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Model 4802A
Zero Two Series Control Module
The inf ormation and technical data disclosed in
this document may be used and d is seminated
only f or the purposes and to the extent
specif ically authorized in writing by General
Monitors.
Instruction Manual
General Monitors reserves the right to change
published specif ications and designs without
prior notice.
Part No.
Revision
CR:
08-21
MAN4802A
J/08-21
800000049951
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Summary of Contents for MSA Zero Two Series
- Page 1 Model 4802A Zero Two Series Control Module The inf ormation and technical data disclosed in this document may be used and d is seminated only f or the purposes and to the extent specif ically authorized in writing by General Monitors.
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Page 2: Table Of Contents
Model 4802A Table of Contents MODEL 4802A ..........................I WARRANTY STATEMENT.....................VI Special Warnings......................... vi System Integrity Verif ication ....................vii 1.0 QUICK-START GUIDE .....................IX Control Module Installation..................ix Rear Terminal Connections..................x Sensor Connections ....................xi Applying Power ......................xi 2.0 INTRODUCTION........................ 1 General Description .................... -
Page 3: Model 4802A
Zero Two System ..................49 7.7.2 4802A Control Module .................. 50 Volatile Liquids and Solvents..................51 Engineering & Technical Drawings ................53 7.9.1 Outline & Terminal Connections ..............53 7.9.2 Final Assembly .................... 54 7.10 Zero Two Series Modules ..................55... - Page 4 Model 4802A List of Figures Figure 1: Control Module Coding Strip ....................ix Figure 2: Wire Strip Length ........................x Figure 3: Rear Terminal Designations....................x Figure 4: Sensor/Controller Connections ....................xi Figure 5: Rear Power Connections....................... xii Figure 6: Model 4802A ........................1 Figure 7: Control Module Coding Strip ....................
- Page 5 Model 4802A List of Tables Table 1: Terminal Designations for Sensor Wires ..................xi Table 2: Terminal Designations for A2 Alarm Outputs ................6 Table 3: A2 Alarm Relay Contacts......................6 Table 4: Terminal Designations for A1 Alarm Outputs ................6 Table 5: A1 Alarm Relay Contacts......................
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Page 6: Warranty Statement
Combustible & flammable gases and vapors are very dangerous. Extreme caution should be used when combustible & flammable gases and vapors are present. All Zero Two Series Modules contain components, which can be damaged by static electricity. Special care must be taken when wiring the system to ensure that only the connection points are touched. -
Page 7: System Integrity Verification
Model 4802A Quick-Start Guide System Integrity Verification General Monitors’ mission is to benefit society by prov iding s olutions t hrough indust ry- leading safety products, services and systems that save lives and protect capital res ources f rom the dangers of hazardous flames, gases and vapors. The saf ety products you have purchased should be handled caref ully and installed, calibrated, and maintained in accordance with the respective product ins truct ion manual. - Page 8 Model 4802A Quick-Start Guide When testing produces results outside of the manufacturers’ specifications, re-calibration or repair/replacement of the suspect device(s) should be performed as necessary. Calibrat ion intervals should be independently established through a documented procedure, including a calibration log maintained by plant personnel, or third party testing services. Specific Conditions of Use •...
