FINAL_GM Model 4802A MAN4802A_rK_US

Operating Manual
General Monitors® Model 4802A

Zero Two Series Control Module
Order No.: MAN4802A/K
CR: 800000058296
US MSAsafety.com
WARNING!
Read this manual carefully before using or maintaining the device. The device will perform as designed only if it is used and
maintained in accordance with the manufacturer's instructions. Otherwise, it could fail to perform as designed, and persons
who rely on this device could sustain serious injury or death.
The warranties made by MSA with respect to the product are voided if the product is not installed and used in accordance with
the instructions in this manual. Please protect yourself and your employees by following the instructions.
Please read and observe the WARNINGS and CAUTIONS inside. For additional information relative to use or repair, call
1-800-MSA-2222 during regular working hours.
The Declaration of Conformity can be found under the following link: https://MSAsafety.com/DoC.
MSA is a registered trademark of MSA Technology, LLC in the US, Europe and other Countries. For all other trademarks visit
https://us.msasafety.com/Trademarks.
General Monitors
16782 Von Karman Avenue, Unit 14
Irvine, CA 92606
1-949-581-4464
For your local MSA contacts, please go to our website www.MSAsafety.com
© MSA 2021, 2023. All rights reserved

Contents
1 Warranty 5
2 Warnings 5
3 System Integrity Verification 5

3.1 Commissioning Safety Systems 6
3.2 Periodic Testing / Calibration of Field Devices 6
4 Quick-Start Guide 6
4.1 Control Module Installation 6
4.2 Rear Terminal Connections 7
4.3 Sensor Connections 8
4.4 Applying Power 8
5 Introduction 9
5.1 General Description 9
5.2 Features and Benefits 10
5.3 Applications 10
6 Installation 11
6.1 Upon Receipt of Equipment 11
6.2 Control Module Installation 11
6.3 Rear Terminal Connections 11
6.4 Sensor Location Considerations 17
6.5 Sensor Poisons 18
6.6 Applying Power 18
7 Operation 18
7.1 General Maintenance 18
7.2 Field Calibration 18
7.3 Electrical Inputs 19
7.4 Electrical Outputs 19
7.5 Accepting Alarm Conditions 20
7.6 Resetting Latched Alarms 20
7.7 CAL/INH Open Collector 21
7.8 Card Test Feature 21
7.9 Fault Diagnostics 21
8 User Interfaces 22
8.1 Types of User Interfaces 22
8.2 Calibration Check Mode 22
8.3 Calibration Mode 24
8.4 Setup and Setup Check Modes 29
8.5 Inhibit Mode 39
8.6 Setup Mode Block Diagram 40
9 Customer Support 41
9.1 General Monitors' Offices 41
10 Appendix 42
10.1 Principle of Operation 42
10.2 Spare Parts and Accessories 42
10.3 System Specifications 48
10.4 Mechanical Specifications 49
10.5 Electrical Specifications 49
US General Monitors Model 4802A 3

10.6 Environmental Specifications 50
10.7 Engineering Specifications 50
10.8 Volatile Liquids and Solvents 51
10.9 Engineering and Technical Drawings 53
10.10 Zero Two Series Modules 54
11 Addendum 55
4 General Monitors Model 4802A US

1 Warranty
1 Warranty
General Monitors warrants the Model 4802A to be free from defects in workmanship or material under normal use and
service within two (2) years from the date of shipment. General Monitors will repair or replace without charge any such
equipment found to be defective during the warranty period. Full determination of the nature of, and responsibility for,
defective or damaged equipment will be made by General Monitors’ personnel.
Defective or damaged equipment must be shipped prepaid to the General Monitors’ plant or the representative from which
the shipment was made. In all cases, this warranty is limited to the cost of the equipment supplied by General Monitors.
The customer will assume all liability for the misuse of this equipment by its employees or other personnel.
All warranties are contingent upon proper use in the application for which the product was intended and do not cover
products which have been modified or repaired without General Monitors’ approval or which have been subjected to
neglect, accident, improper installation or application, or on which the original identification marks have been removed or
altered.
Except for the express warranty stated above, General Monitors disclaims all warranties with regard to the products sold,
including all implied warranties of merchantability and fitness and the express warranties stated herein are in lieu of all
obligations or liabilities on the part of General Monitors for damages including, but not limited to, consequential damages
arising out of/or in connection with the use or performance of the product.
2 Warnings
WARNING!
• 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.
• Only catalytic bead sensors designed by General Monitors will work with the Model 4802A. Any attempt to use a
sensor that has not been designed by General Monitors will void the warranty.
• Installation and maintenance must be carried out by suitably skilled and competent personnel only.
• Full backward compatibility can be specified at the time of order. If this configuration is specified, the rear terminal
output designations will be identical to the previous generation of Zero Two Series Modules.
• This generation of product can be distinguished from the previous generation by the lack of a door on the front panel.
Adjustments are not necessary on the current generation of this product.
Failure to follow these warnings can result in serious personal injury or death.
3 System Integrity Verification

General Monitors’ mission is to benefit society by providing solutions through industry leading safety products, services
and systems that save lives and protect capital resources from the dangers of hazardous flames, gases and vapors.
The safety products you have purchased should be handled carefully and installed, calibrated, and maintained in
accordance with the respective product instruction manual.
Remember, these products are for your safety.
To ensure operation at optimum performance, General Monitors recommends that certain maintenance items are
performed.

4 Quick-Start Guide
3.1 Commissioning Safety Systems
Before power up, verify wiring, terminal connections and stability of mounting for all integral safety equipment including, but
not limited to:
• Power supplies
• Control modules
• Field detection devices
• Signaling / output devices
• Accessories connected to field and signaling devices
After the initial application of power (and any factory specified warm-up period) to the safety system, verify that all signal
outputs, to and from devices and modules, are within the manufacturers’ specifications. Initial calibration / calibration
checking / testing should be performed per the manufacturers’ recommendations and instructions.
Proper system operation should be verified by performing a full, functional test of all component devices of the safety
system, ensuring that the proper levels of alarming occur.
Fault/Malfunction circuit operation should be verified.
3.2 Periodic Testing / Calibration of Field Devices
Periodic testing/calibrating should be performed per the manufacturers’ recommendations and instructions.
Testing/Calibrating procedures should include, but not be limited to:
• Verify zero reading
• Apply a known concentration of gas, or a simulated test device provided by the manufacturer
• Verify integrity of all optical surfaces and devices
When testing produces results outside of the manufacturers’ specifications, re-calibration or repair/replacement of the
suspect device(s) should be performed as necessary. Calibration 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

• The Model 4802A Hydrocarbon Point Gas Detector was not assessed to EN 50271 Clause 4.8. For the Model 4802A
the current firmware version is S.
• The Model 4802A Hydrocarbon Point Gas Detector complies with combustible gas detection performance according
to EN 60079-29-1: 2016 for detection of 0-100% LFL methane only.
• Guidance for installation of fixed gas detection systems are set out in EN 60079-29-2 which has not been covered in
the scope of this assessment.
• Guidance for functional safety of fixed gas detection systems are set out in EN 60079-29-3 which has not been
covered in the scope of this assessment.
4 Quick-Start Guide
4.1 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. The rack and panel mounted chassis are available in 4, 8, and 16 channel sizes. Multiple 16-channel
chassis may be connected to each other to form larger systems.
In installations where two or more module types are to be mixed in the same chassis, ensure that the individual coding
strips match the channel application. The coding strips are preconfigured at the factory and the male portion is already on
each module.
The female portion, if un-mounted, must be fastened into position on the mounting strip of the desired chassis channel so
as to mate with its counterpart on the module (Figure 1 ).

4 Quick-Start Guide
A - male portion
Figure 1 Control Module Coding Strip
NOTE: Zero Two Series Modules require air circulation to avoid excessive heat build-up. If chassis are stacked vertically
within an enclosure, forced air circulation may be required. The control modules are, to a great extent, immune to
electromagnetic interference (EMI). However, they should not be mounted in close proximity to radio transmitters or similar
equipment.
4.2 Rear Terminal Connections
All wire connections to the Model 4802A are made to the terminal block located at t he rear of 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 .
Figure 2 Wire Strip Length
CAUTION!
Contact with PC Board components should be avoided in order to prevent damage by static electricity.
Failure to follow this caution can result in minor or moderate injury.
To connect wires to the terminal block on the Model 4802A, loosen the desired screw, insert the stripped end of the wire
and tighten.
For the rear terminal designations refer to Figure 3
Figure 3 Rear Terminal Designations

4 Quick-Start Guide
4.3 Sensor Connections
The terminal designations for the sensor wires are:
Label Term Description

BLK 26d, z Black Sensor Wire
RED 28d, z Red Sensor Wire
WHT 30d, z White Sensor Wire
Table 1 Terminal Designations for Sensor Wires
NOTE: Only 1 sensor may be connected to a Model 4802A.
Figure 4 illustrates the Sensor/Controller connections.
A - Black Sensor Lead
B - Red Sensor Lead
C - White Sensor Lead
Figure 4 Sensor/Controller Connections
4.4 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 type of modules in the system, as well as the number
and type of field devices.
NOTE: If the application of power does not turn ON the unit, check fuse, F1 on the control board. If the unit displays an F4
condition upon power-up first try to clear this condition by calibrating the sensor. If this condition persists, replace the
sensor.
Figure 5 indicates where the power connections for the chassis are made.

