Basic Setup Step Function Display Firmware and Bootloader Version Example: F1.01 - Firmware version 1001 - Firmware build number B1.01 - Bootloader version 1001 - Bootloader build number ATEX Mode A= ATEX mode activated nA = non ATEX mode activated If ATEX mode is set then some functions are limited according to ATEX Directive or general safety requirements...

  • Page 42: Access Code 7 - Peripheral Addresses

    Settings Parameters Access Code 7 - Peripheral Addresses Step Function Note RS485 Address Permissible values 1-247 RS485 Baud Rate Default setting is 38400 Permissible values 9600 or 38400 Bd Ethernet Configuration OFF - Ethernet is not enabled dhcP - IP Address provided by DHCP server Stc - Use static IP address Default: DHCP Static IP Address...

  • Page 43: Access Code 52 - Input And Output Setup

    Settings Parameters Access code 52 - Input and Output Setup Step Function Note Digital Output Type Define the outputs hardware configuration Common for both of the chan- nels 1 = Relay 2 = not used Input Signal Type If catalytic combustion detectors Setting the type of input signal input is set in ATEX mode then 1 = catalytic combustion detectors...

  • Page 44: Access Code 53 - Default

    Settings Parameters Access Code 53 - Default Settings Step Function Load Factory Default Settings "def" symbol is displayed if menu is activated. Press ENTER to load factory default values. Load User Default Settings "defC" symbol is displayed if menu is activated. Press ENTER to load user default values. Default Factory Configuration Access Code Description...
  • Page 45 Settings Parameters Access Code Description Default Value AC4 P10/ P14/ P18 Alarm Delay C=0, W=0. A=0 (Disabled) Analog Output Settings (in a normal operating AC4 P19 4-20 mA condition) AC4 P20 Analog Output Settings (in a failure condition) 2 mA AC4 P21 Decimal Places AC4 P27...

  • Page 46: Access Code 223 - "Admin" Password Setup

    The set password, cannot be displayed unless the same password is re-entered, or via the super password, known only by the MSA Technical Support Department. This super password will not be relayed to third parties. With Control Unit 9020 SIL it is sufficient to set the password once corresponding to channel A.

  • Page 47: Calibration

    Calibration Calibration WARNING! During calibration, the detectors being calibrated are set to inhibit and the control unit does not ensure the safe operation of the site. During this phase, the alarms are inhibited, and the 4/20 mA analog output is as set in Access Code 4, P20; the failure indication for the ATEX mode is active.
  • Page 48 Calibration Action Display Hold ENTER until green configuration diode starts flashing. Display shows "0" Set password using UP or DOWN keys and press ENTER to Display shows "0" confirm the choice. 9010 only: Display shows "P1" Set Access Code 1 using UP or DOWN keys and press ENTER to confirm 9020 only: Display shows "Cha"...

  • Page 49: Maintenance

    In the event of a failure, contact local MSA representative. MSA shall not be held liable for damage to items or persons if such checks are not made period- ically as indicated above. Be Aware of the Procedures for Handling Electrostatically Sensitive Electronics The device contains electrostatically sensitive components.

  • Page 50: Failure, Error And Status Messages

    Failure, Error and Status Messages Failure, Error and Status Messages 901/9020 SIL - Failure Indications In case of malfunctions, the following messages are displayed: Failure **Failure Description Code Priority The supply current to the connected transmitter is too high >350 mA for 9020 F1.1* >450 mA for 9010 Check the connected transmitter or a short-circuit between P+ and P-.
  • Page 51 Failure, Error and Status Messages Failure **Failure Description Code Priority Testing voltage is too high If voltage >0.1 V on the S+ terminal is measured. F5.6 Check detector connection. (For semiconductor detectors only) The transmitter supply voltage on the P+ pin is above the acceptable limit F5.7 (28.0 VDC) The transmitter supply voltage on the P+ pin is below the acceptable limit...
  • Page 52 Failure, Error and Status Messages Failure **Failure Description Code Priority Selftest CPU Failure F8.6 Unit has to be replaced. Selftest Clock Failure F8.7 Unit has to be replaced. Some settings were changed because of switching to ATEX mode in Access Code 6 / P2 F9.1 Verify settings Factory default values were loaded...

