Bacharach MGD-100 Operating Manual

Gas Detector and Controllers

Installation and Operation Manual

Instruction 6109-9000

Revision 4 – June 2014

Product Leadership • Training • Service • Reliability

MGD-100 Manual

WARRANTY POLICY

BACHARACH, INC. WARRANTS THIS INSTRUMENT, EXCLUDING SENSORS, TO BE
FREE FROM DEFECTS IN MATERIALS AND WORKMANSHIP FOR A PERIOD OF ONE
YEAR FROM THE DATE OF PURCHASE BY THE ORIGINAL OWNER. THE SENSORS
HAVE A WARRANTY PERIOD OF ONE YEAR FROM THE DATE OF PURCHASE. IF
THE PRODUCT SHOULD BECOME DEFECTIVE WITHIN THIS WARRANTY PERIOD,
WE WILL REPAIR OR REPLACE IT AT OUR DISCRETION.

THE WARRANTY STATUS MAY BE AFFECTED IF THE INSTRUMENT HAS NOT BEEN
USED AND MAINTAINED PER THE INSTRUCTIONS IN THIS MANUAL OR HAS BEEN
ABUSED, DAMAGED, OR MODIFIED IN ANY WAY. THIS INSTRUMENT IS ONLY TO BE
USED FOR PURPOSES STATED HEREIN. THE MANUFACTURER IS NOT LIABLE FOR
AUXILIARY INTERFACED EQUIPMENT OR CONSEQUENTIAL DAMAGE.

DUE TO ONGOING RESEARCH, DEVELOPMENT, AND PRODUCT TESTING, THE
MANUFACTURER RESERVES THE RIGHT TO CHANGE SPECIFICATIONS WITHOUT
NOTICE. THE INFORMATION CONTAINED HEREIN IS BASED ON DATA CONSIDERED
ACCURATE. HOWEVER, NO WARRANTY IS EXPRESSED OR IMPLIED REGARDING
THE ACCURACY OF THIS DATA.

ALL GOODS MUST BE SHIPPED TO THE MANUFACTURER BY PREPAID FREIGHT.
ALL RETURNED GOODS MUST BE PRE-AUTHORIZED BY OBTAINING A RETURN
MERCHANDISE AUTHORIZATION (RMA) NUMBER. CONTACT THE MANUFACTURER
FOR A NUMBER AND PROCEDURES REQUIRED FOR PRODUCT TRANSPORT.

SERVICE POLICY

BACHARACH, INC. MAINTAINS AN INSTRUMENT SERVICE FACILITY AT THE
FACTORY. SOME BACHARACH DISTRIBUTORS / AGENTS MAY ALSO HAVE
REPAIR FACILITIES, HOWEVER, BACHARACH ASSUMES NO LIABILITY FOR
SERVICE PERFORMED BY ANYONE OTHER THAN BACHARACH PERSONNEL.
REPAIRS ARE WARRANTED FOR 90 DAYS AFTER DATE OF SHIPMENT
(SENSORS, PUMPS, FILTERS AND BATTERIES HAVE INDIVIDUAL
WARRANTIES). SHOULD YOUR INSTRUMENT REQUIRE NON-WARRANTY
REPAIR, YOU MAY CONTACT THE DISTRIBUTOR FROM W HOM IT W AS
PURCHASED OR YOU MAY CONTACT BACHARACH DIRECTLY.

IF BACHARACH IS TO DO THE REPAIR WORK, SEND THE INSTRUMENT,
PREPAID, TO BACHARACH, INC. AT THE FOLLOWING ADDRESS.

BACHARACH, INC.
621 HUNT VALLEY CIRCLE
NEW KENSINGTON, PA 15068
ATTENTION: SERVICE DEPARTMENT

ALWAYS INCLUDE YOUR RMA #, ADDRESS, TELEPHONE NUMBER, CONTACT
NAME, SHIPPING/BILLING INFORMATION AND A DESCRIPTION OF THE
DEFECT AS YOU PERCEIVE IT. YOU WILL BE CONTACTED WITH A COST
ESTIMATE FOR EXPECTED REPAIRS PRIOR TO THE PERFORMANCE OF ANY
SERVICE WORK. FOR LIABILITY REASONS, BACHARACH HAS A POLICY OF

2 6109-9000 Rev 4

PERFORMING ALL NEEDED REPAIRS TO RESTORE THE INSTRUMENT TO
FULL OPERATING CONDITION.

PRIOR TO SHIPPING EQUIPMENT TO BACHARACH, CONTACT OUR OFFICE
FOR AN RMA # (RETURNED MERCHANDISE AUTHORIZATION). ALL RETURNED
GOODS MUST BE ACCOMPANIED WITH AN RMA NUMBER.

