Bacharach 3015-4256 User Manual

HGMSZ

Halogen Gas Monitor Single Zone

Instruction 3015-4256

Installation / Operation / Maintenance

Rev. 0 – January 2004

Complies with
UL 61010A-1 and
CSA 22.2 No. 1010.1

HGMSZ

HALOGEN GAS MONITOR SINGLE ZONE

MONITOR

ON

SYSTEM

FAULT

ENTER

SILENCE / QUIT

ALARM

Product Leadership • Training • Service • Reliability

Declaration of Conformity

Manufacturer’s name: Bacharach, Inc.

Manufacturer’s address: 621 Hunt Valley Circle
New Kensington, PA 15068

European Operations: Bacharach Europe
Sovereign House, Queensway
Royal Leamington Spa
Warwickshire CV31 3JR
United Kingdom

Product Name: HGMSZ (Halogen Gas Monitor Single Zone)
conforms to the following specifications:
EMC Directive 89/336/EEC
Low Voltage Directive 73/23/EEC
EN61326-1 (Electrical Equipment for Measurement)
EN55081-2:1993 (Radiated Emission)
EN50082-1:1998 (Electrostatic & Electromagnetic Immunity)

Notice:

Product improvements and enhancements are continuous; therefore the specifications
and information contained in this document may change without notice.

Bacharach, Inc. shall not be liable for errors contained herein or for incidental or
consequential damages in connection with the furnishing, performance, or use of this
material.

No part of this document may be photocopied, reproduced, or translated to another
language without the prior written consent of Bacharach, Inc.

Revision Date: 9/21/2004

Copyright © 2004, Bacharach, Inc., all rights reserved.

®

BACHARACH
names, service marks and logos referenced herein belong to their respective owners.

is a registered trademark of Bacharach, Inc. All other trademarks, trade

A Instruction 3015-4256

Table of Contents

INTRODUCTION........................................................................................................................................... 1

How to Use This Manual ......................................................................................................................... 1

Warning Statements................................................................................................................................ 1

Caution Statements ................................................................................................................................. 1

Hazard Symbols on Monitor.................................................................................................................... 1

Safety Precautions ................................................................................................................................... 2

AC Power Supply.................................................................................................................................. 2

Protective Grounding ........................................................................................................................... 2

Explosive Atmosphere.......................................................................................................................... 2

Proper Exhaust Venting ...................................................................................................................... 2

Working Inside Monitor ....................................................................................................................... 2

Misuse and Modifications to Monitor.................................................................................................. 2

In Case of Malfunction ......................................................................................................................... 2

Fusing.................................................................................................................................................... 2

Installation Category ........................................................................................................................... 2

Altitude Limit .......................................................................................................................................2

Cleaning ................................................................................................................................................ 2

Functional Overview................................................................................................................................ 3

General Description ............................................................................................................................. 3

Understanding Monitoring Levels ......................................................................................................3

Response to the Presence of Multiple Refrigerants ........................................................................... 3

Suggested Location of Sampling Point ............................................................................................... 4

INSTALLATION............................................................................................................................................ 5

Installation Considerations ..................................................................................................................... 5

Warnings and Cautions ....................................................................................................................... 5

Inspection.............................................................................................................................................. 5

Locating the Monitor............................................................................................................................ 5

Mounting Instructions ............................................................................................................................. 6

Connecting Gas Sample and Exhaust Lines .......................................................................................... 6

Overview ............................................................................................................................................... 6

Tubing Considerations ......................................................................................................................... 7

Connecting the Gas-Sample Line........................................................................................................ 7

Connecting the Exhaust Line .............................................................................................................. 7

Interior Schematic ................................................................................................................................... 8

Electrical Wiring ...................................................................................................................................... 9

Connecting External Alarms................................................................................................................. 10

Overview ............................................................................................................................................. 10

Connection ..........................................................................................................................................10

4–20 mA Current Loop Interface ..........................................................................................................11

OPERATION............................................................................................................................................... 13

Front Panel Display and Controls ........................................................................................................ 13

General Operation ................................................................................................................................. 13

Display Screens ...................................................................................................................................... 14

Initial Power Up ................................................................................................................................. 14

Data Display Screen........................................................................................................................... 14

Function Screens ................................................................................................................................ 15

Working with Gas Alarms ..................................................................................................................... 18

Functional Overview .......................................................................................................................... 18

Clearing / Silencing a Gas Alarm ...................................................................................................... 18

Viewing the Gas Alarm Log............................................................................................................... 18

Working with System Faults ................................................................................................................ 18

Functional Overview.......................................................................................................................... 18

Clearing / Silencing a Fault Alarm ................................................................................................... 18

Viewing the Fault Log ....................................................................................................................... 19

Fault Codes......................................................................................................................................... 19

Clearing the Stored PPM Log, Alarms & Faults Data........................................................................ 20

Entering Custom Refrigerant Calibration Values............................................................................... 20

Reset to Factory Default Settings......................................................................................................... 20

Working with the DIAGNOS Function ................................................................................................ 21

Overview ............................................................................................................................................. 21

Keypad Functions .............................................................................................................................. 21

First Diagnostic Screen ..................................................................................................................... 21

Second Diagnostic Screen .................................................................................................................. 21

Working with the P-CHK Function...................................................................................................... 22

Overview ............................................................................................................................................. 22

Keypad Functions .............................................................................................................................. 22

Screen Display.................................................................................................................................... 22

Working with the Calibration Function............................................................................................... 23

Overview ............................................................................................................................................. 23

Calibration Procedure........................................................................................................................ 23

Adjusting Calibration Factor ............................................................................................................ 23

MAINTENANCE ......................................................................................................................................... 25

Warnings and Cautions......................................................................................................................... 25

Charcoal Filter....................................................................................................................................... 25

Hydrophobic Filter................................................................................................................................. 25

Servicing Air Lines ................................................................................................................................ 25

Fuses....................................................................................................................................................... 25

Clock Battery ......................................................................................................................................... 25

Sample Pump ......................................................................................................................................... 25

Replacement Parts & Optional Accessories......................................................................................... 26

Replacement Parts ............................................................................................................................. 26

Optional Accessories .......................................................................................................................... 26

APPENDIX.................................................................................................................................................. 27

Table of Recommended Alarm Settings ............................................................................................... 27

WARRANTY and SERVICE ................................................................................................................. 28

Warranty ............................................................................................................................................ 28

Service................................................................................................................................................. 28

Return Procedure................................................................................................................................... 29

Field Repair............................................................................................................................................ 29

Specifications ......................................................................................................................................... 30

ii Instruction 3015-4256

Introduction

How to Use This Manual

Thank you for investing in a BACHARACH HGMSZ (Halogen Gas Monitor Single Zone).

This manual provides important information on how to install, operate, and service the HGMSZ
monitoring unit.

To assure operator safety and the proper use of the monitor, please read, understand, and follow the
contents of this manual.

If you have a working knowledge of refrigerant monitors, you will find this manual useful as a reference
tool. If you are new to the use of refrigerant monitors, you can educate yourself about the principles of
refrigerant gas detection and the proper operation of this device by reading this manual thoroughly.

Warning Statements

The use of the word WARNING in this manual denotes a potential hazard associated with the use of this
equipment. It calls attention to a procedure, practice, or condition, or the like, which if not correctly
performed or adhered to, could result in personal injury or death.

Caution Statements

The use of the word CAUTION in this manual denotes a potential hazard associated with the use of this
equipment. It calls attention to a procedure, practice, condition, or the like, which if not correctly
performed or adhered to, could result in damage to the equipment.

Hazard Symbols on Monitor

This symbol indicates the need to consult this operating
instruction manual when opening the enclosure.

WARNING: A potential risk exists if the operating instructions
are not followed.

This symbol indicates the presence of electric shock hazards when
the enclosure is opened.

WARNING: To avoid risk of injury from electric shock, do not open
the enclosure.

Safety Precautions

AC Power Supply

The HGMSZ uses a universal power supply that is capable of accepting inputs of 100 to 240 VAC,
50/60 Hz. The monitor’s power consumption is 15 Watts. It is highly suggested that the monitor be
connected directly to the AC power source, preferably on its own circuit (with UPS or surge protection).

