Bacharach MGD-100 User manual

Gas Detector and Controllers
Installation and Operation Manual
Instruction 6109-9000
Revision 3 – June 2013
Product Leadership •Training •Service •Reliability

M GD-100 M anual
2 6109-9000 Rev 3
WARRANTY POLICY
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HAVE A WARRANTY PERIOD OF ONE YEAR FROM TH E DA T E O F PU R CHA S E. IF
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M GD-100 M anual
6109-9000 Rev 3 3
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THIS UNIT MUST BE INSTALLED BY A SUITA BLY QUALIFIED TECHNICIA N W HO
WILL INSTALL THIS UNIT IN A CCORDA NCE WITH THESE INSTRUCTIONS A ND
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RESPONSIBL E IN THIS REGA RD.

M GD-100 M anual
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Table of Contents
SECTION 1. OVERVIEW ..............................................................................................5
1.1. Gen era l I nformati on..........................................................................................5
1.2. Technical Specifications..................................................................................10
SECTION 2. PLACING SENSORS ..............................................................................13
2.1. Installation Warnings ......................................................................................13
2.2. Gen era l Gui deli nes ..........................................................................................13
2.3. Machi nery Rooms............................................................................................15
2.4. Refri gerated Spa ces .........................................................................................16
2.5. Chillers...............................................................................................................16
2.6. Air Conditioning (Direct Systems VRF/VRV)................................................17
SECTION 3. HOUSING DIMEN SIONS .....................................................................18
SECTION 4. WIRING INSTRUCTIONS .....................................................................23
4.1. Wiri ng MGD-100s ...........................................................................................23
4.2. External Audible Alarm and DC Output .......................................................24
4.3. Relays.................................................................................................................25
4.4. Power Conn ecti on ...........................................................................................25
SECTION 5. OPERA TION AND STA BILIZA TION ....................................................31
SECTION 6. FUNCTIONAL TESTS AND CALIBRATION.........................................33
6.1. Introduction......................................................................................................33
6.2. Electri cal Res et of One-Al arm Systems ........................................................35
6.3. El ectri cal Res et of T wo-Alarm Sys tems........................................................36
6.4. Bump Testing....................................................................................................37
6.5. Calibration Overview.......................................................................................40
6.6. Calibration Options..........................................................................................40
6.7. Sensor Board Exchange ..................................................................................40
6.8. On-Site Gas Calibration (One-Alarm Unit)...................................................41
6.9. Gas Calibration (Two-Alarm Units)...............................................................43
SECTION 7. TRO UBLESHOO TIN G...........................................................................44
DECLARATION OF CONFORMITY ................................................................................47

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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 t he 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 Cont roller is required. With the MGD-100, it creates a
stand-alone gas detection system and is used to remotely monit or 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 De s cr ip t io n
Pow er Supply 120 VA C 60 Hz , 220 VAC 50 Hz, or 12 VDC (specified at
time of order); Max power 20W
1- and 2-
channelsystems
4- and 6-
channelsystems
Audible Alarm (Buzzer ) Internal,
continuous
Internal,
intermittent
(low),
continuous
(high)
External,
continuous
External,
continuous
Alarm Silence Jumper Key Sw itch Jumper Key Sw itch
Alarm Levels 1 Level 2 Levels 1 Level 2 Levels
Alarm Reset Automatic Automatic
( low alarm),
manual
(high alarm)
Automatic Automatic
( low alarm),
manual
(high alarm)
A lar m Delay Selectable Preset
25 s ec ( low )
30 sec (high)
Selectable Preset
25 s ec ( low )
30 sec (high)
Visual Alarm LED(s) Red Yellow , Red Red Yellow , Red
Fault Indications Red LED, relay Red LED, relay
Pow er Monitoring LED Green Green
Alarm Relay(s) 10 A, 120V/230V 10 A, 120V/230V
Communications Wiring 4-conductor cable, 200 ft
(61 m) max w / 22 AWG
4-conductor cable, 500 ft
(152 m) max , 22 AWG
Warm-up Delay Min imu m of 3 minutes

