ARJAY ENGINEERING 4200-IR-4 User manual

MODEL 4200-IR-2 (Up to 2 Sensors)
MODEL 4200-IR-4 (Up to 4 Sensors)
MODEL 4200-IR-6 (Up to 6 Sensors)
Refrigerant Monitor
User Manual
Technical Support
Continental North America Toll Free 1-[phone]
Ph: [phone] Fx: [phone]
A Product of Arjay Engineering Ltd.
Oakville, Ontario, Canada
www.ArjayEng.com
MODEL:
HARDWARE NO.:
SOFTWARE NO.:
SERIAL NO.:

Model: 4200-IR User Manual Rev: 3.0
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TABLE OF CONTENTS
1.0 INSTRUMENT OVERVIEW ............................................................................................ 3
1.1 Features ............................................................................................................. 6
1.2 Main Panel Model Number ................................................................................ 6
1.3 Specifications ..................................................................................................... 6
1.4 Gas Levels ......................................................................................................... 7
2.0 INSTALLATION ............................................................................................................... 8
2.1 Main and Remote Panel Installation .................................................................. 8
2.2 Sensor Installation .............................................................................................. 8
2.3 Electrical Installation .......................................................................................... 9
2.4 Glossary of Symbols .......................................................................................... 11
3.0 STARTUP AND CALIBRATION ...................................................................................... 12
3.1 Startup ................................................................................................................ 12
3.2 Screen Menu Background Information .............................................................. 13
3.2.1 Keypad Main Menu Entry .................................................................... 13
4.0 SYSTEM CONFIGURATION .......................................................................................... 14
4.1 Alarm Setup ....................................................................................................... 14
4.2 Diagnostic Information ....................................................................................... 15
4.3 Sensor Setup ..................................................................................................... 16
4.3.1 Individual Sensor Setup ...................................................................... 16
4.3.2 Number of Sensors.............................................................................. 17
4.3.3 Analog Input Trim ................................................................................ 17
4.4 System Test ....................................................................................................... 17
4.5 Factory Setup ..................................................................................................... 18
4.6 Factory Defaulted Sequence of Operation ........................................................ 18
4.7 Date and Time .................................................................................................... 18
5.0 MAIN DISPLAY ............................................................................................................... 19
6.0 SENSOR CALIBRATION ................................................................................................ 20
7.0 TROUBLESHOOTING .................................................................................................... 21
8.0 MODBUS MAP AND DETAIL (if ordered) ....................................................................... 22
8.1 Modbus Commands Supported ......................................................................... 22
8.2 Register Map ...................................................................................................... 22
9.0 DETAILED ELECTRICAL AND DIMENSIONAL DRAWINGS ........................................ 23
TABLE OF FIGURES
Figure 1 – System Overview .......................................................................................................... 4
Figure 2 – Electrical Installation Overview ................................................................................... 10
Figure 3 – Startup Main Screen View .......................................................................................... 12
Figure 4 – System Configuration Main Screen View ................................................................... 14
Figure 5 – Alarm Setup Screen View ........................................................................................... 14
Figure 6 – Diagnostic Information Screen View ........................................................................... 15
Figure 7 – Sensor Setup Screen View ......................................................................................... 16
Figure 8 – Analog Input Trim Screen View .................................................................................. 17
Figure 9 – System Test Screen View ........................................................................................... 17
Figure 10 – Date and Time Screen View ..................................................................................... 18
Figure 11 –Main Display Screen View ......................................................................................... 19

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1.0 INSTRUMENT OVERVIEW
The Arjay Model 4200-IR monitors for refrigerant leaks in Mechanical Equipment Rooms (MER)
and chiller rooms.
The monitoring system is comprised of three main components: One main control panel (4200-IR-
MP), a minimum of one remote alarm panel and a minimum of one remote sensor.
Depending on the installation requirements, there may be up to 3 remote alarm panels with HMI
display (Model: 4200-IR-RP) for indoor use or 6 remote panels with mechanical switch for outdoor
use (Model: 4200-IR-N4-RP) and up to 6 remote sensors
Main control Panel Models:
4200-IR-MP-2 Up to 2 Sensors
4200-IR-MP-4 Up to 4 Sensors
4200-IR-MP-6 Up to 6 Sensors (With Separate Power Supply)
Note: For additional remote panel and sensors, consult factory.
The Model 4200-IR is designed in accordance with guidelines indicated by ASHRAE Standard 15
and CSA B52. Local or site specific regulations may apply to your application. Be aware and
compliant with all applicable regulations for your installation.
SYSTEM WITH OUTDOOR REMOTE PANEL