A switch or circuit breaker rated 1.0 A, 250 VAC, with a minimum terminal spacing of 3.0 mm must be
attached to the monitor’s AC power leads. This switch must also be located in close proximity to the
monitor, and be in easy reach of the operator. This switch should also be clearly marked as the monitor’s
main AC disconnect device.

Protective Grounding

Under no circumstances should the HGMSZ be operated without connection to a protective ground. Doing
so poses a potential shock hazard and is also a violation of electrical safety standards applicable to this
type of equipment.

Explosive Atmosphere

Do not operate this equipment in the presence of flammable liquids, vapors or aerosols. Operation of any
electrical equipment in such an environment constitutes a safety hazard.

Proper Exhaust Venting

It is imperative that the monitor’s exhaust port be vented as described in this manual. Failure to do so
may constitute a safety hazard.

Working Inside Monitor

Extreme care should be exercised when accessing the interior of the monitor. Only qualified electrical
maintenance personnel should perform connections and adjustments. Always remove AC power before
working inside the monitor.

Misuse and Modifications to Monitor

The protection provided by the monitor may be impaired if the monitor is used in a manner not specified by
Bacharach, Inc. Changes or modifications to this monitor, not expressly approved, will void the warranty.

In Case of Malfunction

Do not continue to use this equipment if there are any symptoms of malfunction or failure. In the case of
such occurrence, de-energize the power supply and contact a qualified repair technician or the nearest
Bacharach Service Center. Use ONLY the provided knockouts for electrical and communication wiring.
Drilling into the box will void the warranty.

Fusing

F1, F2: 1.0 A, 250 V, Type “F”

Installation Category

Installation Category II, Pollution Degree II, as defined by UL.

Altitude Limit

6,562 ft (2,000 m)

Cleaning

To clean the outside of the case, DO NOT use soap and water. USE a dry cloth.

2 Instruction 3015-4256

Functional Overview

General Description

Refrigerant monitors are specified to support compliance to federal, state and local safety codes governing
refrigerant emissions. Avoiding significant refrigerant loss reduces equipment replacement costs,
maintains equipment efficiency, promotes safety, and protects the environment.

The Bacharach HGMSZ (Halogen Gas Monitor Single Zone) is easily programmed to continuously monitor
the level of any one of several types of refrigerant gases in an area that is located up to 50 ft (15.2 m) away
from the monitor. The HGMSZ displays the type of gas being monitored, along with displaying both the
current gas level and the peak gas level detected in that area on its front panel LCD. The monitor retains
a log of previous readings that can be easily accessed for analysis.

An audible alarm and front panel indicators are provided to signal alarm and fault conditions, and relay
contacts are provided that can be used to trigger external alarm devices in the event of a system fault, or if
a leak (small), spill (medium), or evacuation (large) level of gas is detected. The system also includes a
4−20 mA current loop interface that can be connected to remote monitoring equipment.

The HGMSZ requires only minor periodic maintenance such as the occasional replacement of filters. The
monitor incorporates active diagnostics that continuously check the system for proper operation. A front
panel indicator is provided to alert an operator of system malfunctions, and fault codes are generated that
enable the operator to identify the cause of the fault.

Understanding Monitoring Levels

Effective use of this monitor requires an understanding of what constitutes reasonable alarm set points for
the type of gas being monitored. All AC&R systems leak some refrigerant. In a good “tight” installation
these background levels will be acceptably low and often do not require corrective action. You can reduce
nuisance alarms and needless service calls if the alarm levels are set at practical limits.

Refrigerant manufacturers define allowable exposure levels and threshold limit values in units of parts
per million (ppm). Bacharach has developed recommended monitoring levels based on compliance to
ANSI/BSR ASHRAE 15-1994 and ASHRAE Safety Code 34-1992. These reference levels are listed in the
Appendix (Page 27).

Setting the monitor at these recommended alarm levels will satisfy the needs of most users. However, the
ppm levels generated by system leaks into the environment are greatly influenced by the volume of air in
the sampling area, air circulation, size of the leak, distance to the monitoring point, and a host of other
variables. In some cases the set points may need to be adjusted either up or down to achieve effective
monitoring.

Response to the Presence of Multiple Refrigerants

The HGMSZ is a refrigerant level monitor, not a gas analyzer. You must program the monitor to test for a
specific refrigerant, and it will only return accurate concentration readings for that particular refrigerant.
If a leak occurs of another refrigerant gas type, the monitor may return incorrect readings.

Most applications only require detection of a single refrigerant and the problems that are associated with
monitoring multiple gases are rarely an issue. If there is a possibility of multiple refrigerants leaking in
the same sampling zone, then you should carefully consider which refrigerant compound you program the
unit to monitor.

Instruction 3015-4256 3

Suggested Location of Sampling Point

At the point of a refrigerant leak the gas is nearly pure. As the refrigerant is dispersed into the air, the gas
molecules diffuse causing a dilution of the original concentration. The HGMSZ measures the refrigerant
concentration at the point the sample is collected. Therefore, if the termination of the collection line is not
at the exact point of the refrigerant leak, then the monitor will read a diluted mixture of the refrigerant
gas and air.

It should also be noted that halogen refrigerant gas is heavier than air and tends to collect below the point
of a leak. Therefore a sample taken near the floor will have a greater concentration of gas than that
collected above the source of a leak. Consequently, the sampling point should ideally be located as close as
possible to the source of a potential leak. If this is impractical, then the alarm set points should be
adjusted to compensate for the dilution of the refrigerant gas.

The HGMSZ should be mounted outside of the mechanical room or at least just inside of a door to the
room. This is the “split architecture design” for safety of the operator. The monitor should be readily
accessible for easy visual monitoring and servicing. The gas-sample line can be up to 50 ft (15.2 m) in
length. If the area around the monitor is not well ventilated, then an optional exhaust line can be run to
an outside location. The length of the exhaust line cannot exceed 50 ft (15.2 m).

It may be necessary to perform a “smoke” test of the mechanical room to determine the best monitoring
point. The smoke test would provide the pattern of air currents present in the room.

HGMSZ Refrigerant Gas Leak Monitor Mechanical Room Placement

4 Instruction 3015-4256

Installation

Installation Considerations

Warnings and Cautions

WARNING: Drilling holes in the HGMSZ enclosure

will void the warranty. Please use knockouts provided
for electrical connections.

WARNING: Do not mount the HGMSZ in an area that
may contain flammable liquids, vapors or aerosols.
Operation of any electrical equipment in such an
environment constitutes a safety hazard.

WARNING: Always disconnect AC power before
working inside monitor.

CAUTION: The HGMSZ contains sensitive electronic
components that can be easily damaged. Be careful
not to touch or disturb any of these components.

Inspection

The HGMSZ has been thoroughly inspected and tested prior to shipment from the factory. Nevertheless, it
is recommended that the monitor be re-checked prior to installation. Inspect the outside of the enclosure to
make sure there are no obvious signs of shipping damage. Open the enclosure and inspect the interior of
the monitor for loose components that may have become dislodged during shipment. If damage is
discovered, please contact the nearest Bacharach Service Center for assistance.

Locating the Monitor

Locate the HGMSZ so that no more than 50 ft (15.2 m) of tubing will be needed to reach the sampling
area, and that no more than 50 ft (15.2 m) of tubing will be required for the exhaust. Since the monitor
uses ambient air to zero its gas sensor, the monitor should be located in an area that normally does not
contain refrigerant gas. If an exhaust line is not used, then locate the monitor in a well ventilated area so
that the exhaust gas does not accumulate around the monitor’s ventilation holes.

The HGMSZ should be operated in an environment that is between 32 and 122°F (0 and 50°C), has a
relative humidity of between 5 and 90% non-condensing, and is at an altitude of no more than 6,562 ft
(2,000 m). The area should also be relatively free of dirt, grease, and oils that could adversely affect the
operation of the monitor.

The location should allow the monitor to be easily accessible for visual monitoring and servicing.

