Bacharach MGD-100 User manual

Gas Detector and Controllers
Installation and Operation Manual
Instruction 6109-9000
Revision 4 – June 2014
Product Leadership •Training •Service •Reliability

MGD-100 Manual
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WARRANTY POLICY
BACHARACH, INC. WARRANTS THIS INSTRUMENT, EXCLUDING SENSORS, TO BE
FREE FROM DEFECTS IN MATERIALS AND WORKMANSHIP FOR A PERIOD OF ONE
YEAR 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.
THE WARRANTY STATUS MAY BE AFFECTED IF THE INSTRUMENT HAS NOT BEEN
USED AND MAINTAINED PER THE INSTRUCTIONS IN THIS MANUAL OR HAS BEEN
ABUSED, DAMAGED, OR MODIFIED IN ANY WAY. THIS INSTRUMENT IS ONLY TO BE
USED FOR PURPOSES STATED HEREIN. THE MANUFACTURER IS NOT LIABLE FOR
AUXILIARY INTERFACED EQUIPMENT OR CONSEQUENTIAL DAMAGE.
DUE TO ONGOING RESEARCH, DEVELOPMENT, AND PRODUCT TESTING, THE
MANUFACTURER RESERVES THE RIGHT TO CHANGE SPECIFICATIONS WITHOUT
NOTICE. THE INFORMATION CONTAINED HEREIN IS BASED ON DATA CONSIDERED
ACCURATE. HOWEVER, NO WARRANTY IS EXPRESSED OR IMPLIED REGARDING
THE ACCURACY OF THIS DATA.
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FOR A NUMBER AND PROCEDURES REQUIRED FOR PRODUCT TRANSPORT.
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621 HUNT VALLEY CIRCLE
NEW KENSINGTON, PA 15068
ATTENTION: SERVICE DEPARTMENT
ALWAYS INCLUDE YOUR RMA #, ADDRESS, TELEPHONE NUMBER, CONTACT
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ESTIMATE FOR EXPECTED REPAIRS PRIOR TO THE PERFORMANCE OF ANY
SERVICE WORK. FOR LIABILITY REASONS, BACHARACH HAS A POLICY OF

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PERFORMING ALL NEEDED REPAIRS TO RESTORE THE INSTRUMENT TO
FULL OPERATING CONDITION.
PRIOR TO SHIPPING EQUIPMENT TO BACHARACH, CONTACT OUR OFFICE
FOR AN RMA # (RETURNED MERCHANDISE AUTHORIZATION). ALL RETURNED
GOODS MUST BE ACCOMPANIED WITH AN RMA NUMBER.
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DURING SHIPPING TO OUR FACILITY.
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TECHNICIAN USE ONLY
THIS UNIT MUST BE INSTALLED BY A SUITABLY QUALIFIED TECHNICIAN WHO
WILL INSTALL THIS UNIT IN ACCORDANCE WITH THESE INSTRUCTIONS AND
THE STANDARDS IN THEIR PARTICULAR INDUSTRY/COUNTRY. OPERATORS
OF THE UNIT SHOULD BE AWARE OF THE REGULATIONS AND STANDARDS IN
THEIR INDUSTRY/COUNTRY FOR THE OPERATION OF THIS UNIT. THESE
NOTES ARE ONLY INTENDED AS A GUIDE AND THE MANUFACTURER BEARS
NO RESPONSIBILITY FOR THE INSTALLATION OR OPERATION OF THIS UNIT.
FAILURE TO INSTALL AND OPERATE THE UNIT IN ACCORDANCE WITH THESE
INSTRUCTIONS AND WITH INDUSTRY GUIDELINES MAY CAUSE SERIOUS
INJURY INCLUDING DEATH AND THE MANUFACTURER WILL NOT BE HELD
RESPONSIBLE IN THIS REGARD.

