Bacharach H25-IR User Manual

H25-IR

Infrared Refrigerant Gas Leak Detector

Instruction 3015-4342

Operation & Maintenance

Rev. 8 – June 2010

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 shelf-life 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.

Register your warranty by visiting

www.mybacharach.com

Notice:

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

Bacharach, Inc. shall not be liable for errors contained herein or for incidental or consequenti al d amages 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.

Copyright © 2005–2009, Bacharach, Inc., all rights reserved.
BACHARACH

referenced herein belong to their respective owners.

®

is a registered trademark of Bacharach, Inc. All other trademarks, trade names, service marks and logos

A Instruction 3015-4342

H25-IR Contents

Table of Contents

1 Introduction ................................................................................................................................ 1

1.1 Purpose of Instruction Manual ...........................................................................................................1

1.2 Safety Precautions...............................................................................................................................1

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

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

1.2.3 Hazard Symbols ....................................................................................................................1

1.2.4 AC Power and Grounding.....................................................................................................1

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

1.2.6 Accessing the Interior of the Instrument ............................................................................2

1.2.7 Misuse and Modifications to Instrument ............................................................................2

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

1.2.9 Cleaning.................................................................................................................................2

1.3 Ordering Information ..........................................................................................................................3

1.4 Unpacking and Initial Checks ............................................................................................................3

1.5 Features and Capabilities ...................................................................................................................4

1.6 Functional Overview ...........................................................................................................................5

1.7 Names and Functions of Components................................................................................................6

1.7.1 Front View .............................................................................................................................6

1.7.2 Rear View ..............................................................................................................................7

1.7.3 Interior...................................................................................................................................7

1.7.4 Standard Probe .....................................................................................................................8

1.7.5 Standard Probe with LED and Programmable Pushbutton ..............................................8

1.7.6 Smart Probe...........................................................................................................................9

1.7.7 Smart Probe Keylock Function ............................................................................................9

1.8 Menu System .....................................................................................................................................10

2 Preparing for Operation ........................................................................................................ 11

2.1 Connecting the Probe ........................................................................................................................11

2.2 Connecting the AC Power Cord ........................................................................................................11

2.3 Battery Pack ......................................................................................................................................11

2.4 Turning ON the Instrument .............................................................................................................11

2.5 System Setup .....................................................................................................................................12

2.5.1 Gas Type ..............................................................................................................................12

2.5.2 Leak Units ...........................................................................................................................12

2.5.3 Relays...................................................................................................................................13

2.5.4 4–20 mA Loop ......................................................................................................................13

2.5.5 Brightness............................................................................................................................14

2.5.6 Clock ....................................................................................................................................14

2.5.7 PCHK Mode.........................................................................................................................14

2.5.8 Probe Button .......................................................................................................................14

2.5.9 Reset Defaults .....................................................................................................................14

2.6 Configuring the SETUPS Function ..................................................................................................15

2.6.1 Setup Name .........................................................................................................................15

2.6.2 Range ...................................................................................................................................15

2.6.3 Gas Type ..............................................................................................................................16

2.6.4 Feedback Mode....................................................................................................................16

2.6.5 Setpoint................................................................................................................................16

2.6.6 Search Auto Zero.................................................................................................................17

2.7 External Relay Connections..............................................................................................................18

2.8 4–20 mA Current Loop Connection ..................................................................................................19

3 Calibration................................................................................................................................. 21

3.1 Selecting Internal or External Calibration ......................................................................................21

3.1.1 Internal Calibration Selection............................................................................................21

3.1.2 External Calibration Selection and Setup.........................................................................22

3.2 Internal Calibration ..........................................................................................................................22

3.3 External Calibration..........................................................................................................................23

3.4 CAL Factor .........................................................................................................................................24

Instruction 3015-4342 i

Contents H25-IR

3.4.1 Simulating Other Internal Leak Source Gas Types Using the CAL Factor.................. 25

3.4.2 Improving PPM Measurement Accuracy using the CAL Factor ..................................... 25

3.4.3 Adjusting the CAL Factor ..................................................................................................26

3.5 Restoring Factory Calibration .......................................................................................................... 27

3.6 Storing a New Factory Calibration ..................................................................................................27

4 Operation....................................................................................................................................29

4.1 Instrument Location .........................................................................................................................29

4.2 Using the H25-IR ..............................................................................................................................29

4.2.1 Power ...................................................................................................................................29

4.2.2 Initial Setup ........................................................................................................................29

4.2.3 Range Selection................................................................................................................... 30

4.2.4 Setup Selection ...................................................................................................................30

4.2.5 Volume Adjustment ............................................................................................................ 30

4.2.6 Searching for a Leak...........................................................................................................31

4.2.7 Measuring the Leak Rate................................................................................................... 31

4.2.8 Measuring the PPM Level.................................................................................................. 32

4.2.9 Logging Measured Readings .............................................................................................. 32

4.2.10 Logged Measurements........................................................................................................ 33

4.2.10.1 Viewing Logged Measurements ..................................................................... 33

4.2.10.2 Clearing the Log.............................................................................................. 33

4.2.10.3 Viewing the Total of All Logged Measurements ........................................... 33

4.2.10.4 Setting the Log Limit...................................................................................... 34

4.3 Fault Conditions................................................................................................................................ 34

4.4 PCHK (Atmospheric Pressure CHecK) ............................................................................................ 35

4.5 RS-232 Communication ....................................................................................................................35

4.6 Serial Output Types ..........................................................................................................................35

5 Maintenance...............................................................................................................................37

5.1 Diagnostics Menu ..............................................................................................................................37

5.1.1 Sensor Data.........................................................................................................................37

5.1.2 Last Fault ............................................................................................................................ 38

5.1.3 IR Emitter ...........................................................................................................................39

5.1.4 Pressure............................................................................................................................... 39

5.1.5 Loop Test .............................................................................................................................39

5.1.6 Clear Last Fault..................................................................................................................39

5.1.7 Auto Gain ............................................................................................................................40

5.2 Factory Menu..................................................................................................................................... 40

5.2.1 DIGIPOT .............................................................................................................................40

5.2.2 Leak Rate ............................................................................................................................40

5.2.3 Leak Gas..............................................................................................................................41

5.2.4 Leak Temp...........................................................................................................................41

5.2.5 Leak TEMPCO.................................................................................................................... 41

5.2.6 Sensor Cal ...........................................................................................................................41

5.2.6.1 Pressure Sensor Calibration Screen ..............................................................41

5.2.6.2 Flow Rate Sensor Calibration Screen (Factory Calibration)........................ 42

5.2.6.3 Box Temperature Calibration Screen ............................................................42

5.2.7 Model Select ........................................................................................................................42

5.2.8 Probe Type........................................................................................................................... 43

5.2.9 Firmware .............................................................................................................................43

5.3 Flashing Memory............................................................................................................................... 43

5.4 Part Replacement .............................................................................................................................. 46

5.4.1 Removing the Top Cover .................................................................................................... 46

5.4.2 Fuse Replacement............................................................................................................... 47

5.4.3 Probe Tip Filter & O-Ring Replacement ........................................................................... 47

5.4.4 Internal Filter Replacement ..............................................................................................48

5.4.5 Optical Bench Replacement ...............................................................................................48

5.4.5.1 Top Cover Removal .........................................................................................49

5.4.5.2 Installing the New IR Optical Bench............................................................. 49

5.4.5.3 IR Emitter Adjustment................................................................................... 49

ii Instruction 3015-4342

H25-IR Contents

5.4.5.4 DIGIPOT Adjustment .....................................................................................50

5.4.5.5 Factory Calibration .........................................................................................50

5.5 Replacement Parts...............................................................................................................................52

5.6 Service Centers ..................................................................................................................................53

6 Troubleshooting ....................................................................................................................... 54

7 Specifications............................................................................................................................ 60

APPENDIX A – Factory Defaults ................................................................................................ 62

Instruction 3015-4342 iii

Contents H25-IR

Notes:

iv Instruction 3015-4342

H25-IR Introduction

1 Introduction

1.1 Purpose of Instruction Manual

This instruction manual provides important information on how to install, operate, and service the Bachar ach
H25-IR Refrigerant Gas Leak Detector.

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

Please retain these instructions for future reference.

1.2 Safety Precautions

Safety is essential in the use and maintenance of Bacharach equipment. Therefore this instruction manual and
any markings on the exterior of H25-IR case provide important safety information concerning the operation and
maintenance of this instrument.

1.2.1 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, condition, or the like, which if not correctly performed or
adhered to, could result in injury or death of personnel using this instrument.

1.2.2 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 instrument.

1.2.3 Hazard Symbols

This symbol indicates the need to consult this 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 when AC power is
applied to the instrument.

1.2.4 AC Power and Grounding

The H25-IR uses a universal power supply that is capable of accepting inputs of 100 to 240 VAC, 50/60 Hz.
Under no circumstances should this instrument be operated without connection to a protective ground. Doing so

creates a potential shock hazard and is also a violation of electrical safety standards appli ca ble to this type of
equipment.

Instruction 3015-4342 1

Introduction H25-IR

1.2.5 Explosive Atmosphere

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

1.2.6 Accessing the Interior of the Instrument

Only qualified maintenance personnel should access the interior of this instrument. Always unplug the AC
power cord before performing any wiring or maintenance work.

1.2.7 Misuse and Modifications to Instrument

The operation of the H25-IR may be impaired if the instrument is used in a manner not specified in this
instruction manual. Changes or modifications to the instrument, not expressly approved by Bacharach, will void
the warranty.

1.2.8 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, unplug the AC power cord and contact a qualified repair technician or the nearest Bacharach
Service Center.

1.2.9 Cleaning

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

2 Instruction 3015-4342

H25-IR Introduction

1.3 Ordering Information

The H25-IR instrument along with its Probe type and Hose length are ordered by specifying 3 codes. The codes
must be listed in the following sequence:

Code A – Model Name
Code B – Gas Type
Code C – Probe Type and Hose Length

Table 1-1. H25-IR Instrument, Probe Type & Hose Length Ordering Information

Code A
Code B

Code C

For example: To order an H25-IR that detects CFC type refrigerants; a Standard Probe with LED & Button; and
a 6 foot hose, you would order an H25IR-1-3

Code Description

H25IR Infrared Gas Leak Detector

-1

-2

-3

-4

-5

-1

-2

-3

-4

-5

-6

CFC, HFC, HCFC & Halogen Gases
R600a
SF

6

2

CO
R227
Standard Probe, 6 foot Hose
Standard Probe, 12 foot Hose
Standard Probe, LED & Button, 6 foot Hose
Standard Probe, LED & Button, 12 foot Hose
Smart Probe, 6 foot Hose
Smart Probe, 12 foot Hose

1.4 Unpacking and Initial Checks

Your H25-IR Refrigerant Gas Leak Detector and all accessories were carefully inspected at the factory before
shipment, and packed so as to be highly resistant to damage while in transport.

When you receive the instrument, please unpack it promptly and make a visual inspection to make sure that no
damage has occurred during shipment and that all ordered items have been received. Your order should
consists of:

 H25-IR instrument
 Probe and Hose Assembly
 Both an 8 and 15 inch Flexible Probe Tube
 AC Power Cord or Battery (dependent on model type)
 Instruction Manual.
 Carrying case (with battery powered units)

If damage was found, immediately file a claim with the carrier. If an item is missing, please contact Bacharach’s
Service Department for assistance (refer to Section 5.6 Service Centers).

Instruction 3015-4342 3

Introduction H25-IR

1.5 Features and Capabilities

 Detects and measures (depending on instrument’s part number):

o CFCs, HCFCs, HFCs and halogens
o R600a
o SF
o CO

 Infrared detector
 Internal calibration leak standard
 Provision for external calibration on other types of gases
 User selectable leak rate measurement in either Oz/yr, g/yr, mL/s, PaM
 Easy to read Vacuum Fluorescent Display (VFD)
 Excellent background gas rejection
 420 mA current loop output
 Relay outputs for external equipment control
 On screen menu system for system setup, diagnostics, calibration, and data logging
 Assortment of probe and hose assemblies, available in either 6 or 12 foot

(1.8 or 3.7 m) hose lengths

 Assortment of flexible probe tubes, available in either 8 or 15 inch

(200 or 381 mm) lengths

6

2

3

/s, or ppm

4 Instruction 3015-4342

H25-IR Introduction

1.6 Functional Overview

The H25-IR is an industrial gas leak analyzer for the detection of CFCs, HCFCs, HFCs and halog en gas
compounds, R600a, SF
log and totalize a group of leaks in a system.

The H25-IR’s front panel contains 7 membrane pushbuttons, probe connector, calibration ga s port, an d a 3­¼ x ¾ inch VFD (Vacuum Fluorescent Display) that provides a bright, high-contrast display for easy viewing.
The plug-in instrument is housed in an all-metal case with adjustable handle. The battery operated instrument
version includes a padded carrying case.

The instrument has two modes of operation: Search and Measure. The Search mode is used to locate the
source of a leak. While the Measure mode is used to quantify the size of the leak. A hand-held probe is used to
draw in a gas sample from the area under inspection.

With the instrument in its Search mode, the location of a leak is pinpointed by means of visual and audio
indicators positioned on both the instrument and probe*. As the probe tip approaches the leak source the length
of a bar graph at the bottom of the instrument’s front panel display, the blink rate of an LED on the probe, and
the frequency of an audible tone are all affected in a positive manner (bar graph becomes longer, LED flashes
faster, and the audio tone increases in frequency). There are three search sensitivities available: SM, MED and
LG, indicating the size of the leak being searched for. This feature is useful in avoiding being bothered with
small leaks when searching for larger ones.

In the Measure mode, the probe tip is held over the leak source until the displayed value of the leak rate
stabilizes. Leak rates can be displayed in units of Oz/yr, g/yr, mL/s, PaM
be used to display the quantity of gas contained in a confined space with the instrument set up in its ppm mode.

The leak rate is measured by first capturing all the gas leaking from the component under test. Then by
accurately measuring the flow rate of the sampling stream and the gas concentration within that stream, the
leak rate can be calculated using Equation 1-1. The instrument then converts this data into the desired leak rate
units of measure and displays the leak rate on the instrument’s front panel.

Eq. 1-1
Leak Rate = Flow Rate x Gas Concentration
where:
Leak Rate = rate of gas leak from component under test
Flow Rate = sample flow rate
Gas Concentration = concentration of gas in the sample (ppm)

A leak measurement can be logged in memory with a time/date stamp. Up to 50 leaks can be logged and
totalized. This feature is useful in testing an installation that has a maximum permissible leak rate. Logged data
can be recalled for viewing on the display.

There are four user-defined setups that allow the operator to quickly switch between frequently used
combinations of Gas Type, Range, Feedback Mode, Setpoint, and the Auto Zero Off condition.

Extensive diagnostics keep track of several system parameters. When a fault is detected, the word “FAULT”
blinks on the display and an audible beep is heard every 2 seconds. Text descriptions of all current fault
conditions can be displayed from the instrument’s Diagnostics menu.

