Gas Detector and Controllers Installation and Operation Manual Instruction 6109-9000 Revision 3 – June 2013 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 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.
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. PA CK THE EQUIPMENT WELL (IN ITS ORIGINAL PA CKING IF POSSIBLE), AS BACHA RA CH CA NNOT BE HELD RESPONSIBLE FOR A NY DA MA GE INCURRED DURING SHIPPING TO OUR FA CILITY.
MGD-100 Manual Table of Contents SECTION 1. OVERVIEW..............................................................................................5 1.1. General Information.......................................................................................... 5 1.2. Technical Specifications..................................................................................10 SECTION 2. 2.1. 2.2. 2.3. 2.4. 2.5. 2.6. PLACING SENSORS ........................................................................
MGD-100 Manual 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 t he detection of gases. The system is available with one or two levels of alarm.
MGD-100 Manual Figure 1. MGD-100 1- and 2-Channel Controller PCB (Single Level Alarm) Figure 2.
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MGD-100 Manual Specification Description 1- and 2-channel systems 4- and 6-channel systems MGD-100: IP41 Controller: IP51 MGD-100: IP41 Controller: IP51 8.4” x 4.1” x 3.15” 214 x 105 x 80 mm 2.9 lbs / 1.3 kg 10.3” x 10.4” x 303” 262 x 265 x 84 mm 5.7 lbs / 2.6 kg Standard Enclosure Ratings Dimensions and Weight: Controller Dimensions and Weights IP41 3.35” x 5.59” x 2.09” 86 x 142 x 53 mm 6.3 oz 180 g IP66 6.89” x 6.5” x 3.29” 175 x 165 x 82 mm 1 lb 6 oz 629 g IP66 w / Splash Guard 6.89” x 8.
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 1x1 1x2 1.5 x 1.5 2x2 Pi x 1 x 1 Area (ft 2) 1 2 2.25 4 3.
MGD-100 Manual 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.
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. 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 activat es.
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. Therefore, it is extremely import ant to carefully select the sensor location. Also consider ease of access for maintenance.
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. If a pressure relief vent (PRV ) pipe is fitted to the system, it may be a requirement to mount a sensor to monitor this vent pipe. It could be positioned about 6.5 ft (2 m) above the PRV to allow gas clouds to form.
MGD-100 Manual • • With air-cooled chillers or air-cooled condensers with nonenclosed 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. If there is a possibility of refrigerant leaks into a duct or airhandling unit install a sensor to monitor the airflow. Weatherproof sensors applications. should be used for unprotected outdoor 2.6.
MGD-100 Manual Section 3. Housing Dimensions Figure 6.
MGD-100 Manual Figure 7. MGD-100 Exd Housing Figure 8.
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.
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MGD-100 Manual Section 4. Wiring Instructions 4.1. Wiring MGD-100s Step Wiring MGD-100s 1 Connect a 4-conductor cable (18 AWG recommended) to a terminal block on the MGD-100 controller (CN1, CN2, etc). 2 Rout e the cable to an MGD-100. For standard (IP 41) MGD-100 housings, remove the lid by: • 3 • turning the cable clamp ½ turn counter clockwise to loosen the internal nut depressing the clip on top of the enclosure to open. 4 Mount the MGD-100. See Section 3 for dimensions.
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. 4.2. External Audible Alarm and DC Output NOTE: This section applies to the external audible alarm and the 12 VDC output (4-6 channel systems only).
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 1-2 Channel Units 4-6 Channel Units Two-Alarm Units CN5: Low-Level Alarm CN4: High-Level Alarm CN10: Low-Level Alarm CN9: High-Level Alarm One-Alarm Units CN4 CN10 CN12: Fault Relay NOTE: N/O (normally open) and N/C (normally closed) refer to contact status in standby mode.
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. Replacement Fuse s (0.
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MGD-100 Manual Section 5. Operation and Stabilization When power to the unit is switched on, there is a 3-minute delay before the system activat es. This allows the sensors to warm up to the correct temperature for gas detection. • • On a t wo-alarm unit the green light on t he alarm panel comes on after the delay, indicating that the system is ready. On a one-alarm unit the green light comes on immediately. NOTE: The 3-minute delay is set by JP1 in single alarm units only.
MGD-100 Manual Operation State Description Idle Only the green light on the panel is on. No gas is present. Power Interrupted If the green light is off, power to the unit has been interrupted. Refer to Section 7. Alarm Conditions One-alarm Units: One or more red lights on the panel turn on. The siren and the relays operate. This indicates that gas at one or more sensors is at a level higher than the alarm point.