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Table of Contents
SECTION 1. OVERVIEW ................................................................................5
1.1. General Information................................................................................ 5
1.2. Technical Specifications ........................................................................ 10
SECTION 2. PLACING SENSORS ..................................................................13
2.1. Installation Warnings ............................................................................ 13
2.2. General Guidelines ................................................................................ 13
2.3. Machinery Rooms ................................................................................. 15
2.4. Refrigerated Spaces............................................................................... 16
2.5. Chillers................................................................................................... 16
2.6. Air Conditioning (Direct Systems VRF/VRV) .......................................... 17
SECTION 3. HOUSING DIMENSIONS ..........................................................18
SECTION 4. WIRING INSTRUCTIONS .......................................................... 23
4.1. Wiring MGD-100s .................................................................................. 23
4.2. External Audible Alarm.......................................................................... 24
4.3. DC Output.............................................................................................. 24
4.4. Relays .................................................................................................... 25
4.5. Power Connection ................................................................................. 25
SECTION 5. OPERATION AND STABILIZATION............................................30
SECTION 6. FUNCTIONAL TESTS AND CALIBRATION ..................................32
6.1. Introduction .......................................................................................... 32
6.2. Electrical Reset ...................................................................................... 34
6.3. Bump Testing......................................................................................... 35
6.4. Calibration Overview............................................................................. 38
6.5. Calibration Options ............................................................................... 38
6.6. Sensor Board Exchange ......................................................................... 38
6.7. On-Site Gas Calibration ......................................................................... 39
SECTION 7. TROUBLESHOOTING ............................................................... 41
DECLARATION OF CONFORMITY....................................................................43

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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 the detection
of gases. The system is available with one or two levels of alarm.
The MGD-100 can be used for:
•detecting refrigerant gases (including NH3and CO2)
•speedy detection of combustible gases
•detection of toxic and VOC gases.
A range of gas detector and sensor enclosures are available for special
applications.
The MGD-100 Controller is required. With the MGD-100, it creates a
stand-alone gas detection system and is used to remotely monitor up to
six MGD-100 devices. Models are available with 1, 2, 4, and 6 channels.
Wiring diagrams are provided later in this manual.

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Figure 1. MGD-100 1- and 2-Channel Controller PCB
(Single Level Alarm)
Figure 2. MGD-100 1- and 2-Channel Controller PCB
(Dual Level Alarm)

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Figure 3. MGD-100 4- and 6-Channel Controller PCB
(Single Level Alarm)

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Figure 4. MGD-100 4- and 6-Channel Controller PCB
(Dual Level Alarm)

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Figure 5. Examples MGD-100 PCBs

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1.2. Technical Specifications
Specification Description
Power Supply 100 - 230 VAC 50 - 60 Hz, or 12 VDC (specified at
time of order)
Alarm Silence Key Switch
Alarm Delay Preset: 25 sec (low), 30 sec (high)
Power
Monitoring LED
Green
Alarm Relay(s) 10 A, 120V/230V
Warm-up Delay Minimum of 3 minutes
Communications
Wiring
4-conductor cable (stranded); 500 ft (152 m) max;
22 AWG; Max 8.8Ω/wire
Approvals UL/CSA/IEC/EN 61010-1; CE
Sensor
Channels
1- and 2-channel
systems
4- and 6-channel
systems
Max Power 15 W 25 W
Alarm Levels 1 Level 2 Levels 1 Level 2 Levels
Audible Alarm
(Buzzer)
Internal,
continuous
Internal,
intermittent
(low),
continuous
(high)
Internal,
continuous
Internal,
intermittent
(low),
continuous
(high)
Alarm Reset Automatic Automatic
(low
alarm),
manual
(high
alarm)
Automatic Automatic
(low
alarm),
manual
(high
alarm)
Visual Alarm
LED(s)
Red Yellow,
Red
Red Yellow,
Red
Fault
Indication(s)
Red LED Red LED Red LED Red LED,
relay

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Specification Description
1- and 2-chan systems 4- and 6-chan systems
Std. Enclosure
Ratings
MGD: IP41
Controller: IP51
MGD: IP41
Controller: IP51
Dimensions
and Weight:
Controller
8.4” x 4.1” x 3.15”
214 x 105 x 80 mm
2.2 lbs / 1.0 kg
10.3” x 10.4” x 303”
262 x 265 x 84 mm
5.1 lbs / 2.3 kg
Sensor
Dimensions
and Weights
Type/Enclosure Dimensions 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 8.9” x 3.29”
175 x 225 x 82 mm
1 lb 9 oz
700 g
IP66 w/ Remote
Sensor
6.89” x 6.1” x 3.29”
175 x 155 x 82 mm
1 lb 11
oz
790 g
IP66 w/ Exd
Remote Head
6.89” x 6.1” x 3.29”
175 x 155 x 82 mm
2 lb 10
oz
1185 g
IP66 w/ PRV
Sensor Head
6.89” x 6.1” x 3.29”
175 x 155 x 82 mm
2 lb 0.3
oz
916 g
IP66 Airflow/
Duct (See Table)
6.89” x 4.9” x 3.29”
175 x 125 x 82 mm
1 lb 4 oz
578 g
Exd (ATEX only) 5.12” x 6.3” x 3.54”
130 x 160 x 90 mm
9 lb 4 oz
4200 g
NOTE: The hazardous area Exd Gas Monitor products are
designed with individually certified Exd
main housing
enclosures and certified Exd
remote or attached sensor
enclosures. The main housing enclosure and its PCB
assembly are also Exd certified, but the final Exd Gas Monitor
assemblies (main enclosure and/or sensor assembly) are not
currently Exd certified, but are pending additional testing.