Four SPDT relays provide control over a variety of external equipment (e.g., horns, bells, strobe lights) that can
be automatically triggered when their associated relays are energized by any one of 11 different operating
conditions.

A 420 mA current loop output can be used for the connection of external monitoring equipment (e.g., chart
recorder). An RS232 serial port can output leak rate data as ASCII text at 10 times per second.

,, or CO2. This instrument can be used to locate and then quantify gas leaks, as well as

6

3

/s. The Measure mode can also

* The Standard Probe does not contain an LED.

Instruction 3015-4342 5

Introduction H25-IR

1.7 Names and Functions of Components

1.7.1 Front View

Front Panel Buttons

ENT

(Enter)
ESC

(Escape)
VOL

(Volume)

SETUP

MODE
RANGE
ZERO
LOG

MENU
CAL

(Calibration)

• Selects a highlighted menu item.

• Saves a selection or manually entered data (e.g. date and time).

• Displays a previously viewed menu or data screen.

• Cancels a data entry function; retains old data; and displays previous screen.
Volume adjustment. The Up and Down buttons slowly raise and lower the volume; the Left

button sets volume to minimum; and the Right button set volume to maximum.
Selects one of four user-defined setups consisting of: Range, Gas Type, Feedback Mode,

and the Auto Zero OFF condition.
Toggles the operating mode between Search and Measure.
Selects one of three sensitivity ranges (small, medium, or large leak).
Zeros the gas reading.
Logs the currently displayed gas measurement in memory when in the Measure mode,

where it can later be reviewed using the Main menu’s LOG function.
Press both the ENT and ESC buttons at the same time to display the Main menu.
Starts the calibration process where the instrument is calibrated to a known le ak source

using either the instrument’s front panel Calibration Port, or a customer supplied external
leak source.

Menu selection and data entry buttons:
Up  Moves selected (highlighted) menu item up through screen, or increments an

alphanumerical value when entering data.
Down  Moves selected (highlighted) menu item down through screen, or decrements an
alphanumerical value when entering data.

Left  Moves cursor left across screen.
Right  Moves cursor right across screen.

6 Instruction 3015-4342

H25-IR Introduction

1.7.2 Rear View

O

BATTERY POWER
SWITCH (on dual

only)

power

CONNECTOR for
battery cable (on
dual power only)

1.7.3 Interior

Instruction 3015-4342 7

Introduction H25-IR

1.7.4 Standard Probe

HOSE
6 or 12 foot
(1.8 or 3.7 m)

PROBE CONNECTOR
(Align with red dot on
instrument’s front panel
PROBE receptacle)

FLEXIBLE PROBE TUBE
8 inches
(203 mm)

PROBE TIP with FILTER

1.7.5 Standard Probe with LED and Programmable Pushbutton

HOSE
6 or 12 foot
(1.8 or 3.7 m)

PROGRAMMABLE PUSHBUTTON
(Can be programmed to either zero
the instrument, or switch between
the Search and Measure mode of
operation)

PROBE CONNECTOR
(Align with red dot on
instrument’s front panel
PROBE receptacle)

FLEXIBLE PROBE TUBE
8 inches
(203 mm)

PROBE TIP with FILTER

LED
(Flash rate increases as
the detected gas level
increases, or lights
steady when a user
selected leak rate is
detected.)

8 Instruction 3015-4342

H25-IR Introduction

1.7.6 Smart Probe

1.7.7 Smart Probe Keylock Function

The Smart Probe’s keypad can be locked to
prevent accidental key presses when working in
tight spaces.

Instruction 3015-4342 9

Introduction H25-IR

1.8 Menu System

Press the ENT and ESC keys at the same time to access the Main menu. The menu system enables the
operator to perform such functions as setting up the instrument, viewing logged readings, configurin g the four
user-defined setups, entering calibration data, and viewing the instrument’s diagnostic readings. The buttons
on the instrument’s front panel and probe are mapped the same and can be used inter-changeably, with
exception of the CAL button.

Select a menu item by first using the Up and Down buttons to highlight the desired item, and then pressing
ENT to select that item and display its data screen. After an item has been selected, use the Left, Right, Up,
and Down buttons to highlight or change data within a screen. Pressing the ENT button saves the new data,
while pressing the ESC button aborts the operation and displays the previous screen.

Main Menu:

SYSTEM System Menu:

LOG GAS TYPE ........................Gas being monitored

SETUPS LEAK UNITS ..................... Leak rate units of measure

CAL DATA RELAYS ............................Relay set up for activating external equipment

DIAGNOSTICS LOOP ................................420 mA signal’s mA per ppm loop factor

FACTORY* BRIGHTNESS ...................Brightness level of display

CLOCK ..............................Date and time

PCHK MODE .....................Determines when a pressure check is performed

PROBE BUTTON ..............Selects function of button on the Standard Probe

RESET DEFAULTS...........Resets user programmable parameters to factory defaults

(Calibration data is not changed)
Log Menu:

VIEW LOG.........................View individual logged measurements

CLEAR LOG ......................Clear total contents of log

LOG TOTAL.......................View a numerical total of all measurements stored in log (up to 50)

LOG LIMIT .........................Total accumulated leak setpoint

Setup Menu: SETUP NAME..................Text name given to the SETUP selection

SETUP NO.1 RANGE.............................Sensitivity of instrument (small, medium, large)

SETUP NO.2 GAS TYPE .......................Gas being monitored

SETUP NO.3 FEEDBACK MODE ..........Gas-level feedback (continuous, setpoint, H25C)

SETUP NO.4 SETPOINT........................Gas value for the Feedback Mode & Search Auto

SEARCH AUTO ZERO....Sets condition when auto zero is turned OFF

Calibration Data Menu:

CAL TYPE............................Internal or external leak source

EXT RATE............................Leak rate of external leak source

EXT GAS TYPE...................Type of gas in external leak source

CAL FACTOR ......................Calibration factor

RESTORE FACTORY CAL.....Restores factory leak rate calibration (internal leak source only)

CAL INTERVAL ...................Allows user to select amount of time between required calibrations

ENFORCE CAL INTERVAL.Allows user to call for calibration at programmed interval

LAST CAL DATE .................Displays date and time of last calibration cycle performed

Diagnostic Menu:

SENSOR DATA.................Raw data from all sensors

LAST FAULT......................List of all current faults, or last fault

IR EMITTER.......................Infrared emitter’s voltage, amperage, wattage, & resistance

PRESSURE .......................All measured pressures

LOOP TEST.......................Set the 4–20 mA loop output to 0, 4, 10, or 20 mA

CLR LAST FAULT .............Clear fault list of all faults

Factory Menu:

AUTO GAIN .......................Automatically set digital potentiometer (zero gas applied)

DIGIPOT ............................Manually set digital potentiometer (zero gas applied)

LEAK RATE .......................Leak rate of internal leak source

LEAK GAS .........................Gas type used in internal leak source

LEAK TEMP.......................Specified temperature for internal leak source in °C

LEAK TEMPCO .................Temperature coefficient for internal leak source in % per °C

SENSOR CAL....................Pressure, temperature, and flow calibration settings

MODEL SELECT ...............Selects model of unit according to part number

PROBE TYPE....................Selects type of probe connected to instrument

FIRMWARE........................Date firmware was compiled

* The Factory Menu appears only when activated by service technicians who know the correct activation procedure.

SERIAL OUTPUT.............Configures serial data format for RS232 output

AUTO GAIN........ ........Automatically set digital potentiometer (zero gas applied)

10 Instruction 3015-4342

H25-IR Preparing for Operation

2 Preparing for Operation

2.1 Connecting the Probe

Plug the probe connector into the front panel PROBE receptacle
by aligning the red dots on both the connector and receptacle. Screw the
desired flexible probe tube (8 or 15 inches) onto the probe assembly.

2.2 Connecting the AC Power Cord

Dependent on the instrument model the H25-IR may use an AC power cord or a
battery pack. Reference your model number to obtain this information.
Disregard any information that does not apply to your model.

The H25-IR is supplied with a 6 foot grounded AC power cord. Make sure that
an AC power receptacle (socket) compatible with this plug is available nearby.

The instrument uses a universal AC power supply that accepts inputs of 100 to
240 VAC, 50/60 Hz. Power consumption is approximately 15 Watts.

Before connecting the AC power cord, first make sure the instrument’s power switch is OFF. Next, connect the
power cord to the instrument’s rear panel AC power receptacle, and then plug the power cord into a nearby AC
power receptacle.

2.3 Battery Pack

The H25-IR can be ordered as a battery powered instrument. This will allow the user to work in areas where a
receptacle is not easily accessible. This battery powered instrument can also operate on AC power when
battery operation is not needed. The battery powered H25-IR comes with a padded carrying case with th e
following features:

 Inside pocket to hold the battery pack (included with battery pack kit)
 Side pocket to hold the charger (included with battery pack kit)
 Front outside pocket to hold the probe and power cord

2.4 Turning ON the Instrument

WARNING! Explosion Hazard. Do not operate this instrument in the presence of flammable liquids,

vapors or aerosols. Operation of this instrument in such an environment constitutes a safety hazard.
Turn ON the instrument by setting its power switch, located on the rear panel, to ON.

BACHARACH

VERSION x.xx

Immediately afterwards, the instrument enters its warm-up mode and a countdown from 120 seconds is started.
In addition, a graphical display of the countdown period is provided by a bar graph that moves down the screen
during warm-up.

Instruction 3015-4342 11

WARM UP

120

When power is first applied, the instrument produces one short beep and
then performs a self-diagnostic check while displaying the instrument’s
firmware version number (approx. 15 seconds).

Remaining Warm Up Time in Seconds
Graphical Display of Warm Up Time

Preparing for Operation H25-IR

At the end of warm-up the Data Display screen appears. This screen shows the current gas measurement, leak
units, gas type, setup name, range, and mode of operation. In addition, a graphical display of the relative gas
level is provided by a bar graph that moves up the screen with increasing gas levels. Note that the sensitivity of
the bar graph is dependent on the Range setting.

Oz/yr

R134A

SETUP
SM SRCH

Gas Measurement
Leak Units
Gas Type
Setup Name (first 8 characters)
Range and Mode
Graphical Display of Relative Gas Level

2.5 System Setup

When shipped from the factory, the H25-IR has been configured according to its part number as described in
Appendix “A”. To change any of the instrument’s system parameters, first enter System Setup by pressing both
the ENT and ESC buttons on either the instrument’s front panel or Smart probe at the same time to display the
Main menu. Next, use the Up and Down buttons to highlight “SYSTEM”, and then press ENT to display the
System Setup menu.

Main Menu:

SYSTEM

LOG
SETUPS
CAL DATA
DIAGNOSTICS

From the System Setup menu, use the Up and Down buttons to highlight the desired function. Press ENT to
select that function and display its setup screen. Then perform the appropriate system setup procedure as
described in Sections 2.5.1 thru 2.5.9.

System Setup Menu:

GAS TYPE

LEAK UNITS
RELAYS
LOOP
BRIGHTNESS
CLOCK
PCHK MODE
PROBE BUTTON
RESET DEFAULTS

2.5.1 Gas Type

GAS TYPE < R134A
R401A
R402A
< R402B

The GAS TYPE function displays a list of gases that the instrument is programmed to monitor. Refer to Section
6 for a complete list of these gases.

Use the Up and Down buttons to highlight the desired gas. Press ENT to save the selection.

2.5.2 Leak Units

LEAK UNITS Oz/yr

g/yr

mL/s
PaM/s
ppm

The LEAK UNITS function displays a list of leak rate units of measure that the instrument is capable of
displaying. Leak rates can be displayed in units of ounces/year (Oz/yr), grams/year (g/yr), milliliters/second
(mL/s), Pascal Meters

Use the Up and Down buttons to highlight the desired leak units. Press ENT to save the selection.

12 Instruction 3015-4342

3

/second (PaM/s), or parts per million (ppm).

H25-IR Preparing for Operation

2.5.3 Relays

1 = NOT USED

2 = NOT USED
3 = NOT USED
4 = NOT USED

Four SPDT relays (rated 2 A, 250 VAC – inductive / 5 A, 250 VAC - resistive) can be individually programmed
to energize under any one of 11 different operating conditions. The contacts of these relays can be connected
to an external device that will activate when the designated operating condition is met. Refer to Section 2.7
External Relay Connections.

Use the Up and Down buttons to highlight the relay to be programmed. Press ENT to make the selection and
display that relay’s assignment screen.

Use the Up and Down buttons to highlight the desired operating condition for the selected relay. Press ENT to
save the selection.

RELAY 1 ASSIGNED TO
NOT USED
CLOSE >= SETPOINT
CLOSE < SETPOINT
CLOSE ON FAULT
CLOSE DURING CAL
CLOSE IN MEASURE
CLOSE AT LOG LIMIT
CLOSE IN SETUP 1
CLOSE IN SETUP 2
CLOSE IN SETUP 3
CLOSE IN SETUP 4
CLOSE WHEN TESTING

NOTE: SETPOINT is the gas value as entered per Section “2.6.5 Setpoint.”
LOG LIMIT is the total accumulated leak value as entered p er Section “4. 2.10.4 Settin g the Log Limit.”

For example: If Relay 1 is programmed to “CLOSE AT LOG LIMIT,” its N.O. contacts can be connected to an
external alarm device (e.g. strobe light or buzzer) that will activate when the total accumulated leak value in the
data log has reached its programmed limit.

TIP: When measuring the total leak-rate of a system, it’s important to clear the log per Section “4.2.10.2
Clearing the Log” before starting a new series of leak-rate measurements.

2.5.4 4–20 mA Loop

EDIT LOOP FACTOR

0.016ppm

Selecting the 4–20 mA LOOP function allows the current loop factor to be changed from its factory default of

0.016 ppm (corresponds to 0.016 mA per ppm), which provides an output range of 0 ppm (4 mA) to 1,000 ppm
(20 mA). Refer to Equation 3.1.

Use the Left and Right buttons to move the bl inking cursor ac ross the screen to high light the digit to be modif ied,
and then use the Up and Down buttons to modify that digit. P ress ENT to save the new loop factor.

Loop Output in mA = (Loop Factor x ppm) + 4 mA Eq. 3.1
TIP: The loop output can be checked per Section “5.1.5 Loop Test”.

Instruction 3015-4342 13

Preparing for Operation H25-IR

A

2.5.5 Brightness

BRIGHTNESS

PRESS ARROW KEYS TO
ADJUST

The BRIGHTNESS function changes the brightness level of the instrument’s front panel display.
Use the Up, Down, Left, or Right button to change the brightness to any one of four levels. Press ENT to save

the selected brightness level.

2.5.6 Clock

The CLOCK function sets the instrument’s date (MM/DD/YY) and time (24 hour format, where 1:00 PM is
displayed as 13:00). The clock allows measured values to be logged with a date/time stamp (refer to Section

4.2.9 Logging Measured Readings).
Use the Left and Right buttons to move the blinking cursor across the screen to highlight the digits to be

modified, and then use the Up and Down buttons to modify those digits. Press ENT to save the new date and
time values.