PACK THE EQUIPMENT WELL (IN ITS ORIGINAL PACKING IF POSSIBLE), AS
BACHARACH CANNOT BE HELD RESPONSIBLE FOR ANY DAMAGE INCURRED
DURING SHIPPING TO OUR FACILITY.

NOTICES

MGD-100 Manual

COPYRIGHTS: THIS MANUAL IS SUBJECT TO COPYRIGHT PROTECTION; ALL
RIGHTS ARE RESERVED UNDER INTERNATIONAL AND DOMESTIC
COPYRIGHT LAWS. THIS MANUAL MAY NOT BE COPIED OR TRANSLATED, IN
WHOLE OR IN PART, IN ANY MANNER OR FORMAT, W ITHOUT THE WRITTEN
PERMISSION OF BACHARACH, INC.

ALL SOFTWARE USED AND/OR DISTRIBUTED BY BACHARACH IS SUBJECT TO
COPYRIGHT PROTECTION. ALL RIGHTS ARE RESERVED. NO PARTY MAY USE
OR COPY SUCH SOFTWARE IN ANY MANNER OR FORMAT, EXCEPT TO THE
EXTENT THAT BACHARACH GRANTS THEM A LICENSE TO DO SO. IF THIS
SOFTWARE IS BEING LOADED ONTO MORE THAN ONE COMPUTER, EXTRA
SOFTWARE LICENSES MUST BE PURCHASED.

TECHNICIAN USE ONLY

THIS UNIT MUST BE INSTALLED BY A SUITABLY QUALIFIED TECHNICIAN WHO
WILL INSTALL THIS UNIT IN ACCORDANCE WITH THESE INSTRUCTIONS AND
THE STANDARDS IN THEIR PARTICULAR INDUSTRY/COUNTRY. OPERATORS
OF THE UNIT SHOULD BE AWARE OF THE REGULATIONS AND STANDARDS IN
THEIR INDUSTRY/COUNTRY FOR THE OPERATION OF THIS UNIT. THESE
NOTES ARE ONLY INTENDED AS A GUIDE AND THE MANUFACTURER BEARS
NO RESPONSIBILITY FOR THE INSTALLATION OR OPERATION OF THIS UNIT.

FAILURE TO INSTALL AND OPERATE THE UNIT IN ACCORDANCE WITH THESE
INSTRUCTIONS AND WITH INDUSTRY GUIDELINES MAY CAUSE SERIOUS
INJURY INCLUDING DEATH AND THE MANUFACTURER WILL NOT BE HELD
RESPONSIBLE IN THIS REGARD.

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MGD-100 Manual

Table of Contents

SECTION 1.

OVERVIEW ................................................................................ 5

1.1. General Information ................................................................................ 5

1.2. Technical Specifications ........................................................................ 10

SECTION 2. PLACING SENSORS .................................................................. 13

2.1. Installation Warnings ............................................................................ 13

2.2. General Guidelines ................................................................................ 13

2.3. Machinery Rooms ................................................................................. 15

2.4. Refrigerated Spaces ............................................................................... 16

2.5. Chillers ................................................................................................... 16

2.6. Air Conditioning (Direct Systems VRF/VRV) .......................................... 17

SECTION 3. HOUSING DIMENSIONS .......................................................... 18

SECTION 4. WIRING INSTRUCTIONS .......................................................... 23

4.1. Wiring MGD-100s .................................................................................. 23

4.2. External Audible Alarm .......................................................................... 24

4.3. DC Output .............................................................................................. 24

4.4. Relays .................................................................................................... 25

4.5. Power Connection ................................................................................. 25

SECTION 5. OPERATION AND STABILIZATION ............................................ 30

SECTION 6. FUNCTIONAL TESTS AND CALIBRATION .................................. 32

6.1. Introduction .......................................................................................... 32

6.2. Electrical Reset ...................................................................................... 34

6.3. Bump Testing ......................................................................................... 35

6.4. Calibration Overview ............................................................................. 38

6.5. Calibration Options ............................................................................... 38

6.6. Sensor Board Exchange ......................................................................... 38

6.7. On-Site Gas Calibration ......................................................................... 39

SECTION 7. TROUBLESHOOTING ............................................................... 41

DECLARATION OF CONFORMITY .................................................................... 43

4 6109-9000 Rev 4

Section 1. Overview

1.1. General Information

The MGD-100 is the ideal gas detection solution for installations
requiring a quality and affordable stand-alone gas detector. It consists of
1 to 6 remote gas sensors connected to and powered by a controller.
The controller provides visual, audible, and relay alarms on the detection
of gases. The system is available with one or two levels of alarm.