Mounting Instructions

p

)

The HGMSZ should be installed plumb and level and securely fastened to a rigid mounting surface.

The enclosure utilizes keyhole mounting brackets designed for #12 pan head screws. Locate the four
screws as shown in the diagram below and leave the screw heads protruding approximately 3/16".

Enclosure Mounting Specs

MONITOR

ON

14-1/4"

SYSTEM

FAULT

ALARM

ENTER

SILENCE / QUIT

4"

HGMSZ

HALOGEN GAS MONITOR SINGLE ZONE

Hold the monitor flat against the mounting surface and allow it to slide down engaging the screw heads in
the keyhole slots of the mounting brackets. Adjust the screws as necessary to hold the monitor securely
against the mounting surface.

Connecting Gas Sample and Exhaust Lines

Overview

A single gas-sample line needs to be run from the HGMSZ to the area of the facility to be monitored. An
optional exhaust line can also be installed to vent refrigerant gas away from the monitor. All tubing
connections are made on the bottom of the enclosure as shown in the illustration below.

HGMSZ Bottom View

½" / ¾" SERVICE KNOCKOUTS (There is an
additional Service Knockout on to

of the case

GAS SAMPLE
PORT

EXHAUST
PORT

6 Instruction 3015-4256

Tubing Considerations

¼" outside diameter (0.040" wall) flex tubing is used for all air lines (P/N 304-2743) or equivalent. The
tubing should be clean and free of moisture or other contaminants. The tubing should be cut cleanly with a
sharp knife and care should be taken not to distort the tubing end.

Connecting the Gas-Sample Line

To connect the gas-sample line to the monitor, simply push the tubing into the Gas Sample Port. All
tubing bends should have a radius of no less than 5" to insure proper airflow. If kinks or obstructions occur
in the line the monitor may not function properly.

Please refer to Section Suggested Location of Sampling Point (Page 4) to learn more about where to take a
sample.

The gas-sample line can be up to 50 ft (15.2 m) in length. The end of this line should be placed near the
potential leak source and positioned to reduce the possibility of mists, aerosols, oil, water, dust, or other
contaminates being drawn into the monitor. For added protection, a termination filter (P/N 3015-3420)
should be attached to the end of this line.

CAUTION: The introduction of contaminants through
the gas-sample line can result in serious and
permanent damage to the monitor.

Connecting the Exhaust Line

The exhaust line functions to carry the exhausted gas sample away from the monitor, and is required if
the monitor is located in a confined, poorly ventilated area. Note that if the monitor is exposed to usually
high level of refrigerant gas for prolonged periods of time, its charcoal filter will quickly become saturated
and no longer to able to clean the purge-air of refrigerant gas.

The exhaust line can be up to 50 ft (15.2 m) in length. Ideally this line should terminate outdoors in a
location that is not exposed to the elements. Connect the exhaust line to the monitor by firmly pushing the
tubing onto the Exhaust Port’s barbed fitting. If the exhaust line terminates outside the building, position
the tubing so that no water or moisture can enter the line. Note that this line does not require a
termination filter.

Termination Filter

Instruction 3015-4256 7

Interior Schematic

LINE FUSES

1.0A, 250V, F

HYDROPHOBIC
FILTER

Interior Schematic

UNIVERSAL
POWER
SUPPLY

FACTORY
DEFAULT
SWITCH SW3

SAMPLE

CLOCK

AC INPUT
TERMINALS

GND LINE LINE
1 2

CHARCOAL
FILTER (Used to
remove refrigerant
gas from the
purge air)

EXTERNAL
ALARM
RELAYS

4–20 MA
(Signal Out.
Do not apply
power!)

CPU
RESET
SWITCH

8 Instruction 3015-4256

Electrical Wiring

The HGMSZ uses a universal power supply that is capable of accepting inputs of 100 to 240 VAC,
50/60 Hz. The monitor’s power consumption is 15 Watts. It is highly recommended that the monitor be
connected directly to the AC power source, preferably on its own circuit. The connection should be
completed with UL approved multi-conductor wire (14−18 AWG), rated 300 VAC at 105°C.

Locate a convenient service knockout and install electrical conduit in the typical manner. Locate the AC
Input Terminals on the inside of the monitor (Page 8) and secure the incoming AC power leads to the
GND, LINE 1, and LINE 2 terminals as shown in the diagram below.

A switch or circuit breaker rated 1.0 A, 250 VAC, with a minimum terminal spacing of 3.0 mm must be
attached to the monitor’s AC power leads. This switch must also be located in close proximity to the
monitor, and be in easy reach of the operator. This switch should also be clearly marked as the monitor’s
main AC disconnect device.

AC Power Connector Board

GND LINE1

NEUTRAL

LINE2

WARNING: Drilling holes in the HGMSZ enclosure will
void the warranty. Please use knockouts provided for
electrical connections.

WARNING: Electrical installation should be performed by
a certified electrician, and should comply with all
applicable NEC/CEC and local electrical safety codes.

WARNING: Connection of the mains wiring must be made
to terminals LINE1, LINE2, and GND. Under no
circumstances should this monitor be operated without a
protective ground. Doing so poses a potential shock
hazard, and is also a violation of electrical safety
standards applicable to this type of equipment.

Instruction 3015-4256 9

Connecting External Alarms

Overview

The HGMSZ includes four SPDT relays whose contacts are rated 3 A at 240 VAC. These relays are used
for the connection of external alarm devices that are activated when the relay is energized. The relays are
factory assigned to energize under the following conditions:

Relay #1 Leak Alarm Point 100 ppm
Relay #2 Spill Alarm Point 300 ppm
Relay #3 Evacuate Alarm Point 500 ppm
Relay #4 Fault System Fault Event

Note that the alarm points of relays #1, #2, and #3 are set using the monitor’s LEAKLVL, SPILLLVL,
and EVACLVL function screens (Page 17).

Connection

Use any of the service knockouts to gain cable access to the interior of the monitor. Locate the external
alarm relay connector (Page 8) and remove it from the circuit board. Secure the leads from the external
alarm device and its power source to the connector as shown in the diagram below. When you are through
securing the connections, carefully plug the connector back onto the circuit board.

The second diagram on Page 11 shows a typical connection to Relay 1. Note how power to the alarm device
is being tapped off the monitor’s AC input.

External Alarm Relay Connector

Each relay may be connected as normally open (NO), or normally closed (NC).

The relay contacts are rated 3 A at 250 VAC.

Power for the external alarm devices may be supplied from an external power source, or from
the monitor’s AC input terminal strip.

10 Instruction 3015-4256

Typical External Alarm Relay 1 Wiring

Jumper the ‘Neutral’ line of an external power source or the monitor’s AC input to the ‘Common’ terminals on
the relay connector.

Connect one end of the strobe or horn to the ‘NO’ terminal of whichever level of alarm is appropriate for the
application.

The other end of the strobe or horn is connected to the other leg of the external power source. For protection,
install an in-line fuse of the appropriate size and design for the external alarm device being used.

4–20 mA Current Loop Interface

An external 4−20 mA monitoring device (e.g., chart recorder) can be connected to the HGMSZ using a
shielded-twisted-pair cable. Use any of the service knockouts to gain access to the interior of the monitor.
Locate the 4−20 mA connector (Page 8), remove it from the circuit board, and then remove the resistor or
shorting wire from its terminals.

IMPORTANT! The monitoring device must be isolated from ground (floating).

NOTE: A 100 ohm, ¼ W resistor must be connected to the 4–20 mA connector if no external monitoring

device is used. Failure to install this resistor will cause loop-fault code 0010 to occur (Page 19).

Secure the wire leads from the external monitoring device to the 4−20 mA connector as shown in the
diagram below, making sure that the polarity at this connector matches the wiring at the monitoring
device. When you are through securing the connections, carefully plug the connector back onto the circuit
board.

The default current-to-ppm factor is set to 0.016 mA = 1 ppm, providing a measurement range of 0 ppm
(4 mA) to 1,000 ppm (20 mA). Note that the current-to-ppm factor can be changed using the monitor’s
LOOP function (Page 16).