SET DATE & TIME

07/16/04 13:13

2.5.7 PCHK Mode

PCHK MODE
AT CAL

The PCHK Mode setting determines when the instrument performs an ambient pressure check a s follo ws:

AUTO – A pressure check is performed once every 60 minutes.
AT CAL – A pressure check is performed at the end of every calibration.

Note that a pressure check is always performed when the instrument is first turned ON just before the warm-up
period begins, regardless of the PCHK Mode setting.

Use the Up and Down buttons to highlight the desired setting. Press ENT to save the selection.

UTO

2.5.8 Probe Button

PROBE BUTTON
DISABLED
MODE KEY
ENTER KEY

The PROBE BUTTON function selects what action is performed by the pushbutton on the Standard Probe with
LED and Pushbutton.

DISABLED – No action performed.
MODE KEY – Toggles the instrument between its Search and Measure mode.
ENTER KEY – Performs the same function as the ENT / ZERO key on the instrument’s front panel.

Use the Up and Down buttons to highlight the desired setting. Press ENT to save the selection.

2.5.9 Reset Defaults

CONFIRM RESET TO
DEFAULTS BY PRESSING
THE UP ARROW

The RESET DEFAULTS function returns the instrument to its factory default settings per Appendix “A”.
This operation requires a three key press. Simultaneously press the ENTER+ESCAPE+VOL buttons to reset

defaults.

14 Instruction 3015-4342

H25-IR Preparing for Operation

2.6 Configuring the SETUPS Function

There are four user-defined Setups that allow the operator to quickly switch between frequently used
combinations of Gas Type, Range, Feedback Mode, Setpoint, and the Auto Zero Off condition. Program the
four Setup configurations as follows:

First enter the Setups menu by pressing both the ENT and ESC buttons on either the instrument’s front panel or
Smart probe at the same time to display the Main menu. Next, use the Up and Down buttons to highlight
“SETUPS”, and then press ENT to display the Setups menu.

Main Menu:

SYSTEM

LOG
SETUPS
CAL DATA
DIAGNOSTICS

NOTE: The names listed in the Setups menu are user defined, and may vary from what is shown above.

From the Setups menu, use the Up and Down buttons to highlight the desired Setup. Press ENT to select that
Setup and display its Configuration menu.

From the Configuration menu, use the Up and Down buttons to highlight the desired function. Press ENT to
select that function and display its setup screen. Perform the appropriate setup procedure as described in
Sections 2.6.1 thru 2.6.6.

Setups Menu:

SETUP NO.1

SETUP NO.2
SETUP NO.3
SETUP NO.4

Configuration Menu:

SETUP NAME
RANGE
GAS TYPE
FEEDBACK MODE
SETPOINT
SEARCH AUTO ZERO

2.6.1 Setup Name

SETUP NAME #1
SETUP NO. 1

The SETUP NAME function allows the operator to give each Setup a unique name that will appear on the Data
Display screen. Use the Left and Right buttons to move the blinking cursor across the screen to highlight the
character to be modified, and then use the Up and Down buttons to modify that character. When finished
entering the desired characters, press ENT to save the new name.

2.6.2 Range

RANGE LG
SETUP NO. 1 MED
SM

The RANGE function sets the sensitivity of the gas-level graphical display (bar graph located at the bottom of
the display), audible tone frequency, and the hand-held probe’s LED blink rate in relation to the detected gas
level. Use the Up and Down buttons to highlight the desired sensitivity. Press ENT to save the selection.

NOTE: The range setting has no affect on the accuracy of the gas reading as displayed on the instrument when
making a leak-rate measurement.

Instruction 3015-4342 15

Preparing for Operation H25-IR

2.6.3 Gas Type

GAS TYPE < R134A
SETUP NO. 1 R401A
R402A
< R402B

The GAS TYPE function sets the type of gas being monitored. Use the Up and Down buttons to highlight the
desired gas. Press ENT to save the selection.

NOTE: The gases displayed depend on which optical bench is installed. Refer to Section “6 .”

2.6.4 Feedback Mode

FEEDBACK MODE
SETUP NO. 1
CONTINUOUS
SETPOINT
H25C SETPOINT

The FEEDBACK MODE function provides the operator both visual and audible feedback in regard to the
measured leak rate. This function determines how the gas-level graphical display (bar graph located at the
bottom of the display) and audible tone operate as follows:

CONTINUOUS – The bar graph and audible tone continuously increase and decrease their val ues in step with
the leak rate. For example, when the leak rate increases, the bar graph moves upscale and the audible tone
increases in frequency. Their maximum values at various leak rates are determined by the Range setting.

SETPOINT – Both the bar graph and audible tone go to their maximum values when the leak rate equals or
goes above the setpoint. Enter a setpoint value per Section 2.6.5 Setpoint.

H25C SETPOINT – This setting emulates the operation of the H25C Industrial Halogen Lea k Dete ctor. The bar
graph and audible tone are suppressed when the leak rate is below the setpoint. They both go to their 50%
values when the leak rate reaches the setpoint, and then they both continuously increase in value as the leak
rate increases until reaching their maximum values at 2-times the setpoint. Enter a setpoint value per
Section 2.6.5 Setpoint.

Use the Up and Down buttons to highlight the desired function. Press ENT to save the selection.

2.6.5 Setpoint

SETPOINT
SETUP NO. 1

00.0000 Oz/yr

The SETPOINT function establishes a leak rate at which the graphical display and audible tone are turne d ON
as determined by the Feedback Mode setting (refer to the previous section).

The setpoint value also sets the leak rate at which one or more of the instrument’s relays is energized
whenever the leak rate equals, exceeds, or falls below the setpoint value (refer to Section 2.5.3 Relays), plus it
establishes a reference point where the instrument’s auto-zero function can be turned OFF whil e in the Search
mode (refer to Section 2.6.6 Search Auto Zero).

Use the Left and Right buttons to move the cursor across the screen to highlight the digit to be modified, and
then use the Up and Down buttons to modify that digit. Press ENT to save the new setpoint.

16 Instruction 3015-4342

H25-IR Preparing for Operation

2.6.6 Search Auto Zero

SEARCH AUTO ZERO
SETUP NO.1
< ALWAYS ON
ALWAYS OFF
BELOW SETPOINT
BELOW 90% OF SP
BELOW 75% OF SP
BELOW 50% OF SP

The SEARCH AUTO ZERO function allows the operator to select one of the following conditions when the auto­zero function is disabled while in the Search mode:

NOTE: This function works in conjunction with the setpoint value as entered in Section “2.6.5 Setpoint.”
ALWAYS ON – The background gas level is always zeroed. If the probe is held over a gas leak, the instrument

will automatically zero-out the reading.
ALWAYS OFF – The background gas level is never zeroed. If the probe is held over a gas leak, the instrument

will not zero-out the reading, similar in operation to the Measure mode.
BELOW SETPOINT – The auto-zero function is ON when the leak-rate is below the setpoint value. If the leak

rate goes above the setpoint value, then the auto-zero function turns OFF, allowing the probe to stay on the
leak without the reading being zeroed-out.

For example: If the Setpoint is 2 Oz/yr, then the auto-zero function is ON for leaks rates that are <2 Oz/yr. If
the leak rate is 2 Oz/yr, then the auto-zero function turns OFF.

BELOW 90% OF SP – The auto-zero function is ON when the leak-rate is below 90% of the setpoint value. If
the leak rate goes above 90% of the setpoint value, then the auto-zero function turns OFF, allowing the probe
to stay on the leak without the reading being zeroed-out.

For example: If the Setpoint is 2 Oz/yr, then the auto-zero function is ON for leaks rates that are <1.8 Oz/yr.
If the leak rate is 1.8 Oz/yr, then the auto-zero function turns OFF.

BELOW 75% OF SP – The auto-zero function is ON when the leak-rate is below 75% of the setpoint value. If
the leak rate goes above 75% of the setpoint value, then the auto-zero function turns OFF, allowing the probe
to stay on the leak without the reading being zeroed-out.

For example: If the Setpoint is 2 Oz/yr, then the auto-zero function is ON for leaks rates that are <1.5 Oz/yr.
If the leak rate is 1.5 Oz/yr, then the auto-zero function turns OFF.

BELOW 50% OF SP – The auto-zero function is ON when the leak-rate is below 50% of the setpoint value. If
the leak rate goes above 50% of the setpoint value, then the auto-zero function turns OFF, allowing the probe
to stay on the leak without the reading being zeroed-out.

For example: If the Setpoint is 2 Oz/yr, then the auto-zero function is ON for leaks rates that are <1 Oz/yr. If
the leak rate is 1 Oz/yr, then the auto-zero function turns OFF.

Instruction 3015-4342 17

Preparing for Operation H25-IR

2.7 External Relay Connections

The H25-IR includes four SPDT relays whose relay contacts are rated 2 A at 250 VAC (inductive) and 5 A at
250 VAC (resistive). External alarm devices (e.g., horns, bells, strobe lights, etc.) can be connected to these
relays and activated when their associated relay is energized. Refer to Section 2.5.3 Relays.

Locate the external relay connector on rear of unit (refer to Section 1.7.2 Rear View).
Secure the leads from the external device and its power source to the external relay connector as sho wn in the

diagram below. This diagram shows a typical alarm device being connected to Relay 1. Repeat this procedure,
as necessary, for the remaining relays.

Typical Relay 1 Wiring

 Each relay may be connected as normally open (NO), or normally closed (NC).
 The relay contacts are rated 2 A at 250 VAC (inductive) and 5 A at 250 VAC (resistive).
 Power for the external alarm devices is supplied from an external power source.
 Jumper the ‘Neutral’ line of an external power source to the ‘Common’ terminals on the relay connector.
 Connect one end of the alarm device to the ‘NO’ terminal of the desired relay.
 The other end of the alarm device 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.

18 Instruction 3015-4342

H25-IR Preparing for Operation

2.8 4–20 mA Current Loop Connection

An external 420 mA monitoring device (e.g., chart recorder) can be connected to the H25-IR using a shield ed­twisted-pair cable.

IMPORTANT! The monitoring device must be isolated from ground (floating).
Locate the 420 mA connector on the rear of the unit (refer to Section 1.7.2 Rear View), and then remove the

resistor or shorting wire from its terminals.

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 a “Loop Open Error” to occur (refer to Section “4.3 Fault ”).

Secure the wire leads from the external monitoring device to the connector as shown in the di agram below,
making sure that the polarity at this connector matches the wiring at the monitoring device.

4–20 mA Current Loop Connector

CAUTION: Never apply power to the 4–20 mA Current Loop Connector from an

external power supply. In addition, connect only a load resistor or a floating
measurement device.

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 instrument’s LOOP
function (refer to Section 2.5.4 4–20 mA Loop).

TIP: The loop output can be checked per Section “5.1.5 Loop Test”.

Instruction 3015-4342 19

Preparing for Operation H25-IR

Notes:

20 Instruction 3015-4342

H25-IR Calibration

3 Calibration

It is recommended that a calibration be performed after the initial warm up and then once every 2 – 4 hours
there after. During the calibration cycle internal pressures and flow rates are stored which are used to
determine leak rate and detect proper flow. A flow fault indicates a change in pressure since the time of the last
calibration cycle. This can be due to particulate build up on the probe tip or internal filters as well as swings in
atmospheric pressure due to weather changes (if a long time has elapsed since the last calibration cycle). Most
flow faults can be cleared by simply performing a new calibration.

When the instrument is supplied with an internal leak source, the operator can choose between two types of
calibration: Internal or External. Internal calibration uses the instrument’s built-in leak source, while External
calibration uses a customer supplied calibrated leak source.

If the instrument is supplied without a leak source, then the option of selecting the calibration type is removed
from the menu system. The only option for this model of instrument is to calibrate using an external leak source.

3.1 Selecting Internal or External Calibration

Use the Main Menu > CAL DATA > CAL TYPE function to select either Internal or External calibration. If
External calibration is selected, then also use the EXT RATE and EXT GAS TYPE functions to enter the
characteristics of the external leak source.

Display the Calibration Data menu by first pressing both the ENT and ESC buttons on either the instrument’s
front panel or Smart probe at the same time to display the Main menu. Next, use the Up and Down buttons to
highlight “CAL DATA”, and then press ENT to display the Calibration Data menu.

Main Menu:

SYSTEM

LOG
SETUPS
CAL DATA
DIAGNOSTICS

Calibration Data Menu:

CAL TYPE

EXT RATE
EXT GAS TYPE
CAL FACTOR
RESTORE FACTORY CAL
CAL INTERVAL
ENFORCE CAL INTERVAL
LAST CAL DATE

3.1.1 Internal Calibration Selection

From the Calibration Data menu, use the Up and Down buttons to highlight “CAL TYPE”, and then press ENT
to display its setup screen. Use the Up and Down buttons to highlight “INTERNAL”, and press ENT to make the
selection and return to the Calibration Data menu. Press ESC as required to return to the Data Display screen.

CAL TYPE INTERNAL
EXTERNAL

Instruction 3015-4342 21

Calibration H25-IR

3.1.2 External Calibration Selection and Setup

When using an external leak source, the instrument must be setup for external calibration along with entering
the leak rate and gas type of the external leak source.

Select external calibration and enter the parameters of the external leak source as follows:
Select External Calibration: From the Calibration Data menu, use the Up and Down buttons to highlight “CAL

TYPE”, and then press ENT to display its setup screen. Use the Up and Down buttons to highlight
“EXTERNAL”, and press ENT to make the selection and return to the Calibration Data menu.

CAL TYPE INTERNAL
EXTERNAL

Enter External Leak Rate: From the Calibration Data menu, highlight “EXT RATE” and press ENT to display its
setup screen. Use the Left and Right buttons to move the blinking cursor across the screen to highlight the
digit to be modified, and then use the Up and Down buttons to modify that digit. Press ENT to save the new
external leak rate value and return to the Calibration Data menu.

IMPORTANT! Be sure to enter the leak rate using the same units of measure as displayed on the EXT RATE
screen. In this example, the units of measure is g/yr. If your leak source is marked in Oz/yr, then multiply that
value by a factor of 28.35. For example: If the leak source is marked 0.9 Oz/yr, then enter a leak rate of (0.9 x

28.35=) 25.5 g/yr.
NOTE: The minimum calibration leak rate is 2 g/yr.

EXT RATE 25.5 g/yr

Enter External Gas Type: From the Calibration Data menu, highlight “EXT GAS TYPE” and press ENT to
display its setup screen. Use the Up and Down buttons to highlight the type of gas contained in the external
leak source. Press ENT to save the new external gas type and return to the Calibration Data menu.

NOTE: The gases displayed depend on which optical bench is installed. Refer to Section “6 Troubleshooting.”

EXT GAS TYPE < R134A
R401A
R402A
< R402B

Press ESC as required to return to the Data Display screen.

3.2 Internal Calibration

Internal calibration uses the instrument’s built-in leak source. Properties of the leak source (i.e. gas type, leak
rate, temperature coefficient, and specification temperature) are entered at the factory and do not need to be
changed by the operator.