5 Introduction
Figure 5 Rear Power Connections
The instrument is now ready to operate. Consult the manual for more information on the instrument’s many features.
5 Introduction
This section provides a brief description of the Model 4802A, its features & benefits, and a list of some of its applications.
More detailed information on the features and benefits listed in 5.2 Features and Benefits will be presented in later
sections.
5.1 General Description
The General Monitors’ Model 4802A (Figure 6 ) is a single channel combustible gas detection control module designed for
use in Zero Two Series Gas and Flame Detection Systems. This module connects to the wires from a field mounted
General Monitors’ catalytic bead sensor and monitors the presence of combustible gases and vapors. The 4802A is
electrically and physically compatible with the other gas detection, flame detection, and system modules in the 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 for use in non-hazardous environments.
Figure 6 Model 4802A

5 Introduction
5.2 Features and Benefits
Automatic Calibration
The unit’s display indicates simple automated calibration prompts to the operator with no calibration adjustments.
Calibration Check Mode
Verifies the integrity of the sensor by allowing the operator to apply a test gas and view the response on the display.
Calibration Level
The user specifies the gas concentration to be used for calibration.
Microprocessor-Based Electronics
Monitors fault conditions; sensor inputs and provides outputs in the form of display codes, analog signal, relay contact and
open collector activation.
Setup Mode
Allows the user to set parameters such as alarm output options, test options, etc. These parameters are viewed on the
display during the Setup Mode.
Password Option
Prevents unauthorized alteration of the setup parameters (can be disabled).
Setup Check Mode
Allows the user to view the setup parameters, which have been set by the factory and/or operator.
LED Test
Tests the integrity of each LED and each segment of the digital display on the front panel.
Card Test
Tests the functionality of the card through the microprocessor, ramping the signal from 0 to full-scale.
Live Insertion / Removal
Allows the user to insert or remove a module while power is applied to the system, without damage to any of the
components in the system.
5.3 Applications
The 4802A is a Combustible Gas Control Module designed for Zero Two Series Applications.
Table 2 is a partial list of applications
Refineries Gas turbines

Drilling platforms and rigs Solvent vapors
Gas and oil production platforms Hydrogen storage
Gas collection facilities Wastewater treatment plants
Oil well logging operations Chemical plants
LPG/LNG processing and storage
Table 2 Partial List of Zero Two Series Applications

6 Installation
6 Installation
This section discusses what to do when a Model 4802A is received, the terminal connections and designations, sensor
location considerations, and what to be aware of when applying power.
WARNING!
Installation and Maintenance must be carried out by suitably skilled and competent personnel only.
Failure to follow this warning can result in serious personal injury or death.
6.1 Upon Receipt of Equipment
All equipment shipped by General Monitors is packaged in shock absorbing containers, which provide considerable
protection against physical damage. The contents should be carefully removed and checked against the packing slip. If
any damage has occurred or if there is any discrepancy in the order, notify General Monitors as soon as possible. All
subsequent correspondence with General Monitors must specify the equipment part and serial numbers. Each Model
4802A is completely checked at the factory; however, a complete checkout i s necessary upon initial installation and start-
up to ensure system integrity
6.2 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. The
rack and panel mounted chassis are available in 4, 8, and 16 channel sizes. Multiple 16-channel chassis may be
connected to each other to form larger systems.
In installations where two or more module types are to be mixed in the same chassis, ensure that the individual coding
strips match the channel application. The coding strips are pre-configured at the factory and the male portion is already on
each module.
The female portion, if un-mounted, must be fastened into position on the mounting strip of t he desired chassis channel so
as to mate with its counterpart on the module (Figure 7 ).
A - male portion
Figure 7 Control Module Coding Strip
NOTE: Zero Two Series Modules require air circulation to avoid excessive heat build-up. If chassis are stacked vertically
within an enclosure, forced air circulation may be required. The control modules are, to a great extent, immune to
electromagnetic interference (EMI). However, they should not be mounted in close proximity to radio transmitters or similar
equipment.
6.3 Rear Terminal Connections
All wire connections to the 4802A are made to the terminal block located at the rear of 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 8 .

6 Installation
Figure 8 Wire Strip Length
CAUTION!
Contact with PC Board components should be avoided in order to prevent damage by static electricity.
Failure to follow this caution can result in minor or moderate injury.
To connect wires to the terminal block on the 4802A, loosen the desired screw, insert the stripped end of the wire, and
tighten.
For the rear terminal designations refer to Figure 9 .
Figure 9 Rear Terminal Designations
6.3.1 A2 Alarm
The terminal designations for the A2 alarm outputs are:
LABEL TERM DESCRIPTION

A2-C1 2d Relay Common (1 & 2)
A2-1 4d Relay Contact
A2-C2 12d Relay Common (3 & 4)
A2-OC 14d Open Collector (OC)
LA2 24z OC Logic for A2 LED
Table 3 Terminal Designations for A2 Alarm Outputs
The A2 alarm outputs are DPDT relays, 1 open collector output (A2-OC) that follows the logic of the relays and 1 open
collector output (LA2) that follows the blinking pattern of the front panel LED. The A2-C1 designation is common for A2-1
and A2-2. The A2-C2 designation is common for A2-3 and A2-4. The normally open (NO) and normally closed (NC)
contacts depend on a user selectable option (Chapter 5).
Table 4 refers to the proper open and closed A2 alarm relay contacts while the unit is on power:

6 Installation
User Selected Relay Status Normally Open Normally Closed

Normally Energized A2-C1 & A2-1 A2-C1 & A2-2
A2-C2 & A2-4 A2-C2 & A2-3
Normally De-Energized A2-C1 & A2-2 A2-C1 & A2-1
A2-C2 & A2-3 A2-C2 & A2-4
Table 4 A2 Alarm Relay Contacts
6.3.2 A1 Alarm
The terminal designations for the A1 alarm outputs are:

A1-C1 2z Relay Common (1 & 2)
A1-1 4z Relay Contact
A1-C2 12z Relay Common (3 & 4)
A1-OC 14z Open Collector (OC)
LA1 24d OC Logic for A1 LED
Table 5 Terminal Designations for A1 Alarm Outputs
The A1 Alarm outputs are DPDT relays, 1 open collector output (A1-OC) that follows the logic of the relays and 1 open
collector output (LA1) that follows the blinking pattern of the front panel LED. The A1-C1 designation is common for A1-1
and A1-2. The A1-C2 designation is common for A1-3 and A1-4. The normally open (NO) and normally closed (NC)
contacts depend on a user selectable option (Section 5.0).
Table 6 refers to the proper open and closed A1 alarm relay contacts while the unit is on power:
User Selected Relay Status Normally Open Normally Closed

Normally Energized A1-C1 & A1-1 A1-C1 & A1-2
A1-C2 & A1-4 A1-C2 & A1-3
Normally De-Energized A1-C1 & A1-2 A1-C1 & A1-1
A1-C2 & A1-3 A1-C2 & A1-4
Table 6 A1 Alarm Relay Contacts
6.3.3 Fault Alarm
The terminal designations for the Fault outputs are:

F-C 16z Relay Common
F-1 18z Relay Contact (NO)
F-2 20z Relay Contact (NC)
F-OC 22z Open Collector (OC)
FUA 32d Open Collector (OC)
Table 7 Terminal Designations for Fault Outputs

6 Installation
The Fault outputs are SPDT relays, 1 open collector output (F-OC) that follows the logic of t he relays and 1 open collector
output (FUA) dedicated to new fault indications.
NOTE: If the backward compatible configuration is ordered, the FUA will not be present (pin 32d will be for +B).
The fault outputs are always normally energized when power is applied to the module.
The contact ratings for the A2 & A1 alarm and fault relays are 4A @ 250 Vac, 3A @ 30 Vdc, resistive, maximum.
Inductive loads (bells, buzzers, relays, etc.) on dry relay contacts must be clamped down. Unclamped inductive loads can
generate voltage spikes in excess of 1000 volts. Spikes of this magnitude may cause false alarms and contact damage.
Figure 10 shows recommended relay protection circuits for AC and DC loads, respectively.
Protection circuit for relay contacts when switching an Protection circuit for relay contacts when switching a DC
AC load load
Figure 10 Recommended Relay Protection Circuits
6.3.4 Other Open Collector Outputs
The terminal designation for the Un-accept and the Discrete Calibration / Inhibit Mode outputs are:

UA-OC 18d Un-accept Output
CAL/INH 32z CAL-Inhibit Mode Output
Table 8 Terminal Designations for Un-accept and Calibration/Inhibit Mode
NOTE: If the backward compatible configuration is ordered, the CAL/INH will not be present (pin 32z will be for 0v).
The electrical rating for all open collector outputs is 100mA @ 35Vdc.
Figure 11 illustrates some typical open collector external circuits.

