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 3 Calibration................................................................................................................................. 21 1.1 Purpose of Instruction Manual ..........
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.
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 ........................................................................................
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 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 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.
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,, or CO2. 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 BATTERY POWER SWITCH (on dual power only) O CONNECTOR for battery cable (on dual power only) 1.7.
Introduction H25-IR 1.7.4 Standard Probe FLEXIBLE PROBE TUBE 8 inches (203 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 inches (203 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 inter-changeably, 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 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.
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.
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.
Preparing for Operation H25-IR 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 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 2.6 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.
Preparing for Operation H25-IR 2.6.3 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 “6 .” 2.6.4 Feedback Mode FEEDBACK MODE SETUP NO.
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.
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).
H25-IR Preparing for Operation 2.8 4–20 mA Current Loop Connection An external 420 mA monitoring device (e.g., chart recorder) can be connected to the H25-IR using a shieldedtwisted-pair cable. IMPORTANT! The monitoring device must be isolated from ground (floating). Locate the 420 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 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.
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 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 TARGET O/YR R134A MEASURED O/YR Oz/yr R134A SETUP INT CAL 3.
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 0.00 TARGET O/YR R134A MEASURED O/YR Oz/yr R134A SETUP EXT CAL 3. Ensure that the instrument is set up for “EXT CAL” (external calibration) as indicated at the bottom-right of the display. If “INT CAL” (internal calibration) is displayed, press the ESC key to perform the procedure in Section 3.
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 being measured. This allows the operator to calibrate the instrument using the internal leak source, regardless of the gas contained in the leak source.
Calibration H25-IR Calibration is best performed at or near full scale, it can however, be done at any concentration 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.
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.
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 0.
H25-IR Operation TIP: If additional volume is required, connect an amplified speaker 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 Oz/yr ADJUST SPEAKER VOLUME ------ R134A SETUP SM SRCH 2. Press the Up button to increase volume, and press the Down button to decrease volume.
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 2.80 SM MEASR(1) SETUP SM MERS 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.
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.
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.
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.
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 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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 toward the rear of the instrument.
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.
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.
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 SF6 .........................................................................
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: 724-334-5051 Fax: 724-334-5723 Email: help@mybacharach.com Canada Bacharach of Canada, Inc. 20 Amber Street Unit #7 Markham, Ontario L3R SP4 Canada Phone: 905-470-8985 Fax: 905-470-8963 Email: bachcan@idirect.
H25-IR Specifications 6 Troubleshooting H25 IR FAULT CODE TROUBLE SHOOTER 0001 BOX TEMP ERROR Inside chassis temperatures greater than 55degC or less than -5degC NO YES NO Does fault code Also Indicate A/D failure 0400? Temp sensor defective Replace motherboard YES A/D defective (other faults will also result) Replace motherboard Move to cooler or warmer environment to correct Bacharach Inc.
H25-IR Operation H25 IR FAULT CODE TROUBLE SHOOTER 0004 MANIFOLD PRESSURE SENSOR ERROR Manifold pressure Is greater than 16.0psia or less than 3.
Specifications H25-IR H25 IR FAULT CODE TROUBLE SHOOTER 0020 INTERNAL CAL ERROR YES Fix loose or broken connection And recalibrate Indicates one or more of the 4 flow parameters collected during the internal cal cycle, deviate from the “factory” value by 25% or more NO Break in sample line In probe assembly NO Probe removed during Cal cycle NO YES NO YES Repeat internal cal cycle Bad or weak pump Probe tip filter clogged YES Replace internal filter and store new “factory” calibration Repl
H25-IR Operation H25 IR FAULT CODE TROUBLE SHOOTER DIAGNOSTIC / PRESSURE SCREEN 0100 LEAK PRESSURE FAULT Internal leak pressure transducer 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 Leak transducer pressure NO Internal leak is low Or empty YES Recalibrate box temp sensor In factory ‘sensors’ menu YES Leak pressure transducer Cable disconnected Or faulty NO NO NO Pressure de
Specifications H25-IR H25 IR FAULT CODE TROUBLE SHOOTER 0800 SEARCH FLOW FAULT Indicates current pressure drop in search Mode deviates from the value store during The last calibration cycle by more than 20% YES Fix loose or broken connection And recalibrate Break in sample line In probe assembly NO NO Too long since last cal And ambient pressure Or filter flow has changed NO YES Probe tip filter clogged NO Internal filter clogged YES Repeat cal cycle YES Replace internal filter and store ne
H25-IR Operation H25 IR FAULT CODE TROUBLE SHOOTER 4000 ZERO VOLT ERROR Indicated the sensor voltage stored during auto or manual zero was less that 3.9V or greater than 4.5V NO Sensor voltage is zero Or near zero Adjust sensor voltage with digipot in Factory menu to 4.2V ±0.05V DETECTOR CABLE CHECK BOTH ENDS YES IR Emitter resistance Show **.
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 • SF6 Detection Method....................... Infrared Measurement Units............
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.
H25-IR Operation 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.mybacharach.com • E-mail: help@mybacharach.com Printed in U.S.A.
