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Bacharach MGD-100 Installation And Operation Manual

Gas detector and controllers
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Gas Detector and Controllers
Installation and Operation Manual
Instruction 6109-9000
Revision 3 – June 2013
Product Leadership • Training • Service • Reliability

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Summary of Contents for Bacharach MGD-100

  • Page 1 Gas Detector and Controllers Installation and Operation Manual Instruction 6109-9000 Revision 3 – June 2013 Product Leadership • Training • Service • Reliability...
  • Page 2 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 TWO YEARS 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.
  • Page 3 MGD-100 Manual PERFORMING ALL NEEDED REPA IRS TO RESTORE THE INSTRUMENT TO FULL OPERA TING CONDITION. PRIOR TO SHIPPING EQUIPMENT TO BA CHA RA CH, CONTA CT OUR OFFICE FOR A N RMA # ( RETURN ED MERCHA NDISE A UTHORIZATION). ALL RETURNED GOODS M UST BE A CCOMPA NIED WITH AN RMA NUMBER.

  • Page 4: Table Of Contents

    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.

  • Page 5: Section 1. Overview

    The MGD-100 Cont roller is required. With the MGD-100, it creates a stand-alone gas detection system and is used to remotely monit or up to six MGD-100 devices. Models are available with 1, 2, 4, and 6 channels. Wiring diagrams are provided later in this manual.
  • Page 6 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) 6109-9000 Rev 3...
  • Page 7 MGD-100 Manual Figure 3. MGD-100 4- and 6-Channel Controller PCB (Single Level Alarm) 6109-9000 Rev 3...
  • Page 8 MGD-100 Manual Figure 4. MGD-100 4- and 6-Channel Controller PCB (Dual Level Alarm) 6109-9000 Rev 3...
  • Page 9 MGD-100 Manual Figure 5. Examples MGD-100 PCBs 6109-9000 Rev 3...

  • Page 10: Technical Specifications

    MGD-100 Manual 1.2. Technical Specifications Specification Description Pow er Supply 120 VAC 60 Hz, 220 VAC 50 Hz, or 12 VDC (speci f ied at time of order); Max power 20W 1- and 2-channel systems 4- and 6-channel systems Audible Alarm (Buzzer)
  • Page 11 MGD-100 Manual Specification Description 1- and 2-channel systems 4- and 6-channel systems Standard Enclosure MGD-100: IP41 MGD-100: IP41 Ratings Controller: IP51 Controller: IP51 Dimensions and Weight: 8.4” x 4.1” x 3.15” 10.3” x 10.4” x 303” Controller 214 x 105 x 80 mm 262 x 265 x 84 mm 2.9 lbs / 1.3 kg...
  • Page 12 MGD-100 Manual Supported CFM and Duct Sizes for the Duct Mount Housing Units Duct Size Inches 12 x 12 12 x 24 18 x 18 24 x 24 24 round Feet 1 x 1 1 x 2 1.5 x 1.5...

  • Page 13: Section 2. Placing Sensors

    NOTE: The MGD-100 should be installed plumb and level and securely fastened to a rigid mounting surface. The MGD-100 cont roller and its sensor(s) should be positioned carefully to avoid mechanical damage (from moving machinery, doors, etc.) and thermal extremes (close to heaters).
  • Page 14 MGD-100 Manual A void routing sensor c abling 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 mechanic al fixing is used.

  • Page 15: Machinery Rooms

    MGD-100 Manual 2.3. Machinery Rooms There is no absolute rule in det ermining t he number of sens ors and their locations. However, a number of simple guidelines will help to make a decision. Sens ors monitor a point as opposed to an area. If the gas leak does not reach the sensor then no alarm will be triggered.

  • Page 16: Refrigerated Spaces

    MGD-100 Manual Otherwise, a gas leak might pass by in a high-speed jet and not be det ected by the sensor. • Make sure that pits, stairwells and trenches are monitored since they may fill with stagnant pockets of gas.

  • Page 17: Air Conditioning (Direct Systems Vrf/Vrv)

    MGD-100 Manual • With air-cooled chillers or air-cooled condensers with non- enclosed condenser sections it is difficult to effectively monitor leaks in the coil sections. With some designs it will be possible using an airflow sensor to monitor airflow to the start–up fans in the front or rear sections.