6 Installation
Figure 11 Open Collector External Circuits
6.3.5 Sensor Connections
The terminal designations for the sensor wires are:

BLK 26d, z Black Sensor Wire
RED 28d, z Red Sensor Wire
WHT 30d, z White Sensor Wire
Table 9 Terminal Designations for Sensor Wires
NOTE: Only 1 sensor may be connected to a Model 4802A.
Figure 12 illustrates the Sensor/Controller connections.

6 Installation
A - Black Sensor Lead
B - Red Sensor Lead
C - White Sensor Lead
Figure 12 Sensor/Controller Connections
6.3.6 Card Test Switch
The terminal designation for the card test input is:

CT 16d Switch Connection
Table 10 Terminal Designation for Card Test Input
Figure 13 is a block diagram that shows the switch connections for the card test feature.
A - Rear Terminal
Figure 13 Switch Connections for Card Test Feature
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 for as long as the test time is to be run.
6.3.7 Analog Output Signal

AO+ 20d Analog Signal (plus)
AO- 22d Analog Signal (minus)
NOTE: If the analog signal is not used, a jumper must be placed between 20d and 22d.
Figure 14 is a diagram of the analog signal connections.

6 Installation
NOTE: The maximum load resistance between AO+ and AO- cannot exceed 500 ohms.
Figure 14 Analog Signal Connections
Figure 15 indicates where the power connections for the chassis are made.
Rear View
Figure 15 Power Connections
6.4 Sensor Location Considerations
There are no standard rules for sensor placement, since the optimum sensor location is different for each application. The
customer must evaluate conditions at the sensor site in order to make this determination.
6.4.1 General Sensor Location Considerations
The sensor should be easily accessible for calibration checks. Ensure that sufficient clearance exists to allow the use of
field calibration devices such as the RGC or a Portable Purge Calibrator for combustible gas applications.
The sensor head should always be pointing down to prevent water build up on the sensing element. Remember that some
combustible gases are heavier than air; however, do not rely too heavily on this fact when selecting a sensor position.

7 Operation
The sensor should be located in areas where leaks are suspected (i.e. near valves & pipe connections, etc.).
The sensor should not be placed where contaminating substances may coat it.
6.5 Sensor Poisons
Sensors may be adversely affected by prolonged exposure to certain atmospheres.
The more important poisons are:
• Prolonged exposure to Hydrogen Sulfide (H2S) Gas

• Halides (compounds containing Fluorine, Chlorine, Bromine and Iodine)
• Heavy Metals (e.g. Tetraethyl lead)
Silicones contained in greases or aerosols are the most common “coating” agents. These are not true sensor poisons, but
reduce sensor response. Other damaging materials, which attack the sensor physically, include mineral acids and caustic
vapors.
The presence of such poisons and vapors does not exclude the use of General Monitors’ Catalytic Bead Sensors. A careful
analysis of ambient conditions should be undertaken and the customer should be aware that sensor calibration might need
to occur at more frequent intervals.
6.6 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 type of modules in the system, as well as the number
and type of field devices.
NOTE: If the application of power does not turn ON the unit, check fuse, F1 on the control board. If the unit displays an F4
condition upon power-up first try to clear this condition by calibrating the sensor. If this condition persists, replace the
sensor.
7 Operation
This section discusses what general maintenance to perform, describes the electrical inputs, outputs, accepting and
resetting alarm and fault conditions and fault diagnostics.
7.1 General Maintenance
Once the Model 4802A has been installed, very little maintenance is required other than periodic checks to verify the
integrity of the system.
• The user should evaluate conditions at the sensor site to determine how frequent calibration checks should be
performed.
• A functional test of the system should be performed at least once each year. This test should include full operation of
stand-by systems or back up power for the prescribed period.
• The power, sensor and output wiring should be checked for tightness, verifying that all of the components and
devices are connected correctly.
• If the “Password” is disabled, periodic checks of the setup parameters should be performed.
7.2 Field Calibration
4802A Zero Two Series Control Module needs to be calibrated in field upon installation. Therefore, please adhere to the
following instructions upon receipt and installation of your system.
• The 4802A should be calibrated using the proper calibration equipment (GMI P/N 1400150-X) (X=50% LEL of the
type of gas being detected) after its initial installation. All alarm outputs should also be checked to ensure the integrity
of the end-users system.

7 Operation
• There is no set timeframe for calibrating a system after its initial (start-up) calibration. Each and every application’s
calibration time can vary depending on a number of different parameters. To best determine the calibration
frequency for your application; the accuracy of your system should be checked every 2 weeks after the system’s
initial calibration until the sensor’s readings fall outside of your company’s acceptance. However, no system should
go more than 90 days between calibrations.
7.3 Electrical Inputs
There are two electrical inputs to the Model 4802A.
• General Monitors’ catalytic bead sensor (field device)

• Card test input
Both of these input connections (sensor and card test) are made to the rear terminal block (see 6 Installation for more
detailed installation information).
• The catalytic bead sensor input consists of the standard three lead connections used with General Monitors’ catalytic
bead sensors, see Figure 4 .
• The card test input consists of a single termination for remote testing of the Model 4802A’s functions. For detailed
information on the card test, see Figure 13 .
7.4 Electrical Outputs
The electrical outputs on the 4802A consist of relay contacts, open collectors and an analog current signal.
The following outputs have rear terminal relay contacts:
Output Rear Terminal Relay Contacts

A1 Alarm DPDT relay contacts
A2 Alarm DPDT relay contacts
Fault SPDT relay contacts
Table 11 Rear Terminal Relay Contacts
All of the relay contacts on the Model 4802A have a maximum rating of:
• 4A @ 250Vac, 3A @ 30Vdc resistive
The following outputs have rear terminal open collectors:
• A1 Alarm & LED Mimic

• A2 Alarm & LED Mimic
• Fault
• UA - Unaccepted Alarm
• FUA - Unaccepted Fault
• CAL/INH - Inhibit, Calibration & Calibration Check Modes
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 concentrations and status information to remote devices. The maximum
analog load may not exceed 500 ohms including the wire/cable that the signal is sent on.
The analog output is a 0 to 20mA current signal with 4 to 20mA being proportional to 0 to 100% of full scale.
When the 4802A is placed in calibration, calibration check, setup, setup check, or inhibit mode a 1.5mA signal is generated
by this output. During calibration mode, the digital display will indicate prompts associated with the calibration procedure.
During calibration check mode, th digital display will indicate the gas concentration with a flashing digit or pair of digits.

7 Operation
When the Model 4802A enters into a fault condition a 0mA signal is generated by this output. During a fault, the display will
indicate a fault code (“F” followed by a digit).
If the sensor attached to the Model 4802A is seeing gas in excess of 100% of full scale, this output will generate a signal
between 20 and 21.7mA (not proportional). An over range condition is indicated by a flashing digital display reading full-
scale (99).
7.5 Accepting Alarm Conditions
Whenever a new alarm condition occurs, the front panel LED and open collector associated with that alarm (LA1 or LA2)
would begin to flash. In addition, the associated alarm outputs and the un-accept outputs (4802A UA open collector &
FM002A UA relay) will activate, unless they are already activated. The flashing front panel alarm LED and rear terminal
open collector indicate that a new alarm has been activated. New alarms should be acknowledged, or accepted. This is
accomplished with the Master Accept button located on the Facilities Module.
Pressing the Master Accept button de-activates the UA outputs and causes the associated front-panel alarm LED, and
rear terminal open collector to stop flashing and energize.
NOTE: Alarms that latch must be accepted before they can be reset (0.1 Inhibit Mode).
There is a unique situation that may occur with some frequency in certain applications. An alarm may occur and the
operator will accept this alarm by pressing the Master Accept Button. If the alarm output is latching and the condition at
the sensor returns to normal (safe) the alarm output will need to be reset, as previously stated in 7.4 Electrical Outputs. If,
however, the alarm output is not reset and that alarm set point is exceeded again, the front panel LED, the associated
mimic open collector, and the un-accept outputs will re-flash or re-activate. This gives the operator an indication of a new
alarm condition that must be re-accepted.
A type of alarm, other than the A1 and A2 alarms, is the fault alarm. The fault alarm can be accepted similarly to the A1 and
A2 alarms. The front panel Fault LED will flash and the fault unaccept (FUA) open collector will energize when a fault is
detected. By pressing the Accept button on the front panel, the FUA output will de-energize and the Fault LED will stop
flashing. It will stay illuminated until the fault condition is corrected.
7.6 Resetting Latched Alarms
The user may select a “latching” or “non-latching” alarm output for A1 and/or A2. If an alarm output activates and the
condition that caused that activation is no longer present, a nonlatching alarm output will reset automatically. A latched
alarm output needs to be reset manually.
Resetting latched alarm outputs is accomplished with the Master Reset button located on the Facilities Module (FM002A).
Pressing the Master Reset button will reset any latched conditions that are no longer valid.
NOTE: Latched alarm conditions cannot be reset until they have been accepted (7.4 Electrical Outputs).
EXAMPLE: The sensor detects a gas concentration in excess of an alarm set point (trip level). The associated alarm
outputs will activate. After a few moments, the gas concentration drops below the alarm set point. If the alarm outputs
are latched and accepted, the operator can press the Master Reset button and the latched alarm outputs will return to
their normal (safe) state.
7.6.1 LED Test
The Master Reset button performs another function. If the operator presses and holds the Master Reset button for two or
more seconds, all of the LED’s and LED segments in the digital display will illuminate for as long as the operator presses
the button. This is called the LED test. The LED test cannot be performed while the unit is in alarm or fault, or during a card
test.