To facilitate loop zero and span checking, note that when the LOOP function is selected the loop output is
set to 20 mA, and upon exiting this function the loop output is set to 4 mA.

4–20 mA Current Loop Connector

CAUTION: Never apply power to the 4–20 mA

Current Loop Connector from an external power
supply. Connect only a load resistor and/or a floating
measurement device.

Instruction 3015-4256 11

Notes:

12 Instruction 3015-4256

Operation

p

(

)

M

pp

Front Panel Display and Controls

HGMSZ

KEYPAD
Use these buttons:

1) To move the arrow
(>) on the display
screen to the desired
function

2) Scroll through data

3) Change a
function’s value

HALOGEN GAS MONITOR SINGLE ZONE

MONITOR

SYSTEM

ON

FAULT

MONITOR ON
LIGHT (Green)

Flashes during
warm-u

ENTER

SILENCE / QUIT

ALARM

SYSTEM FAULT

ALARM LIGHT

Red

DISPLAY
SCREEN

ENTER
Press to save a
displayed value

SILENCE / QUIT
Press this button:

1) To acknowledge
an alarm and turn
OFF the Alarm Light

2) Return to the
previous screen
without saving data

General Operation

Once the HGMSZ has been installed, set up, and powered ON, it will make measurements in the area
being sampled for refrigerant gas without further operator intervention. The results of those
measurements are displayed on the front panel display.

EASURE 00485pk

45

In the example shown above, MEASURE indicates that the HGMSZ is actively monitoring for refrigerant
gas, and that currently 45 ppm of R-134a gas is being detected. This display also indicates that a peak
measurement of 485 ppm has been made.

An operator can reset the peak value to zero by pressing the ENTER button.

A log of up to 200 previous measurements can be viewed using the PPM LOG screen (Page 15).

If the detected gas level exceeds the preset Leak, Spill, or Evacuate alarm point, then the monitor
responds by turning ON the front panel ALARM (red) light and energizing the corresponding alarm relay.
If the internal audible alarm is turned ON, it too will activate. Optional external alarm devices can be
connected to the alarm relays to alert personnel that a Leak, Spill, or Evacuate alarm condition has
occurred. Pressing the front panel SILENCE button will acknowledge an alarm and turn OFF all alarm
indicators. The alarm circuit will reactivate, however, if the alarm condition is not cleared within the time
period set by the SILENCE function (Page 16).

m R134A

Instruction 3015-4256 13

If a system fault occurs (see Fault Code list on Page 19), the monitor responds by turning ON the front

H

M

pp

P

pp

P

R

pp

panel SYSTEM FAULT (yellow) light and energizing the fault relay. If the internal audible alarm is
turned ON, it too will activate. An optional external alarm device can be connected to the fault relay to
alert personnel that a system fault has occurred. The SYSTEM FAULT light will turn OFF only after the
cause of the fault has been eliminated.

A log of the alarm and fault events can be viewed using the monitor’s ALARMS and FAULTS function
(Page 15).

Display Screens

Initial Power Up

When first powered up all front panel lights are turned ON, and a splash screen appears showing the
monitor’s firmware revision level. After a brief moment the Warm Up screen is display along with the
front panel MONITOR ON light (green) blinking.

BACHARACH INC

GMSZ REV 1.0

The monitor takes 15 minutes to warm up; after which, the MONITOR ON light glows steady and the
Data Display screen is displayed.

WARM UP

Data Display Screen

EASURE 00485pk

0

During normal operation, the Data Display screen shows when the monitor is performing the following
three functions:

MEASURE indicates that the monitor is actively monitoring for refrigerant gas. In the example screens
shown above, the monitor is currently detecting 0 ppm of R-134a gas, and that a peak measurement of
485 ppm has occurred.

To reset the peak value to zero, press the ENTER button.

PURGE is displayed when the monitor is resetting its infrared detector to a baseline of 0 ppm using
ambient air as the gas sample. This purging process is performed on an “as needed” basis, which is
normally once every 6 to 8 minutes.

Note that a charcoal filter (Page 8) is present in the purge-air stream to filter out any refrigerant gas that
would otherwise cause the baseline level to be something other than 0 ppm.

PRES CHK is displayed when the monitor is performing an atmospheric pressure check, which is done to
ensure the accuracy of the gas measurement under varying atmospheric conditions. This pressure check is
performed every 30 minutes.

m R134A

URGE 00485pk

0

m R134A

ES CHK 00485pk

0

m R134A

14 Instruction 3015-4256

Function Screens

-

C

>

The Function screens are used to display stored data and to set up the monitor.

From the Data Display screen, press any Keypad button to display the first Function Menu screen.
Next, use the Keypad buttons to move the arrow (>) through the menu screens until the arrow is next to
the desired function, and then press the ENTER button to select that function.

>PPM LOG FAULTS
ALARMS DIAGNOS

>SILENCE ZONETMP
SQUELCH CAL

Once a function has been selected, use the Keypad to scroll through the displayed data or to change a
parameter associated with that function. Press ENTER to save newly entered parameters. Press the
QUIT button to return to the previous screen without saving.

Note that if no buttons are pressed within 90 seconds after selecting a function, the monitor returns to the
Data Display screen.

>GASTYPE SPILLVL
LEAKLVL EVACLVL

>P

HK CUST K2

CUST K1 CUST K3

LOG INT AUDALRM
LOOP CLOCK

PPM LOG – Contains records of the last 200 measurements. Each

record shows the measurement’s date, time, and ppm level. Note that the
interval at which the measurements are logged is determined by the
LOG INT function.

Use the Keypad Up and Down buttons to change the record number by
a factor of 1. Use the Right and Left buttons to change the record
number by a factor of 10. Press QUIT to return to the previous screen.

In the example on the right, record #025 shows that a level of 425 ppm
was measured on 11/07/03 at 15:35.

Note that the PPM Log can be cleared as described in Section Clearing
the Stored PPM Log, Alarms & Faults Data on Page 20.

ALARMS – Contains records of the last 30 alarm events. The most

recent alarm is displayed when the Alarm screen is first displayed. After
30 events have been recorded, the newest record overwrites the oldest.
Each record displays either LEAK, SPILL, or EVAC including the date
and time the alarm occurred. Use any of the Keypad buttons to scroll
through the other alarm records. Press QUIT to return to the previous
screen.

Note that the ppm levels at which alarms occur are set using the
LEAKLVL, SPILLLVL, and EVACLVL functions.

In the example on the right, record #03 shows that a spill event occurred
on 11/10/03 at 15:06.

#025 425PPM @
11/07/03 15:35

#03 SPILL @
11/10/03 15:06

FAULTS – Contains records of the last 30 fault events. The most recent

fault is displayed when the Fault screen is first displayed. After 30
events have been recorded, the newest record overwrites the oldest. Each
record lists an event’s numeric fault code (refer to Working with System
Faults on Page 18) plus the date and time the fault occurred. Use any of
the Keypad buttons to scroll through the other fault records. Press
QUIT to return to the previous screen.

In the example on the right, record #15 shows that a Purge Flow Fault
<1000> occurred on 11/10/03 at 12:37.

Instruction 3015-4256 15

#15 <1000> @
11/10/03 12:37

DIAGNOS – Enters the diagnostic function. Press the Up Arrow

T

g

S

pp

R

L

E

S

4

2

0

Keypad button to toggle between the monitor’s two diagnostic screens.
Refer to Working with the DIAGNOS Function (Page 21).

SILENCE – Used to enter a length of time for which the internal

audible alarm and the external alarm are turned OFF when the front
panel SILENCE button is pressed. The factory default is 300 seconds
(5 minutes). If the cause of the alarm/fault has not been cleared at the
end of this time period, the internal audible alarm and the external alarm
device are reactivated. Use the Keypad to enter the desired time period,
and then press ENTER to save that value and return to the previous
screen.

.26500v <0000>

4.5cD 14.00psi

0.4ppm 0.00
.00002au 4.260v

ILENCE TIMEOUT
0300 sec

ZONETEMP – Used to enter the temperature of the area being

monitored in °C, thus giving a more accurate ppm reading. The factory
default is 25°C. Use the Keypad to enter the desired temperature, and
then press ENTER to save that value and return to the previous screen.