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SYSTEM WITH INDOOR REMOTE PANEL
Figure 1 – System Overview

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Main Panel
The main panel is located inside the machinery room and is typically installed near a main door for
ease of access and observation of alarms. In large rooms, you may want to consider additional
remote alarms.
A warning alarm is activated at a low level setpoint and is indicated by the touch screen flashing
yellow. The screen text also shows a low alarm and indicates the ppm refrigerant level. Typically,
no action is required at this level; it is a warning only. R1 relay can be set as Low Alarm or Fault.
High alarm relays are activated above the TWA-TLV ppm level determined for the refrigerant gas
being monitored. One DPDT relay each is provided for BAS or Boiler, Chiller and Ventalation Fan.
During a high alarm, the main panel provides a visual flashing amber beacon and an audio buzzer.
The buzzer can be silenced during an alarm condition but the beacon will only turn off when a gas
alarm has cleared and the alarm condition has been acknowledged at the panel.
The main panel screen provides a Push-to-Test and additional user interface menus for
diagnostics, set-up and general Help information.
Remote Panel
A remote panel is located outside of each ‘entranceway’ to the machinery room. Remote Panels
are required to indicate an alarm condition to warn of entry into the room. Arjay remote panels
include an amber flashing beacon and buzzer in addition to the screen display. For outdoor
application it is recommended to use Model: 4200-IR-RP-N4 version. This model replaces the HMI
display and uses mechanical switches. This model can operate in temperature of -20°C to +55°C.
A buzzer is not required by code but is included on the standard Arjay remote panel. It can be
silenced during an alarm condition and will reset when the alarm condition is cleared.
The touch screen display indicates the ppm concentration and will flash at warning and high alarm
levels.
A Push-toTest can be accessed on the remote panel by passcode (not applicable for outdoor
versions). Diagnostic and Help menus are also accessible on the remote screens.
Fan and Chiller Override Switches
Although chiller switches are not required as part of the refrigerant monitoring panels, code
guidelines require Ventilation Fan ON switches to be available inside and outside a refrigeration
machinery room. Arjay panels include Ventilation ON switches and Chiller OFF switches on all
panels. These will override the corresponding relay within the Main Control Panel. The switches on
the remote panel are passcode protected or Keylocked (outdoor version).
Since the codes do not require the chiller to be interlocked with Refrigerant Panel, the Chiller OFF
switch is not shown on the factory shipped screen. This can be enabled in alarm setup.
Remote Sensor
The sensor is a non-dispersive infrared technology designed to selectively target the refrigerant
gas type.
The sensor continuously monitors the air and sends a signal to main control panel. The signal is
proportional to the ppm refrigerant concentration at the sensor. Routine testing and calibration is
recommended to ensure the sensor is responsive and accurate. Calibration is done at the sensor
(see sensor manual).

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Fan Running Indication
A fan running icon appears in the main screen when the fan operating input voltage (24VDC) is
connected thru the auxillary starter contacts to the main panel. The icon will indicate low fan and/or
high fan speed. Refer to ventilation light wiring diagram for more detail.
1.1 Features
• Microprocessor based Controller
• Relays for Alarm Outputs:
 Four Relays for 4200-IR-2-MP
 Five Relays for 4200-IR -4-MP
 Six Relays for 4200-IR-6-MP
• Touch Screen interface with passcode protection and display ppm value
• Diagnostic, set-up and Help menus on all screens
• Non-dispersive infrared sensor for long life and gas selectivity
• Designed in accordance with CSA B52 and ASHRAE Standard 15
1.2 Main Panel Model Number
• 4200-IR-2-MP Two Sensor Inputs
• 4200-IR-4-MP Four Sensor Inputs
• 4200-IR-6-MP Six Sensor Inputs (With separate power supply)
**Maximum Remote Panel: 3 for Indoor version (consult factory if more than 3 required) or
6 for Outdoor version for all above models
1.3 Specifications
Power Input: 100-240 vac, 50/60 Hz,
1.95A max. (for 2 and 4 sensor models) or 4A max (for 6 sensor model)
User Interface:
Touch Screen Full Colour 6 “ display on Main Panel
Monochrome 4” on Remote (Indoor Version Only)
Outputs:
Relay Output DPDT relay, 8 A @ 250 vac dry contacts
Selectable failsafe or non-failsafe
Programmable time delay: 0 – 1200 seconds ON and OFF
One relay each for:
• Low Setpoint or Fault (Selectable)
• High Setpoint Boiler or BAS interlock
• High Setpoint Fan Interlock
• High Setpoint Chiller Interlock*
*(2x DPDT for 4200-IR-4-MP and 3x DPDT for 4200-IR-6-MP)
RS485 Modbus Optional
Analog Output Optional
Bacnet Optional