  • Page 18: Section 3. Housing Dimensions

    MGD-100 Manual Section 3. Housing Dimensions Figure 6. MGD-100 Standard Housing 6109-9000 Rev 3...
  • Page 19 MGD-100 Manual Figure 7. MGD-100 Exd Housing Figure 8. MGD-100 IP66 Housing (with Splash Guard) 6109-9000 Rev 3...
  • Page 20 MGD-100 Manual Figure 9. MGD-100 IP66 Housing with Remote Sensor See Figure 8 for mounting locations. Cut out in duct for pitot 22mm Figure 10. MGS-100 IP66 Housing with Airflow Duct Mount 6109-9000 Rev 3...
  • Page 21 MGD-100 Manual Figure 11. 4- & 6-Sensor Controller Housing 6109-9000 Rev 3...
  • Page 22 MGD-100 Manual Figure 12. 1- to 2-Sensor Controller Housing 6109-9000 Rev 3...

  • Page 23: Section 4. Wiring Instructions

    Connect the other end of the cable to the MGD-100 using terminal block CN1 positions 1,2,3 & 4. (installation should be such that pin 1 of the MGD-100 controller is connected to pin 1 of the MGD-100). Close the housing.

  • Page 24: External Audible Alarm And Dc Output

    MGD-100 Manual IMPORTANT: Ensure that connections 1 to 4 on the sensor connect to their corresponding numbers on the terminal block in the main control unit, otherwise it could c ause damage to the MGD-100. NOTE: You may use different cables and longer distances provided t he corresponding resistance shown above is not exceeded.

  • Page 25: Relays

    MGD-100 Manual 4.3. Relays Connect leads to terminal block for Common (COM) and N/O and/or N/C connections as required. Note that relays are rated as 10A @ 120/230 VAC. Relay Wiring Type Two-Alarm Units One-Alarm Units CN5: Low-Level Alarm 1-2 Channel...
  • Page 26 MGD-100 Manual NOTE: The main power supply cable should be of an approved type based on local regulations. NOTE: The blanking plugs for cable entries s hould only be removed if being replaced by conduit fittings. NOTE: If replacement of the main power fuse is required, use only the appropriate type from the table below.
  • Page 27 MGD-100 Manual Figure 13. 1- & 2-Sensor, One-Alarm Installation Diagram 6109-9000 Rev 3...
  • Page 28 MGD-100 Manual Figure 14. 1- & 2-Sensor, Two-Alarm Installation Diagram 6109-9000 Rev 3...
  • Page 29 MGD-100 Manual Figure 15. 4- & 6-Sensor, One-Alarm Installation 6109-9000 Rev 3...
  • Page 30 MGD-100 Manual Figure 16. 4- & 6-Sensor, Two-Alarm Installation 6109-9000 Rev 3...

  • Page 31: Section 5. Operation And Stabilization

    (Use the key switch on two-alarm units. Remove link on jumper JP1 in the case of one-alarm units). After t he MGD-100 has been installed in accordance with the installation instructions, the MGD-100 system is ready to monitor the chosen air space and detect gas leaks.
  • Page 32 MGD-100 Manual Operation Description State Idle Only the green light on the panel is on. No gas is present. Power If the green light is off, power to the unit has been Interrupted interrupted. Refer to Section 7. Alarm One-alarm Units: Conditions One or more red lights on the panel turn on.

  • Page 33: Section 6. Functional Tests And Calibration

    IMPORTANT: If the MGD-100 is exposed to a large leak it should be tested to ensure correct functionality by electrically resetting the zero setting and carrying out a bump test. See procedures below.
  • Page 34 In applications where life safety is critical, calibration should be done quarterly (every 3 months) or on a more frequent basis. Bacharach is not responsible for setting safety practices and policies. Safe work procedures including calibration policies are best det ermined by company policy, industry standards, and local codes.