SQUELCH – Sets a value of between 0.0 and 99.9 ppm that prevents

the display of measurements below that value. Factory default is 0 ppm.
For example, if the squelch setting is set to 50 ppm, then the monitor will
not display measurements that are below that value. Use the Keypad to
enter the desired value, and then press ENTER to save that value and
return to the previous screen.

CAL – Used to change a calibration factor for a specific gas. This

function is to be used ONLY with instructions from a Bacharach Service
Center. Factory default is 1.000.

LOG INT – Sets the interval at which measurements are logged to

memory from 1 to 9999 minutes. Factory default is 10 minutes. Note that
the logged measurements can be viewed using the PPM LOG function.
Use the Keypad to enter the desired value, and then press ENTER to
save that value and return to the previous screen.

EMP AT ZONE =
25 de

QUELCH BELOW

50.0

134A CALFACTOR

1.000

OG INTERVAL IS
0010 min

C

m

LOOP – Use to adjust the loop factor of the 4–20 mA current loop.

Factory default is 0.016 mA per ppm, which provides an output range of
0 ppm (4 mA) to 1,000 ppm (20 mA). Use the Keypad to set the desired
loop factor, and then press ENTER to save that value and return to the
previous screen.

To facilitate loop zero and span checking, note that when the LOOP
function is selected the loop output is set to 20 mA, and upon exiting this
function the loop output is set to 4 mA.

16 Instruction 3015-4256

DIT LOOP FACTOR

0.016 ma/PPM

AUDALRM – Allows the monitor’s internal audible alarm to be

E

A

5

E

0

E

C

C

yyyy.yyy

C

-

0

associated with any function of the monitoring system. Factory default is
OFF. Use the Keypad to select the desired audible alarm function, and
then press ENTER to save that value and return to the previous screen.

Audible Alarm Settings: OFF, ANY ALARM, SYSTEM FAULT, LEAK ALARM,
SPILL ALARM, EVAC ALARM, MONITOR STOPPED

NOTE: MONITOR STOPPED indicates there is a critical system fault, and the
monitor is no longer functioning correctly.

UDIBLE ALARM IS

OFF

CLOCK – Sets the monitor’s date and time. Use the Keypad to enter

the correct date and time, and then press ENTER to save those values
and return to the previous screen. Note that time is displayed in a
24 hour format, while the date is displayed as mm/dd/yy.

GASTYPE – Used to select of any one of 24 gas types plus one custom gas

for monitoring. Factory default is R-134a. Note that the factory can
program a custom gas type as specified on the sales order, or a custom gas
can programmed into the monitor at a later time using the CUST K1, K2,

K3 function. Use the Keypad to select the desired gas type, and then press
ENTER to save the selection and return to the previous screen.

Gases Available for Selection: R-11, R-12, R-22, R-23, R-113, R-114, R-123,
R-124, R-134a, R-401a, R-402a, R-402b, R-404a, R-407a, R-407c, R-408a, R-409a,
R-410a, R-500, R-502, R-503, R-507, R-508b, H1301, CUSTOM

LEAKLVL – Sets the Leak Alarm level, adjustable from 1 to 300 ppm.

Factory default is 100 ppm. Note that the Leak Alarm level cannot be set
higher than either the Spill or Evacuate Alarm levels. Refer to Appendix
for recommended alarm settings for other gases. Use the Keypad to set
the desired Leak Alarm level, and then press ENTER to save that level
and return to the previous screen.

SPILLLVL – Sets the Spill Alarm level, adjustable from no lower than

the Leak Alarm level to a maximum value of 500 ppm, but not higher
than the Evacuate Alarm level. Factory default is 300 ppm. Refer to
Appendix for recommended alarm settings for other gases. Use the
Keypad to set the desired Spill Alarm level, and then press ENTER to
save that level and return to the previous screen.

SET DATE & TIME
11/10/03 1

SELECT GAS TYPE
R134A

DIT LEAK LEVEL

DIT SPILL LEVEL

0300 PPM

100 PPM

:30

EVACLVL – Sets the Evacuate Alarm level, adjustable from no lower

than the Spill Alarm level to 9999 ppm. Factory default is 500 ppm. Refer
to Appendix for recommended alarm settings for other gases. Use the
Keypad to set the desired spill level alarm level, and then press ENTER
to save that level and return to the previous screen.

P-CHK – This Pressure Check function displays the current manifold

pressure and the stored ambient pressure in psia, along with the difference
between these two pressures and the current fault code. Refer to Working
with the P-CHK Function (Page 22).

CUST K1, K2 & K3 – Used to enter custom calibration data for a blend

of refrigerant gases that is not part of the monitor’s standard 24 refrigerant
gas library. Before using this function, the operator must contact the
factory and provide information about the blend of refrigerant gases to be
monitored. Custom calibration data will then be supplied to enable the
HGMSZ to accurately monitor that particular gas blend. To enter this data,
refer to Section Entering Custom Refrigerant Calibration Values (Page 20).

Instruction 3015-4256 17

DIT EVAC LEVEL

0500 PPM

14.07 * AMB14.05
.02dif <1000>

USTOM CAL K^1

xxxx.xxx

USTOM CAL K^2

USTOM CAL K^3

zzzz.zzz

Working with Gas Alarms

Functional Overview

If the refrigerant level in the area being monitored exceeds its preset Leak, Spill, or Evacuate Alarm level
(Page 17), the HGMSZ will detect this alarm condition and turn ON the front panel ALARM light.
Additionally, an external alarm device may activate and the monitor’s internal audible alarm may sound if
those features have been enabled (Pages 10 & 17).

Clearing / Silencing a Gas Alarm

Once the gas-alarm circuit has been triggered all alarm indicators remain turned ON, even after the
detected gas level returns to normal. Press the SILENCE button to clear all gas-alarm indicators after the
cause of the alarm has been cleared and the detected gas level has dropped below all alarm levels.

Pressing the SILENCE button while a gas-alarm condition still exists causes the internal audible alarm
and all external alarm devices that are connected to the alarm relays to turn OFF for a period of time as
set by the SILENCE function (Page 16). The front panel ALARM light remains ON, however, as an
indication that an alarm condition still exists, but will automatically turn OFF once the gas level returns
to normal. The alarm circuit will reactivate at the end of the silence period if the detected gas level is still
above an alarm level.

Viewing the Gas Alarm Log

From the Data Display screen, use the Keypad buttons to place the arrow (>) on the display next to the
ALARMS function. Then press ENTER to display the alarm log.

The alarm log shows the type of alarm (LEAK, SPILL, or EVAC), plus the date and time it occurred. If
CLEAR is displayed, this indicates that an alarm was acknowledged at the date and time shown.

Immediately after selecting the ALARMS function, the most recent alarm event is displayed. In the
example below, record #03 shows that a Spill Alarm occurred on 11/10/03 at 15:06. Note that if more than
30 alarm events have occurred, then the newest event overwrites the oldest.

#03 SPILL @
11/10/03 15:06

Note that the Alarm Log can be cleared as described in Section Clearing the Stored PPM Log, Alarms &
Faults Data on Page 20.

Working with System Faults

Functional Overview

If a system malfunction occurs (see Fault Code list on Page 19), the HGMSZ will detect the problem and
turn ON the front panel SYSTEM FAULT light. Additionally, an external alarm device may activate and
the monitor’s internal audible alarm may sound if those features have been enabled (Pages 10 & 17).

Clearing / Silencing a Fault Alarm

The SYSTEM FAULT light and all other fault indicators will automatically turn OFF after the cause of
the fault has been eliminated.

Pressing the SILENCE button while a fault-alarm condition still exists causes the internal audible alarm
and the external alarm device that is connected to the fault relay to turn OFF for a period of time as set by
the SILENCE function (Page 16). The front panel SYSTEM FAULT light remains ON, however, as a
reminder that a fault condition still exists. The alarm circuit will reactivate at the end of the silence period
if the cause of the fault condition has not been corrected. The SYSTEM FAULT light will automatically
turn OFF once the fault has been cleared.