The MGD-100 can be used for:

MGD-100 Manual

• detecting refrigerant gases (including NH

and CO2)

3

• speedy detection of combustible gases

• detection of toxic and VOC gases.

A range of gas detector and sensor enclosures are available for special
applications.

The MGD-100 Controller is required. With the MGD-100, it creates a
stand-alone gas detection system and is used to remotely monitor up to
six MGD-100 devices. Models are available with 1, 2, 4, and 6 channels.
Wiring diagrams are provided later in this manual.

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MGD-100 Manual

Figure 1. MGD-100 1- and 2-Channel Controller PCB

(Single Level Alarm)

Figure 2. MGD-100 1- and 2-Channel Controller PCB

(Dual Level Alarm)

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MGD-100 Manual

Figure 3. MGD-100 4- and 6-Channel Controller PCB

(Single Level Alarm)

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MGD-100 Manual

Figure 4. MGD-100 4- and 6-Channel Controller PCB

(Dual Level Alarm)

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MGD-100 Manual

Figure 5. Examples MGD-100 PCBs

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MGD-100 Manual

1.2. Technical Specifications

Specification Description

Power Supply 100 - 230 VAC 50 - 60 Hz, or 12 VDC (specified at

time of order)

Alarm Silence Key Switch

Alarm Delay Preset: 25 sec (low), 30 sec (high)

Power

Green

Monitoring LED

Alarm Relay(s) 10 A, 120V/230V

Warm-up Delay Minimum of 3 minutes

Communications
Wiring

4-conductor cable (stranded); 500 ft (152 m) max;
22 AWG; Max 8.8Ω/wire

Approvals UL/CSA/IEC/EN 61010-1; CE

Sensor
Channels

1- and 2-channel

systems

4- and 6-channel

systems

Max Power 15 W 25 W

Alarm Levels 1 Level 2 Levels 1 Level 2 Levels

Audible Alarm
(Buzzer)

Alarm Reset Automatic Automatic

Visual Alarm
LED(s)

Fault
Indication(s)

Internal,

continuous

Internal,

intermittent

(low),

continuous

(high)

Internal,

continuous

Internal,

intermittent

(low),

continuous

(high)

Automatic Automatic

(low

alarm),

manual

(high

alarm)

Red Yellow,

Red

Red Yellow,

(low

alarm),

manual

(high

alarm)

Red

Red LED Red LED Red LED Red LED,

relay

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main housing

remote or attached sensor

enclosures. The main housing enclosure and its PCB

Specification Description

Std. Enclosure
Ratings

Dimensions
and Weight:
Controller

Sensor
Dimensions
and Weights

1- and 2-chan systems 4- and 6-chan systems

MGD: IP41

Controller: IP51

8.4” x 4.1” x 3.15”

214 x 105 x 80 mm

2.2 lbs / 1.0 kg

Type/Enclosure Dimensions

IP41

IP66

IP66 w/ Splash
Guard

IP66 w/ Remote
Sensor

IP66 w/ Exd
Remote Head

IP66 w/ PRV
Sensor Head

IP66 Airflow/
Duct (See Table)

Exd (ATEX only)

3.35” x 5.59” x 2.09”
86 x 142 x 53 mm

6.89” x 6.5” x 3.29”
175 x 165 x 82 mm

6.89” x 8.9” x 3.29”
175 x 225 x 82 mm

6.89” x 6.1” x 3.29”
175 x 155 x 82 mm

6.89” x 6.1” x 3.29”
175 x 155 x 82 mm

6.89” x 6.1” x 3.29”
175 x 155 x 82 mm

6.89” x 4.9” x 3.29”
175 x 125 x 82 mm

5.12” x 6.3” x 3.54”
130 x 160 x 90 mm

NOTE: The hazardous area Exd Gas Monitor products are
designed with individually certified Exd
enclosures and certified Exd

MGD-100 Manual

MGD: IP41

Controller: IP51

10.3” x 10.4” x 303”
262 x 265 x 84 mm

5.1 lbs / 2.3 kg

Weights

6.3 oz
180 g

1 lb 6 oz
629 g

1 lb 9 oz
700 g

1 lb 11
oz

790 g

2 lb 10
oz

1185 g

2 lb 0.3
oz

916 g

1 lb 4 oz
578 g

9 lb 4 oz
4200 g

assembly are also Exd certified, but the final Exd Gas Monitor
assemblies (main enclosure and/or sensor assembly) are not
currently Exd certified, but are pending additional testing.