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Page 9: Quick-Start Guide
(Figure 1). Figure 1: Control Module Coding Strip NOTE: Zero Two Series Modules require air circulation to avoid excess iv e heat b uild-up. If chassis are stacked vertically within an enclosure, f orced air circulation may be required. -
Page 10: Rear Terminal Connections
Model 4802A Quick-Start Guide Rear Terminal Connections All wire connections to the Model 4802A are made to the terminal block located at t he rear o f the chassis. The terminal block accepts 16 AWG to 20 AWG, stranded or solid core wire. 14 AWG wire may be used if it is properly stripped according to Figure 2. -
Page 11: Sensor Connections
Figure 4: Sensor/Controller Connections Applying Power Zero Two Series Modules do not have an ON/OFF power switch. Each module in the Zero Two Series operates from 24Vdc. Current requirements will vary according to the number and ty pe of modules in the system, as well as the number and type of field devices. -
Page 12: Figure 5: Rear Power Connections
Model 4802A Quick-Start Guide Figure 5 indicates where the power connections for the chassis are made. Figure 5: Rear Power Connections The instrument is now ready to operate. Please consult the manual for more information on the instrument’s many features. -
Page 13: Introduction
Zero Two Series. It is distinguished from the other modules by its blue border and “4802A " in the upper right corner of the front panel. The 4802A is designed f or use in no n-hazardous environments. -
Page 14: Features & Benefits
Model 4802A Features & Benefits Automatic Calibration The unit’s display indicates simple automated calibration prompts to the operator with no calibration adjustments. Calibration Check Mode Verif ies the integrity of the sensor by allowing the operator to apply a t es t gas and v iew t he response on the display. -
Page 15: Applications
Model 4802A Applications The 4802A is a Combustible Gas Control Module designed for Zero Two Series Applic ations. Below is a partial list of applications: Ref ineries Gas Turbines • • • Drilling platforms and rigs • Solvent Vapors Gas and oil production Hydrogen Storage •... -
Page 16: Installation
Control Module Installation A rack or panel mounted chassis will be required when installing any Zero Two Series Module. These chassis should be mounted in non-hazardous, weather-protected locations and should be subjected to minimal shock and vibrations. -
Page 17: Rear Terminal Connections
Model 4802A NOTE: Zero Two Series Modules require air circulation to avoid excess iv e heat b uild-up. If chassis are stacked vertically within an enclosure, f orced air circulation may be required. The control modules are, to a great extent, immune to electromagnetic interf erence (EMI). -
Page 18: A2 Alarm
Model 4802A 3.3.1 A2 Alarm The terminal designations for the A2 alarm outputs are: LABEL TERM DESCRIPTION A2-C1 Relay Common (1 & 2) A2-1 Relay Contact A2-2 Relay Contact A2-3 Relay Contact A2-4 Relay Contact A2-C2 Relay Common (3 & 4) A2-OC Open Collector (OC) OC Logic for A2 LED... -
Page 19: Fault Alarm
Model 4802A on a user selectable option (Section 5.0).The table below ref ers to the proper open and clos ed A1 alarm relay contacts while the unit is on power: User Selected Normally Normally Relay State Open Closed Normally A1-C1 & A1-1, A1-C1 &... -
Page 20: Other Open Collector Outputs
Model 4802A 3.3.4 Other Open Collector Outputs The terminal designation f or the Un-accept and the Discrete Calibration / Inhibit Mode outputs are: Label Term Description UA-OC Un-accept Output CAL/INH CAL-Inhibit Mode Output Table 7: Terminal Designations for Un-accept and Calibration/Inhibit Mode NOTE: If the backward compatible configuration is ordered, the CAL/INH will no t be pres ent (pin 32z will be f or 0v). -
Page 21: Sensor Connections
Model 4802A 3.3.5 Sensor Connections The terminal designations for the sensor wires are: Label Term Description 26d,z Black Sensor Wire 28d,z Red Sensor Wire 30d,z White Sensor Wire Table 8: Terminal Designations for Sensor Wires NOTE: Only 1 sensor may be connected to a Model 4802A. Figure 12 illustrates the sensor/controller connections. -