18 Instruction 3015-4256

Viewing the Fault Log

F

F

From the Data Display screen, use the Keypad buttons to place the arrow (>) on the display next to the
FAULTS function. Then press ENTER to display the fault log.

Immediately after selecting the FAULTS function, the most recent fault event is displayed. The fault log
identifies the type of fault, plus the date and time it occurred. In the example below, record #03 shows that
a Zone Flow Fault (fault code <0800>) occurred on 11/12/03 at 08:17.

#03 <0800> @
11/12/03 08:17

The cause of the fault is identified by a numeric fault code. To convert the fault code into a text
description of the fault, first press the ENTER button and then use the Keypad buttons to scroll through
the display until the text description of the fault appears. If the fault code is a combination of two or more
faults, then continue to use the Keypad buttons until all fault text descriptions have been displayed. For
example, the fault code <1800> represents the combination of both a Zone Flow <0800> and a Purge Flow
<1000> fault as shown below:

AULT CODE<1800>

12 ZONE FLOW

Note that the Fault Log can be cleared as described in Section Clearing the Stored PPM Log, Alarms &
Faults Data on Page 20.

AULT CODE<1800>

13 PURGE FLOW

Fault Codes

<0001> Box Temperature Fault: Enclosure
temperature is outside normal range (or IR
detector has failed). Check that the monitor is not
being subjected to extreme temperatures. Verify
that the ventilation holes are not obstructed. Use
the DIAGNOS function to check the Box
Temperature.

<0002> Bench Temperature Fault: Optical
bench is outside normal operating range (or IR
detector has failed). Check that the monitor is not
being subjected to extreme temperatures.

<0004> - Manifold Pressure Fault: The manifold
pressure is outside normal operating range (or IR
detector has failed). Enter the DIAGNOS function
and record ALL data. Call the factory with this
information for further instructions.

<0010> Loop Fault: The 4–20 mA current loop is
open, or there is a high resistance in the circuit. Check
the wiring to the load/monitoring circuit. If this
feature is not being used, a 100 ohm resistor must be
connected to the 4–20 mA connector (Page 11).

<0100> Zero Filter Fault: A purge filter failure
has occurred. Replace the unit’s charcoal filter.

<0200> Gain Set Fault: The digipot autotune
sequence has failed. This fault will only occur on
first boot up or after a firmware upgrade. Call the
factory for further instructions.

<0400> A/D Fault: A fault has occurred in the
analog-to-digital circuitry. Contact the factory with
this information for further instructions.

<0800> Zone Flow Fault: Check for: A kink in
the gas-sample line or exhaust line; a blocked line­end filter; a failed pump.

<1000> Purge Flow Fault: Check that the
internal charcoal filter inlet (Page 8) is not blocked.
Once the blockage has been cleared, the monitor
will return to normal operation after the monitor
completes a purge cycle.

<4000> Zero Fault: The IR detector’s output
voltage is out of tolerance. Enter the DIAGNOS
function and record ALL data. Call the factory with
this information for further instructions.

<8000> Clipping Fault: The detector voltage may
be out of tolerance. Use the DIAGNOS function to
check the IR detector voltage. Call the factory with
this information for further instructions.

FAULT CODES ARE ADDITIVE. For example:
A fault code of <1800> indicates that both a Purge
Flow Fault <1000> and a Zone Flow Fault <0800>
have occurred.

Instruction 3015-4256 19

Clearing the Stored PPM Log, Alarms & Faults Data

Up to 200 refrigerant gas ppm measurements, and 30 alarm and fault events are stored by the monitor.

To clear stored data, first display the data to be cleared by using the PPM Log, Alarms or Faults
function (Pages 15). Next, press and hold down the Right Arrow Keypad button, and then press the
ENTER button. A single, long tone should be heard when the data has been successfully cleared.

Entering Custom Refrigerant Calibration Values

In addition to the 24 refrigerant gases available for selection, a custom gas can be added by using the
CUST K1, K2 & K3 function. Before using this function, the user must contact the factory and provide
information about the gas to be monitored. The factory will then supply values for K1, K2, and K3, which
are the coefficients of a polynomial equation that represent the calibration curve of the custom gas.

From the Data Display screen, use the Keypad buttons to place the arrow (>) on the display next to the
CUST K1 function. Then press ENTER to display the CUSTOM CAL K^1 screen. Use the Keypad
buttons to enter the 1
in memory.

Repeat the above procedure to enter the values for K2 and K3.

Select the custom gas for monitoring by using the GASTYPE function (Page 17) and selecting CUSTOM.

st

coefficient value (K1) as received from the factory. Press ENTER to save this value

Reset to Factory Default Settings

IMPORTANT! Performing this function will wipe out all program parameters, alarms, faults, and ppm

log files.

Press and hold down switch SW3 inside the HGMSZ (Page 8). Cycle AC power OFF then ON. Listen for
beep and then release switch. If needed, reprogram the HGMSZ to the desired settings.

Factory Default Settings

Parameter Factory Default

4–20 mA Factor ........................ 0.016 mA/ppm

Bench Voltage........................... 4.200

Calibration Factor.................... 1.000

Evacuate Alarm........................ 500 ppm

Gas Type ................................... R-134a

Leak Alarm............................... 100 ppm

Log Interval .............................. 10 minutes

Silence Timeout........................ 300 seconds (5 minutes)

Spill Alarm................................ 300 ppm

Squelch...................................... 0 ppm

Zone Temperature.................... 25°C

20 Instruction 3015-4256

Working with the DIAGNOS Function

p

0

0

p

Overview

The DIAGNOS function displays sensor data and status information useful to a service technician for
troubleshooting various fault conditions. Explanations of the data shown in these screens are given below.

Keypad Functions

From the Data Display screen, use the Keypad buttons to place the arrow (>) on the display next to the
DIAGNOS function. Then press ENTER to display the first of two Diagnostic screens.

Press the Up Arrow Keypad button to toggle between the First and Second Diagnostic screen.

First Diagnostic Screen

0.4ppm 0.00
.00002au*4.260v

PPM Level – Parts Per Million Level is the current detected gas level, and is the volume concentration
referenced to standard temperature and pressure.

Average Absorption Unit – This is the optical absorbency. In the absence of refrigerant the absorbency
is 0.00000 au. When sampling refrigerants, its value varies proportionally with the refrigerant
concentration.

µMoles/Liter – This is the absolute concentration in micro-moles per liter of refrigerant.

Detector Voltage – This is a running average of the IR detector’s bench voltage as displayed in the

second Diagnostic screen.

Purge Valve Asterisk (∗) – When viewing the diagnostic screen, the purge valve can be opened and
closed by pressing the Left Arrow Keypad button. An asterisk appears on the display when the purge
valve is open.

PPM Level µMole/Liter

Avg. Absorption Unit ∗ Detector Voltage

Second Diagnostic Screen

4.26500v <0000>

24.5cD* 14.00

In the second diagnostic screen, toggle between displaying the Bench Voltage and the Noise value, and the
Detector Temperature and Box Temperature by pressing the Right Arrow Keypad button.

.00250n <0000>

29.5cB* 14.00

Bench Voltage – This is the current peak-to-peak output of the IR detector. In the absence of refrigerant
this value can range from 3.90000V to 4.50000V.

Noise –The Noise value is a 16 point running average of the noise portion of the IR detector’s output. This
reading is valuable mainly when refrigerant is NOT present.

Detector Temperature – This is the current detector temperature in °C.

Box Temperature – This is the current internal enclosure temperature in °C.

Fault Code – Current fault code. A value of <0000> indicates that no faults are being detected.

Pressure Reading – This is the pressure as measured every purge cycle with the sample pump off and

the gas-sample inlet open. Its value is weather and altitude dependent and can range from 10.0 to

15.5 PSIA.

Purge Valve Asterisk (∗) – When viewing the diagnostic screen, the purge valve can be opened and
closed by pressing the Left Arrow Keypad button. An asterisk appears on the display when the purge
valve is open.

si

si

Bench Voltage Fault Code

Detector Temperature °C ∗ Pressure Reading

Noise Fault Code

Box Temperature °C ∗ Pressure Reading

Instruction 3015-4256 21

Working with the P-CHK Function

-

0

Overview

The P-CHK function (Pressure Check Function) (Page 17) is useful to a service technician for
troubleshooting a flow fault problem. The monitor will trigger a flow fault if the pressure drop from
ambient is less than 0.2 psi during a purge cycle, and 0.5 psi during a measurement cycle.