The properties of the leak source along with the current internal temperature of the instrument are used to
compute the actual leak rate when a calibration is requested. This number is displayed as the “target” value
during calibration. A spring switch located in front of the CAL Port ensures that the probe is kept in place for the
duration of the calibration process. Calibration will fail if the probe is withdrawn too early in the process, or if the
computed parameters deviate from the stored factory calibration by more than 20%.

1. Turn ON instrument and allow it to complete its 120 second warm-up.

22 Instruction 3015-4342

H25-IR Calibration

C

2. Press the front panel CAL button to display the Calibration screen. Note that the display must be
reading a leak rate of “0.00” when the CAL button is pressed; otherwise, the message “LEAK RATE
MUST BE ZERO TO CALIBRATE” will appear. If necessary, press the ZERO button to zero the display
before pressing CAL.

0.89

INSERT
PROBE

3. Ensure that the instrument is set up for internal calibration as indicated by “INT CAL” being displayed at
the bottom-right of the display. If “EXT CAL” (external calibration) is displayed, press the ESC key to
perform the procedure in Section 3.1 Selecting Internal or External Calibration and set the Cal Type to
Internal.

4. Insert the probe tip into the CAL Port within 10 seconds after
pressing the CAL button. Be sure that the probe tip makes
contact with the spring switch. At this time the calibration
process should automatically start.

The top number of the Calibration screen shows the “target”
value (leak source rate), while the bottom number shows the
current measured value. Keep the probe tip firmly against
the back of the port for the duration of the calibration
process, during which time the instrument is calibrated at
both a high and low flow rate.

If the probe tip looses contact with the spring switch before the
calibration process completes, the message “CAL ABORTED” is
displayed. At this time press any key to retain the previous
calibration curve and return to the Data Display screen.

5. After a successful calibration the new calibration data is saved and
the message “CAL OK” followed by “WITHDRAW PROBE FROM
LEAK SOURCE” will appear.

6. Withdrawing the probe causes the display to switch back to the
Data Display screen. Note, however, if the PCHK Mode is set to
AUTO (refer to Section 2.5.7 PCHK Mode), then a pressure check
is performed prior to the display of the Data Display screen.

NOTE: After being calibrated the instrument is automatically placed
into its Search mode.

TARGET
O/YR
R134A
MEASURED
O/YR

Oz/yr

R134A

SETUP
INT CAL

TARGET

0.89

0.00

O/YR
R134A
MEASURED
O/YR

AL

OK

WITHDRAW PROBE

FROM LEAK

SOURCE

Oz/yr

R134A

SETUP
INT CAL

Oz/yr

R134A

SETUP
INT CAL

Oz/yr

R134A

SETUP
INT CAL

PCHK

Oz/yr

R134A

SETUP
SM SRCH

3.3 External Calibration

External calibration uses a customer supplied leak source that matches the gas to be monitored. Properties of
the leak source must be entered by the operator using the EXT RATE and EXT GAS TYPE functions as
described in Section 3.1.2 External Calibration Selection and Setup. The EXT RATE entry is the number
displayed as the “target” value during calibration.

IMPORTANT! The operator is responsible for ensuring that the external leak-rate value has been co rrected
for daily changes in ambient temperature and pressure at the time of calibration. It is also the operator’s
responsibility to ensure that a good calibration has been performed.

1. Turn ON instrument and allow it to complete its 120 second warm-up.

2. Press the front panel CAL button to display the Calibration screen. Note that the display must be
reading a leak rate of “0.00” when the CAL button is pressed; otherwise, the message “LEAK RATE

Instruction 3015-4342 23

Calibration H25-IR

MUST BE ZERO TO CALIBRATE” will appear. If necessary, press the ZERO button to zero the gas
display before pressing CAL.

0.89

3. Ensure that the instrument is set up for “EXT CAL” (external calibration) as indicated at the bottom-right

4. Insert probe tip into the Calibration Port of the external leak source.

5. The top number of the Calibration screen shows the “target” value (leak source rate), while the bottom

6. After the calibration cycle is complete, the new calibration data is saved and the display automatically

0.00

of the display. If “INT CAL” (internal calibration) is displayed, press the ESC key to perform the
procedure in Section 3.1 Selecting Internal or External Calibration and set the Cal Type to External.

number shows the current “measured” value. Keep the probe tip inserted in the Calibration Port for the
duration of the calibration process, during which time the instrument performs a calibration at both a
high and low flow rate.

0.89

0.89

switches back to the Data Display screen. Note, however, if the PCHK Mode is set to AUTO (refer to
Section 2.5.7 PCHK Mode), then a pressure check is performed prior to the display of the Data Display
screen.

NOTE: After calibration the instrument is automatically placed into its Search mode.

TARGET
O/YR
R134A
MEASURED
O/YR

TARGET
OZ/YR
R134A
MEASURED
OZ/YR

Oz/yr

R134A

SETUP
EXT CAL

Oz/yr

R134A

SETUP
EXT CAL

Oz/yr

R134A

SETUP

3.4 CAL Factor

The factory default CAL Factor of 1.000 will provide the level of accuracy as stated in Section 6 Troubleshooting
for all gases.

The CAL Factor can be changed for the following two reasons:

 Allow the instrument’s internal leak source to be used to calibrate the instrument,

regardless of the gas being measured

 Improve the accuracy of ppm measurements

Leak-rate accuracy can be maintained by periodically calibrating the instrument on the gas being measured. If
the instrument’s internal calibration gas is the same as the gas being measured, then it is a simple matter o f
calibrating the instrument using the internal leak source. When measuring a gas that is not the same as th e
instrument’s internal calibration gas, then there are two options for maintaining accuracy. The instrument can
either be calibrated using an external leak source, or the CAL Factor can be adjusted to make the internal leak
source simulate the gas being measured as described in Section 3.4.1.

The CAL Factor can also be used to improve the accuracy of ppm measurements as described in Section 3.4.2.

24 Instruction 3015-4342

H25-IR Calibration

3.4.1 Simulating Other Internal Leak Source Gas Types
Using the CAL Factor

When measuring the leak rate of a gas that is not the same as the instrument’s internal calibration gas, the CAL
Factor can be adjusted make the instrument’s internal calibration gas simulate the gas b eing measured. This
allows the operator to calibrate the instrument using the internal leak source, regardless of the gas contained in
the leak source. Note that this procedure is not necessary for single-gas instruments.

Material Required:

 Calibrated External Leak Source set up for 5 to 10 times the leak rate

that the instrument is expected to detect

IMPORTANT! Remember that the accuracy will not be better than that of the
external leak source used for calibration.

Procedure:

1. Turn ON the instrument and allow it to warm up for 30 minutes before proceeding.

2. Program the instrument for the Gas Type contained in the external leak source (refer to Section

2.5.1 Gas Type).

3. Verify that the current CAL Factor is set to 1.000 by selecting the Main Menu > CAL DATA > CAL
FACTOR function. If necessary, reset the CAL Factor to 1.000. Refer to Section 3.4.3 Adjusting the
CAL Factor.

4. Perform an internal calibration in the normal way using the internal leak source (refer to Section 3.2
Internal Calibration). Note that it doesn’t matter that the gas in the internal leak source doesn't match
the Gas Type entered in Step 2.

5. Press the MODE key to place the instrument into its Measure mode.

6. Measure the leak rate of the external leak source and record the displayed reading.

7. Compute the new CAL Factor by dividing the actual leak rate of the external leak source by the reading
recorded in Step 6. For example, if the leak rate of the external leak source is 0.4 oz/yr and the
measured rate was 0.43 oz/yr, then the new CAL Factor is 0.4  0.43 = 0.930.

This new CAL Factor establishes the relationship between the internal calibration gas and the gas type
selected to be measured.

8. Enter the new CAL Factor as described in Section 3.4.3 Adjusting the CAL Factor. Note that the
displayed Gas Type should match the gas selected in Step 2.

9. From this point on the operator can perform an internal calibration and get accurate measurements for
other gas types using whatever gas is contained in the internal leak source.

3.4.2 Improving PPM Measurement Accuracy using the CAL Factor

The CAL Factor can be adjusted to improve the accuracy of the ppm measurement by calibrating the
instrument on the gas being measured. The accuracy of the ppm measurement after performing this proce dure
will equal the accuracy of the gas sample, ±1%. Note that the accuracy of the instrument’s ppm measurement
depends on the accuracy of the gas sample.

The new CAL Factor is determined by sampling a known dilution of gas whose accuracy is better than the ppm
measurement accuracy as stated in Section 6 Troubleshooting. The concentration of the sample must also be
corrected for ambient temperature and pressure at the time of calibration. A minimum sample size of 5 liters is
required.

Instruction 3015-4342 25

Calibration H25-IR

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

The instrument should be operating for at least 30 minutes prior to performing a calibration.
Verify that the current CAL Factor is set to 1.000 by selecting the Main Menu > CAL DATA > CAL FACTOR

function. If necessary, reset the CAL Factor to 1.000. Refer to Section 3.4.3 Adjusting the CAL Factor.
With the instrument operating in its ppm measurement mode (refer to Section 4.2.8 Measuring the PPM Level),

insert the probe tip into the gas-sample bag and allow the instrument to sample until the ppm reading on the
display is stable. At this time record the ppm reading. The new CAL 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. Enter the
new CAL Factor as described in Section 3.4.3 Adjusting the CAL Factor.

IMPORTANT! If the instrument is switched back to measuring the leak-rate, then the instrument must be
recalibrated on the gas being measured.

3.4.3 Adjusting the CAL Factor

Display the Calibration Data menu by first pressing both the ENT and ESC buttons on either the instrument’s
front panel or Smart probe at the same time to display the Main menu. Next, use the Up and Down buttons to
highlight “CAL DATA”, and then press ENT to display the Calibration Data menu.

Main Menu:

SYSTEM

LOG
SETUPS
CAL DATA
DIAGNOSTICS

From the Calibration Data menu, highlight “CAL FACTOR” and press ENT to display its setup screen. Use the
Left and Right buttons to move the blinking cursor across the screen to highlight the digit to be modified, and
then use the Up and Down buttons to modify that digit. Press ENT to save the new CAL factor value and return
to the Calibration Data menu.

CAL FACTOR 1.000
FOR R134A

K1=310.89 K2=703.7 K3=1460.3
K4=0.0 K5=0.0

Calibration Data Menu:

CAL TYPE

EXT RATE
EXT GAS TYPE
CAL FACTOR
RESTORE FACTORY CAL
CAL INTERVAL
ENFORCE CAL INTERVAL
LAST CAL DATE

26 Instruction 3015-4342

H25-IR Calibration

3.5 Restoring Factory Calibration

NOTE: Factory calibration cannot be restored if the instrument was calibrated using an external leak source.

Restore an instrument to its factory calibration value as follows:
Display the Calibration Data menu by first pressing both the ENT and ESC buttons on either the instrument’s

front panel or Smart probe at the same time to display the Main menu. Next, use the Up and Down buttons to
highlight “CAL DATA”, and then press ENT to display the Calibration Data menu.

Main Menu:

SYSTEM

LOG
SETUPS
CAL DATA
DIAGNOSTICS

From the Calibration Data menu, use the Up and Down buttons to highlight “RESTORE FACTORY CAL”, and
then press ENT to display the RESTORE FACTORY CAL screen.

RESTORE FACTORY CAL
HIT ENTER TO CONFIRM

Press the ENT button to confirm restoring the instrument to its factory calibration values.

Calibration Data Menu:

CAL TYPE

EXT RATE
EXT GAS TYPE
CAL FACTOR
RESTORE FACTORY CAL

CAL INTERVAL

ENFORCE CAL INTERVAL
LAST CAL DATE

3.6 Storing a New Factory Calibration

For all models fitted with an internal leak source, "factory" calibration data is stored in memory and used to
validate all subsequent internal calibrations performed by the user. An internal calibration failure will occur when
the calibration data collected during an internal calibration cycle, performed by the user, deviates from the
"factory" calibration data. This can occur when the internal particulate filter needs to be replaced or if a probe is
changed. When the internal filter or probe is replaced, or the optical sensor, pump or pneumatics is serviced, a
new "factory" calibration must be stored. This is accomplished by first performing an internal calibration, which
may fail due to the changes to the instrument, then pressing the ENT and CAL keys together.

PRESS ENTER TO
STORE LAST CAL
AS REFERENCE

g/yr

FAULT

SETUP NO.1
SM SRCH

Press ENT to confirm. This will take the data collected from the calibration just completed and store it as the
"factory" or reference calibration for validation of all future internal calibrations.

Instruction 3015-4342 27

LAST CAL HAS
BEEN STORED
AS REFERENCE

g/yr

FAULT

SETUP NO.1
SM SRCH

Calibration H25-IR

Notes:

28 Instruction 3015-4342

H25-IR Operation

4 Operation

4.1 Instrument Location

The H25-IR Refrigerant Gas Leak Detector should be placed on a flat, horizontal surface such as a bench or
table top when in use.

When searching for leaks, the instrument does not need to be in a gas-free area. This is becau se of the
instrument’s ability to automatically zero-out background gases and still be able to locate gas leaks.

When making leak-rate measurements, the instrument needs a location where the air is clean and free of the
gas being monitored  this is necessary for zeroing purposes. If the area is contaminated, then a fresh-air
source (e.g., fresh air piped in from the outside) must be made available so the operator can manually zero the
instrument before making a measurement.

4.2 Using the H25-IR

4.2.1 Power

Plug the instrument into the nearest AC outlet (100 to 240 VAC, 50/60 Hz) or use the battery pack (depending
on your model number), and then set the rear panel power switch to its ON position. After power up, the
instrument requires 120 seconds to warm-up. A detailed description of the front panel display scree ns that are
shown during turn-on and warm-up is contained in Section 2.3 Battery Pack.

4.2.2 Initial Setup

At this time the H25-IR should already be set up as described in Section 2 Preparing for Operation.
After warming up, the instrument’s Data Display screen will show the current Gas Measurement, Leak Units,

Gas Type, Setup Name, Range, and Mode of Operation. In addition, a graphical display of the relative gas level
is provided by a bar graph at the bottom of the screen whose length increases up the screen as the gas level
increases. An audible tone may also be heard whose pitch increases in frequency as the gas level increases.
Note that the sensitivity of the bar graph and audible tone for any given gas level is dependent on the Range
setting.

When using the Smart probe, its LCD will show the current Gas Measurement, Range, Mode of Operation, and
Setup Number in parentheses. If the probe contains a red LED, the blink rate of the LED will increase as the
gas level increases. Note that the sensitivity of the LED’s blink rate for any given gas level is dependent on the
Range setting.

Instrument Display Smart Probe Display

The Leak Units can be changed per Section 2.5.2 Leak Unit; the Gas Type changed per Se ction 2.5.1 Gas
Type; the Setup changed by pressing the SETUP button; the Range changed by pressing the RANGE button;

and the Mode changed by pressing the MODE button. Note that if the Gas Type is changed during operation,
the Setup Name and Number changes to a dash (), indicating that the previously selected Setup is no longer
valid.