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Sensor Non-Dispersive Infrared
24 vdc powered from Main Panel
Expected life: 5-7 years under normal conditions
Environmental:
Ambient Temperature 0°C to +55 °C (Main & Remote panels with HMI displays must be installed
indoor).
-20°C to +55 °C (4200-IR-RP-N4 Remote Panel with Mechanical Switch)
Relative humidity 0 to 95% (non-condensing)
Installation Category II
Pollution Degree 2
Mechanical Specification: Refer to dimensional drawing
1.4 Gas Levels
These factory defaulted settings can be changed in the field by the customer to suit specific
requirements.
GAS NAME LOW LEVEL HIGH LEVEL RANGE
R123 30 50 1031
R134A 500 800 1031
R22 500 800 1031
R11 500 800 1031
R404A 500 800 1031
R407A 500 800 1031
R407C 500 800 1031
R410A 500 800 1031
R507 500 800 1031

Model: 4200-IR User Manual Rev: 3.0
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2.0 INSTALLATION
NOTE: If any damage to the instrument is found, please notify an Arjay Engineering Ltd.
representative as soon as possible prior to installation.
2.1 Main and Remote Panel Installation
Choose a mounting location in accordance with good instrument practice. Extremes of ambient
temperature and vibration should be avoided (see specifications and installation drawing).
Sensors and remote panels can be mounted up to 300 meters away from the main panel.
Important Note: The controller can be set in a Failsafe mode. This means that the relays are in
an energized state during normal operation. The N.O. relay contact will be held closed and the
N.C. relay contact will be held open during a normal condition. This will allow the relay to return to
its non-energized (shelf) state during an alarm, fault or power failure condition. Wire accordingly.
2.2 Sensor Installation
The sensor is to be mounted near the refrigerant leak source and protected from extremes of
temperature and damage. Keep the sensor accessible for routine calibration. Do not block with
equipment or store materials or containers in front of the sensor.
It should be mounted so the bottom of the sensor housing is approximately 250mm to 450mm (10”
to 18”) above floor grade to protect it from damage from cleaning equipment and minor wash
down.
The sensor should be mounted close to the potential refrigerant leak source on the downstream
side of any room ventilation currents. One sensor can often be used to monitor two adjacent
chillers.
The sensor should be mounted above any risk of flooding.
Note: Sensor cable shall have a minimum specification:
- 18 AWG, 4 Wire, 2 Pair, Twisted, Shielded Cable (i.e. Belden 9552 or equivalent).

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2.3 Electrical Installation
Refer to the drawings provided by the contractual engineer for your project and the drawings
included with this manual.
SYSTEM WITH OUTDOOR REMOTE PANELS

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SYSTEM WITH INDOOR REMOTE PANELS
Figure 2 – Electrical Installation Overview

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2.4 Glossary of Symbols
Attention, consult accompanying documents
Attention, veuillez consulter les documents ci-joints.
Protective Earth
Terre de protection
Fuse
Coupe-circuit; fusible
Direct Current (DC)
Courant continu
Normally open relay contacts
Contacts travail
Normally closed relay contacts
Contacts Repos
Power off
ArróÕ (mise hors tension)
Power on
Marche (mise sous tension)
L
Live
Sous tension
N
Neutral
Neutre
G
Ground
Terre

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3.0 STARTUP AND CALIBRATION
3.1 Startup
Check that the power wiring, sensor and remote panel connections, and interfaced equipment
are wired in accordance with the electrical installation drawings.
Power On the unit.
The main screen will light up and run through initialization. After any operator power start up or
power interruption, an operator must acknowledge the power-up condition. The display will
indicate it was non-gas power-up condition and that it must be acknowledged to proceed.
The main and remote panels are set to factory defaults or customer specifications. The sensor
is factory tested prior to shipment. As such, the system will be operational upon start-up.
After the power-up is acknowledged, confirm the screen reads similar as follows.
Figure 3 – Startup Main Screen View
All screen shots herein are provided for
illustration purposes only. Actual screen may
vary depending on control panel model.