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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 1 x 1 1 x 2 1.5 x 1.5 2 x 2 Pi x 1 x 1
Area (ft2) 1 2 2.25 4 3.14
CFM Ft/min (Based on CFM and Duct Size)
2800 2800 n/a n/a n/a n/a
3000 3000 n/a n/a n/a n/a
3400 3400 n/a n/a n/a n/a
3800 3800 n/a n/a n/a n/a
4000 4000 n/a n/a n/a n/a
4400 4400 n/a n/a n/a n/a
4800 4800 n/a n/a n/a n/a
5000 5000 2500 n/a n/a n/a
5400 5400 2700 n/a n/a n/a
5800 5800 2900 2578 n/a n/a
6000 6000 3000 2667 n/a n/a
6400 6400 3200 2844 n/a n/a
6800 6800 3400 3022 n/a n/a
7000 7000 3500 3111 n/a n/a
7400 7400 3700 3289 n/a n/a
7800 7800 3900 3467 n/a n/a
8000 8000 4000 3556 n/a 2548
8400 8400 4200 3733 n/a 2675
8800 8800 4400 3911 n/a 2803
9000 9000 4500 4000 n/a 2866
9400 9400 4700 4178 n/a 2994
9800 9800 4900 4356 n/a 3121
10000 10000 5000 4444 2500 3185

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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.
WARNING: Explosion hazard! Do not mount the MGD-100 in
an area that may contain flammable liquids, vapors, or
aerosols. Operation of any electrical equipment in such an
environment constitutes a safety hazard.
CAUTION: The MGD-100 contains sensitive electronic
components that can be easily damaged. Do not touch nor
disturb any of these components.
NOTE: The mounting location of the monitor should allow it to
be easily accessible for visual monitoring and servicing.
NOTE: The monitor must be connected by a marked, suitably
located and easily reached switch or circuit-breaker as means
of disconnection.
NOTE: Connect monitor power and signaling terminals using
wiring that complies with local electrical codes or regulations
for the intended application.
2.2. General Guidelines
NOTE: The MGD-100 should be installed plumb and level
and securely fastened to a rigid mounting surface.
The MGD-100 controller and its sensor(s) should be positioned carefully
to avoid mechanical damage (from moving machinery, doors, etc.) and
thermal extremes (close to heaters). Units should not be placed
unprotected in direct strong drafts/airflows and areas where water or
moisture is present unless an appropriate enclosure is used.

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Avoid routing sensor cabling 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 mechanical 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 activates. This allows the sensors to warm up to the correct
temperature for gas detection. On a two-alarm unit, the green light on the
alarm panel comes on after the delay, indicating that the system is ready.
On a one-alarm system the green light comes on immediately. When a
unit has been off or stored for a long time the stabilizing period may be
longer than 3 minutes. After the 3 minutes has expired, alarms may
activate. You may deactivate the siren until stabilization is complete.
(Use the key switch on two-alarm units. Remove jumper JP1 in the case
of a one-alarm unit).
Mount the controller using the mounting holes in the base such that the
sensor cable terminal blocks are at the bottom of the unit in a convenient
position.
Sensors must be located within the appropriate wire lengths from the
controller.
In all cases the sensor supplied is designed for maximum sensitivity to a
particular gas. However, in certain circumstances false alarms may be
caused by the occasional presence of sufficiently high concentrations of
other gaseous impurities. Examples of situations where such
abnormalities may arise include the following:
•Plant room maintenance activity involving solvent or paint fumes
or refrigerant leaks.
•Accidental gas migration in fruit ripening/storage facilities
(bananas - ethylene, apples - carbon dioxide).
•Heavy localized exhaust fumes (carbon monoxide, dioxide,
propane) from engine-driven forklifts in confined spaces or close
to sensors.
A sensor response delay is built in to the system to minimize the
possibilities of false alarms.