7 Operation
7.7 CAL/INH Open Collector
There is an open collector that will energize anytime the unit is put in the:
• Calibration
• Calibration check
• Setup
• Setup check
• Inhibit mode
This open collector output is referenced to the system’s ground/common. Energizing this output merely provides a path to
ground as is the case with all energized open collector outputs. Deenergized, this output will be in a high impedance state.
7.8 Card Test Feature
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 and the other end is connected to system common (Figure 13 ).
To activate the card test feature, simply press and hold the switch. The front panel LED’s and digital display will begin
ramping up at the start of the card test. They will continue to ramp-up for the software selectable ramp time specified by the
operator (3 or 10 seconds) during setup mode (0.1 Setup and Setup Check Modes). Each alarm level (A1 and A2) will trip
when the alarm set point is exceeded.
The analog output signal will ramp from 4 to 20mA during the test, if the active option has been selected during setup
mode. At the conclusion of the card test, the A1 and A2 outputs will automatically reset (overriding any latching option). A
card test cannot be initiated if the unit is in alarm or fault or during an LED test.
NOTE: There is an option that allows active outputs during a card test. If this option has been selected the relays (A1 and
A2) and open collector outputs are active, and will trip during the card test.
7.9 Fault Diagnostics
In addition to the Fault LED on the front panel, the Model 4802A provides a fault code on the digital display whenever a
fault condition occurs. The fault codes that can appear on the digital display are summarized in Table 12
Fault
Description Solution
Code
F1 Open analog output signal Check connections on rear terminal pins 20d and 22d
F2 Failed to complete If this fault occurs, remove the gas and allow the sensor to see clean air for at least five
calibration minutes. Then attempt another calibration. If the second attempt fails, replace the
sensor. If this fault continues to occur after the sensor has been replaced, consult the
factory or your GMI Representative.
F3 Software checksum error This fault occurs during initial power-up of the unit. If this fault occurs, remove and
reapply power to the unit. If the fault continues to occur, replace the unit and consult the
factory or your GMI Representative.
F4 Sensor connections are Make sure the sensor wires are connected properly (in the field and at the rear of the
open or shortcircuited or unit) and re-calibrate if necessary. If this fault continues to occur, replace the sensor.
there is excessive zero
drift
F5 Not used at this time This code has been reserved for future use.
F6 Low supply voltage Make sure the supply voltage level at the chassis is 24Vdc.
F7 EEPROM verification This fault will occur if the microprocessor cannot store calibration or setup information
failure in the EEPROM. If this fault occurs consult the factory or your GMI Representative.
F8 Failed to complete setup This fault may occur during or immediately after the Setup Mode. Press the Master
Reset Switch on the Facilities Module to clear this fault.
F9 Calibration check period If the calibration checks gas is left on the sensor for more than 6 minutes, this fault will
exceeded occur. Remove the gas and allow the sensor to see clean air.
Table 12 Fault Codes

8 User Interfaces
In each of the fault cases listed, when the fault occurs, the FUA output is activated. Pressing the ACCEPT button on the
Facilities Module (FM002A) will acknowledge the fault, de-activate the FUA output and the fault LED will stop flashing and
remain ON until the fault is corrected.
8 User Interfaces
This section discusses the user interfaces along with the Calibration Check Mode, the Calibration Mode, the Setup Check
Mode and the Setup Mode.
8.1 Types of User Interfaces
User interfaces are provided so that the operator may interpret and direct the Model 4802A in the performance of its
various functions. User interfaces (Figure 16) consist of a digital display, status indicators, and a mode/select switch.
• The digital display provides the user with the gas concentration at the sensor site, fault diagnostic codes, calibration
prompts, and setup parameters.
• The status indicators provide the user with an indication of the current mode of operation (alarm, fault, ready,
calibration, and setup).
• The Mode/Select switch provides the user access to the Calibration, Setup/Inhibit, Calibration Check and Setup
Check modes.
A - Digital Display
B - Front Panel Status Indicators
C - MODE/SELECT Switch
Figure 16 Front Panel Display
8.2 Calibration Check Mode
To perform a calibration check, follow the procedure listed below:
1. Place the cup from the portable purge calibrator over the sensor (Figure 17 ).

8 User Interfaces
A - Sensor
B - Cal Cap
C - Screen
D - Hose
E - ON/OFF Valve
F - Regulator
G - Cylinder Valve
H - Lecture Bottle
Figure 17 Portable Purge Calibrator
* The Calibration Check Mode cannot be entered if the 4802A is in alarm.
2. Enter the Calibration Check mode by pressing and holding the Mode/Select switch until the CAL LED begins to flash
(about ten seconds). When the CAL LED begins to flash, release the Mode/Select switch. The unit is now in the
Calibration Check mode (Figure 18 ).
A - Flashing CAL LED
B - Mode/Select Switch
Figure 18 Entering CAL Check Mode

3. When the Mode/Select switch is released, the display will indicate a flashing pair of bars (- -) for about ten seconds.
4. When the display indicates a flashing 0, apply the test g as to the sensor (open the valve on the cylinder and the
ON/OFF valve) and wait for a few seconds. The display will begin to go up scale as the sensor sees the gas. If the
display does not change after 6 minutes, the unit will return to the normal operating mode.
8 User Interfaces
5. If the sensor does see the gas, the read-out on the display will be flashing for as long as the unit remains in the
Calibration Check mode.
6. The reading will stabilize af ter 30 to 60 seconds of exposure to the test gas. This response time may increase due to
the presence of the TGA-1, RC-3, Dust Guard, Splash-Guard or other sensor accessories.
7. The operator should compare the reading with the gas concentration applied and determine if it is necessary to
calibrate the sensor.
8. The A1 and A2 alarms are disabled during the Calibration Check Mode. Use the Inhibit Mode to verify the alarm set
points for A1 and A2.
9. If the reading is acceptable remove the gas and allow the sensor to see clean air.
10. If the operator determines that a calibration is necessary, do one of the following:
• If the applied gas concentration is equivalent to the user specified calibration level, place the unit in the calibration
mode by pressing the Mode/Select switch, or
• If the applied gas concentration is not equivalent to the user specified calibration level, remove the gas, allowing the
sensor to see clean air, and then follow the calibration procedure listed in 8.3 Calibration Mode.
NOTE: If the 3-Liter Calibration Chamber is used with vapors or fumes from a volatile liquid/solvent, use the procedures
listed in 10 Appendix.
8.3 Calibration Mode
Calibrating the Model 4802A
1. Make sure the calibration gas is the same concentration as the user specified calibration level.
2. Make sure the sensor is seeing clean air.
3. Place the cup from the portable purge calibrator over the sensor (Figure 19 ).
A - Sensor
B - CAL Cup
C - Screen
D - Hose
E - On/Off Valve
F - Regulator
G - Cylinder Valve
H - Lecture Bottle

4. Enter the Calibration Mode by following the procedure for entering the Calibration Check Mode, continuing to press
and hold the Mode/Select switch until the CAL LED turns on steady, about fifteen seconds (Figure 20 ).

8 User Interfaces
A - Steady CAL LED
Figure 20 Entering CAL Mode

5. When the CAL LED is on steady, release the Mode/Select switch. The display will show f lashing bars (- -) f or about
ten seconds, then an AC indication on the display. The unit is now in Calibration Mode (Figure 21 ).

8 User Interfaces
Figure 21 AC Display during CAL Mode

6. Apply the gas by opening the valve on the cylinder and the ON/OFF valve and watch the display change from AC to
CP as the sensor sees gas (Figure 22 ).
NOTE: If the display does not change from AC to CP after six minutes, the Model 4802A will return to normal
operation.