  • Page 53: Error Indications

    Failure, Error and Status Messages Error Indications These error messages are shown in the display during the calibration or when calibration is complete. Display Triggered levels Description E1 symbol indicates that detector Catalytic combustion detectors: sensitivity is too low. If signal Ux < 0.1 mV/%LEL New calibration values will not be Semiconductor detectors accepted, the original calibration...

  • Page 54: Technical Data

    Technical Data Technical Data 9010 SIL 9020 SIL Number of connected detectors 1 Catalytic combustion detectors Semiconductor detectors Detectors types 0 (4) - 20 mA transmitters Digital inputs AC: 85 VAC - 265 VAC 50/60 Hz Power supply DC: 19 - 32 VDC, ripple included, ripple <5 %...
  • Page 55 Maximum network segment expansion 100 m USB 2.0 Fullspeed Maximum cable length 3 m USB interface Connector Mini USB A The USB interface is reserved for MSA service access only. Alarm Management Reset mode automatic (1A, 2A) or manual (1M, 2M) 0-600 s...
  • Page 56 Wall Mounted Unit: 255 x 180 x 90 mm 19"rack module 450 g Weight Wall mounted version:1.3 kg Markings, Certificates and Approvals 10.1 ATEX Directive MSA Europe GmbH Manufacturer: Schlüsselstr.12 CH - 8645 Rapperswil-Jona Product: CONTROL UNIT 9010 / 9020 SIL...
  • Page 57 Markings, Certificates and Approvals 10.2 Special Conditions for Safe Use According to EU-Type Examination Certificate • The control unit shall be operated with activated ATEX mode to meet the requirements of the standards EN 60079-29-1, EN 50104 and EN 50271 •...
  • Page 58 Markings, Certificates and Approvals 10.3 Special Conditions for the Safe Use of the Gas Warning Unit 9010/9020 in SIL Applications Safety Relevant Parameters for the Gas Warning Unit 9010/9020 Structure 1oo1 or 1oo2 0 or 1 MTTR 72 h 1 Year (Proof-Test-Interval) β...
  • Page 59 (19) It is only allowed to use the approved Hardware and Software Versions. 10.4 Permitted Hardware/Software Versions Module Hardware Version Software Version Control Unit 9010 SIL 1.02.1000 Control Unit 9020 SIL 1.02.1000 The actually used hardware version can be found on the printed circuit board. The firmware version is printed or on the label on the back of backplane connector.
  • Page 60 10164882 19" Rack (10 modules) 10164883 Plastic Rails (Set of 10 pcs) 10164870 9010 SIL Lid for wall mounted unit (with display) 10164888 9020 SIL Lid for wall mounted unit (with display) 10164887 9010 SIL Mainboard PCBA (wall mount) 10164886...
  • Page 61 Appendix Appendix 12.1 Alarms Sequence - Reset Modes Fig. 10 1A - Automatic reset configuration Fig. 11 1M - Manual reset configuration Model 9010/9020 SIL...
  • Page 62 Appendix Fig. 12 2A - Automatic reset configuration with alarm memorisation Fig. 13 2M - Manual reset configuration with alarm memorisation Model 9010/9020 SIL...
  • Page 63 Appendix 12.2 Outline Dimensions 19” Rack Versions Fig. 14 Rack for 2 modules (Panel cut out 124 x 133 mm) Fig. 15 Rack for 5 modules (Panel cut out 246 x 133 mm) Model 9010/9020 SIL...
  • Page 64 Appendix Fig. 16 Rack for 10 modules (Panel cut out 448 x 133 mm) 12.3 Wall Mounted Version Fig. 17 Wall mounted plastic housing for 1 (9010) or 2 (9020) channels Maximum screw diameter 5 mm Maximum screw head diameter 8 mm 12.4 External earth Connection Fig.