Keypad Functions

The Left Arrow Keypad button toggles the purge valve open and closed. Note that an asterisk (*)
appears when the purge valve is open (purging).

The Down Arrow Keypad button toggles the pump ON and OFF.

Pressing the ENTER button stores the current manifold pressure shown on the left to the ambient
pressure shown on the right (must be done with the pump OFF).

Screen Display

14.07 * AMB14.05
.02dif <1000>

Current Manifold Pressure – Current manifold pressure in psia.

Stored Ambient Pressure – Stored ambient pressure in psia.

Current Manifold Pressure ∗ Stored Ambient Pressure

Pressure Difference Fault Code

Pressure Difference – The difference between the current manifold pressure and the stored ambient
pressure.

Fault Code – Current fault code (Page 19).

Purge Valve Asterisk (∗) – When viewing the pressure-check screen, the purge valve can be opened

and closed by pressing the Left Arrow Keypad button. An asterisk appears on the display when the
purge valve is open.

22 Instruction 3015-4256

Working with the Calibration Function

Overview

If greater than standard accuracy is desired on any particular gas, the factory’s default calibration factor
of 1.000 may be adjusted by performing the calibration procedure as described below, and then selecting
the monitor’s CAL function to enter the new calibration factor.

IMPORTANT! Changing the calibration factor will VOID the factory calibration. Typically, the monitor will
remain within the factory-calibrated accuracy indefinitely and no calibration is required. Complex software
algorithms adjust for temperature drift, IR source aging, and pressure changes in order to keep the unit
within factory accuracy specifications.

Calibration Procedure

The calibration factor is determined by sampling a known dilution of the refrigerant to be adjusted. The
sample must be prepared to less than half the desired accuracy and the concentration must be corrected
for ambient temperature and pressure at the time of measurement.

Calibration is best performed at or near full scale (1,000 ppm), it can however, be done at any
concentration and ideally in the range where maximum accuracy is desired down to, but not below,
100 ppm.

A cylinder of a certified calibration gas must be used to ensure sampling occurs at ambient conditions.
A minimum sample size of 5 liters is required.

The HGMSZ should be operating for at least one hour prior to performing a calibration.

Prepare the HGMSZ for sampling by using the CAL function to set the calibration factor for the
refrigerant being measured to 1.000. Also, use the LOG INT function to set the log interval to 1 minute.

With the HGMSZ operating normally, connect the gas-sample bag directly to the gas-inlet port and allow
the monitor to sample the entire bag. When sampling is complete view the logged ppm values using the
PPM LOG function. If the bag was large enough for multiple samples, average the most stable ones. The
new calibration factor is computed by dividing the known gas concentration value by the measured value.
Typically this number will be between 0.95 and 1.05. Use the CAL function as described below to enter
the new calculated calibration factor

Adjusting Calibration Factor

From the Data Display screen, use the Keypad buttons to place the arrow (>) on the display next to the
CAL function. Then press ENTER to display the Calibration screen.

R134A CALFACTOR

1.000

With the Calibration screen displayed, use the Keypad buttons to enter the new calibration factor.

Press ENTER to save this value.

Instruction 3015-4256 23

Notes:

24 Instruction 3015-4256

Maintenance

Warnings and Cautions

WARNING: Always disconnect AC power before

working inside the monitor.

CAUTION: When working inside the monitor, be very
careful not to dislodge any electrical wiring or pneumatic
tubing. The HGMSZ contains sensitive electronic
components that can be easily damaged. Be careful not
to touch or disturb any of these components.

Charcoal Filter

The charcoal filter (Page 8) removes refrigerant gas from the purge-air stream during the purging process.
Replace the charcoal filter (P/N 3015-4306) about every 6 months, when a zero filter fault occurs (fault
code <0100>), or after the monitor itself has been exposed to unusually high levels of refrigerant gas, such
as after an evacuation alarm.

Hydrophobic Filter

The hydrophobic filter (Page 8) prevents water from entering the IR detector. A zone flow fault will occur
(fault code <0800>) if this filter should become blocked. Replace the hydrophobic filter as required
(P/N 07-1650).

Servicing Air Lines

The gas sample line and optional exhaust line should be checked periodically for obvious signs of kinks,
damage, and contamination. Replace the tubing as required (P/N 304-2743).

The gas sample line termination filter should be checked periodically and replaced when there are obvious
signs of contamination. To service the filter simply remove it from the line and replace it with a new one
(P/N 3015-3420).

Fuses

The HGMSZ is protected from electrical damage by two, 1 A, 250 V, type “F” fuses (Page 8). Carefully
remove the fuses from their fuse clips and visually inspect each fuse for damage. Replace the fuses as
required (P/N 04-2620).

Clock Battery

The clock battery (Page 8) maintains the correct date and time when AC power is not applied to the
monitor. Replace this battery about every 2 years (P/N 204-0020).

Sample Pump

The sample pump (Page 8) draws the gas sample into the monitor, through the IR detector, and discharges
the sample out the monitor’s exhaust port. When replacing the pump, remove its inlet and outlet tubing,
disconnect the AC power wires from the pump itself, and remove pump from monitor. Install a new sample
pump (P/N 3015-4239).

Instruction 3015-4256 25

Replacement Parts & Optional Accessories

Replacement Parts

Item Description Part Number

HGMSZ, complete assembly........................................... 3015-4200

Battery, Panasonic BR2032, 3 V .................................... 204-0020*

Filter, Charcoal, Zero Air................................................ 3015-4306

Filter, Hydrophobic ......................................................... 07-1650

Filter, Termination (gas-sample line)............................ 3015-3420

Fuse, 1.0 A, 250 V, Type “F” ........................................... 04-2620

Pump ................................................................................ 3015-4239

Tubing, ¼" OD (specify length when ordering) ............. 304-2743

* WARNING: To preserve agency approvals and maintain the safety integrity

of the monitor, the battery must be replaced with the specified
Bacharach replacement part.

Optional Accessories

Item Description Part Number

120 VAC Surge Protector................................................ 3015-4121

230 VAC Surge Protector................................................ 3015-4122

4–20 mA Surge Protector................................................ 3015-4123

Audible Alarm, 120 VAC................................................. 3015-3070

Audible/Visual Alarm, 120 VAC..................................... 3015-3076

Visual Alarm, 120 VAC................................................... 3015-3069

26 Instruction 3015-4256

Appendix

Table of Recommended Alarm Settings

Refrigerant Leak PPM Spill PPM Evacuate PPM

R11 100 300 500

R12 100 300 500

R22 100 300 500

R23 100 300 500

R113 100 300 500

R114 100 300 500

R123 25 35 35

R124 100 300 500

R134a 100 300 500

R401a 100 300 500

R402a 100 300 500

R402b 100 300 500

R404a 100 300 500

R407a 100 300 500

R407c 100 300 500

R409a 100 300 500

R410a 100 300 500

R500 100 300 500

R502 100 300 500

R503 100 300 500

R507 100 300 500

R508b 100 300 500

H1301 100 300 500

Allowable Exposure Level (AEL) ASHRAE 34-1992.

Instruction 3015-4256 27

WARRANTY and SERVICE

Warranty

Subject to the terms herein, Seller warrants the original equipment cataloged or manufactured by the
Seller and furnished hereunder is free from defects in material and workmanship, and will be of the kind
and quality designated or described on the quotation. The Seller will warrant the original equipment for
24 months from the date of shipment from the manufacturing facility unless different or additional
conditions are specified and shall be binding through a written contract signed by an officer of the Seller.

Seller also warrants that certain consumable parts as hereunder identified, have a one (1) year warranty
period from the date of shipment and will be free from all defects in material during that period. Seller
does not warrant these parts however, beyond the initial installation due to variables associated with
normal usage. These certain consumable parts include, but are not limited to, the air flow filters.