Oz/yr

R134A

SETUP
SM SRCH

Gas Measurement
Leak Units
Gas Type Mode
Setup Name (first 8 characters)
Range & Mode
Graphical Display of Gas Level

0.00 SM
SRCH (1)

Range
(Setup No.)

Instruction 3015-4342 29

Operation H25-IR

r

4.2.3 Range Selection

The H25-IR has three sensitivity ranges: SM (small), MED (medium), and LG (large). The range used when
searching for a leak depends on the size of the leak and the type of gas being monitored.

Press the RANGE button until the desired range is displayed on either the instrument’s Data Display screen, or
on the LCD of the Smart probe.

Instrument Display Smart Probe Display

Oz/yr

R134A

SETUP NO
SM SRCH

NOTE: The range setting has no affect on the accuracy of the gas reading as displayed on the instrument when
making a leak-rate measurement. It does, however, change the sensitivity of the bar graph at the bottom of the
Data Display screen, the audible tone frequency as heard from the speaker, and the blink rate of the red LED
on the hand-held probe.

The “SM” range is the highest sensitivity level, and is most likely used for fluorine based gases like R134a and
most fluorine based refrigerant blends.

The “MED” range is used for chlorine and chlorine based gases like R12, R22, R12 3, etc. This position is also
useful for locating large R134a or other fluorine based refrigerant leaks of 12 Oz/yr.

The “LG” range is used to locate very large leaks.
TIP: Blowing out the test area with shop air may enable the operator to locate a large leak more quickly.

Range: SM, MED, LG

0.00 SM
SRCH (1)

4.2.4 Setup Selection

There are four user-defined Setups that allow the operator to quickly switch between frequently used
combinations of Gas Type, Range, Feedback Mode, Setpoint, and the Auto Zero Off condition (refer to Section

2.6 Configuring the SETUPS Function).
When first turned ON, the instrument returns to the last Setup selected. To select a different Setup, first press the

SETUP button to display the Setup Selection menu. Next, use the Up and Down buttons to highlight the desired
Setup, and then press ENT to make the selection and be returned to the Data Display screen. The name of the
newly selected Setup will appear on the Data Display screen.

SETUP NO. 1
SETUP NO. 2
SETUP NO. 3
SETUP NO. 4

NOTE: The names listed in the Setup Selection menu are user defined, and may vary from wh at is
shown above. The number of each setup, however, is what appears on the display of the Smart probe.

Instrument Display Smart Probe Display

Oz/yr

R134A

SETUP NO

Setup Name
and Numbe

0.00 SM
SRCH (1)

4.2.5 Volume Adjustment

A speaker at the rear of the instrument produces an audible tone whose frequency increases as the detected level of
gas increases. An earphone when plugged into the instrument’s earphone jack automatically disconnects the
speaker, allowing the operator to listen to the unit’s audible tone in high-noise environments.

30 Instruction 3015-4342

H25-IR Operation

TIP: If additional volume is required, connect an amplif ied speake r to the earphone jack.
Adjust the speaker and earphone volume as follows:

1. Press the VOL (volume) button to display the ADJUST SPEAKER VOLUME screen.

Speaker Volume
Bar Graph

ADJUST SPEAKER

VOLUME

------

Oz/yr

R134A

SETUP
SM SRCH

2. Press the Up button to increase volume, and press the Down button to decrease volume. Pressing the
Left button sets the volume to minimum, while pressing the Right button sets it to maximum. A visual
indication of the volume level is provided by a bar graph at the bottom of the Data Display screen.

3. Press ENT to save the new volume level.

4.2.6 Searching for a Leak

Use the following procedure to locate a leak.

1. Press the MODE button to display “SRCH” at the bottom of the Data Display screen or on the Smart
probe.

The Search Mode is used to locate leaks because of its ability to auto-zero or block out background
contamination. This greatly reduces and/or eliminates false positives while retaining the sensitivity to
quickly locate small to large leaks.

TIP: The auto-zero function can be turned OFF, or configured to automatically turn OFF at a user-
defined leak rate. Refer to Section “2.6.6 Search Auto Zero”.

2. Begin leak testing by moving the probe tip slowly toward the area being tested. Pinpointing leaks
requires continuous probe movement. (2 inches [50 mm] per second is recommended as specified in
SAE J1627 and J1628.) When the gas being monitored is detected the instrument responds in a
positive manner as follows:

 The gas reading increases
 The bar graph at the bottom of the Data Display screen moves upscale
 The audible tone from the speaker increases in frequency
 If the hand-held probe contains an LED, its blink rate will increase

3. If the probe tip is held over the leak source the instrument will zero-out the leak, causing all gas
indicators to return to their idle state. Briefly moving the probe away from the leak allows the instrument
to quickly regain its sensitivity. Returning to the leak source will again cause the instrument to respond
in a positive manner.

4. By repeating Step 3, the instrument will reliably and repeatedly pinpoint the leak with each pass over
the leak source.

4.2.7 Measuring the Leak Rate

After finding a leak, a measurement can be made to determine its leak rate as follows:

1. Press the MODE button to display “MERS” at the bottom of the Data Display screen or “MEASR” on the
Smart probe.

2. Allow the instrument to sample fresh air. The gas reading must
necessary, press the ZERO button to zero the reading while sampling fresh air.

Instruction 3015-4342 31

be “0.00” before proceeding. If

Operation H25-IR

3. While observing the gas reading, hold the probe tip over the leak source until the reading stabilizes. In
the examples below, a leak rate of 2.80 Oz/yr of R134a is being measured.

Instrument Display Smart Probe Display

Oz/yr

R134A

SETUP
SM MERS

2.80 SM
MEASR(1)

4.2.8 Measuring the PPM Level

The H25-IR can be used to measure a gas’s ppm level within a confined space, and display that level within the
range of 0 to 1,000 ppm. Set up the instrument to measure ppm levels as follows:

NOTE: Although the H25-IR can display ppm levels above its rated range of 0 to 999 ppm, the accuracy of the
reading above 999 ppm is unspecified. Refer to Section “6Troubleshooting.”

1. Set up the instrument’s Leak Units to ppm as described in Section 2.5.2 Leak Unit.

2. Press the MODE button to display “MERS” at the bottom of the Data Display screen or “MEASR” on the
Smart probe.

3. Allow the instrument to sample fresh air. The gas reading must
ZERO button to zero the gas reading while sampling fresh air.

4. Place probe in area to be measured. In the example below, 38.0 ppm of R134a is being measured.
Note that the display is auto ranging, causing the decimal point to turn off above 99.9 ppm.

Instrument Display Smart Probe Display

ppm

R134A

SETUP
SM MERS

38.0 SM
MEASR(1)

be “00.0” before proceeding. Press the

4.2.9 Logging Measured Readings

The H25-IR can log up to 50 measurements, which can then be viewed and analyzed at a later time. Each
logged measurement is given a date & time stamp for identification. The measurements are stored in non­volatile memory, and will not be erased when the instrument is turned OFF.

With the instrument in its Measure mode, press the LOG button to log the measurement that is currently being
displayed on the Data Display screen. Note that logged data is stored on a first-in, first-out basis. Once 50
measurements have been stored, the newest stored measurement overwrites the oldest.

NOTE: Only non-zero measurements will be logged.

In the following example, a reading of 0.48 Oz/yr is about to be logged in memory location 11. Pressing the
ENT button will confirm this action and then display a Measurement Logged screen, which confirms that the
data has been saved while also showing the current total of all leaks logged.

LOG 0.48
AS 11 OF 50
PRESS ENTER
TO CONFIRM?

Oz/yr

R134A

SETUP
SM MERS

IMPORTANT! The instrument does not perform a units-of-measure conversion. It is therefore very important
that the operator not change the leak units value after beginning to log measurements.

32 Instruction 3015-4342

MEASUREMENT
LOGGED
TOTAL=55.8

Oz/yr

R134A

SETUP
SM MERS

H25-IR Operation

TIP: When measuring the total leak-rate of a system, it’s important to clear the log per Section “4.2.10.2
Clearing the Log” before starting a new series of leak-rate measurements.

4.2.10 Logged Measurements

Each of the 50 logged measurements can be individually viewed, or the total accumulated value of all 50
measurements can be displayed. In addition, a log limit can be set that establishes a set point at which a relay
is energized when the total of all logged measurements (up to 50) equals the log limit.

Enter the Log menu by first pressing both the ENT and ESC buttons on either the instrument’s front panel or
Smart probe at the same time to display the Main menu. Next, use the Up and Down buttons to highlight
“LOG”, and then press ENT to display the Log menu.

Main Menu:

SYSTEM

LOG
SETUPS
CAL DATA
DIAGNOSTICS

4.2.10.1 Viewing Logged Measurements

Log Menu:

VIEW LOG

CLEAR LOG
LOG TOTAL
LOG LIMIT

Display the Log menu as described in Section 4.2.10. Next, use the Up and Down buttons to highlight “VIEW
LOG” and then press the ENT button to display the first logged data point.

LOG POINT # 1
08/09/04 07:35
LEAK RATE=2.80 Oz/yr
L/R ARROW TO CLEAR

Use the Up and Down buttons to scroll through the other log points (1 thru 50).
Use the Left or Right button to clear only the current log point. To clear all log points, refer to Section 4.2.10.2

Clearing the Log.

4.2.10.2 Clearing the Log

Display the Log menu as described Section 4.2.10. Next, use the Up and Down buttons to highlight “CLEAR
LOG” and then press the ENT button to display the Clear Log screen.

CLEAR LOG

HIT ENTER TO CONFIRM

Press the ENT button to clear the log of all stored measurements.

CLEAR LOG

CLEARING LOG DATA.

4.2.10.3 Viewing the Total of All Logged Measurements

The ability to display the total of all logged measurements (up to 50) is useful in situations where it is necessary
to test an installation or piece of equipment that has a maximum permissible total leak rate. For example, a
halogen fire suppression system can have leaks, but the combined leak rate or the sum of all the leaks cannot
exceed a certain level, which is typically specified as a fraction of the total charge per year.

To display the total of all logged measurements, first display the Log menu as described Section 4.2.10. Next,
use the Up and Down buttons to highlight “LOG TOTAL” and then press the ENT button to display the Log

Instruction 3015-4342 33

Operation H25-IR

Total screen. Note that the display is auto ranging, causing the decimal point to turn off above the value 99.9. In
the example below, the total of all logged measurements is 78.5 Oz/yr.

LOG TOTAL
COMBINED LEAK RATE

= 78.5 Oz/yr

4.2.10.4 Setting the Log Limit

The ability to set a log limit is useful when using the H-25IR to log the leak rate of a system that has a maximum
permissible total leak rate. A relay can be programmed to energize when the total of all logged measurements
(up to 50) equals the log limit (refer to Section 2.5.3 Relays).

To set the log limit, first display the Log menu as described in Section 4.2.10. Next, use the Up and Down
buttons to highlight “LOG LIMIT” and then press the ENT button to display the Log Limit screen. Use the Left
and Right buttons to move the blinking cursor across the screen to highlight the digit to be modified, and then
use the Up and Down buttons to modify that digit. Press ENT to save the log limit value and return to the Log
menu.

LOG LIMIT
IS 999.00 Oz/yr

4.3 Fault Conditions

When the instrument’s diagnostics detects that a fault has occurred, the word “FAULT” appears in place of the
Gas Type, and a beep will be heard every 2 seconds.

Oz/yr

FAULT

SETUP
SM SRCH

The cause of the fault can be determined by viewing the Diagnostic menu’s Last Fault function. To display the
Diagnostics menu, first press both the ENT and ESC buttons on either the instrument’s front panel or Smart
probe at the same time to display the Main menu. Next, use the Up and Down buttons to highlight
“DIAGNOSTICS” and then press ENT to display the Diagnostics menu.

Main Menu:

SYSTEM

LOG
SETUPS
CAL DATA
DIAGNOSTICS
FACTORY

Select “LAST FAULT” to display the Last Fault screen. Refer to Section 5.1.2 Last Fault for a listing of the type
of faults that are tracked by the diagnostics, and for information on how to possibly correct the fault.
When the cause of the fault has been corrected, the FAULT message and the beep are automatically
turned OFF.

Fault has occurred

Diagnostics Menu:

SENSOR DATA

LAST FAULT
IR EMITTER

PRESSURE
LOOP TEST
CLR LAST FAULT
AUTO GAIN

34 Instruction 3015-4342

H25-IR Operation

4.4 PCHK (Atmospheric Pressure CHecK)

The instrument maintains its accuracy under varying atmospheric conditions by performing an atmospheric
pressure check once every hour, or immediately after calibration (refer to Section 2.5.7 PCHK Mode.) When a
PCHK is performed, the unit beeps once, the pump stops, a valve opens exposing the pressure sensor to the
atmosphere, and “PCHK” appears at the bottom-right of the display. During this time the instrument measures
the current atmospheric pressure, and then uses this value along with the current temperature and the ideal gas
law to compute the gas level. When the pressure check is complete (approximately 5 seconds), the unit beeps,
the valve closes, and the pump restarts.

Oz/yr

R134A

SETUP

PCHK

Pressure check in progress

4.5 RS-232 Communication

The RS-232 connector located on the rear of the instrument (refer to Section 1.7.2 Rear View) is used to flash
the instrument’s memory. Refer to Section 5.3 Flashing Memory.

Additionally, leak rate data can be output from the port as ASCII text in two formats.

4.6 Serial Output Types

<CLOCK
PCHK MODE

SERIAL OUTPUT

<PROBE BUTTON

Text Packet

 When TEXT PACKET is selected, a 16 character ASCII string is output approximately 10 times per

second. The string is formatted as follows:
<STX> XX.X,-p.pp<ETX>cc

 XX.X is the leak rate as displayed on the front panel, -p.pp is the internal pressure drop in PSI and cc is

a two byte checksum.

Text Only

 When TEXT ONLY is selected, a 10 character ASCII string is output approximately 10 times per

second.

 The string is formatted as follows:

XX.X,-p.pp <CR><LF>

 XX.X is the leak rate as displayed on the front panel and –p.pp is the internal pressure drop in PSI. CR

and LF stand for carriage return and line feed. This option is convenient for capture to file using
Hyperterminal or similar software.

SERIAL OUTPUT TYPE

NONE

TEXT PACKET
TEXT ONLY

Instruction 3015-4342 35

Operation H25-IR

Notes:

36 Instruction 3015-4342

H25-IR Maintenance

5 Maintenance

5.1 Diagnostics Menu

The Diagnostics menu provides information about the instrument’s operation that will be useful to service
technicians for the purpose of troubleshooting various fault conditions.

To display the Diagnostics menu, first press both the ENT and ESC buttons on either the instrument’s front
panel or Smart probe at the same time to display the Main menu. Next, use the Up and Down buttons to
highlight “DIAGNOSTICS” and then press ENT to display the Diagnostics menu.