Page 22: Analog Output Signal
Model 4802A The card test input is provided so that the user can access the card test feature remotely. One end of a normally open SPST switch is connected to this termination. The other end is connected to system common. To activate the feature, simply press and hold the switch f or as long as the test time is to be run. -
Page 23: Sensor Location Considerations
Model 4802A Figure 15 indicates where the power connections for the chassis are made. Figure 15: Power Connections Sensor Location Considerations There are no standard rules f or sensor placement, since the optimum sensor location is dif ferent for each application. The customer must evaluate conditions at the sensor site in order to make this determination. -
Page 24: Sensor Poisons
Applying Power Zero Two Series Modules do not have an ON/OFF power switch. Each module in the Zero Two Series operates from 24Vdc. Current requirements will vary according to the number and ty pe of modules in the system, as well as the number and type of field devices. -
Page 25: Operation
• perf ormed. Field Calibration 4802A Zero Two Series Control Module needs to be calibrated in f ield upon installation. Theref ore, please adhere to the following instructions upon rec eipt and installation of y our system. The 4802A should be calibrated using the proper calibration equipment (GMI p art # •... -
Page 26: Electrical Inputs
Model 4802A Electrical Inputs There are two electrical inputs to the Model 4802A. General Monitors’ catalytic bead sensor (f ield device) • Card test input • Both of these input connections (sensor and card test) are made to the rear terminal block (see Chapter 3 f or more detailed installation information). -
Page 27: Accepting Alarm Conditions
Model 4802A All of the open collector outputs on the 4802A have a maximum rating of: • 100mA @ 35Vdc The analog output signal is used for sending gas concentrat ions and s tat us inf ormation t o remote devices. The maximum analog load may not exceed 500 ohms including the wire/cable that the signal is sent on. -
Page 28: Resetting Latched Alarms
Model 4802A Resetting Latched Alarms The user may select a “latching” or “non-latching” alarm output for A1 and/ or A 2. If an alarm output activates and the condition that caused that activation is no longer pres ent, a non- latching alarm output will reset automatically. -
Page 29: Fault Diagnostics
Model 4802A To activate the card test feature, simply press and hold the switch. The f ront panel LED’s and digital display will begin ramping up at the start of the card test. They will continue t o ramp-up f or the software selectable ramp time specified by the operator (3 or 10 seconds) during s etup mode (Section 5.4). -
Page 30: Table 11: Fault Codes
Model 4802A Failed to complete This f ault may occur during or immediately after the setup Setup Mode. Press the Master Reset Switch on the Facilities Module to clear this fault. Calibration check If the calibration checks gas is left on the sensor for more period exceeded than 6 minutes, this fault will occur. -
Page 31: User Interfaces
Model 4802A 5.0 User Interfaces This chapter discusses the user interf aces along with the Calibration Check Mode, the Calibration Mode, the Setup Check Mode and the Setup Mode. Types of User Interfaces User interf aces are provided so that the operator may interpret and direct the Model 4802A in the perf ormance of its various functions. -
Page 32: Calibration Check Mode
Model 4802A Calibration Check Mode To perf orm a calibration check, follow the procedure listed below: 1. Place the cup from the portable purge calibrator over the sensor (Figure 17). Figure 17: Portable Purge Calibrator * The Calibration Check Mode cannot be entered if the 4802A is in alarm. 2. -
Page 33: Calibration Mode
Model 4802A 3. When the Mode/Select switch is released, the display will indicat e a f lashing pair of bars (- -) f or about ten seconds. 4. When the display indicates a flashing 0, apply the test g as t o t he sens or (open t he valve on the cylinder and the ON/OFF valve) and wait for a few seconds. -
Page 34: Figure 19: Portable Purge Calibrator