  • Page 65 Appendix 12.5 4-20 mA Transmitter Connections Control Units 9010 SIL and 9020 SIL can accept, respectively, one or two input signals originating from transmitters. These transmitters, with a 4-20 mA circuit will have to have the right CE (EU) type certificate and will have to conform to Section 1.5 of Attachment II of Directive 2014/34/EU.
  • Page 66 Appendix 12.6 Detectors Connection Data Sheet Detectors Connection Data Sheet Series 47K- PRP (S47K- ST) Gas Detector WARNING! Before connecting the measuring head reduce detector current to minimum The cable screen is connected to the control unit only. Detector type: Catalytic/passive/constant current supply (3 wire passive) Detector simulation module: Order No.
  • Page 67 Appendix Open / Short Circuit Failure Indication X - Signal Failure (Failure LED) XX - Alarm LEDs, Signal exceeded, Signal Failure (Failure LED) XXX - Alarms only XXXX – No change of indication Wire (Terminal No.) Disconnect P+ (14 or 30) S+ (15 or 31) P- (13 or 29) plug...
  • Page 68 Appendix Detectors Connection Data Sheet Series 47K- HT-PRP WARNING! Before connecting the measuring head reduce detector current to minimum The cable screen is connected to 9010/9020 SIL module only. Detector type: Catalytic/passive/constant current supply (3 wire passive) Detector simulation module: Order No. 10030263 Bridge current 280 mA Maximum nominal current...
  • Page 69 Appendix Open / Short Circuit Failure Indication X - Signal Failure (Failure LED) XX - Alarm LEDs, Signal exceeded, Signal Failure (Failure LED) XXX - Alarms only XXXX – No change of indication Wire (Terminal No.) Discon- (14 or 30) (15 or 31) (13 or 29) nect plug...
  • Page 70 9 ….17 mm Cross section per wire allowed 0.75 - 2.5 mm Simulation Module: Order No. 10030262 MSA recommended transmitters PrimaX I, Ultima XE (2 wire), UltraSonic IS-5 Recommended safety barriers See manual of transmitter Open / Short Circuit Failure Indication...
  • Page 71 0.75 - 2.5 mm Simulation Module: Order No. 10030262 PrimaX P, PrimaX IR, Ultima XE (3 wire), Ultima XIR, Ultima MOS 5, Ultima MOS 5E, FlameGard 5 MSIR, MSA recommended transmitters FlameGard 5 UV/IR, FlameGard 5 UV/IR-E, UltraSonic Ex 5 Recommended safety barriers See manual of transmitter Conditions for use: For further details see operation manual of the transmitter.
  • Page 72 Appendix Open / Short Circuit Failure Indication X - Signal Failure (Failure LED) XX - Alarm LEDs, Signal exceeded, Signal Failure (Failure LED) Wire (Terminal No.) 4-20 mA +24 VDC Disconnect (Terminal 15 or 31) (Terminal 14 or 30) (Terminal 13 or 29) plug Open circuit at 9010/9020...
  • Page 73 Cable diameter 9 ….17 mm Cross section per wire allowed 0.75 - 2.5 mm Simulation Module: Order No. 10030262 MSA recommended transmitters Ultima OPIR 5, Recommended safety barriers See manual of transmitter Open / Short Circuit Failure Indication X - Signal Failure (Failure LED)
  • Page 74 Appendix Digital Input Display Open circuit Closed circuit Model 9010/9020 SIL...
  • Page 75 For local MSA contacts, please visit us at MSAsafety.com Because every life has a purpose...
  • Page 76 Thank you for reading this data sheet. For pricing or for further information, please contact us at our UK Of ce, using the details below. Please note — Product designs and speci cations are subject to change without notice. The user is responsible for determining the suitability of this product.

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