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3.2 Screen Menu Background Information
3.2.1 Keypad Main Menu Entry
Below the touch screen are 4 touch keys.
Home
At any time, you can press the Home Key to return directly to the Home Screen
Help
This provides an overview of the system operation and components. Contact details for
technical help are included at the end of the text.
Tools
Access this section to view or configure the screen and control settings, view diagnostics or to
do a system alarm test.
Silence
During an alarm condition the audio can be silenced. Silencing at any panel will silence all
panels. The audio alarm will automatically re-set when the alarm clears.

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4.0 SYSTEM CONFIGURATION
This section describes the screen, alarm and interface features accessed through the of
the Main Panel.
Press “ “
Figure 4 – System Configuration Main Screen View
Log Off: This feature is used if user wants to manually log off from passcode protected menu at
any time. When user is in a passcode protected menu, it will stay logged in for 20 minutes from
last activity.
4.1 Alarm Setup
Figure 5 – Alarm Setup Screen View
The Passcode 2000 will be required to make changes in this section.
There are two alarm settings: Low alarm and High Alarm.
The low alarm is on early warning level that refrigerant gas is present. It is not unusual to have
trace levels of gas present during maintenance operations on refrigerant equipment. The screen
will flash yellow and conditions: Low Alarm. If required R1 relay can be set as Low Alarm
instead of fault.
The high alarm is for activation of the audio/visual alarms, ventilation fans and other customer
interlocks. The screen will flash red and conditions: High Alarm. Three relays are provided:
Boiler/Bas alarm, Fan Relay, Chiller Relay. The Fan and Chiller relays can be overridden with a
touch screen override switch.
Relay1 is factory set as Fault. If sensor is in fault, the screen will flash red and conditions:
Sensor Fault.

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DELAY SETUP
The low and high alarm delay settings are as follows:
Delay ON. This is the time, in seconds, that the relays will delay before activating when the
ppm setpoint has been reached. Delay ON is used to suppress a nuisance alarm that may be
caused by a spurious or momentary alarm of gas.
Delay OFF. The time, in seconds, that the relays will stay on after the ppm has dropped below
the setpoint. Delay OFF is used to keep ventilation fans running after the sensor has cleared to
assist ventilating any areas that may not be clear due to poor ventilation.
FAILSAFE SETUP
Failsafe will determine if the relays are energized or de-energized during a normal operating
state (no alarm condition).
If Failsafe is YES, the relay will be energized during a normal operating condition. An alarm or
power failure will de-energize the relay to the alarm state.
When in Failsafe mode and during a normal condition, the N.O. contact is closed and the N.C.
contacts is open. WIRE ACCORDINGLY.
CHILLER RELAY AND CHILLER OVERRIDE SWITCH
There is an option to Disable or Enable Chiller relay. If disabled, the Chiller relay can only be
activated by the manual Override Switch and will not turn off automatically if there is any alarm
condition.
Chiller Switch Yes will make the Chiller switch accessible to manually override the relay and
turn off the chiller.
If the Chiller relay is not wired to turn to off Chiller, is recommended to set the Chiller Switch to
No so that it is hidden and not mistaken as active.
ALARM DEFAULT SETUP
These keys are only activated when a unique user passcode is entered. It is used during factory
setup only.
4.2 Diagnostic Information
Figure 6 – Diagnostic Information Screen View
This is a View Only screen. It provides the alarm and sensor setup details that have been
entered for this unit. Setup and sensor changes can be made through the passcode protected
Alarm and Sensor Setup menu.