If within 24 months of the date of shipment, the equipment does not meet the warranties specified above,
and Purchaser notified Seller of this promptly, Seller shall there upon correct any such defects or any non­conformance to the specifications within a reasonable time period. Material found to be defective shall be
returned to the seller freight prepaid. At the Seller’s option, the defective material shall be repaired or
replaced and returned to the purchaser via the lowest freight rate available. Any repairs or
alternations made by unauthorized personnel will automatically void warranty.

Labor cost for warranty service at the manufacturing facility is the Seller’s responsibility for a period of 90
days following date of shipment. Beyond 90 days, Purchaser is responsible for all labor costs. Purchaser
must contact the Seller’s Service Department prior to shipment and obtain a Return Authorization (RA)
number. The package must be clearly marked with the assigned RA number. Purchaser may elect to have
Seller’s Service Department repair the equipment at Purchaser’s facility. Purchaser must contact Seller’s
Service Department in Newnan, Georgia to arrange for a Service call. Parts will be free under the above
terms, but there will be a charge for labor and travel expenses from Seller’s facility in Newnan, Georgia.

The conditions of any tests or equipment hereunder alleged to be defective shall be mutually agreed upon
and Seller shall be notified of, and may be present or represented at all tests that may be made. Seller’s
liability to Purchaser or that of Seller’s Agent/Representative, arising out of the supplying of the
equipment or its use, whether based on warranty, contract, or negligence shall not in any case, exceed the
cost of correcting defects in the equipment as herein provided but shall, in all events, be limited to a
maximum of the purchase price. Upon the expiration of the applicable warranty period mentioned above,
all such liability shall terminate. The foregoing shall constitute Purchaser’s sole remedy and Seller’s sole
liability. IN NO EVENT SHALL SELLER BE LIABLE FOR SPECIAL, INCIDENTAL OR

CONSEQUENTIAL DAMAGES.

Register Your Warranty by Visiting

www.bacharach-inc.com

Service

Pursuant to the stated warranty, Bacharach, Inc. warrants the products to be free of manufacturers defect
for two (2) years from the date of shipment or installation and will replace any part free of charge during
that period. Labor beyond ninety (90) days of shipment or installation is subject to charge. FAILURE TO

LOCATE THE HGMSZ IN A LOCATION COMPATIBLE WITH THE CRITERIA SET FORTH IN
THIS MANUAL CONSTITUTE ABUSE OF THE EQUIPMENT AND MAY VOID THE
WARRANTY. Shipments are tracked by the factory and the purchaser will be responsible for providing
acceptable documentation to prove the installation date. FAILURE TO NOTIFY THE FACTORY
WITHIN TWO (2) WEEKS OF INSTALLATION OF THE EQUIPMENT, WILL VOID THE
COVERAGE OF THE LABOR SPECIFIED IN THE WARRANTY. Should any of the products covered

(refer to following section - Products Covered under Warranty and Service Policy) incur a failure or
damage contact the factory service department (678-423-2481) and request instructions.

28 Instruction 3015-4256

Return Procedure

To return equipment to the factory for repair a Return Authorization (RA) number should be
requested from the factory. Normal factory repair time is approximately two (2) weeks, unless special
provisions have been pre-negotiated prior to the issuance of an RA number. Equipment will not be
received without an RA number. Returned equipment should be sent to the factory at the following
address:

Bacharach, Inc.

2 Dart Road,

Newnan, Georgia 30265 USA

Attn.: Refrigerant Gas Monitor Service Department

Field Repair

Field repair of equipment will be considered after all reasonable attempts to diagnose and rectify the
problem via phone or fax have been exhausted or if return of the equipment to the factory is not
practical. To initiate warranty service in the field, a customer purchase order must be issued, prior to
dispatch, for the estimated travel time, expenses and applicable service fees for a Bacharach
representative to travel to the site. Bacharach will bill expenses to the customer at actual cost. The
customer will be invoiced for all applicable charges for parts, labor and expense at the non-warranty
rates if it has been determined that the failure is a result of abuse of the equipment, improper
installation, or failure to thoroughly read and comply with the instructions provided in the
Operations and/or Service Manuals. Scheduling of all field servicing is at the discretion of the
Factory Service Department and will be based upon customer need and the availability of personnel.
Warranty field service shall be limited to the continental United States.

Bacharach, Inc. is not liable for any charges, from the customer, purchaser or any third party that
may be acting on the behalf of the purchaser, customer or end user, resulting from non-warranty field
service, field upgrades, preventative maintenance, etc. Bacharach, Inc. is not liable for any charges,
from the customer, purchaser or any third party that may be acting on the behalf of the purchaser,
customer or end user, resulting from warranty field service or repair activities unless prior approval
is granted by an authorized member of Bacharach, Inc. prior the dispatch and performance of the
field service or repair activity. This is to include but not limited to: manpower requirements for
Bacharach and/or non-Bacharach personnel to perform or assist with the field service or repair
activity.

Instruction 3015-4256 29

Specifications

Product Type........................ Multiple refrigerant gas monitoring system for low level continuous monitoring

of refrigerant gases

Gas Library .......................... CFC: R-11, R-12, R-113, R-114, R-502

HFC: R-404a (HP62), R-407a, R-407c (AC9000), R-134a, R-410a (AZ20),
R-507 (AZ50), R-508b (SUVA95)
HCFC: R-22, R-23, R-123, R-124, R-401a (MP39), R-402a (HP80),
R-402b (HP81), R-408a, R-409a, R-500, R-503
HALON: 1301

Coverage............................... Single zone

Measuring Range................. All gases 0 to 1,000 ppm

Monitoring Distance............ Up to 50 ft (15.2 m) maximum gas-sample line length

Front Panel .......................... 3 Indicator lights:

MONITOR ON – Green light ON when the unit is operating normally,
or flashing during warm-up

SYSTEM FAULT – Yellow light ON when there is a system fault
ALARM – Red light ON when the gas level is above an alarm setting

Alarms.................................. Four SPDT relays are provided (rated 3 A, 240 VAC):

three assigned to ppm level alarms – one assigned to system faults

Internal audible alarm programmable for any of the following conditions: system

fault, leak alarm, spill alarm, evacuation alarm, monitoring stopped or off

Detector Type....................... Infrared, Non-Dispersive

Sensitivity ............................ All gases 1 ppm

Accuracy ............................... All gases ±10 ppm from 0 to 100 ppm

All gases ±10% of reading from 100 to 1,000 ppm

Response Time/Flow Rate... Dependent on gas-sample line length; 0.25" OD x 0.17" ID tubing:

Gas-Sample Line

Feet (Meters)

0 (0) 9 675
10 (3.0) 13 664
20 (6.1) 17 653
30 (9.1) 22 642
40 (12.2) 26 631
50 (15.2) 30 620

Response Time

Seconds

Flow Rate

ml/min

Temperature Drift............... ±0.8% (R-134a) of reading per °C

System Noise ....................... Less than 40dB(A) at 10 ft (3 m)

Conditioned Signal .............. 4–20 mA current loop

Power Safety Mode .............. Fully automatic system reset; all programmed parameters retained

Operating Temp................... 32 to 122°F (0 to 50°C)

Ambient Humidity............... 5% to 90% RH (non-condensing)

Altitude Limit ...................... 6,562 ft (2,000 m)

AC Power.............................. 100 – 240 VAC

Power Consumption ............ 15 Watts

Size/Weight .......................... 7.4"H x 15"W x 3.3"D / 5 lbs (188 x 381 x 84 mm / 2.27 kg)

Certification ......................... UL 61010A-1, CAN/CSA 22.2 No. 1010-1B:1997,

CE Mark (see inside front cover), UL 2075

Warranty.............................. 2 Years from date of shipment

30 Instruction 3015-4256

2 Dart Road, Newnan GA 30265

Printed in U.S.A. ® Registered Trademark of Bacharach Inc.

Website: www.bacharach-inc.com • E-mail: [e-mail]

Ph: 678-423-2481 • Fax: [phone]

Bacharach, Inc.