8 User Interfaces
Figure 22 CP Display during CAL Mode

7. Wait for the display to change from CP to CC when the calibration routine is complete (about 1 minute, Figure 23 ). If
the display indicates F2 remove the gas and recalibrate after 5 minutes.

8 User Interfaces
Figure 23 CC Display during CAL Mode

8. Remove the gas and watch the display return to normal operation, 0, when the new calibration values have been
stored in the EEPROM. If the unit cannot store the new calibration values in the EEPROM, the Model 4802A will
display an “F7” fault code (EEPROM verification failure, Figure 24 ). If an F7 calibration fault occurs, it will be
necessary to replace the Model 4802A.
NOTE: If the Model 4802A fails to calibrate, the unit will use the previously stored calibration values.

8 User Interfaces
A - Flashing Fault LED
Figure 24 F7 Display during CAL Mode
8.4 Setup and 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 time and then it will return to normal operation. The Setup Mode allows the operator to change the operating
parameters by making choices for selected options.
The Setup Check & Setup Modes display identical information with the following exceptions:
• The Setup Check Mode allows the user to view the operating parameters of the Model 4802A, whereas the Setup
Mode allows the user to change the operating parameters of the Model 4802A.
• Entering the optional password is only available in the Setup Mode.
• The Inhibit Mode may only be entered from the Setup Mode. If the Inhibit Mode is entered, the A1 and A2 outputs will
be inhibited until the Mode/Select switch is pressed.
NOTE: The Setup and Setup Check Modes cannot be entered if the unit is in alarm or fault.
During the Setup Mode the operator will be allowed to select options.
The selection procedure is the same for most of the options. Pressing the Mode/Select switch toggles the available
choices. When the display has indicated a choice for five consecutive seconds, without the operator pressing the
Mode/Select switch, the Setup routine will accept that selection and move on to the next option available.

8 User Interfaces
NOTE: Before entering the Setup Mode to make changes, the user should fill out the form and become familiar with the
block diagram in 8.6 Setup Mode Block Diagram. This will aid the user during the selection process in the Setup Mode.
The password, the A1 and A2 alarm set points, and the calibration level options offer the operator more than two choices.
While these options are being selected, pressing the Mode/Select switch repeatedly will sequence the display to the next
available choice for that option.
To enter the Setup Check Mode or the Setup Mode, follow the procedure for entering the Calibration Mode. Press and hold
the Mode/Select switch until the SETUP LED begins flashing (about twenty seconds). When the SETUP LED is flashing,
release the Mode/Select switch to enter the Setup Check Mode (Figure 25 ). Continuing to press and hold the Mode/Select
switch until the SETUP LED stops flashing (about five seconds more) will allow the operator to enter the Setup Mode.
When the SETUP LED stops flashing and stays on, release the Mode/Select switch and the unit will enter the Setup Mode
(Figure 25 ).
A - Setup LED (flashing for Setup Check Mode, steady for Setup Mode)
Figure 25 Entering Setup and Setup Check Modes

8 User Interfaces
8.4.1 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 will appear in the left digit on the
display (Figure 26 ). Press the Mode/Select switch until the first number of your password is displayed and then wait
about five seconds.
• The left digit of the display will then blank out and a 0 will appear in the right digit on the display (Figure 26 ). Press the
Mode/Select switch until your correct password number is displayed and then wait about five seconds. If the
password is correct the unit will proceed to the inhibit option. If the password is incorrect the user will not be able to
proceed and the unit will return to the normal operating mode. Once in the operating mode the user may attempt to
re-enter the Setup Mode. The factory default password is 00.
A - Right Digit is Blank
B - Left Digit is Blank
C - Steady Setup LED (Setup Mode only)
D - Mode/Select Switch
Figure 26 Entering the Password
8.4.2 Inhibit Mode
If the password option is disabled, or after the correct password has been entered, the display will indicate “In” for five
seconds (Figure 27 ). Pressing the Mode/Select switch while “In” is displayed will cause the unit to enter Inhibit mode by
inhibiting the alarm output s. As the unit enters Inhibit mode, the 4802A will automatically return to normal operation. If it is
desired to enter Setup Mode, do not press the Mode/Select switch for the f ive seconds that “In” is displayed.

8 User Interfaces
A - Steady Setup LED (Setup mode only)
Figure 27 Entering Inhibit Mode
8.4.3 A2 Alarm Options
Next, the A2 LED will be flashing while the energized/de-energized option is displayed (F ). The display will indicate the
current selection, (En or dE). Press the Mode/Select switch to toggle the selection. De-energized is the factory default for
this selection.

8 User Interfaces
A - Flashing A2 LED
B - Setup LED (flashing for setup check mode; steady for setup mode)
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). The display
will indicate the current selection, (nL or LA). Press the Mode/Select switch to toggle the selection. Latching is the factory
default for this selection.
A - Flashing A1 LED
Figure 29 A2 Latching/Non-Latching Alarm Option
The last A2 alarm option to appear on the display will be the alarm set point (trip level). If this 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). Press the Mode/ Select switch repeatedly, until the desired A2 alarm set point appears on the display.
Sixty (60) is the factory default for this selection.

8 User Interfaces
A - Alarm Setpoint
B - Flashing A2 LED
C - Setup LED (flashing for setup check mode; steady for setup mode)
Figure 30 A2 Alarm Set Option
NOTE: The A2 set point cannot be set lower than the current A1 set point. To accomplish this, you will need to go through
Set-up twice. The A1 set point should be set lower than the desired A2 set point, then re-enter the Setup Mode and set the
A2 set point.
8.4.4 A1 Alarm Options
Next, the A1 LED will be flashing while the energized/de-energized option is displayed (Figure 32 ). The display will
indicate the current selection, (En or dE). Press the Mode/Select switch to toggle the selection. De-energized is the factory
default for this selection.

8 User Interfaces
A - Flashing A1 LED
Figure 31 B - Setup LED (flashing for setup check mode; steady for setup mode)
Figure 32 A1 Energized - De-Energized Alarm Option
The A1 LED on the front panel will be flashing while the latching/non-latching option is displayed (Figure 33 ). The display
will indicate the current selection, (nL or LA). Press the Mode/Select switch to toggle the selection. Non-latching is the
factory default for this selection.
A - Flashing A1 LED
Figure 33 A1 Latching/Non-Latching Alarm Option
The last A1 alarm option to appear on the display will be the alarm set point (trip level). If this level is reached or exceeded,
the A1 alarm outputs will activate. The display will indicate the current A1 alarm set point (Figure 34 ). Press the
Mode/Select switch repeatedly, until the desired A1 alarm set point appears on the display (10 to the A2 set point in
increments of 5). The A1 set point cannot be set higher than the A2 set point. 30 is the factory default for this selection.

8 User Interfaces
A - Alarm Setpoint
B - Flashing A1 LED
C - Setup LED (flashing for setup check mode; steady for setup mode)
Figure 34 A1 Set Point Option
8.4.5 Calibration Level Option
After the A1 alarm options have been selected, the user will choose the calibration level (Figure 35 ). The display will
indicate “CL” for 5 seconds, then the current calibration level. The acceptable range of calibration level, in % LEL (lower
explosive limit), is between 25 and 90, inclusive. 50 is the factory default for this selection.
A - CAL LED (flashing in setup mode)
Figure 35 Calibration Level

8 User Interfaces
8.4.6 Fault / Inhibit Option
Next, the user will select the fault/inhibit option. The FAULT LED on the front panel will be flashing while the display
indicates “Ac” (active) or “nA” (not active) (Figure 36 ). An “Ac” selection specifies that the 4802A will activate the fault
circuit while the unit is in the Inhibit Mode. A “nA” selection specifies that the 4802A will not activate its fault circuit when the
unit is placed in the Inhibit Mode. A “nA” selection will not disable the fault circuit; therefore, if a fault occurs during the
Inhibit Mode, the unit will activate the fault circuit. Not active is the factory default for this selection.
A - Flashing Fault LED
Figure 36 Fault / Inhibit Option
A - Setup LED (flashing for setup check mode; steady for setup mode)
Figure 37 Entering Card Test Options

8 User Interfaces
8.4.7 Card Test Options
After the fault/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” for about five seconds (Figure 38 ) followed by
the ramp up time (3 or 10) during the card test (Figure 39 ). Three (3) is the factory default for this selection.
Figure 38 Card Test Ramp Time
Next, the display will indicate the alarm output option during a card test as either “Ac”, active or “nA”, not active Figure 39 ).
Not active is the factory default for this selection.
Figure 39 Alarm Output during a Card Test
NOTE: Selecting nA option for the card test will not inhibit the fault or A1/A2 alarm circuits in the event of a malfunction or
gas condition.
8.4.8 Password Options
Once the card test options have been selected, the user will either enable or disable the password option (Figure 40 ). The
display will indicate either “PE”, for enabled or “Pd”, for disabled. Password disabled is the factory default for this selection.

