Bacharach 3015-4286 User Manual

AGMSZ

Ammonia Gas Monitor Single Zone

Instruction 3015-4286

Installation / Operation / Maintenance

Rev. 0 – September 2005

Product Leadership • Training • Service • Reliability

WARRANTY

Bacharach, Inc. warrants to Buyer that at the time of delivery this Product will be free from defects in material and manufacture and will conform substantially to Bacharach Inc.'s applicable specifications. Bacharach's liability and Buyer's remedy under this warranty are limited to the repair or replacement, at Bacharach's option, of this Product or parts thereof returned to Seller at the factory of manufacture and shown to Bacharach Inc.'s reasonable satisfaction to have been defective; provided that written notice of the defect shall have been given by Buyer to Bacharach Inc. within two (2) years after the date of delivery of this Product by Bacharach, Inc.

Bacharach, Inc. warrants to Buyer that it will convey good title to this Product. Bacharach's liability and Buyer's remedy under this warranty of title are limited to the removal of any title defects or, at the election of Bacharach, to the replacement of this Product or parts thereof that are defective in title.

The warranty set forth in paragraph 1 does not apply to parts the Operating Instructions designate as having a limited shelflife or as being expended in normal use (e.g., filters).

THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED IN LIEU OF (I) ANY AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE: AND (II) ANY OBLIGATION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACT OR TORT, WHETHER OR NOT ARISING FROM BACHARACH'S NEGLIGENCE, ACTUAL OR IMPLIED. The remedies of the Buyer shall be limited to those provided herein to the exclusion of any and all other remedies including, without limitation incidental or consequential damages. No agreement varying or extending the foregoing warranties, remedies or this limitation will be binding upon Bacharach, Inc. unless in writing, signed by a duly authorized officer of Bacharach.

www.bacharach-inc.com

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 Leamington Spa Warwickshire CV31 3JR United Kingdom

Product Name: AGMSZ (Ammonia Gas Monitor Single Zone) conforms to the following harmonized European EMC standards: EN61326-1 EN61000 EN55022

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.

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

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

A Instruction 3015-4286

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

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, Purge, and Exhaust Lines ............................................................................. 6

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

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

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

Connecting the Purge 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

Overview ............................................................................................................................................. 18

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

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

Instruction 3015-4286 i

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

Overview ............................................................................................................................................. 18

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

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

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

Clearing the Stored PPM Log, Alarm & Fault Data ........................................................................... 20

Working with the P-CHK Function...................................................................................................... 20

Overview ............................................................................................................................................. 20

Keypad Functions .............................................................................................................................. 20

Screen Display.................................................................................................................................... 20

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

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

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

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

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

Working with the Calibration Function............................................................................................... 22

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

Calibration Procedure........................................................................................................................ 22

Adjusting Calibration Factor ............................................................................................................ 22

MAINTENANCE ......................................................................................................................................... 23

Warnings and Cautions......................................................................................................................... 23

Hydrophobic Filters ............................................................................................................................... 23

Servicing Air Lines & Termination Filters .......................................................................................... 23

Clock Battery ......................................................................................................................................... 23

Sample Pump ......................................................................................................................................... 23

Replacement Parts & Optional Accessories......................................................................................... 24

Replacement Parts ............................................................................................................................. 24

Optional Accessories .......................................................................................................................... 24

Service Centers ...................................................................................................................................... 25

Specifications ......................................................................................................................................... 26

ii Instruction 3015-4286

Introduction

How to Use This Manual

Thank you for investing in a BACHARACH AGMSZ (Ammonia Gas Monitor Single Zone).

This manual provides important information on how to install, operate, and service the AGMSZ 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 gas monitors, you will find this manual useful as a reference tool. If you are new to the use of gas monitors, you can educate yourself about the principles of 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 without first disconnecting AC power.

Instruction 3015-4286 1

Safety Precautions

AC Power Supply

The AGMSZ 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 AGMSZ 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 3015-4286

Functional Overview

General Description

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

The Bacharach AGMSZ (Ammonia Gas Monitor Single Zone) is designed to continuously test for the presence of ammonia gas in an area that is located up to 50 ft (15.2 m) away from the monitor. The AGMSZ 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 AGMSZ 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. Most systems leak some gas. 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.

The AGMSZ is shipped with its leak, spill, and evacuate alarm levels set at 100, 300, and 500 ppm, respectively. 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 alarm set points may need to be adjusted either up or down to achieve effective monitoring.

Instruction 3015-4286 3

Suggested Location of Sampling Point

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

It should be noted that when ammonia gas is cold it is heaver than air and settles below the leak point, but as the gas warms to room temperature it becomes lighter than air and tends to collect above the leak point. 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 ammonia gas.

The AGMSZ 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 and purge line can be run to an outside location. The length of the exhaust line cannot exceed 50 ft (15.2 m), while the length of the purge line cannot exceed 100 ft (30.4 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.

AGMSZ Refrigerant Gas Leak Monitor Mechanical Room Placement

4 Instruction 3015-4286

Installation

Installation Considerations

Warnings and Cautions

WARNING: Explosion hazard! Do not mount the AGMSZ 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: Shock hazard! Always disconnect AC power before working inside the monitor.

CAUTION: Drilling holes in the AGMSZ enclosure may damage the unit and will void the warranty. Please use knockouts provided for electrical connections.

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

Inspection

The AGMSZ 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 AGMSZ so that no more than 50 ft (15.2 m) of tubing will be needed to reach the sampling area.

Since the monitor uses ambient air to purge its gas sensor, the monitor should be located in a well ventilated area that does not contain refrigerant gas. If this is not possible, then it is

recommended that a separate purge line be run to an area known to contain fresh (zero) air. The length of this purge line should not exceed 100 ft (30.4 m). If the monitor is located in a confined space, then it is also recommended that a separate exhaust line be run to the outside. The length of this exhaust line should not exceed 50 ft (15.2 m).

The AGMSZ 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.

Instruction 3015-4286 5

Mounting Instructions

The AGMSZ 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

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, Purge, and Exhaust Lines

Overview

A single gas-sample line needs to be run from the AGMSZ to the area of the facility to be monitored. An optional purge line can be run to bring fresh (zero) air into the monitor for detector zeroing purposes. And an optional exhaust line can be installed to vent the sample gas away from the monitor. All tubing connections are made on the bottom of the enclosure as shown in the illustration below.

AGMSZ Bottom View

½" / ¾" SERVICE

KNOCKOUT*

* There is an additional Service Knockout on top of the case

PURGE AIR INLET PORT

½" / ¾" SERVICE KNOCKOUT*

GAS SAMPLE INLET PORT

GAS SAMPLE EXHAUST PORT

6 Instruction 3015-4286

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