  • Page 35: Electrical Reset Of One-Alarm Systems

    For one-alarm systems you should deactivat e the 3-min alarm delay (if selected) by moving jumper JP1 to the “off” position. • Ideally, for bump t est or calibration the MGD-100 should be powered up overnight. See Section 5 for more information.

  • Page 36: Electrical Reset Of Two-Alarm Systems

    MGD-100 Manual Step Electrical Re set of One-Alarm System s Connect a voltmeter between Pins 4 (-Ve) and 2 (+Ve) of the sensor terminal connector block for each channel in turn (CN1, CN2, etc.) and adjust the corresponding calibration pot (P1, P2, etc.) to the sensor standby voltage (SSV) value as...

  • Page 37: Bump Testing

    NOTE: P rocedures for bump test and calibration vary depending on the sensor technology used and the gas in question. The MGD-100 is available in two sensor versions: Semiconductor (S C) and Infrared (IR). NOTE: Do not pressurize the sensor.
  • Page 38 MGD-100 Manual Step Bump Testing Usi ng Calibration Gas Cylinders Remove the enclosure lid of the gas sensor and controller (not applicable to Exd Remote sensor and vent pipe model as monitoring of voltage can be done on controller). Connect the voltmeter to the channel under test between Pin 4 and Pin 2 (for single-level alarm units), or TP5 and TP 4 (for dual-alarm units), to monitor sensor response.
  • Page 39 MGD-100 Manual Figure 18. Gas Ampoules for Bump Testing Step Bump Testing Usi ng Ga s Ampoule s Make sure that both the ampoules and the calibration beaker are clean and dry. Unscrew the beaker wing nut and plac e the ampoule so that it sits in the base of the beaker (see Figure 18).

  • Page 40: Calibration Overview

    MGD-100 Manual Step Bump Testing Usi ng Ga s Ampoule s Remove the beaker from the sensor. Carefully remove any ampoule remains from the gas detector and beaker. 6.5. Calibration Overview To comply with t he requirements of EN378 and t he E uropean F-GAS regulation, sensors must be tested annually.

  • Page 41: On-Site Gas Calibration (One-Alarm Unit)

    6.8. On-Site Gas Calibration (One-Alarm Unit) This section and the next cover calibration using calibration gas cylinders. Bacharach offers a c alibration kit that consists of a calibration gas cylinder and a flow regulation valve with flexible non-absorbent tubing and vented calibration hood.
  • Page 42 MGD-100 Manual First disable the 3-minute alarm delay on a one-alarm system by moving the jumper link at JP1 to the off position. Two adjustments are required and they are both performed on the controller unit. The alarm threshold volt age (A TV ) is the voltage at which the alarm and relay activat e at a given gas concentration.

  • Page 43: Gas Calibration (Two-Alarm Units)

    For one-alarm units, refer to the previous section. NOTE: The delay on a two-alarm system is approximately 25 seconds and cannot be deactivated. All adjustments are performed on the MGD-100 sensor P CB. Sensor Standby Voltage and two Alarm Threshold Voltages must be adjusted.

  • Page 44: Section 7. Troubleshooting

    • This may indicate a wiring fault between the Cont roller is on, controller and sensor or a sensor fault. but the MGD-100 Check power supply to the cont roller. Check is not connections between the controller and the...
  • Page 45 MGD-100 Manual Place the negative probe on terminal position 4 and with the positive on 1, 3, 2, check the values. The readings are lower at the sensor due to power drop in the line. The terminals should have the values shown in the table below.
  • Page 46 MGD-100 Manual 6109-9000 Rev 3...

  • Page 47: Declaration Of Conformity

    Gases , Toxi c Gases, or Oxygen Signature: Name: Doug Keeports Title: VP of Product Development Date: 5 October 2012 The technical documentation file required by this directive is maintained at the corporate headquarters of Bacharach, Inc. 6109-9000 Rev 3...
  • Page 48 MGD-100 Manual World Headquarters 621 Hunt Valley Circle, New Kensington, Pennsylvania 15068 Phone: 724-334-5000 • Toll Free: 1-800-736-4666 • Fax: 724-334-5001 Website: www.MyBacharach.com • E-mail: help@MyBacharach.com 6109-9000 Rev 3...

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