8 User Interfaces
Figure 40 Password Enabled/Disabled Option
If the password is disabled, the unit will return to normal operation. If the password is enabled, the user will be able to enter
a new password (Figure 41 ). The unit will display the left digit of the existing password (flashing on the display). The right
digit will be blank until the left digit has been selected. Press the Mode/Select switch repeatedly until the desired value is
displayed. Once the left digit is correct, wait for five seconds and the right digit of the display will begin flashing and the left
digit will be blank. Press the Mode/Select switch repeatedly, until the desired value is displayed. Wait about five seconds
and the unit will execute the Set up Check Mode and then return to normal operation. See 8.4 Setup and Setup Check
Modes for default password.
A - Right Digit is Blank
B - Left Digit is Blank
C- Steady Setup LED (setup mode only)
D - Mode/Select Switch
Figure 41 Entering a New Password
8.5 Inhibit Mode
Whenever the Inhibit Mode is entered, the A1 and A2 alarm outputs are inhibited. The front panel LED’s will still function
normally in cases where sufficient gas is present at t he sensor. Once this mode has been entered, the user may exit the
Inhibit Mode by pressing the Mode/Select switch.
NOTE: Any latched alarms must be reset before exiting the Inhibit Mode.
There is a user selectable option that will place the unit in fault every time the Inhibit Mode is entered. If the user does not
select this option, the fault circuit will function norm ally during Inhibit Mode.
While the unit is in the Inhibit Mode, the display will indicate “IN” for 5 seconds, then the gas concentration will be displayed
for 5 seconds. This sequence will repeat for as long as the unit is in Inhibit Mode.

8 User Interfaces
The Inhibit Mode is provided so that the operation of the Model 4802A can be verified without tripping external devices that
are connected to the A1 and A2 alarm outputs.
8.6 Setup Mode Block Diagram
This section is provided to aid the operator in making selections during Setup Mode. It is recommended that the operator
fill-in the selections in the proper blanks and then use this page as a reference while programming the Model 4802A. The
blocks shown below indicate the order of options in Setup Mode. To the right of each block is a description of the choices
that are available for that option. More information about making each selection is provided in 8.4 Setup and Setup Check
Modes.
OPTION DESCRIPTION ENTER SELECTION

Password Enter the Password, if the Password is enabled
Inhibit Mode Enter the Inhibit Mode, if desired
A2 Alarm Set the Energized (EN) / De-Energized / De-Energized (dE) Option __________________
Set the Latching (LA) / Non-Latching (nL) Option __________________
Set the A2 alarm set point (from 10 to 60, in increments of 5) __________________
A1 Alarm Set the Energized (EN) / De-Energized (dE) Option __________________
Set the Latching (LA) / Non-Latching (nL) Option __________________
Set the A1 alarm set point (from 10 to the A2 set point) __________________
Calibration Level Set the calibration level, LEL (from 25 to 90 in increments of 1) __________________
Fault / Inhibit Set the Fault Activate (Ac) or not (nA) during Inhibit Mode __________________
Card Test Display will indicate "ct" for 5 seconds
Set the ramp time for the Card Test Mode (3 or 10 seconds) __________________
Set the Alarm outputs for Active (Ac) or not Active (nA) __________________
Password Set the Password to be Disabled (Pd) or Enabled (PE) __________________
If the Password option to be changed from Disabled to Enabled: __________________
Left______________
Set the password digits
Right _____________
Table 13 Setup Display Options
After all of the options have been selected, the 4802A will enter the Setup Check Mode.

9 Customer Support
9 Customer Support
9.1 General Monitors' Offices
Area Phone/Fax/Email
UNITED STATES
16782 Von Karman Ave., Unit 14 Phone: +9-949-581-4464
Irvine, CA 92606 Email: gm.info@MSAsafety.com
IRELAND
Ballybrit Business Park Phone: +353-91-751175
Galway Fax: +353-91-751317
Republic of Ireland H91 H6Ps Email: info.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 14 GM Locations

10 Appendix
10 Appendix
10.1 Principle of Operation
General Monitors uses a low temperature catalytic bead to detect the presence of combustible 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 change in the electrical resistance of the bead.
By taking a matched pair of catalytic beads and coating one, so that it does not respond to the presence of combustible
gases and vapors, we can compare the change in resistance between the two beads. The bead that is coated is called the
reference bead and the other bead is the active bead (Figure 42 ). Environmental factors can also influence the
temperature of the catalytic beads. Because the beads are matched pairs, they will respond to changes in ambient
temperature, humidity and pressure equally.
By connecting one end of each catalytic bead together, a series circuit is formed. This circuit is supplied with a constant
current. The voltage drop across each bead will be identical in the absence of combustible gases and vapors. As
combustible material is converted to heat, the resistance across the active bead increases causing the voltage drop across
each bead to be different. This difference is proportional to the amount of combustible gas or vapor that is present at the
sensing elements (catalytic beads).
A - Teflon Thermal Barrier
B - Platinum Wire
C - Mounting Base
D - Mechanical Support Post
E - Reference Bead
F - Active Bead
Figure 42 Catalytic Sensor Diagram
10.2 Spare Parts and Accessories
This section provides a description of the types of field devices (sensors), and the accessories, which can be used with the
Model 4802A.
10.2.1 Sensors
General Monitors offers a variety of Catalytic Bead Sensors with sensor bodies and flame arrestors:
Part Number Description Sensor Body Temperature Rating Approvals

Material
10001-1 General Purpose, screen Aluminum -40°C to +75°C CSA, FM
10001-1R General Purpose, Poison Aluminum -40°C to +75°C CSA
Resistant, screen
10014-1 High-temp, screen Aluminum -40°C to +200°C CSA, FM
10022-1 General Purpose, sintered Aluminum -40°C to +75°C CSA
10058-1 General Purpose, Screen Stainless Steel -40°C to +75°C CSA, FM
10058-1R General Purpose, poison Stainless Steel -40°C to +75°C CSA
resistant, screen
10164-1 Hydrogen Specific, screen Aluminum -40°C to +75°C CSA

10 Appendix
Part Number Description Sensor Body Temperature Rating Approvals

Material
11159-1 General Purpose, poison Stainless Steel -40°C to +75°C (CSA) ATEX, IECEx, CSA,
resistant, sintered -40°C to +75°C EAC/GOST
(ATEX/IECEx*)
-40°C to +120°C
(ATEX/IECEx**)
11159-1L General Purpose, poison Stainless Steel, -40°C to +75°C (CSA) ATEX, IECEx, CSA,
resistant, sintered Lugs -40°C to +75°C EAC/GOST
(ATEX/IECEx*)
-40°C to +120°C
(ATEX/IECEx*)
11159-2 High Temp, poison Stainless Steel -40°C to +180°C ATEX, IECEx, CSA,
resistant, sintered (ATEX/IECEx***) EAC/GOST
-40°C to +200°C
(CSA****)
11159-2L General Purpose w/Lugs, Stainless Steel, -40°C to +180°C ATEX, IECEx, CSA,
poison resistant, sintered Lugs (ATEX/IECEx***) EAC/GOST
-40°C to +200°C
(CSA****)
11159-3 Super Poison Resistant, Stainless Steel -40°C to +75°C ATEX, IECEx,
sintered (ATEX/IECEx*) EAC/GOST
-40°C to +120°C
(ATEX/IECEx**)
11159-3L General Purpose w/Lugs, Stainless Steel, -40°C to +75°C ATEX, IECEx,
poison resistant, sintered Lugs (ATEX/IECEx*) EAC/GOST
-40°C to +120°C
(ATEX/IECEx**)
10102-1 Sensor Simulator Aluminum n/a n/a
*when installed to increased safety 'e' enclosure B13-020
** when installed to increased safety 'e' enclosure B13-022
***when installed to increased safety 'e' enclosure B13-021
****when using 10252-3 junction box only
10.2.2 Sensor Housing
General Monitors offers an explosion proof housing that is rated for use in Class I, Division 1, Group B, C and D hazardous
locations (Figure 43 ).