Model 4802A 3. Place the cup from the portable purge calibrator over the sensor (Figure 19). Figure 19: Portable Purge Calibrator 4. Enter the Calibration Mode by f ollowing the procedure f or entering the Calibration Check Mode, continuing to press and hold the Mode/Select switch until the CAL LE D turns on steady, about fifteen seconds (Figure 20). -
Page 35: Figure 21: Ac Display During Cal Mode
Model 4802A Figure 21: AC Display during CAL Mode 6. Apply the gas by opening the valve on the cylinder and the ON/OFF valve and watc h the display change from AC to CP as the sensor sees gas (Figure 22). If t he display does not change f rom AC to CP af ter six minutes, the Model 4802A will return to normal operation. -
Page 36: Figure 23: Cc Display During Cal Mode
Model 4802A 7. Wait f or the display to change from CP to CC when the calibration routine is c omplete (about 1 minute, Figure 23). If the display indicates F2 remove the gas and recalibrat e af ter 5 minutes. Figure 23: CC Display during CAL Mode 8. -
Page 37: Setup & Setup Check Modes
Model 4802A Setup & Setup Check Modes The Setup Check Mode allows the operator to view the selected options for the module without allowing any changes to be made. Once this mode has been entered, the module will automatically display each of the selected options for a short period of t ime and t hen it will return to normal operation. -
Page 38: Entering The Password
Model 4802A Figure 25: Entering Setup and Setup Check Modes 5.4.1 Entering the Password This option applies to the Setup Mode only: If the password option is enabled, the right digit of the display will be blank and a 0 •... -
Page 39: Inhibit Mode
Model 4802A Figure 26: Entering the Password 5.4.2 Inhibit Mode This option applies to the Setup Mode only: If the password option is disabled, or after the correct password has been entered, the display will indicate “In” f or f ive seconds (Figure 2). Pressing the Mode/Select switch while “In” is displayed will cause the unit to enter Inhibit mode by inhibiting the alarm output s. -
Page 40: A2 Alarm Options
Model 4802A 5.4.3 A2 Alarm Options Next, the A2 LED will be flashing while the energized/de-energized option is displayed (Figure 28). The display will indicate the current selection, (En or dE). Press the Mode/Select switch t o toggle the selection. De-energized is the factory default for this selection. Figure 28: Energized/De-Energized Alarm Option The A2 LED on the f ront panel will be f lashing while the latching/non-latching option is displayed (Figure 29). -
Page 41: A1 Alarm Options
Model 4802A The last A2 alarm option to appear on the display will be the alarm set point (trip level). If t his level is reached or exceeded, the A2 alarm outputs will activate. The display (Figure 30) will indicate the current A2 alarm set point (10 to 60 in increments of 5). P ress the Mode/ Select switch repeatedly, until the desired A2 alarm set point appears on the display. -
Page 42: Figure 31: A1 Energized-De-Energized Alarm Option
Model 4802A Figure 31: A1 Energized-De-Energized Alarm Option The A1 LED on the f ront panel will be f lashing while the latching/non-latching option is displayed (Figure 32). The display will indicate the current selection, (nL or LA). Press the Mode/Select switch to toggle the selection. -
Page 43: Calibration Level Option
Model 4802A The last A1 alarm option to appear on the display will be the alarm set point (trip level). If t his level is reached or exceeded, the A1 alarm outputs will activate. The display will ind ic ate t he current A1 alarm set point (Figure 33). -
Page 44: Fault/Inhibit Option
Model 4802A 5.4.6 Fault/Inhibit Option Next, the user will select the fault/inhibit option. The FAULT LE D on t he f ront p anel will b e f lashing while the display indicates “Ac” (active) or “nA” (not active) (Figure 35). An “Ac” selection specifies that the 4802A will activate the fault circuit while t he unit is in t he Inhibit Mode. -
Page 45: Card Test Options
Model 4802A 5.4.7 Card Test Options Af ter the f ault/inhibit option has been selected, the user will select the ramp time (3 or 10 seconds) and whether or not the alarm outputs will activate during a card test. The display will indicate “ct”... -