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2.3. Machinery Rooms
There is no absolute rule in determining the number of sensors and their
locations. However, a number of simple guidelines will help to make a
decision. Sensors 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 important to carefully select the sensor location. Also
consider ease of access for maintenance.
The size and nature of the site will help to decide which method is the
most appropriate to use. Locations requiring the most protection in a
machinery or plant room would be around compressors, pressurized
storage vessels, refrigerant cylinders or storage rooms or pipelines. The
most common leak sources are valves, gauges, flanges, joints (brazed or
mechanical), filling or draining connections, etc.
•When mechanical or natural ventilation is present, mount a
sensor in the airflow.
•In machinery rooms where there is no discernible or strong
airflow then options are:
Point Detection, where sensors are located as near as
possible to the most likely sources of leakage, such as
the compressor, expansion valves, mechanical joints or
cable duct trenches.
Perimeter Detection
•For heavier-than-air gases such as halocarbon and
hydrocarbon refrigerants such as R404A, propane, and butane
sensors should be located near ground level.
, where sensors completely surround
the area or equipment.
•For lighter-than-air gas (e.g., ammonia), the sensor needs to
be located above the equipment to be monitored on a bracket or
high on a wall within 12 in (300 mm) of (or on) the ceiling –
provided there is no possibility of a thermal layer trapped under
the ceiling preventing gas from reaching the sensor.
NOTE: At very low temperatures (e.g., refrigerated
cold store), ammonia gas becomes heavier than air.
•With similar density or miscible gases, such as CO or CO2,
sensors should be mounted about head high (about 5 feet
[1.5 m]).
•Sensors should be positioned just far enough back from any
high-pressure parts to allow gas clouds to form and be detected.

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Otherwise, a gas leak might pass by in a high-speed jet and not
be detected 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.
•For racks or chillers pre-fitted with refrigerant sensors, these
should be mounted so as to monitor the compressors. If extract
ducts are fitted the airflow in the duct may be monitored.
2.4. Refrigerated Spaces
In refrigerated spaces, sensors should be located in the return airflow to
the evaporators on a sidewall (below head-high is preferred), or on the
ceiling, not directly in front of an evaporator. In large rooms with multiple
evaporators, sensors should be mounted on the central line between 2
adjacent evaporators, as turbulence will result in airflows mixing.
2.5. Chillers
In the case of small water- or air-cooled enclosed chiller units mount the
sensor so as to monitor airflow to the extract fans. With larger models
also place a sensor inside the enclosure under or adjacent to the
compressors.
In the case of outdoor units:
•For enclosed air-cooled chillers or the outdoor unit for
variable refrigerant volume and variable refrigerant flow
(VRV/VRF) systems, mount the sensor so as to monitor airflow
to the extractor/exhaust fan. With large units also place a sensor
inside the enclosure under or adjacent to the compressors.
In the case of non-enclosed outdoor units:
•If there is an enclosed machinery section, locate a sensor there.
•In the case of units with enclosed compressors, mount sensors
in the enclosures.
•Where you have protective or acoustic panels mount the sensor
low and under the compressors where it is protected by the
panels.

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6109-9000 Rev 4 17
•With air-cooled chillers or air-cooled condensers with non-
enclosed 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 air-
handling unit install a sensor to monitor the airflow.
Weatherproof sensors should be used for unprotected outdoor
applications.
2.6. Air Conditioning (Direct Systems VRF/VRV)
For compliance with EN378, at least one detector shall be installed in
each occupied space being considered and the location of detectors
shall be chosen in relation to the refrigerant and they shall be located
where the refrigerant from the leak will collect. In this case refrigerants
are heavier than air and detectors should have their sensors mounted
low, e.g., at less than bed height in the case of an hotel or other similar
Category Class A spaces. Ceilings or other voids if not sealed are part of
the occupied space.
CAUTION: Monitoring ceiling voids in a hotel room would
not strictly comply with EN378.
Do Mount In-Room Sensors… Don’t Mount Sensors…
…at less than the normal heights of the
occupants. E.g., in a hotel room this is
less than bed height ( between 8 and
20 in [200 and 500 mm] off the floor).
…under mirrors.
…away from drafts and heat sources like
radiators, etc.
…at vanity units.
… to avoid sources of steam. …in or near bathrooms.
IMPORTANT: Carefully consider ramifications of using too few
sensors. A few extra sensors could make a significant
difference if a gas leak occurs.

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Section 3. Housing Dimensions
Figure 6. MGD-100 Standard Housing

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Figure 7. MGD-100 Exd Housing
Figure 8. MGD-100 IP66 Housing (with Splash Guard)

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Figure 9. MGD-100 IP66 Housing with Remote Sensor
Figure 10. MGS-100 IP66 Housing with Airflow Duct
Mount
See Figure 8 for
mounting locations.
Cut out in
duct for
pitot 22mm