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Specification De s cr ip t io n
1- and 2-
channelsystems
4- and 6-
channelsystems
Standard Enclosure
Ratings
MG D-100: IP41
Controller: IP51
MG D-100: IP41
Controller: IP51
Dimensions and Weight:
Controller
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
Dimensions and Weights I P41 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 /
Re mote Sensor
6.89” x 6.1” x 3.29”
175 x 155 x 82 mm
1 lb 11 oz
790 g
IP66 w / Ex d
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 Airf low /
Duct (See
Table)
6.89” x 4.9” x 3.29”
175 x 125 x 82 mm
1 lb 4 oz
578 g
Ex d ( A TEX
only)
5.12” x 6.3” x 3.54”
130 x 160 x 90 mm
9 lb 4 oz
4200 g
NOT E: The haz ardous area Exd Gas M onitor products are
designed with individually certified Exd main housing
enclosures and certified Exd remote or attached sens or
enclosures. The main housing enclosure and its PCB
assembly are als o 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 Du ct 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
Are a (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.
WARNI NG: Explosion hazard! Do not mount the MGD-100 in
an area that may contai n flammable liquids, vapors, or
aerosols. Operation of any electrical equipm ent in such an
environment constitutes a safety hazard.
CAUTION: Th e MG D-100 contains sensitive electronic
components that can be easily damaged. Do not touch nor
disturb any of these components.
NOT E: The mounting l ocation of the monitor should allow it to
be easily accessible for visual monitoring and servicing.
NOT E: The monitor must be connected by a marked, suitably
located and easily reached switch or circuit-breaker as means
of disconnection.
NOT E: Connect monitor power and signaling terminals using
wiring that complies wit h local electrical codes or regulations
for the intended application.
2.2. General Guidelines
NOT E: Th e MG D-100 should be installed plum b and level
and securely fastened to a rigid m ounting surface.
The MGD-100 cont roller 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 i n direct strong drafts/airflows and areas where water or
moisture is pres ent unless an appropriate enclosure is used.

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A void routing sensor c abling outside of premises, or between buil dings
via overhead cables. Also, sensor wiring should be kept to a minim um 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. 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 m ay be
longer than 3 minutes. After the 3 minut es has expired, alarms may
activate. You may deactivate the siren until stabilization is complet e.
(Use the key switch on t wo-alarm units. Remove j umper 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 m ust be located within the appropriate wire lengt hs from the
controller.
In all cases the sensor supplied is designed for maximum sensitivity to a
particular gas. However, in certain circumstanc es false alarms m ay 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 acti vity 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 confi ned spaces or close
to sensors.
A response delay is built in to the system to minimize the possibilities of
false alarms (for two-alarm units only) or it may be selected for one-
alarm units.

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2.3. Machinery Rooms
There is no absolute rule in det ermini ng t he num ber 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 important to carefully select the sensor location. Also
consider ease of access for m aintenance.
The size and nature of the site will help to decide which met hod 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
mechanic al), 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 leak age, such as
the compressor, expansion valves, mechanical joints or
cable duct trenches.
Perimeter Detection, where sensors completely surround
the area or equipment.
•For heavier-than-air gases such as halocarbon and
hydrocarbon refrigerants such as R404A, propane, and butane
sensors should be locat ed near ground level.
•For lighter-than-air gas (e.g., ammonia), the sensor needs to
be locat ed above the equipment to be monitored on a bracket or
high on a wall within 12 i n (300 mm ) of (or on) t he c eiling –
provided there is no possibility of a thermal lay er trapped under
the ceiling preventing gas fr om reaching the sensor.
NOTE: At very low temperatures (e.g., r
efrigerated
cold store), amm oni a gas becomes heavier than air.
•With similar density or miscible gases, such as CO or CO2,
sensors should be mount ed 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 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 requi rement 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 m ounted on the central line between 2
adjacent evaporators, as turbulence will result in airflows mixing.
2.5. Chillers
In the c ase of small water- or air-cooled enclosed c hiller units mount the
sensor so as to monitor airflow to the extract fans. With larger models
also pl ace 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 airfl ow
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 out door units:
•If there is an enclosed machinery section, locate a sensor there.
•In the case of units with enclos ed compressors, mount sensors
in the enclosures.
•Where you have protecti ve or acoustic panels mount the sensor
low and under the compressors where it is protected by the
panels.

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•With air-cooled chillers or air-cooled condensers with non-
enclosed condenser sections it is difficult to effecti vely monitor
leaks in the coil sections. With some designs it will be possible
using an ai rflow sensor to monitor airflow to the start–up fans in
the front or rear sections.
•If there is a possibility of refrigerant l eaks into a duct or air-
handling unit install a sensor to monitor the airflow.
Weatherproof sensors shoul d be used for unprotected outdoor
applications.
2.6. Air Conditioning (Direct Systems VRF/VRV)
For compliance with E N378, at least one detector shall be installed in
each occupied s pace being considered and t he loc ation 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 thei r 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: Monit oring 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 mi rrors.
…away from drafts and heat sources like
radiators, etc.
…at vanity units.
… to avoid sourc es of steam. …in or near bathrooms.
IMPORTANT : Carefully consider ramifications of using too few
sensors. A few extra sensors could make a significant
differenc e 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