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MGD-100 Manual

Supported CFM and Duct Sizes for the Duct Mount Housing

Units Duct Size

Inches

Feet

Area (ft2)

CFM Ft/min (Based on CFM and Duct Size)

2800 2800 n/a n/a n/a n/a

3000 3000 n/a n/a n/a n/a

3400 3400 n/a n/a n/a n/a

3800 3800 n/a n/a n/a n/a

4000 4000 n/a n/a n/a n/a

4400 4400 n/a n/a n/a n/a

4800 4800 n/a n/a n/a n/a

5000 5000 2500 n/a n/a n/a

5400 5400 2700 n/a n/a n/a

5800 5800 2900 2578 n/a n/a

6000 6000 3000 2667 n/a n/a

6400 6400 3200 2844 n/a n/a

6800 6800 3400 3022 n/a n/a

7000 7000 3500 3111 n/a n/a

7400 7400 3700 3289 n/a n/a

7800 7800 3900 3467 n/a n/a

8000 8000 4000 3556 n/a 2548

8400 8400 4200 3733 n/a 2675

8800 8800 4400 3911 n/a 2803

9000 9000 4500 4000 n/a 2866

9400 9400 4700 4178 n/a 2994

9800 9800 4900 4356 n/a 3121

10000 10000 5000 4444 2500 3185

12 x 12 12 x 24 18 x 18 24 x 24 24 round

1 x 1 1 x 2 1.5 x 1.5 2 x 2 Pi x 1 x 1

1 2 2.25 4 3.14

12 6109-9000 Rev 4

Section 2. Placing Sensors

2.1. Installation Warnings

NOTE: This instrument can be equipped with a semiconductor

sensor for the detection of refrigerant, combustible and VOC
gases. Semiconductor sensors are not gas specific and respond
to a variety of other gases including propane exhaust, cleaners,
and solvents. Changes in temperature and humidity may also
affect the sensor’s performance.

WARNING: Explosion hazard! Do not mount the MGD-100 in
an area that may contain flammable liquids, vapors, or
aerosols. Operation of any electrical equipment in such an
environment constitutes a safety hazard.

CAUTION: The MGD-100 contains sensitive electronic
components that can be easily damaged. Do not touch nor
disturb any of these components.

NOTE: The mounting location of the monitor should allow it to
be easily accessible for visual monitoring and servicing.

NOTE: The monitor must be connected by a marked, suitably
located and easily reached switch or circuit-breaker as means
of disconnection.

NOTE: Connect monitor power and signaling terminals using
wiring that complies with local electrical codes or regulations
for the intended application.

MGD-100 Manual

2.2. General Guidelines

NOTE: The MGD-100 should be installed plumb and level

and securely fastened to a rigid mounting surface.

The MGD-100 controller and its sensor(s) should be positioned carefully
to avoid mechanical damage (from moving machinery, doors, etc.) and
thermal extremes (close to heaters). Units should not be placed
unprotected in direct strong drafts/airflows and areas where water or
moisture is present unless an appropriate enclosure is used.

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MGD-100 Manual

Avoid routing sensor cabling outside of premises, or between buildings
via overhead cables. Also, sensor wiring should be kept to a minimum of
20 in (500mm) from the main power supply and telephone cables.

When connecting the main power supply and/or sensor cables ensure a
second mechanical fixing is used. Use a cable tie inside the enclosure
within 1 in (25mm) of the cable termination.

When power to the unit is switched on, there is a 3-minute delay before
the system activates. This allows the sensors to warm up to the correct
temperature for gas detection. On a two-alarm unit, the green light on the
alarm panel comes on after the delay, indicating that the system is ready.
On a one-alarm system the green light comes on immediately. When a
unit has been off or stored for a long time the stabilizing period may be
longer than 3 minutes. After the 3 minutes has expired, alarms may
activate. You may deactivate the siren until stabilization is complete.
(Use the key switch on two-alarm units. Remove jumper JP1 in the case
of a one-alarm unit).

Mount the controller using the mounting holes in the base such that the
sensor cable terminal blocks are at the bottom of the unit in a convenient
position.

Sensors must be located within the appropriate wire lengths from the
controller.

In all cases the sensor supplied is designed for maximum sensitivity to a
particular gas. However, in certain circumstances false alarms may be
caused by the occasional presence of sufficiently high concentrations of
other gaseous impurities. Examples of situations where such
abnormalities may arise include the following:

• Plant room maintenance activity involving solvent or paint fumes
or refrigerant leaks.

• Accidental gas migration in fruit ripening/storage facilities
(bananas - ethylene, apples - carbon dioxide).

• Heavy localized exhaust fumes (carbon monoxide, dioxide,
propane) from engine-driven forklifts in confined spaces or close
to sensors.

A sensor response delay is built in to the system to minimize the
possibilities of false alarms.

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