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4.3 Sensor Setup
The Passcode 2000 will be required to make changes in this section.
4.3.1 Individual Sensor Setup
Select the sensor required to be setup. If the required sensor is not shown then refer to Section
4.3.2. to change quantity.
Figure 7 – Sensor Setup Screen View
Gas Name
You can enter the gas name or identifier. This will show on the main screen adjacent to the
ppm concentration. This has been factory set according the sensor shipped with this panel.
Span
This will determine the 4-20 mA output range (if ordered). This is determined by the sensor type
and is factory set according to the sensor shipped with this panel.
Low Alarm ON
This will determine the ppm concentration at which the low alarm relay activates. At this
setpoint, the screen will flash yellow.
Low Alarm OFF
This will determine the ppm concentration at which the low alarm will turn off. This is typically
10 ppm or more to suppress chattering of alarms if the gas concentration is hovering at the
setpoint. The low alarm will clear automatically if the ppm levels drop below the alarm levels.
High Alarm ON
This will determine the ppm concentration at which the high alarm relays activate. At this
setpoint, the screen will flash red, the beacon will flash at all panels, and all audio alarms will be
activated.
By code, this alarm will latch. If the gas level drops below the alarm level, the audio turns off and
visual alarms will remain on. The screens will indicate that the gas levels are normal. A Push to
Reset button will show on the screen to manually reset the system.
High Alarm OFF
This will determine the ppm concentration at which the screen will indicate the gas condition has
cleared.
Sensors default Values
These keys are only activated when a unique user passcode is entered. It is used during factory
setup only

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4.3.2 Number of Sensors
This button allows user to change the total number of sensors being used in the system. This
feature will require factory consult level 2 passcode. Check model of controller to verify
maximum number of sensors.
4.3.3 Analog Input Trim
This button allows user to trim/modify analog input values. This feature will require factory
consult level 2 passcode.
1) Press Analog Input Trim/Modify
2) Select desire sensor to be trimmed (In this example we will use Sensor 1)
3) Connect mA generator to sensor 1 input. Set the mA generator to 4mA and press 4mA
Input Trim button.
4) Set the mA generator to 20mA and press 20mA Input trim button.
Repeat setup 1 for each sensor.
Figure 8 – Analog Input Trim Screen View
4.4 System Test
Figure 9 – System Test Screen View
The audio and visual alarm functions of the main and remote panels can be tested. Follow the
screen instructions to clear the alarms after testing. The system test can be initiated from any
panel, however, the remote panels are passcode protected.
System Test will activate the Low (if selected), Boiler, and Fan Relays only along with the
audio/visual alarms. Chiller Test will activate the Chiller Relay only along with the audio/visual
alarms.

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4.5 Factory Setup
This screen is to enter the serial, firmware data and title. It is only accessible by a unique user
name and passcode.
4.6 Factory Defaulted Sequence of Operation
(See section 1.4 for list of Alarm Levels)
1. Upon sensing a concentration at the sensor at the low alarm setpoint of 500 ppm for a
Group A refrigerants, the main screen will flash yellow and a Low Level Warning will be
indicated on all screens. No control action is activated. The alarms will automatically de-
activate when the concentration falls below 490 ppm.
2. Upon sensing a concentration at the sensor at the high alarm setpoint of 800 ppm for a
Group A refrigerants, the main screen will flash red and a High Level Alarm will be indicated
on all screens. The buzzer can be manually silenced during the alarm condition. When the
gas concentration decreases to below 790 ppm, the alarms will remain latched and must be
manually acknowledged with the Reset Button to de-activate.
3. The alarm activation is instantaneous and the field settable time delays are set to 0
seconds.
These factory defaulted settings can be changed in the field by the customer to suit specific
requirements. Follow the guideline presented in this manual.
4.7 Date and Time
The 4200-IR has a real time clock to remind users of impending calibration duties.
The reminder frequency can be entered here. When a calibration is performed, Press the
Record calibration icon to initiate reminder countdown timer. In order to change date and time,
follow the steps below:
1. Press "tool" button.
2. Press " Date and Time” icon on HMI display.
3. Press "Change" icon.
4. Enter proper date and time.
5. Press "enter" icon
Figure 10 – Date and Time Screen View

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5.0 MAIN DISPLAY
Figure 11 –Main Display Screen View
A. Calibration Due date.
B. Real date and time
C. Alarm Condition
D. Main title
E. Chiller switch
F. Fan Switch
G. Fan running indication (see ventilation light wiring drawings for detail)
A
B
D
C
F
E
G

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6.0 SENSOR CALIBRATION
Refer to the specific sensor Instruction Manual included with this manual for the sensor
calibration details.
The sensor is factory calibrated and will operate upon installation, however, the sensor
response should be verified after installation with a calibration or test gas. Re-calibrate if
necessary.
Routine verification of the sensor response and confirmation of the panel alarms and interlocks
is recommended. Verification every 6 months is recommended. Re-calibrate as necessary.