10 Appendix
A - Splash-Guard
B - Sensor
Figure 43 Universal Sensor Housing with Sensor and Splash-Guard
Both housing entries are tapped for — NPT threads. The sensor connects to one of these 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 field.
Once the sensor is installed/operating in the field, no attempt should be made to disconnect the sensor, the conduit of the
housing lid without removing power from the Model 4802A; as such an act would compromise the explosion proof integrity
of the field device.
10.2.3 Splash-Guard and TGA-1
General Monitors produces a universal Splash-Guard, P/N 10395-1 that has been
designed for use on all General Monitors’ combustible gas and hydrogen sulfide gas
sensors (Figure 44 ). In addition to the Splash-Guard, a Test Gas Applicator (TGA-1) is
available for delivering a test gas to remotely located sensors, P/N 10460-2.
The Splash-Guard prevents water from rain or equipment wash-downs from being forced
into the sensor cavity and affecting the response of the sensing element. Constructed of
rugged Valox plastic, it has a series of internal baffles to deflect water down and away
from the sensor. This guard (and the TGA-1) is threaded for simple screw-on installation.
The Splash-Guard and TGA-1 are recommended for outside applications where rain or
Figure 44 Splash-Guard frequent hose downs occur, such as offshore platforms.
10.2.4 Dust Guard Assembly
The Dust Guard Assembly (Figure 45 ) is a simple, threaded stainless steel cylinder
with a wire- screen at one end. It is easily removed for cleaning and/ or replacement of
the disposable screen.
This General Monitors’ accessory is specifically designed to prevent dust and

particulate matter from reaching the sensor flame arrestor. Such debris can plug the
screen and limit the amount of gas reaching the active surface of the sensor.
Figure 45 Dust Guard

10 Appendix
The Dust Guard is also available in a kit with twelve replaceable screens (Figure 46 ).
It can also be used as an effective windscreen and is recommended for corrosive,
windy, or high temperature environments.
Figure 46 Dust Guard Assembly

Kit
10.2.5 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 easy to install (Figure 47 ).
A - Sensor
B - O-ring
C - Gasket
D - Cover
E - Screw (4)
F - Lock-nut
Figure 47 Duct Mounting Plate, Assembly Drawing
10.2.6 Calibration Equipment
The Model 4802A uses a Portable Purge Calibrator (Figure 48 ) or the 3-Liter Chamber (Figure 49 ), to accomplish
calibration. The calibration and calibration check procedures and use of the Portable Purge Calibrator are explained in 8.2
Calibration Check Mode and 8.3 Calibration Mode.
A - Cal Cap
B - Screen
C - Hose
D - On/Off Valve
E - Regulator
F - Cylinder Valve
G - Lecture Bottle
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.

10 Appendix
Before the Model 4802A is calibrated with any solvent or volatile liquid, consult the listing in 10.8 Volatile Liquids and
Solvents to determine the volume of solvent/liquid required to produce a 50% LEL concentration in the 3-Liter Chamber.
However, if the user specified calibration level is not 50% LEL, consult the factory for the correct volume. Let the factory
know the calibration level (25 to 90% LEL) and the solvent/liquid being used to calibrate the sensor.
Figure 49 3-Liter Chamber
Before 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 fan using the turnkey on the outside of the chamber.
○ If the fan begins to turn, locate the switch underneath and behind the fan blades on the inside of the chamber
and turn the fan off.
○ Insert the sensor into the sensor hole, open the lid and place the dish at the bottom of the chamber.
○ Draw the correct amount of solvent or liquid into the syringe, according to the listing in 10.8 Volatile Liquids and
Solvents
○ Place the Model 4802A in the Calibration Check or Calibration Mode, following the instructions listed in 8.2
Calibration Check Mode and 8.3 Calibration Mode.
10.2.7 Calibration Check Mode

1. When 0 is flashing on the display (Calibration Check Mode) inject the solvent/liquid into the dish, reach underneath
and behind the fan blades on the inside of the chamber, locate the fan switch; turn it on and close the lid on the 3-Liter
Calibration Chamber.
2. As the sensor begins to respond to the combustible vapor in the chamber, the concentration will begin flashing on the
display.
3. The reading will stabilize after one or two minutes.
4. Remove the sensor from the chamber and allow it to see clean air. When the display has stopped flashing and
indicates a few % LEL and then zeros (0), the Model 4802A has returned to normal operation.
10.2.8 Calibration Mode

1. When AC (Calibration Mode) appears on the display, inject the solvent/liquid into the dish, reach underneath and
behind the fan blades on the inside of the chamber, locate the fan switch; turn it on and close the lid on the 3-Liter
Calibration Chamber.
2. As the sensor begins to respond to the combustible vapor in the chamber, the display will indicate CP (Calibration in
Progress).

10 Appendix
3. After 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 the display indicates a few % LEL and then
zeros (0), the Model 4802A has returned to normal operation.
10.2.9 Calibration Check and Calibration Modes
Remove the Dish from the 3-Liter Chamber and clean thoroughly before using it again.
10.2.10 Calibration Equipment and Part Numbers
Portable Purge Calibrator Assembly
50% LEL Methane Gas 1400150-M

50% LEL Hydrogen Gas 1400150-H
50% LEL Ammonia Gas 1400150-A
50% LEL Butadiene Gas 1400150-BD
50% LEL Butane Gas 1400150-B
50% LEL Ethane Gas 1400150-E
50% LEL Ethylene Gas 1400150-EY
50% LEL Propane Gas 1400150-PR
Portable Purge Replacement Cylinder

50% LEL Ammonia Gas 1400155-A
50% LEL Butadiene Gas 1400155-BD
50% LEL Butane Gas 1400155-B
50% LEL Ethane Gas 1400155-E
50% LEL Ethylene Gas 1400155-EY
50% LEL Propane Gas 1400155-PR
Replacement Parts
Small Calibration Cap 1400152-1

Large Calibration Cap 1400154
Pressure Gauge Regulator 922-009
Cylinder Refills


10 Appendix
10.3 System Specifications
Application Combustible & Flammable Gas and Vapor Detection
Sensor Type General Monitors Low Temperature, Diffusion Limited, Catalytic Bead Sensor
Typical Sensor 3 to 5 years, in normal service

Life
Measuring Range 0 to 99% LEL
Zero Drift Less than 5% of span, per year
Stability Adheres to CSA 22.2 No. 152-M1984. Stabilization occurs in approximately

two (2) minutes.
Response Time T50 < 10 seconds with 100% LEL concentration of Methane (CH4) applied.
T90 < 30 seconds with 100% LEL concentration of Methane (CH4) applied.
Warm-up Time The catalytic bead sensor warm-up time is fifty (50) seconds
Approvals CSA certified to CSA 22.2 No. 152-M1984 and ATEX/UKCA certified to EN
60079-29-1
CML 23ATEX9039X, CML 23ATEX9040X, CML 23UKEX9047X, CML

23UKEX9048X
Warranty 2 years
10.3.1 Converting Test and Calibration Gas Concentrations for % LFL to % Volume
Using %LFL as described in NFPA 325 Guide to Fire Hazard Properties of Flammable Liquids, Gases, and Volatile Solids
1994 Edition it is then used as 100% volume fraction. Example Hydrogen has a 4% LFL is then used as 100% volume
fraction, so that when an environment that has 2% LFL would indicate 50% volume.
10.3.2 Accuracy
The accuracy the 4802A is limited by the accuracy of the standard used to calibrate the system. For many combustible
gases, obtaining a high accuracy standard that is suitable for field calibration use may be difficult (about the best accuracy
of gas concentration achievable is 5%, using a permeation system with good temperature control). For this reason, no fixed
accuracy statement is possible. The accuracy cannot be better than the accuracy of the calibration gas.
The best accuracy to be expected, assuming a perfect standard, is ± 3% LEL up to 50% LEL and ± 5% LEL > 51% LEL, at
reference ambient conditions and when the unit has been calibrated using 50% LEL.
10.3.3 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

10 Appendix
Beyond the standard gases the sensor is configured for. Each gas sensor can be configured to be gas specific. MSA can
conduct an evaluation study to custom configure a gas sensor.
10.3.4 Poisons and Interfering Gases
Sensors require a minimum of 5% oxygen for continuous and reliable operation.
Sensors operating in conditions of less than 5% oxygen will provide erroneous or unstable concentration data.
Fluctuating oxygen concentration during calibration will result in erroneous concentration readings during system
operation. For optimal sensor performance, the oxygen level during calibration should be consistent with the expected
normal ambient atmosphere.
The presence of certain gases and vapors may interfere with sensor operation. General Monitors has tested and
documented some of the known interferents. These include but are not limited to, low vapor silicon, H2S, heavy
hydrocarbons, and light chlorinated products.
10.3.5 Storage
Place the 4802A in the original storage container that was shipped with the unit. This container guards against
contamination from solvents, lubricants, humidity, etc. In the case of long-term storage, the 4802A should be stored as
above in a cool, dry, place, preferably between 0°C and 20°C.
10.4 Mechanical Specifications
Weight 11.2 oz (318 grams)

Length 9.9 inches (251 mm)
Height 6.825 inches (173 mm)
Width 1 inch (25 mm)
10.5 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 for A1 & A2, SPDT f or Fault
Open Collector Rating 100mA @ 35Vdc for A1, A2, Fault, UA, FUA, CAL-OC, LA1 and LA2
10.5.1 Cable Parameters
Recommended 3-wire shielded. Maximum cable lengths allowable between module and sensor with one way resistance of
20 Ohms per sensor lead (40 Ohms loop) @ 24Vdc nominal:
AWG Feet Meters

