H25-IR Infrared Refrigerant Gas Leak Detector Instruction 3015-4342 Operation & Maintenance Rev.
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.
H25-IR Contents Table of Contents 1 Introduction ................................................................................................................................ 1 2 Preparing for Operation ........................................................................................................ 11 1.1 Purpose of Instruction Manual ...........................................................................................................1 1.2 Safety Precautions...........................
Contents H25-IR 3.4 CAL Factor......................................................................................................................................... 25 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 ..................................... 26 3.4.3 Adjusting the CAL Factor .................................................................................................. 27 3.
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 Bacharach 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.
Introduction H25-IR 1.2.5 Explosive Atmosphere Do not operate this instrument in the presence of flammable liquids, vapors or aerosols. Operation of any electrical instrument in such an environment constitutes a safety hazard. 1.2.6 Working Inside 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.
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.
Introduction H25-IR 1.
H25-IR Introduction 1.6 Functional Overview The H25-IR is an industrial gas leak analyzer for the detection of CFCs, HCFCs, HFCs and halogen gas compounds, R600a, SF6, CO2 or R227. This instrument can be used to locate and then quantify gas leaks, as well as log and totalize a group of leaks in a system.
Introduction H25-IR 1.7 Names and Functions of Components 1.7.1 Front View Front Panel Buttons ENT (Enter) • Selects a highlighted menu item. • Saves a selection or manually entered data (e.g. date and time). ESC (Escape) • Displays a previously viewed menu or data screen. • Cancels a data entry function; retains old data; and displays previous screen. VOL (Volume) Volume adjustment.
H25-IR Introduction 1.7.2 Rear View 1.7.
Introduction H25-IR 1.7.4 Standard Probe FLEXIBLE PROBE TUBE 8 or 15 inches (200 or 381 mm) PROBE TIP with FILTER HOSE 6 or 12 foot (1.8 or 3.7 m) PROBE CONNECTOR (Align with red dot on instrument’s front panel PROBE receptacle) 1.7.5 Standard Probe with LED and Programmable Pushbutton FLEXIBLE PROBE TUBE 8 or 15 inches (200 or 381 mm) PROBE TIP with FILTER HOSE 6 or 12 foot (1.8 or 3.
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.
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, configuring 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 interchangeably, with exception of the CAL button.
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 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.
Preparing for Operation H25-IR 2.4 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.
H25-IR Preparing for Operation 2.4.3 Relays 1 = NOT USED 2 = NOT USED 3 = NOT USED 4 = NOT USED Four SPDT relays (rated 3 A, 240 VAC) 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.
Preparing for Operation H25-IR 2.4.5 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. 2.4.6 Clock SET DATE & TIME 07/16/04 13:13 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).
H25-IR Preparing for Operation 2.5 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.
Preparing for Operation H25-IR 2.5.3 Gas Type GAS TYPE SETUP NO. 1 < R134A 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 “7 Specifications.” 2.5.4 Feedback Mode FEEDBACK MODE SETUP NO.
H25-IR Preparing for Operation 2.5.6 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 auto-zero function is disabled while in the Search mode: NOTE: This function works in conjunction with the setpoint value as entered in Section “2.5.5 Setpoint.” ALWAYS ON – The background gas level is always zeroed.
Preparing for Operation H25-IR 2.7 External Relay Connections The H25-IR includes four SPDT relays whose relay contacts are rated 3 A at 240 VAC. 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 2.4.3 Relays. Locate the external relay connector on rear of unit (refer to Section 1.7.2 Rear View).
H25-IR Preparing for Operation 2.8 4–40 mA Current Loop Connection An external 4−20 mA monitoring device (e.g., chart recorder) can be connected to the H25-IR using a shielded-twisted-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.
Preparing for Operation H25-IR Notes: 20 Instruction 3015-4342
H25-IR Calibration 3 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.
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.
H25-IR Calibration 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.
Calibration H25-IR 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.
