Bacharach PGM-IR User manual

Instruction 3015-5508 (Rev 2) 1
Portable Gas Monitor (PGM-IR)
Infrared Sensor Replacement
Instruction 3015-5508
Rev. 2 – March 2013
1. Scope
These instructions describe how to replace the IR
sensor in the Portable Gas Monitor (example shown in
Figure 1). It is assumed that the user is familiar with
the operation of the appropriate monitor model
. If
necessary, refer to
the corresponding instruction
manual for detailed operation and maintenance
information. Table 1 provides a list of the appropriate
instructions and parts necessary for each model, and
additional information to assist in identification
(supported gas types and internal
bladder bag
presence).
IR Sensor (Bench)
Figure 1. Sample Replacement IR Sensor (Left) and PGM-IR in Soft Case (Right)
Table 1: Part Number Information
PGM-IR
Model
Supported
Gas Type
IR Sensor
Replacement
Kit
Solo IR
Sensor*
Instruction
Manual
Purge Air
(Bladder)
Bag?
3015-5148 SF63015-5509 3015-5087 3015-5150 Yes
3015-4484
Refrigerant 3015-4721 3015-5086
3015-4584
3415-5420
3015-5466
No
3015-5696
3015-8000
3015-8003
3015-8001 CO23015-5759 3015-5090 3015-9000
3015-8002
* Not for individual sale.
NOTE:The solo IR sensor part numbers in Table 1 are used for ID purposes only. To order a
replacement kit for your sensor, use the IR Sensor Replacement Kit part number. For
example, to order a replacement kit for a solo sensor labeled with model number 3015-5087,
order IR Sensor Replacement Kit 3015-5509.
Patent 6,590,690

Portable Gas Monitor (PGM-IR) Infrared Sensor Replacement
2 Instruction 3015-5508 (Rev 2)
Figure 2. Internal Components Showing the IR Sensor (Bench) of a PGM-IR
2. Items Required
•IR Sensor Replacement Kit which includes:
oIR sensor assembly (p/n: see Table 1)
ocable ties, qty: 2 (p/n: 3015-2835)
othis instruction manual (p/n: 3015-5508)
•Medium Phillips head screwdriver
•Small flat blade screwdriver
•Wire cutters (for removing cable ties)
3. Disassemble the Chassis
Gain access to the IR sensor by disassembling the monitor’s metal chassis as follows.
Step

Description
1. Unplug the battery pack from the Portable Monitor.
2. Remove the Monitor and its battery pack from the soft carrying case.
3. Remove a total of 10 screws from the locations shown in Figure 3.
4. Carefully separate the metal chassis, being careful not to puncture the purge-air bag.

Portable Gas Monitor (PGM-IR) Infrared Sensor Replacement
Instruction 3015-5508 (Rev 2) 3
Figure 3. Disassembling the Chassis
4. Remove the IR Sensor
Step

Description
5. Review the internal components of the monitor,
shown below, before proceeding. Note that
Figure 4 shows R37 – an analog potentiometer
which is used to adjust the IR emitter drive level.
This component is only present on older models
that do not have the software Digipot feature
(which enables IR emitter adjustments via the
keypad/display rather than the R37
potentiometer).
Figure 4: R37 Component
(On Non Digipot Models Only)
6. Refer to Figure 4 and Figure 5 while performing the following steps to remove the old
IR sensor.
7. If present, turn R37 six full revolutions counter-clockwise.

Portable Gas Monitor (PGM-IR) Infrared Sensor Replacement
4 Instruction 3015-5508 (Rev 2)
Figure 5. Monitor Components in Various PGM-IR Models
Step

Description
8. Disconnect the tubing from the purge-air bag “T”-fitting, and then lay aside the
chassis-half containing the purge-air bag. (This step does not apply to models without
the purge air bladder bag.)
9. Pull the 10-pin and 12-pin electrical connectors from their sockets on the IR sensor.
Note that these connectors may have been secured in place for shipping purposes
with hot-glue or wire ties. As necessary, carefully pry the hot-glue from each
connector or cut off the wire ties.
10. Pull the tubing from the gas-inlet and gas-outlet fittings on the IR sensor.
11. Using wire cutters, cut the two cable ties that secure the IR sensor to the chassis, and
then remove the sensor.