14 7600 2320
16 4800 1460
18 3000 910
20 1900 580
Table 15 Recommended Maximum Cable Lengths between Module and Sensor

10 Appendix
The maximum allowable cable lengths between the analog output connections on the control module with a remote device
in series (maximum loop resistance of 500 Ohms between AO+ & AO-):
AWG Feet Meters

14 9000 2740
16 5200 1585
18 3800 1160
20 2400 730
Table 16 Maximum Allowable Cable Lengths between Analog Output Connections
10.6 Environmental Specifications
Operating Temperature Range Sensor 4802A See 10.2.1 Sensors

0°F to +150°F (-18°C to +66°C)
Storage Temperature Range Sensor 4802A See 10.2.1 Sensors
-40°F to +150°F (-40°C to +66°C)
Pressure Limits 1/2ATM to 3ATM with no impact on performance or operation
Operating Humidity Range 5% to 100% Relative Humidity, non-condensing
10.7 Engineering Specifications
10.7.1 Zero Two System
Each system utilizes modules capable of monitoring gas sensing elements, or a 0 to 21.7mA analog signal from gas or
flame detection transmitters. The system chassis is available in 4, 8, and 16 channels. Each chassis contains a bus for the
following independent signals:
• A1 Alarm
• A2 Alarm
• Fault
• Master Reset
• Master Accept
• Un-accept
• CAL
• +24Vdc
• System Common
Module signals are capable of being bussed from one chassis to another, so that up to 100 modules can comprise a single
system. The gas and flame detection modules are electrically and physically compatible and capable of being used in the
same chassis to form combined fire and gas detection systems. The system consists of Zero Two Series component
modules as manufactured by General Monitors, Irvine, California, U.S.A. (the manufacturing facility is located at 372
Elizabeth Lane, Corona, CA.) or General Monitors, Galway, Ireland.
10.7.2 4802A Control Module
The control module, with sensor, meets the performance requirements of CSA 22. 2 No. 152- M1984 and 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
• Fault or malfunction indicator
• Ready indicator
• Calibration mode indicator
• Setup mode indicator
• 2 digit digital display

10 Appendix
All alarm parameters and user options are software selectable. A functional card test and a front panel LED test are switch
capable without interrupting normal on-line services.
The control module is capable of insertion and removal during power o n conditions without damage to any component
module in the system. The control module meets level 3 for severity and complies with BS 6667 Part 3 / IEC 801-3 for
Radio Frequency Interference (RFI) susceptibility. The control module generates display codes associated with fault
conditions whenever a fault or malfunction occurs. A mode/select switch provides the operator front panel access to:
• Calibration check mode
• Calibration mode
• Setup check mode
• Setup mode
• Inhibit mode
The control module has a 100% backward compatible option available at the time of order. The control module, with
sensor, is capable of calibration with the following display prompts during the calibration routine:
AC = Calibration routine activated,
CP = Calibration in progress, and
CC = Calibration complete.
The control module has a password protected setup routine capable of having the password disabled.
10.8 Volatile Liquids and Solvents
Volatile liquids and solvents are not supplied by General Monitors. Table 17 provides a listing 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.
Reference: NFPA 325, 1994 Edition
Acetaldehyde 136
Acetic Acid 140
Acetone 112
Acetonitrile 96
Acrylonitrile 120
Amyl Acetate 100
Amylamine 156
Benzene 65
Butyl Acetate 137
Butyl Acrylate 148
Butyl Alcohol 78
sec-Butyl Alcohol 95
tert-Butyl Alcohol 138
Butyl Cellosolve 88
Butyraldehyde 102
Cyclohexane 86
Decane 95
Diethyl Ketone 103
Diisobutyl Ketone 82
Dimethylformamide 104
p-Dioxane 104
Dodecane 83
Ethyl Alcohol (Ethanol) 118
Ethyl Acetate 119

10 Appendix
Ethyl Amine 140

Ethyl Benzene 60
Ethyl Ether 120
Ethylene Oxide 89
Gasoline 100 Octane 107
Heptane, Normal 94
Hexane, Normal 86
Table 17
The volatile liquids and solvents listed in Table 18 are intended for use in the 3-Liter chamber for calibrating General
Monitors Catalytic Sensors (not the Model IR2000).
Isopentane 99
Isoprene 89
Isopropyl Alcohol 93
Isopropyl Ether 120
JP-4, Jet Fuel 183
Laktane 76
Methanol 148
Methyl Ethyl Ketone (MEK) 76
Methyl Metacrylate 111
Naptha (Petroleum Ether) 96
Octane 99
Pentane, Normal 105
Propanal 114
2-Propanol 93
Propyl Acetate 106
Propylamine 103
Propylbenzene 68
Propylene Oxide 98
Styrene 63
Tetradecane 79
Tetrahydrofuran 99
Tetrahydrofurfuryl Alcohol 89
Toluene 78
1,1,1-Trichlorethane 456
Trichloroethylene 438
Triethylamine 102
Vinyl Acetate 152
Vinyl Ethyl Ether 99
o-Xylene 83
p-Xylene 83
Xylenes 83
Table 18 Volatile Liquids

10 Appendix
10.9 Engineering and Technical Drawings
10.9.1 Outline and Terminal Connections
Reference Drawing # 11221
Figure 50 Outline and Terminal Connections 4802A

10 Appendix
10.9.2 Final Assembly
Reference Drawing # 11220-1
Figure 51 Final Assembly, 4802A
10.10 Zero Two Series Modules
Model 4802A
Zero Two Series Control Module for Combustible Gas Applications
Model TA102A
Zero Two Series Trip Amplifier Module for Combustible Gas Applications
Model TA202A
Zero Two Series Trip Amplifier Module for Hydrogen Sulfide Gas Applications
Model TA402A
Zero Two Series Trip Amplifier Module for Flame Detection Applications
Model FM002A
Zero Two Series Facilities Module Performs Common Functions for Zero Two Systems
Model RL002
Zero Two Series Relay Module Provides Extra Output Capacity for Zero Two Systems
Model IN042
Zero Two Series Four Zone Input Card for Call points, Smoke & Thermal Detectors
11 Addendum
11 Addendum

For local MSA contacts, please visit us at MSAsafety.com

FINAL_GM Model 4802A MAN4802A_rK_US

Uploaded by

Document Informationclick to expand document information

Copyright:

Available Formats

FINAL_GM Model 4802A MAN4802A_rK_US

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

FINAL_GM Model 4802A MAN4802A_rK_US

Uploaded by

Copyright:

Available Formats

Operating Manual

General Monitors® Model 4802A

Order No.: MAN4802A/K

© MSA 2021, 2023. All rights reserved

3 System Integrity Verification 5

US General Monitors Model 4802A 3

4 General Monitors Model 4802A US

3 System Integrity Verification

Remember, these products are for your safety.

US General Monitors Model 4802A 5

3.1 Commissioning Safety Systems

Fault/Malfunction circuit operation should be verified.

3.2 Periodic Testing / Calibration of Field Devices

Specific Conditions of Use

6 General Monitors Model 4802A US

Figure 1 Control Module Coding Strip

4.2 Rear Terminal Connections

14 AWG wire may be used if it is properly stripped according to Figure 2 .

Figure 2 Wire Strip Length

For the rear terminal designations refer to Figure 3

Figure 3 Rear Terminal Designations

US General Monitors Model 4802A 7

4.3 Sensor Connections

The terminal designations for the sensor wires are:

Label Term Description

Table 1 Terminal Designations for Sensor Wires

NOTE: Only 1 sensor may be connected to a Model 4802A.

Figure 4 illustrates the Sensor/Controller connections.

A - Black Sensor Lead

B - Red Sensor Lead

C - White Sensor Lead

Figure 4 Sensor/Controller Connections

4.4 Applying Power

8 General Monitors Model 4802A US

Figure 5 Rear Power Connections

5.1 General Description

Figure 6 Model 4802A

US General Monitors Model 4802A 9

5.2 Features and Benefits

Calibration Check Mode

The user specifies the gas concentration to be used for calibration.

Prevents unauthorized alteration of the setup parameters (can be disabled).

Setup Check Mode

Live Insertion / Removal

Table 2 is a partial list of applications

Refineries Gas turbines

Table 2 Partial List of Zero Two Series Applications

10 General Monitors Model 4802A US

6.1 Upon Receipt of Equipment

6.2 Control Module Installation

Figure 7 Control Module Coding Strip

6.3 Rear Terminal Connections

14 AWG wire may be used if it is properly stripped according to Figure 8 .

US General Monitors Model 4802A 11

Figure 8 Wire Strip Length

For the rear terminal designations refer to Figure 9 .

Figure 9 Rear Terminal Designations

The terminal designations for the A2 alarm outputs are:

LABEL TERM DESCRIPTION