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
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