H25-IR Calibration 3.4 CAL Factor The factory default CAL Factor of 1.000 will provide the level of accuracy as stated in Section 7 Specifications 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.
Calibration H25-IR 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.
H25-IR Calibration 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.
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 because of the instrument’s ability to automatically zero-out background gases and still be able to locate gas leaks.
Operation H25-IR 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 Oz/yr Smart Probe Display Range: SM, MED, LG R134A SETUP NO SM SRCH 0.
H25-IR Operation 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. TIP: If additional volume is required, connect an amplified speaker to the earphone jack. Adjust the speaker and earphone volume as follows: 1.
Operation H25-IR 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 be “0.00” before proceeding. If necessary, press the ZERO button to zero the reading while sampling fresh air. 3.
H25-IR Operation 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.
Operation H25-IR 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.
H25-IR Operation 4.3 What to Do when a Fault Occurs When the instrument’s diagnostics detects that a fault has occurred, the word “FAULT” appears in place of the Gas Type, and an audible beep occurs every 2 seconds. Fault has occurred Oz/yr FAULT SETUP SM SRCH The cause of the fault can be determined by viewing the Diagnostic menu’s Last Fault function.
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.
Maintenance H25-IR 5.1.2 Last Fault The Last Fault screen provides a text description of all current faults that have been 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.
H25-IR Maintenance 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.
Maintenance H25-IR 5.2.1 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. 5.2.2 DIGIPOT DIGIPOT=197 IR VOLT=4.2000 IMPORTANT! The instrument must be sampling fresh air (zero gas) when adjusting the DIGIPOT value.
H25-IR Maintenance 5.2.6 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.
Maintenance H25-IR 5.2.7.3 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.
H25-IR Maintenance 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 will have been erased.
Maintenance H25-IR 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. 10. Select Setup > File Locations and verify that the coldload.bin, pilot.
H25-IR Maintenance 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 once the flashing process is complete. 15.
Maintenance H25-IR 5.4 Part Replacement WARNING! Shock Hazard. Before performing any service work, remove the AC power cord 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 6.2 Service Centers). 5.4.
H25-IR Maintenance 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 (P/N 604-2610 – spare fuse located in fuse holder) Procedure: 1. Remove AC power cord from instrument. 2. Using a small flat-blade screwdriver, carefully pry the fuse holder out from the fuse compartment. 3. Visually inspect the fuse for damage or check its continuity.
Maintenance 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 What to Do when a Fault Occurs. 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.
H25-IR Parts & Service 6 Parts and Service 6.1 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 SF6 ........................................................
Parts &Service H25-IR 6.2 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: 724-334-5051 Fax: 724-334-5723 Email: help@bacharach-inc.com Canada Bacharach of Canada, Inc. 250 Shields Court Unit #3 Markham, Ontario L3R 9W7 Canada Phone: 905-470-8985 FAX: 905-470-8963 E-mail: bachcan@idirect.com México Bacharach de México Playa Regatas No.
H25-IR Specifications 7 Specifications Gases Detected..........................Detects and measures, depending on instrument’s part number: • CFCs, HCFCs, HFCs and Halogens R11, R12, R22, R23, R113, R114, R123, R124, R134a, R227, R236fa, R401A, R402A, R402A, R404A, R407A, R407C, R408A, R409A, R410A, R500, R502, R503, R507, R508B, H1211, H1301, H2402, N1230, FA188 • R600a • SF6 • CO2 • R227 Detection Method......................Infrared Measurement Units..................
Specifications H25-IR Notes: 52 Instruction 3015-4342
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.
Appendix A H25-IR Notes: 54 Instruction 3015-4342
H25-IR Appendix A Notes: Instruction 3015-4342 55
Headquarters: 621 Hunt Valley Circle, New Kensington, PA 15068 Ph: 724-334-5000 • Fax: 724-334-5001 • Toll Free: 1-800-736-4666 Website: www.bacharach-inc.com • E-mail: help@bacharach-inc.com Printed in U.S.A.