Main Menu:

SYSTEM

LOG
SETUPS
CAL DATA
DIAGNOSTICS

Diagnostics Menu:

SENSOR DATA

LAST FAULT
IR EMITTER
PRESSURE
LOOP TEST
CLR LAST FAULT
AUTO GAIN

5.1.1 Sensor Data

The Sensor Data screen provides information about the sensor’s operating parameters and its surroundin g
environment. When contacting the Bacharach Service Department, the operator may be asked to provide this
information to help in the troubleshooting process.

To display the Sensor Data screen, first display the Diagnostics menu as described in Section 5.1. Next, use
the Up and Down buttons to highlight “SENSOR DATA” and then press ENT.

Sensor Data Screen Information:

LR ..........................Measured Leak Rate

FAULT ...................Current Numerical Fault Code (refer to Section 5.1.2 Last Fault)

OPEN/CLOSED ....Measure / Search Flow Rate Valve Position

DET ....................... Detector Voltage

N ............................Detector’s Output Noise Factor (with no gas detected)

Z ............................ Stored Zero Voltage of Detector

DET ....................... Detector Temperature

SPPM.....................PPM Corrected to Standard Pressure and Temperature

BOX .......................Enclosure Temperature

M ........................... Manifold Pressure

AMB.......................Ambient Pressure

MPM....................... Moles Per Minute

AU..........................Average Optical Absorbency Unit of Gas being detected (0 = no gas)

PPM........................Parts Per Million value of the Current Detected Gas Level

UML........................Absolute Concentration of Gas in Micro Moles per Liter

Instruction 3015-4342 37

Maintenance H25-IR

5.1.2 Last Fault

The Last Fault screen provides a text description of all current faults being detected by the instrument. Once the
cause of the fault(s) has been cleared, its description is removed from the screen. The name of the last fault,
however, is retained on the screen. This is useful in determining the cause of an intermittent type fault.

To display the Last Fault screen, first display the Diagnostics menu as described in Section 5.1. Next, use the
Up and Down buttons to highlight “LAST FAULT” and then press ENT. If necessary, use the Up and Down
buttons to scroll through the fault list. A list of fault messages along with possible causes and remedies for the
fault is shown below. The numbers in brackets “< >” are the fault numerical codes that appear on the
Diagnostics Sensor Data screen (refer to Section 5.1.1).

TIP: The Last Fault screen can be cleared of all faults per Section “5.1.6 Clear Last Fault”.
Fault Codes are Additive: The fault codes

appearing on the Sensor Data, Diagnostics screen
(refer to Section 5.1.1) are additive. For example: A
fault code of <0810> indicates that both a Search
Flow Fault <0800> and a Loop Open error <0010>
have occurred.

Box Temp Error <0001>: Enclosure temperature
is high. Check that the enclosure is not being
subjected to extreme temperatures. Use the Sensor
Data screen to check the box temperature (refer to
Section 5.1.1).

Bench Temp Error <0002>: Optical bench
temperature is high. Check that the enclosure is not
being subjected to extreme temperatures. Use the
Sensor Data screen to check the box temperature
(refer to Section 5.1.1).

Loop Open <0010>: 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 output
connector (refer to Section 2.8).

Internal CAL Error <0020>: An internal calibration
failure has occurred. Repeat internal calibration
procedure per Section 3.2.

External CAL Error <0040>: An external calibra­tion failure has occurred. Repeat external calibra­tion procedure per Section 3.3.

Digipot Range Error <0200>: The digital
potentiometer circuit is out of its normal operating
range. Call Bacharach Service with this information
for further instructions.

A/D Failure <0400>: A failure has occurred in the
instrument’s analog-to-digital circuitry. Call
Bacharach Service with this information for further
instructions.

Search Flow Fault <0800>: This error occurs in
the search mode when the gas flow through the
detector has significantly changed. Check that the
probe connector is plugged into the instrument, the
probe hose is not kinked, and the filter in the probe
tip is not clogged. Also check for a blocked internal
filter or failed pump.

Measure Flow Fault <1000>: This error occurs in
the measure mode when the gas flow through the
detector has significantly changed. Check that the
probe connector is plugged into the instrument, the
probe hose is not kinked, and the filter in the probe
tip is not clogged. Also check for a blocked internal
filter or failed pump.

No Flow <2000>: Gas flow through the detector
has stopped. Check that the probe hose is not
kinked, and the filter in the probe tip is not clogged.
Also check for a blocked internal filter or failed
pump.

Zero Volt Error <4000>: The detector’s output
voltage may be out of tolerance. Use the Sensor
Data screen to check the detector voltage (refer to
Section 5.1.1). Call Bacharach Service with this
information for further instructions.

A/D Clipping Error <8000>: The detector voltage
may be out of tolerance. Use the Sensor Data
screen to check the detector voltage (refer to
Section 5.1.1). Call Bacharach Service with this
information for further instructions.

Leak Pressure Fault <0100>: A low pressure
condition within the internal leak source has been
detected, possibly due to the leak source being out
of gas. Check that the box temperature sensor is
properly calibrated per Section 5.2.6.3. If leak
source is empty, call Bacharach Service.

38 Instruction 3015-4342

H25-IR Parts & Service

(

)

5.1.3 IR Emitter

The IR Emitter screen provides readouts of the detector’s voltage, current, resistance, and power consumption.
When contacting the Bacharach Service Department, the operator may be asked to provide this information to
help in the troubleshooting process.

To display the IR Emitter screen, first display the Diagnostics menu as described in Section 5.1. Next, use the
Up and Down buttons to highlight “IR EMITTER” and then press ENT.

IR EMITTER PARAMETERS
VOLTS=6.1740 mA=129.5
OHMS=47.7 mW=800.0

5.1.4 Pressure

The Pressure screen provides readouts of bench pressure, ambient pressure, the difference between the two
(delta), flow rate through the bench in moles per minute, and the tank pressure of the internal leak source.
When contacting the Bacharach Service Department, the operator may be asked to provide this information to
help in the troubleshooting process.

To display the Pressure screen, first display the Diagnostics menu as described in Section 5.1. Next, use the
Up and Down buttons to highlight “PRESSURE” and then press ENT.

BENCH  AMB DELT

11.73 14.04 2.3 1
FLOW=0.00950Mpm
LEAK PSI=102.1

100.2

This screen also allows a technician to manually turn the pump ON and OFF, along with manually controlling
the position of the measure/search flow-rate valve.

Pressing the Down button toggles the pump ON and OFF.
Pressing the Left button opens and closes the measure/search flow-rate valve. An asterisk () on the display

indicates that the valve is in its measure position.

5.1.5 Loop Test

The Loop Test screen allows the operator to force the instrument’s 4–20 mA loop output to 0, 4, 10, or 20 mA.
This function is useful for checking the calibration of external monitoring equipment such as chart recorders.

To display the Loop Test screen, first display the Diagnostics menu as described in Section 5.1. Next, use the
Up and Down buttons to highlight “LOOP TEST” and then press ENT.

LOOP TEST
DOWN=0ma UP=20ma
LEFT=4ma RIGHT=10ma
ESC TO QUIT

Press the Up, Down, Left, and Right buttons to produce the desired output current. Press ESC to return to the
Diagnostics menu.

5.1.6 Clear Last Fault

The Last Fault screen normally displays the last fault detected by the instrument, even if the fault no longer
exists. This is useful in determining the cause of an intermittent type fault.

To clear the Last Fault screen of all faults: first display the Diagnostics menu as described in Section 5.1; use
the Up and Down buttons to highlight “CLR LAST FAULT”; press ENT; and then confirm this action by pressing
the Up button.

Instruction 3015-4342 39

Parts &Service H25-IR

5.1.7 Auto Gain

DIGIPOT=197
IR VOLT=4.2000

IMPORTANT! The instrument must be sampling fresh air (zero gas) when the Auto Gain function is selected.

Selecting the Auto Gain function automatically sets the IR Detector’s voltage to its baseline 0 ppm level by
controlling the instrument’s digital potentiometer (DIGIPOT) circuit.

5.2 Factory Menu

The Factory menu is used to set up or troubleshoot the instrument. This menu appears only when activated by
factory personnel or service technicians who know the correct activation procedure.

When activated, display the Factory menu by first pressing both the ENT and ESC buttons on either the
instrument’s front panel or Smart probe at the same time to display the Main menu. Next, use the Up and Down
buttons to highlight “FACTORY” and then press ENT to display the Factory menu.

Main Menu:

SYSTEM

LOG
SETUPS
CAL DATA
DIAGNOSTICS
FACTORY

Factory Menu:

DIGIPOT
LEAK RATE
LEAK GAS
LEAK TEMP
LEAK TEMPCO
SENSOR CAL
MODEL SELECT
PROBE TYPE
FIRMWARE

5.2.1 DIGIPOT

DIGIPOT=197
IR VOLT=4.2000

IMPORTANT! The instrument must be sampling fresh air (zero gas) when adju sting the DIGIPOT value.

The DIGIPOT function allows manual and a more precise adjustment of the digital potentiometer, which
controls the voltage of the IR Detector. Use the Up and Down buttons to adjust DIGIPOT value until the IR
VOLT reading is 4.200 ±0.0500 volts. Press ENT to save the new DIGIPOT value.

5.2.2 Leak Rate

LEAK RATE 25.5 g/yr

The Leak Rate value is set to match the leak rate of the internal leak source as indicated on the tag attached to
the leak source. Use the Left and Right buttons to move the blinking cursor across the screen to highlight the
digit to be modified, and then use the Up and Down buttons to modify that digit. Press ENT to save the new
Leak Rate value.

40 Instruction 3015-4342

H25-IR Operation

IMPORTANT! Be sure to enter the leak rate using the same units of measure as displayed on the LEAK RATE
screen. In this example, the units of measure is g/yr. If your leak source is marked in Oz/yr, then multiply that
value by a factor of 28.35. For example: If the leak source is marked 0.9 Oz/yr, then enter a leak rate of (0.9 x

28.35=) 25.5 g/yr.

5.2.3 Leak Gas

LEAK GAS < R134A
R401A
R402A
< R402B

The Leak Gas setting is set to match the gas contained in the internal leak source as indicated on the tag
attached to the leak source. Use the Up and Down buttons to highlight the correct gas, and then press ENT to
select that gas.

5.2.4 Leak Temp

LEAK TEMP 0 23.9degC

The Leak Temperature value is set to match the temperature of the internal leak source at its time of
manufacture as indicated on the tag attached to the leak source. Use the Left and Right buttons to move the
blinking cursor across the screen to highlight the digit to be modified, and then use the Up and Down buttons to
modify that digit. Press ENT to save the new Leak Temp value.

5.2.5 Leak TEMPCO

LEAK TEMPCO 0.54
%/degC

The Leak Temperature Coefficient value is set to match the temperature coefficient of the internal leak source
as indicated on the tag attached to the leak source. Use the Left and Right buttons to move the blinking cursor
across the screen to highlight the digit to be modified, and then use the Up and Down buttons to modify that
digit. Press ENT to save the new Leak Temperature Coefficient value.

TIP: To convert a temperature coefficient from % /
example: 0.3%/

o

F x 1.8 = 0.54%/oC.

o

F to % oC, multiply the oF value by a factor of 1.8. For

5.2.6 Sensor Cal

PRESSURE

FLOW RATE
BOX TEMP

The Sensor Calibration function allows the service technician to manually calibrate the instrument’s Pressure,
Flow Rate, and Box Temperature sensors. Use the Up and Down buttons to highlight the sensor to be
calibrated, and then press ENT to display that sensor’s calibration screen.

5.2.6.1 Pressure Sensor Calibration Screen

ENTER AMBIENT PSIA

14.18

CURRENT OFFSET=0.00

Calibrate the pressure sensor by first measuring the ambient atmospheric pressure using an appropriate
pressure measurement device calibrated to read PSIA. Next, adjust the value displayed on the Pressure
Sensor Calibration screen to match the measured pressure reading by using the Left and Right buttons to

Instruction 3015-4342 41

Parts &Service H25-IR

move the blinking cursor across the screen to highlight the digit to be modified, and then using the Up and

Down buttons to modify that digit. Press ENT to save the new ambient pressure value.
Tip: To convert inHg into PSIA, multiply inHg by 0.491. For example: 30.00 inHg x 0.491 = 14.73 PSIA.

5.2.6.2 Flow Rate Sensor Calibration Screen (Factory Calibration)

S-Mpm/dP M-Mpm/dP

INT 0.0177/-1.33 0.0100/-2.28
FAC 0.0177/-1.33 0.0100/-2.28
ENTER TO SAVE INT AS FACTORY

Set the default factory calibration flow and pressure drop values by first performing an internal calibration as
described in Section 3.2 Internal Calibration.

INT: Flow rate in moles/minute for both the Search and Measure modes after performing a calibration usi ng the
internal leak source, along with showing the manifold’s pressure drop.

FAC: Flow rate and pressure drop values that are currently stored as the default factory calibration values.
These values are used to validate calibrations performed by the operator. A calibration error will occur if the
operator’s calibration and factory values differ by more than 20%.

Press ENT to store the internal calibration numbers as factory values. These are the calibration values that are
reset when RESTORE FACTORY CAL is selected from the CAL Data menu (refer to Section 3.5 Restoring
Factory Calibration).

5.2.6.3 Box Temperature Calibration Screen

ENTER BOX TEMP degC

28.41

OFFSET=0.18 LEAK=28.41

In order to accurately determine when the internal leak source is running out of gas, the enclosure’s
temperature sensor must match the temperature of the leak source, as computed using the pressure/
temperature curve for the gas contained in the leak source and the measured pressure of the leak source.

Before making this adjustment, all enclosure lids must be in place and the instrument must be allowed to warm
up for at least 30 minutes.

Next, adjust the value displayed on the Box Temperature Calibration screen to match the calculated “LEAK”
temperature as displayed in the lower-right corner of the screen. In the example above, set the box temperature
for a reading of 28.41 by using the Left and Right buttons to move the blinking cursor across the screen to
highlight the digit to be modified, and then using the Up and Down buttons to modify that digit. Press ENT to
save the new box temperature value. Note that the “OFFSET” value is the difference between the box
temperature sensor reading, and the box temperature reading adjusted to match the leak source temperature.

5.2.7 Model Select

MODEL SELECT
< 3015-4348 R134A
3015-4464 R600A
< 3015-4465 R600A

The Model Select function is used to set up the instrument’s operating characteristics as defined by its Part
Number (refer to Appendix “A”). Use the Up and Down buttons to select the appropriate Part Number (as
marked on the instrument’s rear panel). Press ENT to activate the selection.

42 Instruction 3015-4342

H25-IR Operation

5.2.8 Probe Type

PROBE TYPE
STD 6ft
STD 12ft
SMART 6 ft
SMART 12 ft

Use the Probe Type function to select the probe type that is connected to the instrument. Use the Up and
Down buttons to select the appropriate probe type. Press ENT to activate the selection. Refer to Sections 1.7.4,

1.7.5, and 1.7.6 for descriptions of available probe types.
In the example below, a Smart 6 ft probe has been selected. A message is also displayed warning that if the

probe type is changed the instrument must be recalibrated, and the new calibration value must be save d as the
default factory calibration as described in Section 5.2.6.2.