Portable Gas Monitor (PGM-IR) Infrared Sensor Replacement
Instruction 3015-5508 (Rev 2) 5
5. Install the New IR Sensor
Step

Description
12. Record calibration label information (found on the new IR sensor) into Table 2 for use
later in this procedure. Refer to Figure 6. Note that calibration information is
dependent on the gas type supported by the IR sensor. For example, refrigerant and
SF6sensors use a single calibration parameter (TEMPCO). CO2sensors use five
parameters.
Figure 6. Sample IR Sensor Labels: Refrigerant and SF6(Left); CO2(Right)
Table 2: Calibration Parameters Worksheet
All Sensors CO2Only
TEMPCO LOTEMP HITEMP LOKCAL HIKCAL
13. To begin the installation of the new IR sensor, remove the protective caps from the
gas-inlet and gas-outlet fittings on the new IR sensor.
14. Position the new sensor inside the chassis so that the end with the 12-pin electrical
connector (IR Source) is located on the right, and that the gas fittings are facing
upwards.
15. Reconnect the tubing that was removed in step 8 to the gas-inlet and gas-out fittings
on the IR sensor.
16. Plug the 12-conductor ribbon cable from IR SOURCE connector J5 on the main board
into the 12-pin IR emitter connector.
17. Plug the 10-conductor ribbon cable from DET connector J6 on the main board into the
10-pin IR sensor connector.
18. Using the two cable ties supplied in the kit, secure the sensor to the cable-tie mounts
on the side wall of the chassis. Note that the 12-conductor ribbon cable is secured in
place by positioning it under the cable tie. Cut off any cable-tie excess.
19. Check to ensure that the new IR sensor is properly secured, and that all tubing and
electrical connectors are tight.
20. Reconnect the tubing from the purge-air bag onto its tee-fitting. (This step does not
apply to models without the purge air bladder bag.)
21. Connect the battery pack to the monitor’s battery connector, and then turn ON the
monitor.
22. Allow the monitor to warm-up for at least ½ hour before proceeding.

Portable Gas Monitor (PGM-IR) Infrared Sensor Replacement
6 Instruction 3015-5508 (Rev 2)
6. Adjust Power Level for IR Emitter
Step

Description
23. To access the monitor’s set-up mode and display the IR emitter power adjustment
screen, locate and view the Portable Monitor’s display.
24. With the monitor in its MEASURE mode, press both the LEFT and RIGHT buttons
simultaneously to display the FUNCTION MENU screen.
25. With the monitor in its FUNCTION MENU, use the keypad buttons to place the arrow
(>) on the display next to the DIAG (models with bladder bag) or CAL (models
without bladder bag) function.
26. Press the RIGHT Arrow and ENTER buttons simultaneously to display the revision
screen and access the FACTORY MENU.
27. Press the ESC button to display FACTORY MENU.
28. Use the keypad buttons to place the arrow (>) on “IR.” Press the ENTER button to
display the IR emitter adjustment screen.
29. Change the IR emitter drive level to a value between 325 and 350 mW by using the
UP/DOWN arrow keys (in newer models).
If the R37 pot (located on main PCB board) is present (in older models), change the
drive level by adjusting R37 clockwise.
30. Press the ESC button and then proceed to the next section and adjust the DIGIPOT
as necessary.
7. Adjust the IR Sensor Voltage
Step

Description
31. With the arrow (>) next to the DIGIPOT function,
press the ENTER button to display the IR sensor
voltage adjustment screen.
32. While observing the IR VOLT reading, use the Up/
Down Arrow buttons to obtain a reading of
4.2 ±0.1 volts. (The last two digits are largely
unstable, so the tenths decimal place is the first
"usable" digit). Note that the DIGIPOT value may
vary from what is shown in the display on the right.
Press ENT to save the DIGIPOT value.
IMPORTANT: If IR VOLT does not reach 4.2 volts by adjusting the digipot, then return to step
23 to reduce the IR emitter power by 75 mW and repeat the DIGIPOT adjustment.

Portable Gas Monitor (PGM-IR) Infrared Sensor Replacement
Instruction 3015-5508 (Rev 2) 7
8. Update Calibration Information
Step

Description
33. Scroll to TEMPCOS and press ENTER. Enter your recorded TEMPCO value from
Table 2 using the keypad buttons. Press ENTER to save the new value.
•For CO2sensors, continue to step 34 to enter additional calibration information.
•For refrigerant and SF6sensors, skip to step 38.
34. Scroll to EDIT LT and press ENTER. Enter the previously recorded LOTEMP value
from Table 2 using the keypad buttons. Press ENTER to save the new value.
35. Scroll to EDIT HT and press ENTER. Enter the previously recorded HITEMP value
from Table 2 using the keypad buttons. Press ENTER to save the new value.
36. Scroll to EDIT LP and press ENTER. Enter the previously recorded LOKCAL value
from Table 2 using the keypad buttons. Press ENTER to save the new value.
37. Scroll to EDIT HP and press ENTER. Enter the previously recorded HIKCAL value
from Table 2 using the keypad buttons. Press ENTER to save the new value.
38. Press the ESC button twice to exit the monitor’s FACTORY and FUNCTION menus.
39. Upon exiting the menus, a purge cycle will be performed. After this, the monitor will
automatically return to its MEASURE mode. Ensure there are no faults present.
40. Turn OFF the monitor and reassemble the chassis using the 10 screws removed
earlier (see page 2).
41. Replace the monitor back into the soft carrying case and connect the battery pack.
42. The monitor can now be placed back into service.
∇∇∇

Portable Gas Monitor (PGM-IR) Infrared Sensor Replacement
8 Instruction 3015-5508 (Rev 2)
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