Page 46: Password Options
Model 4802A NOTE: Selecting nA option for the card test will not inhibit the fault or A1/A2 alarm circ uit s in the event of a malfunction or gas condition. 5.4.8 Password Options Once the card test options have been selected, the user will either enable or disable the password option (Figure 39). -
Page 47: Inhibit Mode
Model 4802A Figure 40: Entering A New Password Inhibit Mode Whenever the Inhibit Mode is entered, the A1 and A2 alarm outputs are inhib it ed. The f ront panel LED’s will still function normally in cases where sufficient gas is present at t he s ensor. Once this mode has been entered, the user may exit the Inhibit Mode by pressing the Mode/Select switch. -
Page 48: Setup Mode Selection Block Diagram
Model 4802A Setup Mode Selection Block Diagram This section is provided to aid the operator in making select ions during S etup Mode. It is recommended that the operator fill-in the selections in the proper blanks and then use this page as a ref erence while programming the Model 4802A. -
Page 49: Customer Support
Republic of Ireland H91 H6P2 Email: inf o.gmil@MSAsafety.com SINGAPORE 35 Marsiling Industrial Estate Road 3, #04-01 Phone: +65-6350 4500 Singapore 739257 Email: msa.singapore@MSAsafety.com MIDDLE EAST PO Box 54910 Dubai Airport Free Zone Phone: +971-299-6741 United Arab Emirates Email: gmdubai.main@MSAsafety.com Table 13: GM Locations... -
Page 50: Appendix
Model 4802A 7.0 Appendix Principle of Operation General Monitors uses a low temperature catalytic bead to detect the presence of combust ible gases and vapors. These gases and vapors are found in many applications. The catalytic bead converts the combustible gases and vapors to heat. This change in heat results in a chang e in the electrical resistance of the bead. -
Page 51: Spare Parts And Accessories
Model 4802A Spare Parts and Accessories This chapter provides a description of the types of field devices (sensors), and the accessories, which can be used with the Model 4802A. 7.2.1 Sensors General Monitors offers a variety of Catalytic Bead Sensors with s ensor b odies and f lame arrestors: 7.2.2 Sensor Housing General Monitors offers an explosion proof housing that is rated for use in Class I, D ivision 1,... -
Page 52: Splash-Guard & Tga-1
Model 4802A Splash- Guard Sensor Figure 42: Universal Sensor Housing with Sensor and Splash-Guard Both housing entries are tapped for NPT threads. The s ens or c onnect s t o one of t hese entries, while the other entry is for conduit runs. The lid of the housing is also threaded to allow the user to gain entry to the sensor connections in the f ield. -
Page 53: Dust Guard Assembly
Model 4802A 7.2.4 Dust Guard Assembly The Dust Guard Assembly (Figure 44) is a simple, threaded stainless steel cylinder with a wire- screen at one end. It is easily removed for cleaning and/ or rep lac ement of t he dispos able screen. -
Page 54: Duct Mounting Plates
Model 4802A 7.2.5 Duct Mounting Plates General Monitors produces a Duct Mounting Plate (P/N 10041) for applications that require the sensor to be mounted in air-conditioning or a heating duct. The Duct Mounting Plate is eas y t o install (Figure 46). Figure 46: Duct Mounting Plate, Assembly Drawing Read and understand the bulleted list below before mounting the sensor into a duct. -
Page 55: Figure 47: Portable Purge Calibrator
Model 4802A Figure 47: Portable Purge Calibrator The procedure using the 3-Liter Chamber (Figure 48) is explained below: The 3-Liter Chamber is used when the 4802A is calibrated with liquid or solvent vapors. Bef ore the Model 4802A is calibrated with any solvent or volatile liquid, c onsult t he lis ting in Appendix B to determine the volume of solvent/liquid required to produce a 50% LEL concentration in the 3-Liter Chamber. -
Page 56: Calibration Check Mode
Model 4802A Bef ore using the 3-Liter Chamber, make sure the following is present: 1. 3-Liter Chamber 2. Dish 3. 250 micro-liter syringe 4. Correct volume of solvent/liquid for calibration and calibration checks. • Orient the chamber so that the lid and sensor hole is on top. It will be necessary to wind up the f an using the turnkey on the outside of the •... -