SMART 6ft SELECTED
IF CHANGED, YOU MUST
RESET FACTORY CAL

5.2.9 Firmware

REV x.xx COMPILED ON
Month Day Year
At hh:mm:ss

The Firmware screen displays the firmware’s revision number, date, and time of compilation.

5.3 Flashing Memory

As updates to the instrument’s firmware become available, the instrument can be upgraded by flashing its
memory as described below.

IMPORTANT! After flashing memory, all operating parameters and sensor calibrations are erased. The
operator must
instrument back into operation:

- DIGIPOT

- Leak rate of internal leak source

- Leak gas of internal leak source

- Leak temperature of internal leak source

- Leak temperature coefficient of internal leak source

- Pressure sensor calibration

- Flow rate sensor calibration

- Box temperature sensor calibration

Items Required:

 9-pin-Female to 9-pin-Male Serial Cable (P/N 104-4027)
 Flash Utility Software and Latest Firmware Image File

 Personal computer:

have access to the Factory menu in order to set up the following parameters before placing the

(downloaded from Website http://www.mybacharach.com/downloa ds.htm)

o Running Windows

®

95/98/2000/NT/XP/Vista

o Open COM port

Procedure:

1. Connect one end of a 9-pin female to 9-pin male serial cable to the instrument’s rear-panel
RS-232 connector.

2. Connect the other end of the cable to and an open COM port connector on the computer (it may be
necessary to use a 9-pin to 25-pin adapter to make the computer connection).

Instruction 3015-4342 43

Parts &Service H25-IR

NOTE: COM1 is the default port used by the Flash Memory Program. If COM1 is already in use by
another device, then connect the instrument to the next available COM port. The software will need to
be reconfigured as described in Step 9 to use this port.

3. With the instrument turned OFF, set DIP switches 1, 2, and 3 located on the instrument’s rear panel to
their UP positions.

4. Turn ON the instrument. Observe that the pump does not start and that the front panel display does not
light.

NOTE: The following steps assume that the operator is familiar with the Windows Operating System, and is
knowledgeable in creating folders, copying files, and navigating the file system using Windo ws Explorer. If
necessary, refer to the Windows help files for information on performing these operations.

5. Create a folder on the computer’s hard drive named “C:\RFU” (Rabbit Field Utility).

6. Copy the flash utility software and the latest firmware image file (xxx.bin – where “xxx” is the name and
version number of the file) into the folder created in Step 5.

7. From the C:\RFU folder, run the flash memory program by
double clicking the file rfu.exe.

8. Select Setup > Communications.

9. Under “Serial Options”, select Use Serial Connection. Then
set the Baud Rate to 115200, and select Enable Processor
Detection.

Note that COM1 is the default Comm Port. If necessary,
change the Comm Port to match the port that the instrument
was connected to in Step 2.

Click OK.

44 Instruction 3015-4342

H25-IR Operation

10. Select Setup > File Locations and verify that the
coldload.bin, pilot.bin, and flash.ini files are all located in the
C:\RFU folder.

Click OK if these files are in the correct folder. If necessary,
use the browse buttons in the Choose File Locations dialog
box to locate each of these files.

11. Select File > Load Flash Image.

12. Click the browse button in the Choose Flash Image
dialog box; navigate to the C:\RFU folder; and then
highlight the bin file of the new firmware’s flash image
file. In this example, the file H25IR 1_20.bin will be
loaded.

Click Open.

13. Click OK to begin the flashing process.

14. A progress-dialog box will appear during the flashing
process, and will disappear when the flashing process is
complete.

15. When flashing is complete: Exit the flash program; turn

OFF the instrument; remove the serial cable; and reset
the DIP switches back to their normal operation
positions.

Instruction 3015-4342 45

Parts &Service H25-IR

16. Turn ON the instrument. The following message should appear:
FULL SYSTEM RESET!

SELECT MODEL FROM
FACTORY MENU AND
REINIT ALL DATA/CALS

NOTE: Flashing memory with the same firmware version will not cause the instrument to reset.
After flashing memory, the instrument will perform a complete system reset, causing all system

parameters and sensor calibration data to be erased! Complete the flashing process by setting all the

parameters contained in the Factory menu (refer to Section 5.2 Factory Menu).

5.4 Part Replacement

WARNING! Shock Hazard. Before performing any service work, remove the AC

power cord or battery to prevent electrical shock.

Part replacement is limited to replacing filters, O-rings, and fuses. It is recommended that all other parts be
replaced by an authorized Bacharach Service Center (refer to Section 5.6 Service Centers).

5.4.1 Removing the Top Cover

When servicing the parts inside the instrument, the instrument’s top cover is removed as follows:

Items Required:

 Medium Phillips head screwdriver

Procedure:

1. Remove both the front and rear bezels by first disengaging the plastic tabs on the right and left sides of
the bezel, and then pulling the bezel straight out.

2. Remove the two top screws that secure the front panel.

3. Remove the four screws that secure the rear panel.

4. Remove the Relay, RS-485, and 4–20mA connectors from the rear panel. DO NOT remove any
connector on the interior side of the rear panel.

46 Instruction 3015-4342

H25-IR Operation

5. Drop down the rear panel far enough to allow the top cover to clear, being careful not to stress the
cables attached to the inside of the panel.

6. Remove top cover by sliding it toward rear of instrument.

5.4.2 Fuse Replacement

The H25-IR is protected from electrical damage by a single 1 A fuse located next to the AC receptacle at the
rear of the instrument.

Items Required:

 Small flat-blade screwdriver
 Fuse (spare fuse located in fuse holder)

Procedure:

1. Remove AC power cord or battery from instrument.

2. Using a small flat-blade screwdriver, carefully pry the fuse holder out
from the fuse compartment.

3. Inspect the fuse for damage or check its continuity. Replace the fuse
as necessary.

5.4.3 Probe Tip Filter & O-Ring Replacement

A filter located in the probe tip is the instrument’s first line of defense against dust, dirt, and moisture from
entering the instrument’s internal plumbing and IR detector. Replace this filter as it becomes dirty. A clogged
filter is identified by a “Search Flow Fault,” “Measure Flow Fault,” or a “No Flow” fault occurring. Refer to
Section 4.3 Fault .

Periodically inspect the probe tube’s O-ring for signs of cracking. If this O-ring becom es defective, air could be
drawn into the instrument through the bottom of the probe tube resulting in inaccurate measurements.

Items Required:

 Probe Tip Filter: Bag of 50: 0.287 in. diameter (7.2 mm)
 Probe Tube O-Ring
 Pin or Tweezers

Procedure:

1. Unscrew probe tip.

2. Pick out old filter with a pin or tweezers.

3. Insert new filter inside probe tip.

4. Replace probe tip.

5. Unscrew probe tube and inspect O-ring. Replace O-ring if defective.

6. Reattach probe tube.

Instruction 3015-4342 47

Parts &Service H25-IR

5.4.4 Internal Filter Replacement

A filter located inside the instrument may become blocked due to dust or water being drawn into the instrument.
A blocked filter is identified by a “Search Flow Fault,” “Measure Flow Fault,” or a “No Flow” fault occurring. Refer
to Section 4.3 Fault .

Items Required:

 Replacement filter (P/N 3015-4415)
 Medium Phillips head screwdriver

Procedure:

1. Remove the instrument’s top cover as described in Section 5.4.1 Removing the Top Cover.

2. Remove the old filter by pulling off the tubing attached to the filter’s inlet and outlet ports.

3. Install the tubing removed in Step 2 onto the new filter.

4. Reassemble the instrument.

5.4.5 Optical Bench Replacement

These instructions describe how to replace the IR Optical Bench in the H25-IR Infrared Gas Leak Detector.
It is assumed that the user is familiar with the operation and menu system of the H25-IR. If necessary, refer to

Instruction 3015-4342 for detailed operation and maintenance information.

Items Required:

 Replacement IR optical bench kit:*
(800 mW)

o CFC, HCFC, HFC & Halogen gases ...... 3015-4253 3015-5086

o R600 ....................................................... 3015-4453 3015-5089

o SF
o CO

..........................................................3015-4282 3015-5087

6

.........................................................3015-4605 3015-5090

2

 Medium Phillips head screwdriver
 Small flat blade screwdriver
 Wire cutter (for removing cable ties)

* Kit contains IR Bench of gas being detected, cable ties (Qty. 2), and this instruction sheet

48 Instruction 3015-4342

(450 mW)

H25-IR Operation

5.4.5.1 Top Cover Removal

(See section 5.4.1 Removing the Top Cover)

5.4.5.2 Installing the New IR Optical Bench

1. Carefully remove tubing and electrical connectors from old IR bench. See illustration below.

2. Cut off two cable ties that secure IR bench to chassis, and remove bench from instrument.

3. Place new IR bench inside chassis, positioning its 10-pin electrical connector to ward the rear

instrument. Rotate the bench so that its gas inlet and outlet fittings and its electrical connectors are
positioned as shown in the illustration below.

4. Remove protective caps from the gas inlet and outlet fittings of the new IR bench.

5. Connect the 12-conductor ribbon cable from IR SOURCE connector J5 on main board to IR bench

emitter connector (front of instrument).

6. Connect the 10-conductor ribbon cable from DET connector J6 on main board to IR bench detector

connector (rear of instrument).

7. Using the two supplied cable ties, secure the IR bench to the chassis by threadin g each cable tie

through its cable-tie mount; around the foam insulation that surrounds the IR bench; and around the
12-conductor ribbon cable. Cut off the cable-tie excess.

8. Connect tubing from pump to the IR bench gas inlet fitting, and connect the IR bench gas outlet

fitting to the instrument’s exhaust port as shown below.

of the

5.4.5.3 IR Emitter Adjustment

WARNING! SHOCK HAZARD. When performing the following step, be careful not to come in contact
with AC voltages when working inside the instrument with the cover off and AC voltage applied.

1. Reconnect the AC power cord, and then turn the instrument ON while holding down the front panel

ENT button to enable the Factory menu

2. Wait until the instrument warms up and the Data Display screen appears before proceeding.

Instruction 3015-4342 49

Parts &Service H25-IR

3. Press the ENT and ESC buttons simultaneously to access the Main menu. From the Main menu,
select DIAGNOSTICS > IR EMITTER to display the IR Emitter Parameters screen.

4. Adjust potentiometer R37 located on the main board for an IR Emitter reading of 800 ±20 or 450
±20 mW, corresponding to the user’s version of part as seen in the items required section
containing the part numbers.

IR EMITTER PARAMETERS
VOLTS=5.7345 mA=77.5
OHMS=75.0 mW=450.0

NOTE: Readings for the other

parameters on this screen may vary.

5.4.5.4 DIGIPOT Adjustment

1. Press ESC twice to return to the Main menu. From the Main menu, select FACTORY > DIGIPOT to
display the DIGIPOT screen.

IMPORTANT! When performing the following Step, the instrument must be sampling fre sh air
(zero gas) when adjusting the DIGIPOT value.

2. Use the Up and Down buttons to adjust the DIGIPOT value until the IR VOLT reading is

4.2000 ±0.0500 volts. Press ENT to save the new DIGIPOT value.

IMPORTANT! If adjusting the DIGIPOT does not reach 4.2000 ±0.0500 volts then return to stepn 18 to

lower the IR Emitter setting. IF the IR Emitter setting is 450 ±20 mW adjust the IR
Emitter setting to 375 ±20 mW. Next, repeat the DIGIPOT adjustment.

DIGIPOT=220
IR VOLT=4.2000

3. Turn OFF instrument and remove AC power cord.

4. Reassemble instrument.

5.4.5.5 Factory Calibration

NOTE: Factory calibration establishes the instrument’s default calib ration setting that is recalled when
“RESTORE FACTORY CAL” is selected from the CAL DATA menu.

1. With all covers in place, turn the instrument back ON while holding down the front panel ENT button to
enable the Factory menu.

IMPORTANT: Before calibrating, allow the instrument to warm up for at least 15 minutes.

2. Perform an internal calibration as described in the H25-IR instruction manual, 3015-4342.

50 Instruction 3015-4342

H25-IR Operation

3. After the instrument has been calibrated, store the flow and pressure calculations of that calibration as
the default factory calibration values as follows:

a) Press the ENT and ESC buttons simultaneously to access the Main menu. From the Main

menu, select FACTORY > SENSOR CAL > FLOW RATE to display the Flow Rate and
Pressure screen:

S-Mpm/dP M-Mpm/dP

INT 0.0177/-1.33 0.0100/-2.28
FAC 0.0177/-1.33 0.0100/-2.28
ENTER TO SAVE INT AS FACTORY

INT: This line shows the flow rate in moles/minute for both the Search and Measure modes
after performing a calibration using the internal leak source, along with showi ng the manifold’s
pressure drop.

FAC: This line shows the flow rate and pressure drop values that are currently stored as the
default factory calibration values. These values are used to validate calibrations performed by
the user. A calibration error will occur if the user’s calibration and factory values differ by more

than 20%.
b) Press ENT to store the internal calibration numbers as the default factory calibration values.
c) Press ESC until the Data Display screen appears.

This completes replacing the IR Optical Bench.

Instruction 3015-4342 51

Parts &Service H25-IR

5.5 Replacement Parts

Item Description Part Number

Complete Instrument ...............................................................................Refer to Section 1.3

Ordering Information

H25-IR Unit:

CFC, HCFC, HFC & Halogen gases..................................................3015-4348

R600a.................................................................................................3015-4464

SF
Standard Probe Assembly:

6 ft (1.8 m) hose.................................................................................3015-4635

12 ft (3.7 m) hose...............................................................................3015-4636

Standard Probe w/ pushbutton and LED Assembly:

6 ft (1.8 m) hose.................................................................................3015-4639

12 ft (3.7 m) hose...............................................................................3015-4640

Smart Probe w/ pushbuttons and LCD Assembly:

6 ft (1.8 m) hose.....................................................................................19-7113

12 ft (3.7 m) hose...................................................................................19-7114

Flexible Probe Tube Assembly (Stainless Steel)

Full Assembly - 8 in (203 mm).................................................. ……….3015-5136

Filters – Located in Probe Tip (50) ........................................... ……….3015-5135

Probe Tip…............................................................................... ……….3015-5099

O-Ring, Probe Tube..……….....................................…………................ 0005-5108

.....................................................................................................3015-4477

6

Bezel, Case...............................................................................................3015-4670

AC Power Cord...........................................................................................304-3459

Battery .....................................................................................................0204-0020

Fuse, 1A......................................................................................................604-2610

Flexible Probe Tube Assembly (Plastic)
Filters:
Located in probe tip:

Pack of 10....................................................................................3015-4515

Pack of 50....................................................................................3015-4516

Located inside instrument................................................................3015-4415

Probe Tip .............................................................................................3015-4629

Spring Switch Replacement Kit ................................................................3015-5169

52 Instruction 3015-4342

H25-IR Operation

5.6 Service Centers

Service and replacement parts can be obtained by contacting one of the following Bacharach Service Centers:

United States

Bacharach, Inc.
621 Hunt Valley Circle
New Kensington, PA 15068
Phone: [phone]
Fax: [phone]
Email: [e-mail]

Canada

Bacharach of Canada, Inc.
20 Amber Street Unit #7
Markham, Ontario L3R SP4 Canada
Phone: [phone]
Fax: [phone]
Email: [e-mail]

Instruction 3015-4342 53

H25-IR Specifications

6 Troubleshooting

H25 I R FA UL T C O D E T R O UB L E S HO O T E R

0001 BOX TEMP ERROR

Inside chassis

temperatures greater than

55degC or less

than -5degC

YES

Move to cooler or warmer environment

to correct

0002 BENCH TEMP ERROR

Bench temp

sensor grea ter than

55degC or less

than -5degC

NO

Does fault code

Also Indicate A/D failure

YES

A/D defective

(other faults will also result)

Replace motherboard

Bacharach Inc. CONFIDENTIAL for internal use on ly

H25 IR FAULT CODE TROUBL E SHOOTER

NO

Is detector ribbon

cable disconnect ed

on either end?