MGD-100 Manual Section 6. Functional Tests and Calibration 6.1. Introduction To comply with t he requirements of EN378 and t he E uropean F-GAS regulation, sensors must be tested annually. However, local regulations may specify the nature and frequency of this test. CAUTION: Check local regulations on c alibration or t esting requirements. CAUTION: The MGD-100 contains sensitive electronic components that can be easily damaged. Do not touch nor disturb any of these components.
MGD-100 Manual IMPORTANT: Before testing the sensors on-site, the MGD100 must have been powered up and allowed to stabilize for at least 24 hours. See Section 5. IMPORTANT: Failure to t est or calibrate t he unit in accordance with applicable instructions and with industry guidelines may result in serious injury or death. The manufacturer is not liable for any loss, injury, or damage arising from improper testing, incorrect calibration, or inappropriate use of the unit.
MGD-100 Manual CAUTION: Before you carry out the bump test or calibration: • Advise occupants, plant operators, and supervisors. • Check if the MGD-100 is connected to external systems such as sprinkler systems, plant s hut down, external sirens and beacons, ventilation, etc. and disconnect as instructed by the customer. • For one-alarm systems you should deactivat e the 3-min alarm delay (if selected) by moving jumper JP1 to the “off” position.
MGD-100 Manual Step Electrical Re set of One-Alarm System s 2 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 per calibration label on side of enclosure. (For IR sensors, set SSV to 2V.) See Figure 13 and Figure 15.
MGD-100 Manual Step Electrical Re set of Two-Alarm System s 1 For the sens or standby voltage, connect a DC voltmet er between TP 5 (0V ) and TP 4 (+V) as shown in Figure 14 and Figure 16. Adjust pot RV 1. 2 For low-level alarm volt age, connect your DC voltmeter between TP 5 (0V ) and TP 2 (+V) as shown in Figure 14 and Figure 16. Adjust pot P8. 3 For high-level alarm voltage, connect your DC voltmeter between TP 5 (0V ) and TP 1 (+V) as shown in Figure 14 and Figure 16. Adjust pot P7. 6.4.
MGD-100 Manual Step Bump Testing Usi ng Calibration Gas Cylinders 1 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). 2 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.
MGD-100 Manual Figure 18. Gas Ampoules for Bump Testing Step Bump Testing Usi ng Ga s Ampoule s 1 Make sure that both the ampoules and the calibration beaker are clean and dry. 2 Unscrew the beaker wing nut and plac e the ampoule so that it sits in the base of the beaker (see Figure 18). 3 Tighten the wing-nut screw onto the ampoule without breaking it. 4 Remove the enclosure lid of the gas detector.
MGD-100 Manual Step 9 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. However, local regulations may specify the nature and frequency of this test. CAUTION: Check local regulations on c alibration or t esting requirements. 6.6.
MGD-100 Manual Step Sensor Board Exchange 1 Power off the unit and remove lid of sensor enclosure. 2 Note the color code of the cable in positions 1,2,3 and 4 of the connector block. 3 Undo the cable and 2 screws securing the sensor board and remove the board. 4 Fit the new pre-calibrated sensor and reconnect the cable in the correct color sequence at positions 1,2,3 and 4. 5 Power on the unit and allow to stabilize for 15 minutes (minimum).
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. This voltage is normally set 3.0V.
MGD-100 Manual 6.9. Gas Calibration (Two-Alarm Units) NOTE: This calibration procedure is for a two-alarm unit. 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. The Sensor Standby Voltage and two Alarm Threshold Voltages must be adjusted.
MGD-100 Manual Section 7. Troubleshooting Symptom No lights displayed on panel Red light is on, but no alarm condition is active (i.e.
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. You can monitor this as follows: One-Alarm System s: Connect a voltmeter and monitor voltage between Pins 4 (-Ve) & 2 (+Ve) of the sensor terminal connector block for each channel in turn (CN1, CN2 Etc.) For IR sensors, monitor between 0V and VS.
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MGD-100 Manual D ECLARATION OF CONFORMITY The manufacturer of the products covered by this declaration: Ba cha rach, Inc. 621 Hunt Valley Ci rcle New Kensington, PA 15068 Year(s) conformity is declared: 2012 (IEC/EN61010), 2011 (EN61326/EN55011) Product(s): MGD Model(s): MGD-100 The undersigned hereby declares tha t the a bove referenced products a re in conformi ty wi th the provisions of the following s tandard(s ) a nd is in accordance with the following di recti ve(s).
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.