Page 57: Calibration Check & Calibration Modes
Model 4802A 3. Af ter one or two minutes the display will indicate CC (Calibration Complete). 4. Remove the sensor from the chamber and allow it to see clean air. When t he display indicates a f ew % LEL and then zeros (0), the Model 4802A has ret urned t o normal operation. -
Page 58: System Specifications
Model 4802A System Specifications Application: Combustible & Flammable Gas and Vapor Detection Sensor Type: General Monitors Low Temperature, Dif f usion Limited, Catalytic Bead Sensor Typical Sensor Life: 3 to 5 years, in normal service Measuring Range: 0 to 99% LEL Zero Drif t: Less than 5% of span, per year Stability:... -
Page 59: Relative Sensitivities
Model 4802A 7.3.3 Relative Sensitivities Methane 100.0 Hydrogen 64.7 Ammonia 132.8 Butadiene 84.6 Butane 66.4 Ethane 86.2 Ethylene 87.1 Propane 77.6 Beyond the standard gases the sensor is configured for. Each gas sensor can be configured t o be gas specific. General Monitors, Inc. can conduct an evaluation study to custom conf igure a gas sensor. -
Page 60: Electrical Specifications
Model 4802A Electrical Specifications Input Power Requirement: 20 to 35Vdc, (24Vdc @ 250mA, 4.8W nominal) (300 mA max) Electrical Classification: Class I, Division 1, Groups B, C & D, designed for use in non- hazardous environments. Relay Contact Rating: 4A @ 250Vac, 3A @ 30Vdc resistive. DPDT f or A1 & A2, SPDT f or Fault. -
Page 61: Environmental Specifications
The system consists of Zero Two Series component modules as manuf actured by General Monitors, Irvine, Calif ornia, U.S.A. (the manuf acturing f acility is... -
Page 62: 4802A Control Module
Model 4802A 7.7.2 4802A Control Module The control module, with sensor, meets the performance requirements of CSA 22. 2 No. 152- M1984 & EN 60079-29-1. It is capable of monitoring 0 to 100% LEL concentration of combustible gases/vapors. The control module has an interface panel, providing a mode/select switch and the following indications: 2 discrete alarm threshold level indicators •... -
Page 63: Volatile Liquids And Solvents
Model 4802A Volatile Liquids and Solvents Volatile liquids and solvents are not supplied by General Monitors. This page provides a list ing of volatile liquids and solvents and the respective volumes required (in micro-liters) to produce a 50% LEL vapor concentration in the 3 Liter Chamber (Section 6.7). Ref erence: NFPA 325, 1994 Edition Acetaldehyde Acetic Acid... - Page 64 Model 4802A The volatile liquids and solvents listed in this section are intended for use in the 3-Liter chamber f or calibrating General Monitors Catalytic Sensors (not the Model IR2000). Isopentane Isoprene Isopropyl Alcohol Isopropyl Ether JP-4, Jet Fuel Laktane Methanol Methyl Ethyl Ketone (MEK) Methyl Metacrylate...
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Page 65: Engineering & Technical Drawings
Model 4802A Engineering & Technical Drawings 7.9.1 Outline & Terminal Connections Ref erence Drawing # 11221 Figure 49: Outline and Terminal Connections 4802A... -
Page 66: Final Assembly
Model 4802A 7.9.2 Final Assembly Ref erence Drawing # 11220-1 Figure 50: Final Assembly, 4802A... -
Page 67: Zero Two Series Modules
Model RL002 Zero Two Series Relay Module Provides Extra Output Capacity for Zero Two Systems Model ZN002A Zero Two Series Zone Control Module Performs Zoning and Voting Funct ions f or Zero Two Systems Model MD002 Zero Two Series Driver Card for Monitoring / Driving High-Current Output Devices Model IN042 Zero Two Series Four Zone Input Card for Call points, Smoke &... - Page 68 Model 4802A ADDENDUM Product Disposal Considerations This product may contain hazardous and/or toxic substances. EU Member states shall dispose according to WEEE regulations. For further General Monitors’ www.msasafety.com/detection product WEEE disposal information please visit: All other countries or states: please dispose of in accordance with existing federal, state and local environmental control regulations.
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