0400?

NO

NO

Temp sensor defective

Replace motherboard

Bad detector PCB

Replace opt ic al sens or

YES

Connect detector end

of a new bench with existing

cable. Is temperature

Normal?

YES

Move to cooler or warmer environment

to correct

YES

Reconnect cable and hot glue in place

Bad ribbon cable, replace

YES

NO

Replace detector ribbon cabl e

And retest

Temperature reading

corrected with new

cable?

NO

Bad SPI Bus connection,

Replace motherboard

Bacharach Inc. CONFIDENT IAL for internal use only

Instruction 3015-4342 54

H25-IR Operation

H25 IR FA ULT CODE TROUBLE SHOOTER

0004 M AN IFOLD

PRESSURE SENSOR ERROR

Manifold pressure

Is greater than 16.0psia

or less th an 3.0psia

YES

Correct over or under pressure

Condition, check probe input and

exhaust output for pressure or

vacuum

Manifold pressure

NO

Bad Pressure transducer

Replace motherboard

Does fault code

Also Indicate A/D failure

0400?

YES

A/D def ective

(other faults will also result)

Replace mo therboard

Bacharach Inc. CONFID ENTIAL for internal use only

NO

NO

Fault cleared?

Snubberorifice blocke d
Replace purpl e snub ber

Stored atmospheric

pressure

0010 LOOP OPE N

Shorting jumper on

Current loop connector

Is missing or loop

resistance
>500ohms

YES

Reconnect Jumper or reduce

Loop resistance

H25 IR FA ULT CODE TROUBLE SHOOTER

NO

Shorting jumper is

Connected?

YES

Does fault code

Also Indicate A/D failure

0400?

YES

A/D def ective

(other faults will also result)

Replace mo therboard

NO

NO

Retest with shorting jumper in place

of loop

Loop circuit defective

replace motherboard

Bacharach Inc. CONFID ENTIAL for internal use only

Instruction 3015-4342 55

Specifications H25-IR

0020 INTERNAL

CAL ERROR

Indicates one or more of the 4 flow

paramete rs collected during the internal

cal cycle, deviate from the “factory” value

by 25% or more

H25 I R FA UL T C O D E T R O UB L E S HO O T E R

Fix loose or broken connection

And recalibrate

YES NO

Break in sample line

In probe assembly

NO

Probe remove d duri ng

Cal cycle

YES

Repeat internal cal cycle

Bad or weak pump

YES

Replace pum p and stor e

New “Factory” calibration

0040 EXTERNAL

CAL ERROR

Indicates leak rate too low during

External calibration cycle

NO

Probe tip filte r

clogged

YES

Replace probe fi lter and recalibr ate

NO

Break or restriction in

Internal plum bi ng

YES

Correct and recalibrate

Bacharach Inc. CONFIDENT IAL for internal use only

H25 I R FA UL T C O D E T R O UB L E S HO O T E R

NO

Internal filter clogged

YES

Replace internal filter and store

new “factory” calibration

NO

Internal leak empty or
Defective (check leak

Pressure)

YES

Replace internal leak, enter new leak

Parameters in cal menu and store

New “factory cal”

Probe removed or

too far from leak during

Cal cycle

YES

Repeat external cal cycle

NO

External leak rate too

Low or empty

NO

YES

Correct and recalibrate

Bad or weak pump?

Check flow on

exhaust

NO

YES

Replace pump and store

New “Factory” calibration

Bacharach Inc. CONFIDENT IAL for internal use only

Break in sample line

In probe assembly

YES

Fix loose or broken connection

And recalibrate

Break or restriction in

Internal plumbing

YES

Correct and recalibrate

NO

NO

56 Instruction 3015-4342

H25-IR Operation

H25 I R FA UL T C O D E T R O UB L E SHO O T E R

0100 LEAK PRESSURE FAULT

Internal leak press ure tra nsducer reports a

pressure that deviates more that 15%

from the pressure predicted from the

box temperature sensor and the pressure

temperature curve for the leak gas type

DIAGNOSTIC / PRESSURE SCREEN

Recalibrate box temp sensor

In factory ‘sensors’ menu

Leak transducer

pressure

YES NO

Pressure derived

from box

temperature

Bad factory temperature

calibration

NO

Internal leak is low

Or empty

YES

Replace internal leak, enter new leak

Parameters and store new “factory”

calibration

0200 DIGIPOT R A NGE ERROR

Gain adjustment of digital potentiometer was

below the minimum value of 150

NO

Leak pressure transd ucer

Cable disconnected

YES

Reconnect or repair cable/connector

Defective pressure transducer

Replace internal leak, enter new

Leak parameters and store

New factory cal

H25 I R FA UL T C O D E T R O UB L E S HO O T E R

Weak emitter, replace optical sensor

Assembly, reset digipot, re-cal

box temp sensor and store new

Factory calibration

YES

Or faulty

NO

Does fault code

Also Indicate A/D failure

0400?

YES

A/D defective

(other faults will also result)

Replace motherboard

NO

Wrong gas type specified

In factory menu for

Internal leak

YES

Correct entry to match tag on leak

Bacharach Inc. CONFIDEN TIAL for internal use only

Sensor voltage is zero

Or near zero

YES

IR Emitter resistance

Show **.* in diagnostic

Emitter screen

YES

Emitter cable loose

Or disconnected

YES

NO

NO

Sensor voltage below

4.2 volts

Detector cable loose

Or disconnecte d

NO

YES

Reconnect cable and readjust digipot

In factory menu

NO

IR Emitter burned out, replace Optical sensor assembly, reset

digipot,re-cal box temp sensor and store new Factory calibration

Reconnect cable and readjust digipot

In factory menu

Set digipot to 151 and go to beginning

Emitte r OK

Emitter burned out or
cable discon nected

Bacharach Inc. CONFIDENT IAL for internal use only

Instruction 3015-4342 57

Specifications H25-IR

H25 I R FA UL T C O D E T R O UB L E S HO O T E R

0800 SEARCH FLOW FAULT

Indicates current pressure drop in se arch

Mode deviates from the value store during

The last calibration cycle by more than

20%

Too long since last cal
And ambient pressure

Or filter flow has

changed

YES

Repeat cal cycle

Fix loose or broken connection

And recalibrate

NO

Probe tip filte r

clogged

YES

Replace probe fi lter and recalibr ate

Bad or weak pump

YES

Replace pu mp and store
New “Factory” calib ration

Bacharach Inc. CONFIDENT IAL for internal use only

H25 I R FA UL T C O D E T R O UB L E S HO O T E R

YES NO

Break in sample line

In probe assembly

NO

NO

Internal filter clogged

YES

Replace internal filter and store

new “factory” calibration

NO

Break or restriction in

Internal plumbing

Or exhaust

YES

Correct and recalibrate

NO

1000 MEASURE FLOW FAULT

Indicates current pressure drop in measure

Mode deviates from the value store during

The last calibration cycle by more than

10%

Too long since last cal
And ambient pressure

Or filter flow has

changed

YES

Repeat cal cycle

Fix loose or broken connection

NO

Probe tip filte r

Replace probe fi lter and recalibr ate

Replace pu mp and store
New “Factory” calib ration

Bacharach Inc. CONFIDENT IAL for internal use only

And recalibrate

clogged

YES

Bad or weak pump

YES

YES NO

Break in sample line

In probe assembly

NO

NO

Internal filter clogged

YES

Replace internal filter and store

new “factory” calibration

NO

Break or restriction in

Internal plumbing

Or exhaust

YES

Correct and recalibrate

NO

58 Instruction 3015-4342

H25-IR Operation

H25 I R FA UL T C O D E T R O UB L E S HO O T E R

4000 ZERO VOLT ERROR

Indicated the sensor voltage stored during

auto or manual zero was less that

3.9V or greater than 4.5V

Sensor voltage is zero

Or near zero

YES

IR Emitter resistance

Show **.* in diagnostic

Emitter screen

YES

Emitter cable loose

Or disconnected

YES

8000 A/D CLIPPING ERROR

Indicates the sensor output

voltage is greater than 4.55V

NO

NO

Adjust sensor voltage with digipot in

Factory menu to 4.2V ±0.05V

Detector cable loose

Or disconnecte d

YES

Reconnect cable and readjust digipot

In factory menu

NO

IR Emitter burned out, replace Optical sensor assembly, reset

digipot,re-cal box temp sensor and store new Factory calibration

Reconnect cable and readjust digipot

In factory menu

H25 IR FA ULT CODE TROUBLE SHOOTER

DETECTOR CA BL E

CHECK B OTH ENDS

EMITT ER CABL E

CHECK BOTH ENDS

Bacharach Inc. CONFID ENTIAL for internal use only

Was new optical sensor

Just installed

NO

Adjust sensor voltage with digipot in

Factory menu to 4.2V ±0.05V

YES

Adjust Emitter power in diaganostic/

IR Emitter screen, per instructions

With new sensor

Adjust sensor voltage with digipot in

Factory menu to 4.2V ±0.05V

Store new “factory” c al

Bacharach Inc. CONFID ENTIAL for internal use only

Instruction 3015-4342 59

Specifications H25-IR

7 Specifications

Gases Detected.........................Detects and measures, depending on instrument’s part number:

• CFCs, HCFCs, HFCs and Halogens
R11, R12, R21, R22, R23, R113, R114, R123, R124, R125, R134a, R227,
R236fa, R245fa, R401A, R402A, R402b, R404A, R407A, R407C, R408A,
R409A, R410A, R422a, R422d, R427a, R500, R502, R503, R507, R508B, HFP,
H1211, H1301, H2402, N1230, FA188, FC72

• R600a

• SF

Detection Method....................... Infrared

Measurement Units....................oz/yr, g/yr, mL/s, PaM

Measurement Range.................0.03 to 5.00 oz/yr

Operating Modes.......................Search: detects presence and location of gas leaks

Response Time.......................... Up to 2.5 seconds (dependent on probe-hose length)

Sensitivity...................................0.03 oz/yr (0.9 g/yr) all gases

Resolution.................................. 0.1 leak units

Accuracy:

Leak Rate..............................±15% of the reading (certified leak source uncertainty)

±1% of reading (instrument uncertainty)

PPM ...................................... ±10% of reading (can be improved to ±1% if recalibrated using a known

Temperature Drift....................... ±0.3% of reading per °C

Calibration.................................. Internal: calibration performed using the unit’s built-in leak source

Relays........................................ Four SPDT relays (rated 2 A at 250 VAC – inductive and 5 A at 250 VAC –

Audio Speaker ...........................Audible indication of leak level

AC Power...................................100 to 240 VAC, 50/60 Hz

Battery........................................16V

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

Warm-Up Time...........................2 minutes (30 minutes to meet published specifications)

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

Storage Temperature.................4 to 122 °F (20 to 50 °C)

Ambient Humidity.......................5 to 90% RH, non-condensing

Dimensions................................4 x 10.75 x 15.5 in.

Weight........................................18 lb (8.2 kg)

6

3

/s, ppm

0.85 to 142 g/yr

0.08 x 10

0.08 x 10

–4

to 100 x 10

–5

to 100 x 10–5 PaM3/s

–4

mL/s

0 to 1,000 ppm

Measure: calculates and displays leak rate

concentration of refrigerant gas)

External: calibration performed using a customer supplied leak
source of a known gas type and leak rate

resistive)), each programmable to energize under 11 different operating
conditions

(101.6 x 273.1 x 393.7 mm)

60 Instruction 3015-4342

H25-IR Operation

Notes:

Instruction 3015-4342 61

H25-IR Appendix A

APPENDIX A – Factory Defaults

Table A-1 lists the factory default parameters that are determined by the instrument’s part number (as marked
on the rear panel), while Table A-2 lists the default parameters that are user definable.

Table A-1. Default Parameters Defined by Part Number

Part No. Gas Type Leak Units Range PCHK Mode Leak Source

3015-4348 R134a* Oz/yr Small Auto Internal
3015-4434 R600a g/yr Small At CAL Internal
3015-4448 R134a* g/yr Small At CAL Internal
3015-4455 R600a g/yr Small At CAL External
3015-4464 R600a Oz/yr Small Auto Internal
3015-4465 R600a Oz/yr Small Auto External
3015-4475 R134a* g/yr Small At CAL External
3015-4477 SF6 Oz/yr Small Auto Internal
3015-4479 SF6 Oz/yr Small Auto External
3015-4485 R134a* Oz/yr Small Auto External
3015-4487 SF6 g/yr Small At CAL Internal
3015-4489 SF6 g/yr Small At CAL External
3015-4578 R134a* g/yr Small At CAL Internal
3015-4588 R600a g/yr Small At CAL Internal
3015-4589 SF6 g/yr Small At CAL Internal
3015-4659 R134a* g/yr Small At CAL External
3015-4660 R600a g/yr Small At CAL External
3015-4661 SF6 g/yr Small At CAL External
3015-4800 SF6 mL/s Small Auto Internal

This instrument is capable of detecting CFC, HCFC, HFC and Halogen g ases
other than R134a. Refer to Section 6 Troubleshooting for a complete list of gases.

Table A-2. Default Parameters Defined by User

Parameter Default Setting

Relays...............................NOT USED

Loop..................................0.016 ppm

Setup Name......................SETUP NO. 1

SETUP NO. 2
SETUP NO. 3
SETUP NO. 4

Feedback Mode................CONTINUOUS

Setpoint.............................00.0000

Log Limit...........................999.00

All of the above parameters can be reset to their default settings as described in Section 2.5.9 Reset Defaults.

Instruction 3015-4342 62

H25-IR Operation

621 Hunt Valley Circle, New Kensington, PA 15068

Ph: 724-334-5000 • Fax: [phone] • Toll Free: 1-800-736-4666

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

Headquarters:

Printed in U.S.A.

Instruction 3015-4342 63